ACV BMV5 Flame Burner Instruction Manual

Instruction Manual for ACV models including: BMV Series, BMV5 Flame Burner, BMV5, Flame Burner, BMV3, BMV4

I , O & M I

en 2 EN FR NL ES IT DE PL RU BMV3 / BMV4 / BMV5: 662Y1000 • C Dear customer, We are pleased that you have decided to purchase an ACV burner. The BMV burner model is a modern generation flame burner.

File Info : application/pdf, 12 Pages, 1.70MB

37d5d95b0d2cf4185fdf1cb2ba220a50

BMV
BMV3 - BMV4 - BMV5
Installation, Operation & Maintenance Instructions

662Y1000 · C

EN FR NL ES IT
Figure 1
DE PL RU
Figure 2 -- BMV3 / BMV4 / BMV5
Figure 3 -- BMV3 / BMV4 en
2

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.

Table of contents

1. Technical data

1.1 Burner performance

1.2 Certification

1.3 Operating range

1.4 Fuel

1.5 Electrical data

1.6 Burner dimensions

1.7 Acoustic emissions

1.8 Burner components

2. Assembly

2.1 Assembly dimensions

2.2 Installing the burner

2.3 Service position

2.4 Change of nozzle

2.5 Nozzle table

2.6 Combustion chamber - minimum dimensions

2.7 Oil supply

2.8 Oil pipes dimensions

2.9 Flexible oil line connection of the burner

2.10 Electrical connection

2.11 General inspections

3. Initial operating and maintenance

3.1 Adjusting burner

3.2 Chimney draft

3.3 Combustion air

3.4 Flame monitoring

3.5 Oil pressure

3.6 Final and safety tests

3.7 Chimney

4. Basic adjustment table

5. Electric wiring diagram : LOA24

6. Burner quick service

7. Troubleshooting

BMV3 / BMV4 / BMV5 : 662Y1000 · C

1. TECHNICAL DATA

1.1.

Burner performance

Type BMV3 BMV4 BMV 5

Oil throughput (kg/h) 1.4 - 4.1 1.4 - 4.1 3.2 - 4.7

Burner output (kW) 16 - 48 16 - 48 38 - 56

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

1.2.

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: Contract no. 14415 (only HL60 E/FLV.2-S)

1.3.

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 testing 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.

1.4.

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)

1.5.

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~

1.6.

Burner dimensions

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

Packing ............................................................................. l 370 / w 350 / h 485 mm

Transport weight..............................................................................................14.5 kg

1.7.

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.

1.8.

Burner components

Item
Motor Oil pump Oil pre-heater Ignition unit Photocell Automatic oil firing unit

Make
Hanning Danfoss Danfoss
Cofi Danfoss Siemens

Ref
O1A095-030 BFP 21 L3 FPHE 5
TRK2-40SHK LDS 057H7097 LOA 24.171B27

EN
0,6
0,5

CombuPsrtieosnsicohna fmobyererpreenssumrbeairn mbar

0,4

BMV5

0,3

BMV3 / BMV4

0,2

0,1

1,0

2,0

3,0

4,0

5,0

6,0

7,0

DOébil imt dases fifloouwl iennkgk/gh/h

Figure 4

Figure 5

Figure 6

BMV3 / BMV4 / BMV5 : 662Y1000 · C

EN FR NL ES
Figure 7
IT DE PL RU

Service screw

Figure 8

1 2

3
spacer ring 2,5 mm

2. ASSEMBLY

2.1.

Assembly dimensions

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

2.2.

Installing the burner

· Install sliding flange and seal onto the heat generator using 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 generator 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.

2.3.

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).

2.4.

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 performance 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.

2.5.

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.

2.6.

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 2.0 - 6.0 kg/h

Ø 225 mm Ø 300 mm

250 - 350 mm 350 - 612 mm

Figure 9
en
4

BMV3 / BMV4 / BMV5 : 662Y1000 · C

Figure 10 One-line system

Pure two-line system

2.7.

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.

2.8.

Oil pipes dimensions (see. fig. 12)

Nominal thermal output of the boiler (kW)

IT
45

Internal pipe Ø (mm)

H* (m)
0 1 2

Max. length of the oil piping (m)
DE

*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).
RU

R
Figure 11

Hmax = 3,5 m

One-line system Figure 12

Pure two-line system

BMV3 / BMV4 / BMV5 : 662Y1000 · C

IT
Figure 13

DE PL RU

Program sequence for firing unit : LOA24

Heat request
Oil pre-heater
Oil pre-heater thermostat Burner motor (Fan / pump) Ignition
Magnet valve
Flame signal

th tprp,tpri
th Heating time of the oil pre-heater tprp Pre-aeration tpri Pre-ignition tpoi Post-ignition ts Safety time

ts tpoi
-- 13 s 13 s 20 s 10 s

Figure 14

2.9. 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.
2.10. 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 wiring.
2.11. 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?
3. 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 startup 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.

Figure 15
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BMV3 / BMV4 / BMV5 : 662Y1000 · C

Figure 16 Figure 17

3.1.

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.

3.2.

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.

3.3.

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 IT
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.

b. Baffle plate (see. fig.16)

· By turning clockwise the baffle plate set-screw, the PL

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 RU

thus the combustion air volume increases with de-

creasing fan pressure thus decreasing the CO2 content 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.

MA 2

3.4.

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 A and 100 A at 230 V~ while in operation. Measuring adapter MA 2 (see fig. 18) available on request.

Figure 18

BMV3 / BMV4 / BMV5 : 662Y1000 · C

IT
Figure 19
DE

Mixing unit

BMV3 / BMV4

BMV5

3.5.

Oil pressure

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

3.6.

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.

3.7.

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 determined according to DlN 4705 and DlN 18160.

Figure 20

BMV3 / BMV4 / BMV5 : 662Y1000 · C

EN
4. BASIC ADJUSTMENT TABLE

Burner model
BMV3 BMV4 BMV5

Burner Output

Oil mass flow

Oil nozzle

kg/h

Usgal/h

2.11

0.60

60°H

2.70

0.60

60°H

3.63

1.00

45°H

Oil pressure
bar 10.0 14.5 12.0

Fan

Air flap scale Baffle plate

pressure [A] fig. 16

scale

[B] fig. 16

mbar

2.5

BMV3 / BMV4 / BMV5 : 662Y1000 · C

W B Br Y/Gr B Bk B Br Y/Gr B Y/Gr Br B Y/Gr Br

EN
5. ELECTRIC WIRING DIAGRAM : LOA24

Siemens LOA24 A1

12 11

3N8

Br B Bk Y/Gr

123 4

LDS

Figure 21
PL

432 1
OFV

13 2
M 1~
BM

4 10 1

V G Bk B Y/Gr

B4 S3 T2 T1 N

L1 X1B

B4 S3 T2 T1 N

X1A
L1

P
TB

P1 H2 H1 TR

HS F1

Connections on boiler

N PE L1

side

1/N, PE 230V 50Hz

A1 Oil firing unit BM Burner motor F1 Fuse max. 6,3 A H1 Failure signal H2 Operation signal HS Main switch LDS Photocell 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)

B Blue Bk Black Br Brown G Grey V Violet W White Y/Gr Yellow / Green

BMV3 / BMV4 / BMV5 : 662Y1000 · C

6. BURNER QUICK SERVICE
Service screw Figure 22 -- Loosening of the service screw
Figure 23 -- Service position

EN
FR
NL
ES
Figure 26 -- Installation position of the air flap
IT
DE
PL
Figure 27 -- Disassembly of the nozzle connection cover
RU

Figure 24 -- Measurement and setting oil pressure

Figure 28 -- Plug connection for motor

Figure 25 -- Disassembly of the oil filter

Figure 29 -- Connection plug for photocell

BMV3 / BMV4 / BMV5 : 662Y1000 · C

EN FR NL

7. TROUBLESHOOTING

Diagnostic

Cause

1 . Oil firing unit Error signal lamp is not on
Error signal lamp on

No voltage present Boiler temperature controller incorrectly adjusted Oil firing unit switched to malfunction Oil firing unit defective Incorrect wiring of terminal socket

ES IT DE PL RU

2 . Motor

Motor does not start

Defective release thermostat of oil pre-heater Defective capacitor

Stiff bearing

Stiff oil pump

Loud noise caused by running motor Motor defective Bearing defective

Oil pump defective

3 . Ignition

No generation of ignition sparks

Ignition unit defective Ignition cable defective

Oil firing unit defective

Insulator defective

Weak ignition spark

Incorrect position of the ignition electrodes Ignition electrodes severely contaminated

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)

5 . Magnetic valve

Magnetic valve does not open

Coil of the magnetic valve defective Oil firing unit defective

6 . Flame monitoring

Fault shut-down without flame generation

Extraneous light (photocell current >5,5 A) Photo conductive cell defective

Fault shut-down with flame generation Photo conductive cell contaminated Photocell current too weak (photocell current < 55 A)

7 . Nozzle

Inconsistent atomisation, high CO and soot emissions

Defective nozzle Oil pressure not in compliance with specification

Diaphragm valve defective

8 . Baffle plate

Baffle plate / burner pipe very contaminated

Incorrect burner adjustment Inconsistent atomisation of the nozzle

9 . Fan Fan delivers not enough air
Loud noise during fan operation

Nozzle is dripping Incorrect nozzle type (spraying angle, spraying characteristics, installation size)
Fan wheel contaminated Fan wheel damaged Fan wheel incorrectly positioned Fan wheel damaged Air flap incorrectly installed

Remedy
Check wiring Adjust Correct malfunction Replace Check wiring Check oil pre-heater
Replace oil pre-heater Replace capacitor Replace motor Replace oil pump Replace motor Replace motor Replace oil pump
Replace ignition unit Replace ignition cable Replace oil firing unit Replace ignition electrodes Position ignition electrodes Clean ignition electrodes
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
Replace coil of the magnetic valve Replace oil firing unit
Remove extraneous light Replace photocell Clean photocell Reset burner
Replace nozzle Adjust oil pressure Replace oil pre-heater
Adjust burner Replace nozzle Replace oil pre-heater Replace oil pre-heater Insert nozzle according to specification
Clean fan wheel Replace fan wheel Correctly position fan wheel Replace fan wheel Correctly install air flap

BMV3 / BMV4 / BMV5 : 662Y1000 · C

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