ACV BMV5 Flame Burner Instruction Manual

ACV BMV5 Flame Burner

Dear customer,
We are pleased that you have decided to purchase an ACV burner. The BMV burner model is a modern generation flame burner. The advantage of this burner construction is the extensive energy saving operation with very low emissions (Sampling test according to
EN 267:1999-11 Class 3, German environmental label “Blue Angel” according to RAL-UZ 9, Sampling test according to the Swiss Emissions Regulation LRV).

Every burner is checked in the scope of a thorough final inspection. In addition to the hydraulic and electrical parameters, the appearance of the flame is also inspected. The warranty period as of the date of purchase (receipt date) is 2 years. Please note that the installation, start up and inspection tasks must be accomplished by a trained technician. The installation and operating instructions that are provided contain important information to this purpose. We recommend a yearly inspection of the burner by a trained technician to guarantee continuous energy saving and low emission operation.

Over view

1. TECHNICAL DATA

   • Burner performance**
     Type| Oil throughput (kg/h)| Burner output (kW)**
     ---|---|---
     BMV3| 1.4 – 4.1| 16 – 48
     BMV4| 1.4 – 4.1| 16 – 48
     BMV 5| 3.2 – 4.7| 38 – 56

* Specifications for units with a low pressure furnace and an exhaust gas loss of approx. 8%.

2. Certification

   • DIN EN 267:1999-11: register number: 5G966/11
   • Class 3 emission limits (only HL60 E/FLV.2-S)
   • German ecolabel “Blue Angel” according to RAL-ZU 9: Con-tract no. 14415 (only HL60 E/FLV.2-S)

3. Operating range

   • In the chart, you find allowed combustion chamber pressure as function of the oil flow (see fig. 4).
   • The operating ranges have been determined on a test-ing unit and refer to an altitude of approx. 100 m above sea-level and a room temperature of approx. 20°C. The oil flow that can be achieved in practice depends on the starting resistance of the heater.
   • The starting resistance is influenced by the combustion chamber, the flue gas line and the starting load. Exact values can therefore only be determined on each respective system.

4. Fuel

   • Fuel oil EL according to DIN 51603-1
   • Heating oil EL, low Sulphur, according to DIN 51603-1
   • Fuel oil EL A Bio 10 (bio fuel oil according to DIN SPEC 51603-6, fuel oil EL, low sulphur, with up to 10% of FAME according to the quality requirements of DIN 14214)

5. Electrical data

   • Nominal voltage .230 V ~ 50 Hz
   • Starting power ca. 435 W
   • Operating power ca. 135 – 235 W
   • Contact rating of the thermostats and switches , min. 6A~

6. Burner dimensions
   Specifications of dimensions in mm (see fig. 5 + 6)

   • Packing l 370 / w 350 / h 485 mm
   • Transport weight 14.5 kg

7. Acoustic emissions
   The sound pressure level at maximum burner performance is 57 dB(A). The measurements were carried out with an accuracy class 2 measuring device according to IEC 60651 at a (horizontal) distance of 2m.
   

8. Burner components****  
   Item| Make| Ref
   ---|---|---
   Motor| Hanning| O1A095-030
   Oil pump| Danfoss| BFP 21 L3
   Oil pre-heater| Danfoss| FPHE 5
   Ignition unit| Cofi| TRK2-40SHK
   Photocell| Danfoss| LDS 057H7097
   Automatic oil firing unit| Siemens | LOA 24.171B27

ASSEMBLY

1. Assembly dimensions
   The dimensions of the burner and boiler connection are according to DIN EN 226 (dimensions in mm), see figure 7.
   

2. Installing the burner

   • Install sliding flange and seal onto the heat generator us-ing the supplied M8 screws. The mounting screw of the sliding flange must be turned upwards.
   • Insert burner with burner pipe into the flange until the burner pipe is flush with the inside of the combustion chamber. Observe special instructions of the heat genera-tor manufacturer, if any.
   • Tighten the mounting screw of the flange clamp. Caution: The flange must be oriented to ensure that the burner is installed with the correct angle (see fig. 6).
   • Install the recirculation tube.

3. Service position
   Loosen the service screw by 1/2 turn using a 4 mm hexagon socket wrench (see fig. 8). Turn the burner to the left and remove it from the burner pipe. Then, place it in the service position (see fig. 9).
   

4. Change of the nozzle

   •  Loosen screw (2) using a 4 mm hexagon socket wrench and remove the baffle plate (1) (see fig. 9).

   • Select a new nozzle according to the required perfor-mance range (see table on page 9).

   • Remove installed nozzle (3) and screw on the selected nozzle (see fig. 9).

   • Check the distance between the baffle plate (1) and the nozzle (3) (see fig. 10).
     Install the baffle plate (1) back in place and tighten the screw (2).
     Caution: The baffle plate and nozzle could be hot!

   • Control and re-adjust the ignition electrodes if necessary (see fig. 10).

   • Bring the burner in operating position and tighten the service screw.

5. Nozzle table
   The oil flow rate specified in the nozzle table refers to a viscosity of the preheated heating oil of approx. 2 mm2/s.

6. Combustion chamber – minimum dimensions
   According to GN 267, low-emission combustion values can only be reached if the combustion chamber minimum dimensions are complied with. Combustion chamber – minimum dimensions

Oil flow rate

|

Diameter resp. height and width

|

Depth from the baffle plate

1.0 – 2.0 kg/h| Ø 225 mm| 250 – 350 mm
2.0 – 6.0 kg/h| Ø 300 mm| 350 – 612 mm

7. Oil supply
   The construction and installation of the system is to be carried out according to DlN 4755. Local regulations are to be observed. The oil line is to be installed to the burner such that the oil hoses can be connected without any constrain. An oil filter with a quick-close valve is to be installed in the connection on the suction side. A return check valve is to be installed in the return flow line. The burner can be operated in a 1 and 2 pipe system. The burner is delivered for a 2-pipe system as standard. The vacuum in the suction line may not exceed 0.4 bar. With a suction height of more than 3.5 m, an oil circulation pump must be installed. With operation with an oil circulation pump or if the oil tank is located higher than the burner pump, the burner must be operated as a 1-pipe system. If the burner is operated as a 1-pipe system, the return flow R must be closed at the burner pump and screw G must be removed (see fig. 11).
   The pressure in the oil line may not exceed 1.5 bar. After complete installation of the oil lines, a leak test must be carried out with a pressure of min. 5 bar according to DlN 4755. The burner may not be connected during the leak test.
   

8. Oil pipes dimensions (see. fig. 12)****  
   Nominal thermal output of the boiler (kW)| ****

25

| ****

35

| ****

45

---|---|---|---
Internal pipe Ø (mm)| 4| 4| 4
*H (m)**| Max. length of the oil piping (m)
0| 30| 30| 20
1| 30| 23| 15
2| 23| 16| 10

• H = max. intake height in m (low sulphur fuel oil EL, oil temperature > 10 °C, up to 700 m above sea level, 1 filter, 1 check valve, 6x 90°bends).

  9. Flexible oil line connection to the burner
     The flexible oil line mounted onto the oil pump can be installed to the left or right side (see fig. 13).
     Caution: Remove the plugs from the flexible oil line. When connecting to the oil filter, pay attention to the arrow marking on the connection end of the hoses.
     

     • 3/8” female connection with coupling.

  10. Electrical connection
      The electrical system is to comply with the relevant CE directives, as well as the requirements of the local power utility company. HS, an all-pole circuit breaker with a min. 3 mm contact gap is to be used as main switch. The connection cable must be wired with a 7-pole Euro-plug (plug component) according to DlN 4791 and in accordance with the wiring diagram. The connection is to be made by plugging together the connection cable with the boiler 7-pole Euro-plug (plug component) and the burner 7-pole Euro-plug (socket component). The burner is delivered with a Euro-plug (socket component) as standard.
      Caution: Check the Euro-plug (plug component) for proper
      

  11. General inspections
      Caution: Before the initial starting up of the burner, the following inspections are to be carried out:
      

      • ls there mains voltage?
      • ls the oil supply correct?
      • Have the caps been removed from the oil hoses and are the oil hoses properly connected?
      • ls the combustion air supply correct?
      • Has the burner been properly installed and are the boiler doors closed?
      •  ls the boiler filled with water?
      • Are the boiler and the exhaust gas duct sealed tight?

INITIAL OPERATION AND MAINTENANCE

For initial operation of the burner, all necessary switches and
controllers must be switched on. lf there is voltage at the burner and oil pre-heater, the green indicator lamp lights up and the heating of the oil pre- heaters begins. The heating up time can last up to 2 minutes. After the target temperature has been reached, the motor starts and the ignition is switched on. After time-out of the preliminary venting time, the solenoid valve opens, the heated oil supply is released, and a flame is formed.

At initial starting up of the burner, if the oil pump does not deliver oil within the safety time, a malfunction shut-off occurs. The burner start-up can be repeated by resetting the automatic oil firing unit. Venting of the oil pump and the oil line system must be carried out via the manometer connection of the oil pump (see fig. 15).

Caution: Do not allow the oil pump to operate without oil.

1. Adjusting the burner
   In order to achieve low-emission combustion values, the burner must be adjusted by measuring the exhaust gas using suitable measuring instruments. The measuring hole (Ø 8 mm) is to be located at a distance of twice the diameter of the exhaust pipe behind the heater and is to be closed after the measurement.
   Caution: The heater and exhaust gas ducts must be sealed tight.
   

2. Chimney draft
   In order to achieve constant combustion chamber pressure, a draft damper must be installed in the exhaust gas line. The draft damper must be installed to ensure that the vacuum in the combustion chamber is not more than 0.1 mbar during operation.
   For overpressure boilers, refer to the boiler operating instructions to adjust the chimney draft.

3. Combustion air
   Each burner has been factory-adjusted with a basic air flow rate, according to the installed nozzle. Depending on the combustion chamber and the nozzle tolerance, the basic factory setting leads to an excess of air and must be re- adjusted in all cases. The required quantity of air is determined from the soot contents and the CO2 measurement. The final adjustment should be performed using the throttle screw.

   • a. Air flap (see. fig.16)
     Turning counter clockwise the air flap set-screw reduces the air flow from the fan. Therefore, the fan pressure measured at the measuring fitting decreases, and the CO2 content in the exhaust gases increases. Turning the set screw clockwise will open the flap and increase the fan pressure, thus reducing the CO2 content in the exhaust gases.

   • Baffle plate (see. fig.16)
     By turning clockwise the baffle plate set-screw, the gap between the burner pipe and baffle plate is re-duced, thus reducing the combustion air volume while increasing fan pressure and the CO2 content of the exhaust gases.
     For reverse direction of rotation, the gap width and thus the combustion air volume increases with de-creasing fan pressure thus decreasing the CO2 con- tent in the exhaust gas.
     Pay attention that the fan pressure is kept between 2,0 – 3,5 mbar. We recommend setting a CO2 content of 12 – 13 vol. %.
     Fan pressure measurement is to be carried out at the pressure measurement fitting (1) (see fig. 17). The soot number may not exceed 0.5 according to the soot number comparison scale.

4. Flame monitoring
   The photo-current is to be measured in series with the photocell (+pole on terminal 12, max. 5 kOhm inner resistance in the instrument) (see fig. 18). The photo-current must be between 55 μA and 100 μA at 230 V~ while in operation.
   Measuring adapter MA 2 (see fig. 18) available on request.

5. Oil pressure
   We recommend setting the oil pressure between 9 – 14 bar, see table on page 9 (see fig. 19).

6. Final and safety tests
   After completion of the exhaust gas measurements, the system must be tested for proper and safe operation of the controller and damper as well as of the automatic oil firing system including safety time.

7. Chimney
   The correct chimney cross-section provides the necessary delivery pressure for proper functioning of the firing system and discharge of the exhaust gases. For the function-related chimney dimensions, the following original values must at least be known:

   • Design and rated heat output of the heater
   • Exhaust gas flow of the heater
   • Exhaust gas temperature at the outlet of the heater
   • CO2 content of the exhaust gas
   • Required delivery pressure for supply air, heater and connection piece
   • Design and length of the connection piece
   • Design of the chimney and effective chimney height The design and version of the chimney are to be de-termined according to DlN 4705 and DlN 18160.

BASIC ADJUSTMENT TABLE

Burner model| Burner Output| Oil mass flow| Oil nozzle| Oil pressure| Fan pressure| Air flap scale [A] fig. 16| Baffle plate scale [B] fig. 16
---|---|---|---|---|---|---|---
kW| kg/h| Usgal/h| ****| bar| mbar| %| mm
BMV3| 25| 2.11| 0.60| 60°H| 10.0| 2.5| 30| 6
BMV4| 32| 2.70| 0.60| 60°H| 14.5| 2.5| 32| 9
BMV5| 43| 3.63| 1.00| 45°H| 12.0| 2.5| 46| 10

ELECTRIC WIRING DIAGRAM : LOA24

A1

BM

| Oil firing unit

Burner motor

| B

Bk

| Blue

Black

---|---|---|---
F1| Fuse max. 6,3 A| Br| Brown
H1| Failure signal| G| Grey
H2| Operation signal| V| Violet
HS| Main switch| W| White
LDS| Photocell| Y/Gr| Yellow / Green
OFV| Oil Pre-heater| |
P1| Operating hours counter| |
TB| Temperature or pressure limiter| |
TR| Temperature or pressure controller| |
TT| Ignition unit| |
V| Magnetic valve| |
X1| Europlug (7 poles)| |

BURNER QUICK SERVICE

TROUBLESHOOTING

1 . Oil firing unit
Error signal lamp is not on| No voltage present

Boiler temperature controller incorrectly adjusted

| Check wiring

Adjust

Error signal lamp on| Oil firing unit switched to malfunction Oil firing unit defective

Incorrect wiring of terminal socket

| Correct malfunction Replace

Check wiring

Check oil pre-heater

2 . Motor
Motor does not start| Defective release thermostat of oil pre-heater Defective capacitor

Stiff bearing

Stiff oil pump

| Replace oil pre-heater Replace capacitor Replace motor

Replace oil pump

Loud noise caused by running motor| Motor defective Bearing defective

Oil pump defective

| Replace motor Replace motor

Replace oil pump

3 . Ignition
No generation of ignition sparks| Ignition unit defective Ignition cable defective Oil firing unit defective

Insulator defective

| Replace ignition unit Replace ignition cable Replace oil firing unit

Replace ignition electrodes

Weak ignition spark| Incorrect position of the ignition electrodes

Ignition electrodes severely contaminated

| Position ignition electrodes

Clean ignition electrodes

4 . Oil pump
Inconsistent oil pressure, loud noise from operating oil pump, no oil pressure is built up| Intake pipe leaking (air entry)

Oil supply not according to the specifications Intake pipe containing air

Oil stop valve closed Coupling defective Oil pump filter dirty

Oil pump drive defective Paraffin sedimentation (+4 °C)

Fuel oil viscous (-1 °C)

| Check oil supply Check oil supply Purge intake pipe Open stop valve Replace coupling

Clean/replace oil pump filter Replace oil pump

Install at a frost-free place

Install at a frost-free place

5 . Magnetic valve
Magnetic valve does not open| Coil of the magnetic valve defective

Oil firing unit defective

| Replace coil of the magnetic valve

Replace oil firing unit

6 . Flame monitoring
Fault shut-down without flame generation| Extraneous light (photocell current

5,5 μA)

Photo conductive cell defective

| Remove extraneous light

Replace photocell

Fault shut-down with flame generation| Photo conductive cell contaminated

Photocell current too weak (photocell current < 55 μA)

| Clean photocell Reset burner
7 . Nozzle
Inconsistent atomisation, high CO and soot emissions| Defective nozzle

Oil pressure not in compliance with specification Diaphragm valve defective

| Replace nozzle Adjust oil pressure

Replace oil pre-heater

8 . Baffle plate
Baffle plate / burner pipe very contaminated| Incorrect burner adjustment Inconsistent atomisation of the nozzle| Adjust burner Replace nozzle

Replace oil pre-heater

Nozzle is dripping| Replace oil pre-heater
Incorrect nozzle type (spraying angle, spraying characteristics, installation size)| Insert nozzle according to specification
9 . Fan
Fan delivers not enough air| Fan wheel contaminated

Fan wheel damaged

| Clean fan wheel

Replace fan wheel

Loud noise during fan operation| Fan wheel incorrectly positioned Fan wheel damaged

Air flap incorrectly installed

| Correctly position fan wheel

Replace fan wheel Correctly install air flap

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