Equipments Bmm Heaters Direct Fired Manual

7/28/2019 Equipments Bmm Heaters Direct Fired Manual

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BMM Heaters Ltd

INSTALLATION,

OPERATION and

MAINTENANCE MANUAL

BMM Heaters Ltd

1 Copeland courtRiverside Park

Middlesbrough

TS2 1RN



Heater Models:

BMGD Ducted Direct fired

BMGHD Horizontal Direct fired

BMGND Ducted Nozzle Direct Fired

BMGDD Downward discharge Direct Fired

BMGED External Direct Fired



TABLE OF CONTENTS

1 TECHNICAL DATA ....................................................................................................... 5

1.1 Specification...............................................................................................5

1.2 Utilities .......................................................................................................6

1.3 Settings (As shipped).................................................................................7

Process and Instrumentation Diagram

General Arrangement

Wiring Diagram

2 GENERAL DESCRIPTION ............................................................................................ 8

2.1 Introduction................................................................................................8

2.2 Gas Burner Assembly................................................................................8

2.3 Control System .......................................................................................... 8

2.3.1 Safety Controls......................................................................8

2.3.2 Temperature Control System ................................................9

2.3.3 Main Control Panel................................................................9

2.3.4 Fuel Gas System...................................................................9

2.3.5 Remote Control Station.......................................................10

2.3.6 Heated Space Temperature Sensor....................................10

3 INSTALLATION........................................................................................................... 11

3.1 Statutory Requirements ...........................................................................11

3.2 Reception and Storage of Goods ............................................................11

3.2.1 Reception ............................................................................11

3.2.2 Off Loading..........................................................................11

3.2.3 Storage................................................................................12

3.3 Limitations of Use ....................................................................................12

3.4 Location of Heaters..................................................................................12

3.5 Fresh Air Inlet and Ventilation..................................................................13

3.5.1 Fresh Air Inlet ......................................................................13

3.5.2 Ventilation............................................................................14

3.6 Air Discharge ...........................................................................................14

3.7 Recirculation Air Entry .............................................................................14

3.8 Remote Station ........................................................................................15

3.9 Visual Check............................................................................................ 15

3.10 Connection of Services............................................................................15

3.10.1 Fuel Gas Supply..................................................................15

3.10.2 Electricity Supply .................................................................16

3.11 Connection to the Main Panel and Remote Station.................................16

3.12 Heated Space Temperature Sensor........................................................ 16

3.13 Duct Sensor .............................................................................................16

3.14 Overheat Limit Control Sensor ................................................................16

3.15 Outside Air Sensor...................................................................................17

3.16 Transit Brackets.......................................................................................17



TABLE OF CONTENTS

3.17 Alignment .................................................................................................18

3.17.1 Installation of Drive Belts.....................................................18

3.17.2 Pulleys.................................................................................18

3.17.3 Alignment.............................................................................18

3.17.4 Belts.....................................................................................18

3.17.5 Installation and Take Up Allowance....................................19

4 COMMISSIONING ...................................................................................................... 20

4.1 Pre-start Checks ......................................................................................20

4.2 Dry Run....................................................................................................21

4.3 Start Up....................................................................................................21

4.3.1 Flame Signal Check ............................................................22

4.3.2 Handover.............................................................................22

5 ADJUSTMENTS .......................................................................................................... 23

5.1 Pilot Adjustment.......................................................................................23

5.2 Burner High Fire Pressure Adjustment....................................................23

5.3 Burner Low Fire Adjustment ....................................................................23

5.4 SUMMER/OFF/WINTER Switch..............................................................24

5.5 RESET Button..........................................................................................24

5.6 Soft Start (If fitted)....................................................................................24

5.7 Post Purge (if fitted) .................................................................................24

6 OPERATING INSTRUCTIONS....................................................................................25

6.1 Heater Start-up ........................................................................................25

6.2 Heater Shut-down....................................................................................25

6.2.1 Shutdown For Short Periods ...............................................25

6.2.2 Shutdown For Prolonged Periods .......................................25

6.3 General Instructions.................................................................................26

6.3.1 Site Clearance Adjacent to Heater......................................26

6.3.2 Air Supply to Heater ............................................................26

6.3.3 Air Filters .............................................................................26

6.3.4 Service.................................................................................26

6.3.5 Spare Parts..........................................................................26

6.3.6 Gas Leaks ...........................................................................26

7 FAULT FINDING.......................................................................................................... 27

7.1 POWER ON light is unlit ..........................................................................27

7.2 AIR FAN ON light is unlit ........................................................................28

7.3 LOCKOUT light is illuminated..................................................................29

7.4 Fan not Operating ....................................................................................29

7.5 Fan Operating..........................................................................................30



TABLE OF CONTENTS

8 SERVICING ................................................................................................................. 31

8.1 Isolation....................................................................................................31

8.1.1 Fuel Gas Isolation................................................................31

8.1.2 Electrical Isolation................................................................31

8.2 Routine Maintenance...............................................................................32

8.3 Annual Service Checks............................................................................32

8.4 Removal Procedure For Replaceable Components ................................33

8.4.1 Burner..................................................................................33

8.4.2 Flame Detector....................................................................33

8.4.3 Igniter Spark Plug................................................................33

8.4.4 Igniter Spark Transformer ...................................................34

8.4.5 Combustion Air Pressure Switch (DPS).............................. 34

8.4.6 Heater Overheat Limit Control.............................................34

8.4.7 Air Fan and Motor................................................................35

8.4.8 Fuel Gas Multi-functional Control - Small Units ..................35

8.4.9 Governor and Block Valves.................................................35

8.4.10 Fuel Gas Flow Control Valve...............................................36

8.4.11 Pilot Gas Governor and Block Valve...................................36

8.4.12 Belt Tensioning Procedure ..................................................37

8.5 Main Panel Controls.................................................................................39

8.5.1 Landis & Gyr LFL1.335 Automatic Sequence Controller ....39

8.5.2 Controls Circuit (24 Volt) Transformer.................................39

8.5.3 Controls Relays, R1, R2 & R3.............................................39

8.5.4 6A MCB ...............................................................................398.5.5 Thermal Overload................................................................39

8.5.6 Main Contactor ....................................................................40

8.5.7 Motor Fuse ..........................................................................40

8.6 Remote Control Station ...........................................................................40

9 RECOMMENDED SPARES ........................................................................................ 41



TABLE OF CONTENTS

APPENDIX 1

SOUNDNESS TESTING THE FUEL GAS LINE ...............................................42

A1.1 Testing the Upstream Pipework and Burner Controls......... 42

A1.2 Testing the Downstream Burner Valve................................43

A1.3 Testing the Downstream Burner Pipework..........................43

A1.4 Testing the Downstream Pilot Pipework .............................43

A1.5 Testing the Burner Connections..........................................44

APPENDIX 2

START SEQUENCE..........................................................................................45

APPENDIX 3

SERVICE CHECK SHEET.................................................................................49

APPENDIX 5

SERVICE CONTRACT OFFER



BMM HEATER LTD1 Copeland Court

Riverside Park

Middlesbrough

TS2 1RN

MODEL No. SERIAL No.

GAD MARKPRODUCTCATEGORY

GAS TYPEPRODUCTID No.

GROSS HEATINPUT MAX

Kw MIN kW

HEAT OUTPUT

MAX kW MIN kW

HEAT INPUT (MAX RECIRC. COND.) ** kW

MAX GAS SUPPLY PRESSURE mbar

PILOT BURNER PRESSURE mbar

MAIN BURNER PRESSURE mbar

SUPPLY VOLTAGE

STARTINGCURRENT

RUNCURRENT

MCB RATING WEIGHT

COUNTRY OF DESTINATION

WARNINGTHIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS

AND THE REGULATIONS IN FORCE, AND ONLY USED IN A SUITABLY VENTILATED LOCATION.READ MANUFACTURER'S INSTRUCTIONS BEFORE INSTALLING OR USING THIS APPLIANCE.





1.2 UTILITIES

HEATER UTILITIES

FUEL

MAXIMUM FUEL SUPPLY PRESSURE

MINIMUM FUEL SUPPLY PRESSURE

ELECTRIC SUPPLY TO CONTROL PANEL WITHNEUTRAL WIRE

SUPPLY RATING (MUST BE MOTOR RATED)

MOTOR MCB



1.3 SETTINGS (AS SHIPPED)

HEATER SETTINGS (AS SHIPPED)

AIR PRESSURE SWITCH

OVERHEAT LIMIT CONTROL

PILOT BURNER GAS PRESSURE

MAXIMUMMAIN BURNER GAS PRESSURES

MINIMUM

MAXIMUM AT RECIRCULATION CONDITION

OVERLOAD

FAN SPEED

MAXIMUMDIFFERENTIAL AIR PRESSURE ACROSS PROFILEPLATE MINIMUM

GAS CONNECTION SIZE

TEMPERATURE CONTROLLER

ACCESS CODE

TEMPERATURE SETPOINT

SAMPLE INTERVAL

DISCHARGE LOW LIMIT

DISCHARGE HIGH LIMIT

Note: For Heater dimensions, please refer to the General Arrangement Drawing.



2 GENERAL DESCRIPTION

2.1 INTRODUCTION

The BMM air heater is a direct fired unit designed to give clean, healthy environmental

conditions and constant even temperature within the heated space.

The main Heater assembly houses the circulating air fan, the gas burner, the fuel gas lineand all necessary safety controls. The burner management system and spacetemperature controller are located in the main control panel mounted on or adjacent tothe side of the Heater. A second control station, supplied loose for mounting remote fromthe Heater within the heated space or other convenient location, houses indicating lights,the control touch screen* and auxiliary operational switches.

A sight glass is fitted on the Heater casing to view the burner during operation.

* For multi unit networked applications, the touch screen is excluded.

2.2 GAS BURNER ASSEMBLY

The BMM Heater incorporates the Maxon NP-II burner. This burner is specially designedfor heating fresh air and is mounted such that a proportion of the incoming air is forcedinto contact with the flame to ensure rapid mixing and combustion within the coderequirements. The burner assembly is built up from modular components to give therequired heat duty.

Each burner assembly is fitted with an integral pilot, spark igniter and UV detector. Theflame detector is used for scanning both the pilot and main flame. Note that the pilot

burner operates in interrupted mode.

The burner module fitted is identified in the Technical Data Section of this manual, and onthe Valve and Instrument list.

2.3 CONTROL SYSTEM

The controls fitted on the Heater are detailed on the Process & Instrumentation Diagramin the Technical Data Section of this manual.

2.3.1 SAFETY CONTROLS

The safety interlocks on the BMM Heater are:

1 Combustion air proving switch (PS)2 Ultra-violet burner flame detector (UV)3 Overheat limit control (OLC)

Failure of either the combustion air switch or flame scanning circuit will cause the Heater to go to LOCKOUT and the burner management system will require a RESET before are-light can be attempted.

The Heater discharge overheat limit control is a manual reset switch. After a failure theswitch will have to be RESET before a re-light can be attempted.




2.3.2 TEMPERATURE CONTROL SYSTEM

The BMM Heater can be fitted with a modulating temperature control system. The space

temperature is sensed by a heated space detector, which inputs to the panel mountedtemperature controller. This achieves control by modulation of the fuel gas flow controlvalve (MV5). The temperature controller additionally limits the Heater air temperature, topre-set high and low limits.

2.3.3 MAIN CONTROL PANEL (If Supplied)

The control panel houses the combustion/circulation air fan starter, the burner management system and the heated space temperature controller. On larger units, aseparate starter panel may be supplied. The panel door is fitted with an interlockedisolator, POWER ON, and LOCKOUT lights and the burner management RESET button.The panel is mounted on or adjacent to the Heater.

2.3.4 FUEL GAS SYSTEM

The PILOT LINE comprises:1 Pilot governor (PV1)2 One British Gas certificated solenoid valve (PV2)3 One pilot gas isolation valve (PV3)4 Pipework and fittings

Note: Two pressure test points are fitted on the pilot line on the inlet and

discharge of the pilot solenoid valve.

The MAIN GAS LINE comprises:

1 Gas isolation valve (MV1)2 Pressure governor (MV2)3 Double block safety shut-off system (MV3/4)4 Gas flow control valve (MV5)5 Burner isolation valve (MV6)6 Pipework and fittings

Note: Four pressure test points are fitted on the main gas line; on the supply, theinlet and discharge of the second block valve and downstream of the flow controlvalve.

Note: On small Heaters items 2 and 3 are combined in one multi-functionalcontrol.

All items above are detailed on the Process & Instrumentation Diagram in Section1 of this manual.




2.3.5 REMOTE CONTROL STATION (If Supplied)

The BMM Heater can also be supplied with a remote control station, which houses the

Heater operating controls, indicating status and the workspace temperature detector if thecontrol station is located in the heated space.

2.3.6 HEATED SPACE TEMPERATURE SENSOR (If Supplied)

The heated space temperature sensor is to be located remotely within the space to beheated.



3 INSTALLATION

3.1 STATUTORY REQUIREMENTS

In accordance with the Gas Safety (Installation and Use) Regulations 1984, installation

of this BMM Heater should only be undertaken by competent personnel who are fullyaware of their responsibilities under the Health and Safety at Work Act 1974.

The installation of this Heater must comply with:

BS6230-1991, Installation of gas-fired forced convection Heaters for commercial andindustrial Space Heating of rated input exceeding 60kW.

The IEE Regulations for Electrical Installations

Gas Safety (Installation and Use) Regulations 1998

Health and Safety at Work Act 1974

Building Regulations 1986

Building Standards (Scotland Only)

The Institution of Gas Engineers Codes of Practice:

IGE/UP/1 Soundness Testing Procedures for Industrial and Commercial GasInstallations.

IGE/UP/2 Gas Installation Pipework, Boosters and Compressors on Industrialand Commercial Premises.

IGE/UP/4 Commissioning Of Gas Fired Plant On Industrial and CommercialPremises

3.2 RECEPTION AND STORAGE OF GOODS

3.2.1 RECEPTION

On receipt of the shipment check that the shipment is complete against the Delivery Advice Note. Check for mechanical damage sustained during transit before off-loadingthe goods. Inform the carrier of any such damage.

3.2.2 OFFLOADING

Heaters are supplied in modular form with flanged connections between each module.Lifting should be either by hand or by eyebolts connected to the flange corner holes. Alternatively, Heaters may be handled by a fork lift truck if supported from flange toflange and the module casing does not rest on the fork lift tines.

Note: The fan and motor sections will always be delivered to site pre-assembled and in the orientation in which they are to be installed. They shouldalways be handled in this orientation.



3 INSTALLATION

3.2.3 STORAGE

Heaters must be stored in a dry environment. Outdoor Heaters must be treated with arust inhibiting product on all external surfaces after installation (Rustban

recommended). This should be applied in uniformed strokes with either a brush or roller to ensure even coverage.

3.3 LIMITATIONS OF USE

The BMM Heater must not be installed in the following locations:

In hazardous areas

In areas where flammable vapours can be present in excess of their threshold limitvalues, as defined in BS5925.

In accordance with BS6230, Clause 5.1.3, where there are any flued appliances in theheated area, and where air is supplied mechanically and there is mechanicalextraction, the design extract rate must be 5% to 10% less than the design inlet rate sothat the room will not be at a lower pressure than the outside air. If the Heater is theonly source of mechanically supplied air, the extract rate must not exceed 95% of thenominal air flow specified in Section 1.1 of this manual.

Note: If it proposed to install the BMM Heater to supply heated air to ahazardous area or in areas where flammable vapours are present, theinstallation must first be approved by BMM Heaters Ltd.

3.4 LOCATION OF HEATERS

The Heater should normally be installed in the location recommended by the BMMHeaters.

Check the proposed location for level and load bearing strength. Ensure that there isadequate clearance, as detailed on the Heater GA in Section 1 this manual, aroundthe unit for access for maintenance purposes. If the Heater is to be installed abovefloor level, a suitably designed service platform should be provided. Such a platformmust have 100mm minimum raised edges around the perimeter. If this is not possible,

all Heater access panels must be fitted with hinged restraints. This is a factorystandard option which should be specified at the time of ordering - check the restraintsare fitted before proceeding with installation.



3 INSTALLATION

3.5 FRESH AIR INLET AND VENTILATION

3.5.1 FRESH AIR INLET

The Heater must be installed where it has a direct and unlimited supply of fresh air from outside the building. Ensure that the air intake is not located near exhausts fromthe building or from any process exhausts such as paint booth exhausts. Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects fromcorners.

The fresh air inlet should be sized for an air velocity of 3m/s. The inlet duct area isdetailed on the General Arrangement drawing located in Section 1 of this manual.

Where the fresh air inlet is made in a load bearing wall, e.g. a brick wall, guidanceshould be obtained from Structural Engineers on the provision of a lintel in the wallover the fresh air opening.

A weather hood must be fitted when the Heater air inlet is at or within 1m of theoutside wall. Additionally the weather hood should have negligible resistance to theairflow, maximum 0.1 mbar at the design air flow rate.

Do not install the BMM Heater where long lengths of duct or bends of an angle greater than 30° are necessary to lead to the Heater from the fresh air opening. If ducting isunavoidable, ensure that the resulting pressure drop is negligible, i.e. less than 0.1mbar for ductless Heaters, and has been accounted for in the original design for ducted Heaters, as detailed in the specification section of this manual, Section 1.1.

Note: If the air intake is located in an area of unrestricted access, warning

notices preventing the blockage of the air intake by temporary stacking shouldbe displayed adjacent to the intake.



3 INSTALLATION

3.5.2 VENTILATION

Where the Heater is in its own plant room or compartment, this shall be ventilated withopenings communicating directly with the outside air to ventilate the room.

The openings shall be fitted with grilles of negligible resistance and shall be sited sothat they cannot easily be blocked or flooded. They shall have a total minimum freearea as follows:

Low Level (inlet): 320cm2

+ 2.7cm2

per kilowatt in excess of 60kW total ratedinput.

High Level (outlet): 160cm2

+ 1.34cm2

per kilowatt in excess of 60kW total ratedinput.

The free area of the grilles shall be not less than the size of the recommendedminimum ventilation opening. Grilles shall be designed to minimise high velocity air

streams in the plant room. For exposed, i.e. free standing plant rooms, ventilationopenings shall be provided on at least two sides, and preferably on all four sides.

Where mechanical ventilation is used, it shall be by mechanical inlet and either naturalor mechanical extraction. Systems of ventilation employing mechanical extraction andnatural air inlet shall not be used.

The minimum flow rates of air supplied shall be not less than 0.6 m3/s per megawatt of

rated heat input.

3.6 AIR DISCHARGEThe Heater should be located with the air discharge into the heated space at aminimum height of 3 metres. The air should not discharge directly onto anyobstructions, and direct discharge on to working personnel should be avoided.

If the air discharge is located in an area of unrestricted access, warning noticespreventing the blockage of the air discharge by temporary stacking should bedisplayed adjacent to the discharge.

Generally it is not necessary to fit distribution ducting to the discharge of the Heater. If ducting is required or specified ensure that the resulting pressure drop has beenaccounted for in the original design specification, as detailed in Section 1 of this

manual.

3.7 ASSEMBLY AND POSITIONING OF HEATER

Unless specified at the time of order Heaters will be shipped in sections. Dischargeheads, grilles, attenuators, duct connecting sections, filters, rain-hoods etc., will besupplied loose for site fitting to the Heater.

Horizontal Heaters must be supported on their steel angle support base. When theHeater is located check for level and adjust as necessary.



3 INSTALLATION

3.8 REMOTE STATION

The BMM Heater can be supplied with a remote control station. This should be

mounted in a position convenient to the end user, generally within 20 metres of themain control panel position.

3.9 VISUAL CHECK

After completion of installation re-check the Heater for signs of damage. Report anyinstance to Rapid.

3.10 CONNECTION OF SERVICES

The Heater requires the connection of fuel gas and electricity.

3.10.1 FUEL GAS SUPPLY

The BMM Heater has been designed for use on Natural Gas. An alternative version isavailable for LPG. The gas type for the Heater supplied is clearly marked on theHeater data badge and on the Specification sheet in Section 1 of this manual. Checkthe gas type is correct and that the supply pressure is within the range marked on thespecification.

The local gas Authority should be consulted about the adequacy of the gas service

and meter supplies for existing and proposed extensions to the installation and for anyrequirements for boosting the gas supply.

Connect the fuel gas supply to the inlet manual valve on the Heater gas train. Theconnection size is detailed in Section 1 of this manual. A further isolation valve andunion should be fitted immediately adjacent to the appliance which, when the valve isclosed, allows the complete burner and control assembly to be disconnected for maintenance or repair.

New gas pipework should be installed to British Gas Publication IM16 and be purgedand pressure tested in accordance with British Gas Publications IM2 and IM5.



3 INSTALLATION

3.10.2 ELECTRICITY SUPPLY

All external wiring shall be carried out and checked by a competent person. Allcomponents shall be checked for suitability for voltage range and frequency.

Means for electric isolation, having a contact separation of at least 3mm in all poles,must be provided adjacent to the Heater. The electrical supply to the appliance shallincorporate suitable means of excess current protection.

The BMM Heater requires a motor rated 3 phase 4 wire supply, which should beconnected to the main control panel. Check the Heater data badge for the correctelectrical supply. The maximum supply requirement is Specified in Section 1 of thismanual. Note that the 240 Volt Heater control circuit is taken from the 'U' phase toNeutral. Connection should be made as shown on the wiring diagram shipped insidethis panel.

The Heater must be earthed in accordance with BS5986 and CP1013.Check all terminal strip terminations for wires which have become loose duringshipment.

3.11 CONNECTION TO THE MAIN PANEL AND REMOTE STATION

Interconnecting wiring between the main panel and remote digital screen should bemade with the six (6) core data cable provided. The remote digital screen should bemounted at a height of approx. 1.8m.

Only the main panel must be earthed in accordance with BS5986 and CP1013.

3.12 HEATED SPACE TEMPERATURE SENSOR

The space temperature sensor located on the remote panel should be connected withscreened cable or twin low voltage signal cable, run in its own separate conduit. Itshould be mounted adjacent to the outlet at a height of approx. 1.8m. If possible, itshould not be mounted on an external wall or where the sensor will be affected by colddraughts or a local source of heat.

3.13 DUCT SENSOR

The duct sensor should be connected with screened cable or twin low voltage signalcable run in its own separate conduit. It should be mounted in the Heater discharge atno more than 1.5 metres from the fan outlet.

3.14 OVERHEAT LIMIT CONTROL SENSOR

The overheat limit control sensor should be connected with twin core cable. It shouldbe mounted in the Heater discharge at no more than 1.5 metres from the fan outlet.



3 INSTALLATION

3.15 OUTSIDE SENSOR

The outside sensor should be connected with screened cable or twin low voltage

signal cable run in its own separate conduit. It should be mounted either in the inletside of the unit inlet ducting or a north facing wall away from direct sunlight.

3.16 TRANSIT BRACKETS

The Heater is shipped with restraining brackets holding the fan/motor frame sub-assembly rigidly to the Heater casing. Prior to start-up these brackets must beremoved. Failure to do so will result in excessive noise generation.



3 INSTALLATION

3.17 ALIGNMENT

3.17.1 INSTALLATION OF DRIVE BELTS

1 On BMM Heaters, it will be necessary to align the pulleys and fit the drive belts before carryingout commissioning of the unit.

3.17.2 PULLEYS

1 Before assembling the drive, check the pulley grooves are free from scores or sharp edges, andall dimensions conform to the relevant standard.

2 The Taper Lock bush is your starting point when it comes to assembly and installation. Driveinstallation is a straightforward job with Taper Lock - but the stages set out on the installationleaflet provided with every Taper Lock bush should be followed closely.

3.17.3 ALIGNMENT

1 Good alignment of pulleys prior to belt installation is important to avoid belt flank wear. Thediagram below shows correct installation of pulleys.

3.17.4 BELTS

1 When the pulleys have been correctly positioned on the shafts, the belts can be installed tocomplete the drive.

2 The drive centre distance should be reduced prior to the installation of the belts so that they maybe fitted without the use of force. Under no circumstances must belts be prised into the grooves.Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulleygrooves.

3 The installation allowance given in the table below is the minimum recommended reduction incentre distance for various belt section and lengths to allow for correct fitting.

4 The take-up allowance given in the same table should be added on to the calculated centredistance to allow for belt stretch.



3 INSTALLATION

3.17.5 INSTALLATION AND TAKE UP ALLOWANCE

Installation Allowance.Belt PitchLength (mm)

SPZ SPA SPB SPC

Take-Up(mm)

410 to 530 5

540 to 840 10

850 to 1160 15

1170 to 1500 20

1510 to 1830 20 25

1840 to 2170 30

2180 to 2830 25 40

2840 to 3500 30 50

3520 to 4160 50 60

4170 to 5140 70

5220 to 6150 85

6180 to 7500 105

7600 to 8500 125

8880 to 10170 145

10600 to 12500 175



4 COMMISSIONING

This appliance must be commissioned by a BMM. approved engineer.

4.1 PRESTART CHECKS

1 Switch the SUMMER/OFF/WINTER switch on the remote station to OFF.

2 Check the correct electric supply is available to the Heater and the appliance isolator installed.

3 Check the correct fuel gas supply is available to the Heater and local isolation valve and unioninstalled. Check that new gas pipe work has been correctly purged and pressure tested and that theisolation valve is in the OFF position.

4 Check the Heater gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual.

5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix3).

6 Close the Heater access door.

7 Close and lock the main Heater control panel.

8 Switch the main panel isolator to position 1. Check the POWER ON light illuminates.

9 Check and set the timed ON/OFF periods in the IAC Controller located on the remote panel. Ensurethat the unit is set to be on during testing. Refer to Appendix 4 for the IAC setting procedure.

10 Close and lock the remote panel.

11 Switch the SUMMER/OFF/WINTER switch on the remote station to SUMMER to start the air fan.Return the switch to the OFF position and check for correct rotation of the fan as the fan slows andstops.

The fan rotation can be observed through the fan section access door or through the Heater accessdoor. Only do this during the fan run-down period. Ensure the door is securely fastened after completion.

Rotation arrows are fitted on the end of the Heater and inside the Heater above the interior bearingsupport. If the rotation is incorrect, two phases should be interchanged, as dictated by the Engineer responsible for the site electrical system.

12 Check the air pressure drop across the burner whilst the fan is operating with a water columnpressure gauge connected to the two pressure test points on the air pressure switch (DPS). Thispressure should be between 1.4 and 1.6 mbar.

If the air differential pressure measured above is not within the operating range, check inlet andoutlet ductwork as appropriate, and any filters fitted. If the pressure differential is still not within

limits, isolate the Heater and report to BMM. before proceeding.

13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal intothe switch. Check the break point on the switch is 1 mbar (falling).

Note: The switch is set and sealed before fitting. The 1 mbar switch point may not coincide with the1 mbar scale reading on the switch.

If, on checking, the switch is not operating correctly, do not tamper with it; return it to BMM. for replacement.



4 COMMISSIONING

4.2 DRY RUN

With all the manual gas isolation valves still in the OFF position, switch the

SUMMER/OFF/WINTER switch to WINTER.

4.3 START UP

1 Attach a manometer to pressure test point F and the low pressure test point on the air pressureswitch (DPS).

2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3). Leave the mainburner isolation valve (MV6) closed. Reset the Heater by pressing the push-button marked RESET on either the main panel or remote station. The Heater pilot will light automatically (after theautomatic damper start check and combustion air pre-purge) and then LOCKOUT after the maingas shut-off valves are addressed.

During the short period that the pilot is in operation, check the pilot gas pressure on the manometer.It should be 10 mbar and the pilot flame approximately 100 - 150mm in length, covering the firstthree or four holes of the mixing plate and have a steady blue colour when viewed through the sightglass on the access side of the Heater. Adjust as necessary - refer to Section 5.1 this manual.Check the flame signal - refer to Section 4.3.1.

3 Open the main burner isolation valve (MV6). RESET the Heater which should now light to mainburner stage. When alight, close the main burner isolation valve to shut down the gas flow to theburner. Check that the unit goes to LOCKOUT.

4 Reset the Heater and drive the burner to low fire by adjusting the temperature controller set point,as described in Appendix 4 of this manual. Check the flame is continuous across the width of the

burner and has a flame length of approx. 50 - 65mm from the burner rail when viewed through thesight glass on the access side of the Heater. Check the burner pressure across pressure test pointD and the downstream (low) pressure test point on the air pressure switch, i.e. on the rear of thepressure switch. This pressure is specified in Section 1 of this manual. Adjust as necessary - refer to Section 5.3 of this manual. Check the flame signal - refer to Section 4.3.1.

Where possible, check the actual gas flow rate by meter reading with all other appliances turned off.

5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55°C,as described in Appendix 4 of this manual. Check the flame is continuous across the burner rail andhas a flame length of approximately 250 - 350mm from the burner rail. Check the burner pressureacross pressure test point D and the downstream (low) pressure test point on the air pressureswitch. This pressure is specified in Section 1 of this manual. Adjust as necessary - refer to Section5.2 of this manual. Check the maximum Heater discharge temperature. Check the flame signal -refer to Section 4.3.1.

Where possible check the actual gas flow rate by meter reading with all other appliances turned off.

6 Check the operation of the overheat limit control by adjusting the temperature controller set pointand high limit to 65°C, as described in Appendix 4 of this manual. Monitor the dischargetemperature on the temperature controller. Check that the overheat control operates as the settemperature is passed. Check that the control must be manually reset by pressing the green resetbutton on the front of the switch. Return the temperature controller to its original settings.

In the event that the ambient temperature is too low for this simple procedure to work, theinstrument will have to be bench tested using a Temperature Bath. Remove and replace the control,as Section 8.4 of this manual, for bench-testing.



4 COMMISSIONING

4.3 1 FLAME SIGNAL CHECK

1 The BMM Heater is fitted with a Test Terminal which can be used to measure the flame scanningsignal. Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points withstandard 2.3 mm test plugs, with the positive lead on the detector side. Disconnect the terminal linkto obtain the signal reading. A minimum signal of 70 microamps is required; typical signals are inthe 250-400 microamp range on both pilot and main flame. After completion, replace the terminallink and remove the test jacks.

2 Drive the burner to high fire as previously described. Measure the carbon dioxide content of thedischarge air stream. This figure must not exceed 2800 ppm. If the discharge exceeds this limit,isolate the Heater and report to BMM. before proceeding.

3 Stop and start the Heater a few times to check for reliability, using the Operating Instructions,(Section 6).

4.3.2 HANDOVER

Complete the Heater Service Check Sheet supplied at the back of this manual. The self-copy sheet must be returned to BMM for checking.

Instruct the User in efficient use and care of the unit, start-up and shutdown (includingemergency shutdown) and recommended service interval. Emphasise the need to keepthe Heater clear of stored items and extraneous material and to maintain the recirculationand fresh air paths to the Heater inlets. Hand all instructions, as applicable, to theUser/Owner for safe keeping.



5 ADJUSTMENTS

If adjustments to the Heater settings are required they should be made by a BMM.approved engineer.

The normal value for all control settings is specified in Section 1 of this manual.

5.1 PILOT ADJUSTMENT

The pilot gas pressure and flame length may be adjusted by altering the dischargepressure of the pilot governor. Screwing the adjusting screw clockwise (located under thetop cap) increases the discharge pressure and the flame length; anti-clockwise decreasesthe pressure and the flame length.

5.2 BURNER HIGH FIRE PRESSURE ADJUSTMENT

At high fire, alter the spring compression on the main burner governor (MV2) by removingthe cap and adjust the spring compression plate; clockwise to increase the burner pressure, anti-clockwise to decrease burner pressure. If the pressure does not increaseon adjusting the spring, the supply is inadequate.

Note: On small Heaters fitted with a multi-functional control, the pressure adjusting screwis located under a swing cap on the first block valve.

5.3 BURNER LOW FIRE ADJUSTMENT

The main burner low fire is adjusted on the flow control valve, MV5 (Process &Instrumentation Diagram).

Remove the top cover of the valve and insert a Terminal Screwdriver in the adjustingscrew of the TOP cam, marked NI.

Drive the burner to low fire by adjusting the temperature controller set-point and high limitto 05°C, as described in Appendix 4 of this manual.

Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow; anti-clockwiseto increase the flow.

Adjust the heated space temperature setpoint (code 00) and low limit (code 02) to 0°C todrive the valve to the minimum position.

Check the heat input and flame signal at the new position are satisfactory and return thetemperature controller to its normal settings.

Replace the control valve cover.



5 ADJUSTMENTS

5.4 SUMMER/OFF/WINTER SWITCH

In the SUMMER position this switch provides ventilation only and is independent of the

programmed ON and OFF periods. This position is manually selected and must bemanually de-selected. Whenever the switch is in this position, the fan is operating.

In the OFF position the Heater is shutdown and will not operate. This overrides any frostprotection fitted. It is suitable for Heater shutdown for short periods such as holidays. Theprogramme memory is unaffected by this switch and assumes control of the Heater whenthe switch is returned to the WINTER position.

In the WINTER position the Heater operates off the programme memory to provideheating.

5.5 RESET BUTTON

Visual indication of Heater lockout is provided. In the event of lockout occurring, theHeater can be reset by depressing the RESET button. This parallels the RESET buttonon the Heater main control panel. If, after 4 attempts to reset the Heater, the lockoutindicator still illuminates, then a Service Engineer should be called to investigate theproblem.

5.6 SOFT START (If fitted)

The Soft Start facility provides a period of gentle heating prior to raising the building to setpoint temperature. The purpose of this is to avoid thermal shock to the building fabric andcontents by raising temperature in a gradual manner. The period of gentle heating iscontrolled by a timer T1, located on the IAC Touch Screen. The period set for Soft Startcan be adjusted by means of the setpoint measured in seconds. Note that the time set for Soft Start is included in any programmed ON period. Due allowance should be made for this when programming the timeclock.

The Soft Start period is as shown in Section 1.3.

5.7 POST PURGE (If fitted)

The Post Purge facility provides outside ventilation at the termination of a programmedON period so that the building is returned to its normal ambient state in a short period of time. The period of outside ventilation is controlled by a timer, T2, located on the IACTouch Screen. The period set for Post can be adjusted by means of the setpointmeasured in seconds. At the conclusion of a programmed ON period the fan will continueto operate for the time set on the relay before switching off. Note that the burner will beswitched off during the post purge period.

The Post Purge period is as shown in Section 1.3.



6 OPERATING INSTRUCTIONS

6.1 HEATER START-UP

1 Open all manual gas valves both on the appliance and on the supply to theappliance. Switch on the Electric Supply to the appliance.

2 On the main Heater panel:

Switch the panel isolator to the 1 position

Check POWER ON light

3 On the remote control station:

For Heating: Switch the SUMMER/OFF/WINTER switch to WINTER.

The Heater will now start automatically in response to the time settings.

In the event of LOCKOUT:

Press the RESET button and the cycle of operations will be repeated. If the Heater goes to LOCKOUT four times in succession call for a Service Engineer.

For Unheated Ventilation: Switch the SUMMER/OFF/WINTER switch to SUMMER.

Note: This prevents the burner firing, giving a controlled supply of ventilation air tothe heated space, as long as the switch is in this position. The Heater will now startautomatically in response to the timeclock demand. To turn the fan off return theswitch to the centre OFF position.

In the event of LOCKOUT:

Press the RESET button and the cycle of operations will be repeated. If the Heater goes to LOCKOUT four times in succession call for a Service Engineer.

6.2 HEATER SHUTDOWN

6.2.1 SHUTDOWN FOR SHORT PERIODS

Switch the SUMMER/OFF/WINTER switch on the remote station to OFF.

6.2.2 SHUTDOWN FOR PROLONGED PERIODS

Switch the main panel isolator to the "O" position and close all manual gas valves both onand leading to the appliance.

Note: Manual gas valves should only be operated when the appliance is to be shutoff for either Servicing or for a prolonged shutdown.





7 FAULT FINDING

The main control panel incorporates two lights to help in fault finding:

POWER ON

LOCKOUT

The remote station also has three lights:

AIR FAN ON

BURNER ON

LOCKOUT

This section gives the possible causes of failure associated with each check light. Theelectrical schematic diagram in this manual and the wiring diagram shipped in the mainHeater panel should be used in conjunction with the notes below. Additionally ServiceEngineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual.

The notes are given for each light; before consulting the notes check for bulb failure.

7.1 POWER ON LIGHT IS UNLIT

Check:

1 Main control panel isolator is in the 1 position.

2Main Panel 6A MCB has not tripped, if a trip has occurred, the switch will be at theOFF position. Reset and test system as required.

3 Also check if the mains electrical supply is isolated. If so, FIND OUT WHY beforetaking any action.



7 FAULT FINDING

7.2 AIR FAN ON LIGHT IS UNLIT

Check:

1 SUMMER/OFF/WINTER switch is not in Position OFF

2 Time period is not set to off.

3 Heater is not at LOCKOUT.

4 Recheck both AIR FAN ON and LOCKOUT bulbs.

Two fault indications are possible:

THE FAN IS NOT OPERATING

If the fan should have started, but is not operating:

1Overload for tripped conditions. Reset the overload and monitor the nextstart-up.

2 Motor Fuses

3 Relays 1, 2 & 3 for failure.

4 Contactor CC1 for failure.

Check

5 Air Pressure Switch (DPS) is failed in the N O Position.

1

Replace the faulty component as described in Section 8.THE FAN IS OPERATING

This indicates that the air pressure switch (DPS) has failed to change over.

Measure the profile plate differential pressure as described in Section 4.1.13. If thepressure is correct, the air pressure switch is faulty. Check the switch as in 4.1.14. If the pressure is not correct:

1 Correct fan belt tension

2 Correct fan rotation

3 The Heater air inlets and discharge are not blocked

4 Correct fitting on filters

2

Check

5The air differential pressure switch impulse lines are not blocked or leaking



7 FAULT FINDING

7.3 LOCKOUT LIGHT IS ILLUMINATED

This light indicates a failure in the burner ignition and flame supervision system.

1 RESET the unit and follow the progress of the start sequence. The full cycle may taketwo minutes.

2 LOCKOUT after 35-40 seconds indicates an ignition failure. RESET the system andobserve the pilot and ignition spark during the start-up attempt.

3 Observe the spark. This should be strong and highly visible. If not, remove and cleanthe spark plug as Section 8.2. Check that the spark plug gap is correctly set at 1.5 mm.

4 Check the pilot flame. If the pilot flame ignites and the unit goes to LOCKOUT, thescanning system is at fault. Remove and clean the detector as Section 8.2. Check theflame signal as in Section 4.3.1.

5 If the pilot does not light, the gas supply system is faulty. Check the pilot system for restriction, and the pilot valve operation.

6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves areaddressed, either the flow control valve is blocked, or one of the main gas block valveshas failed. Fit a manometer on the pressure test point on the outlet flange of the multi-functional control and observe if the pressure rises when the main gas valves areaddressed. No pressure rise will indicate failure of the main gas valves.

7.4 FAN NOT OPERATING

Check:

1 SUMMER/OFF/WINTER switch is not in Position OFF

2 Timeclock is ON.

3 Heater is not at LOCKOUT.

4 Recheck LOCKOUT bulbs.

Fault indications to be checked are:

1 Overload for tripped conditions. Reset the overload and monitor the next start-up.

2 Motor Fuses.

3 Relays 1 & 2 for failure.

4 Contactor CC1 for failure.

5 Air Pressure Switch (DPS) is failed in the ON position.

Replace the faulty component as described in Section 8.



7 FAULT FINDING

7.5 FAN OPERATING

Check:

1 SUMMER/OFF/WINTER switch is in WINTER position.

2 Excess temperature limit control manual reset.

3 Air pressure switch (DPS) failed to change over.

These interlocks prevent the burner management system starting.

If the air pressure switch is indicated as the problem:

1Measure the profile plate differential pressure as described in Section 4.1.12. If thepressure is correct the air pressure switch is faulty. Check the switch as Section 4.1.13.

If the pressure is not correct check:

1 Correct fan belt tension.

2 Correct fan rotation.

3 The Heater air inlets and discharge are not blocked.

4 The air differential pressure switch impulse lines are not blocked or leaking.



8 SERVICING

IMPORTANT

Servicing and maintenance should be only carried out by a BMM. approved engineer.

Only use replacement parts provided by the appliance manufacturer.Check that the air openings for combustion and for ventilation of any plant room or compartment are clear.

8.1 ISOLATION

8.1.1 FUEL GAS ISOLATION

The fuel gas to the BMM Heater should be isolated and locked off at the manual ballvalve mounted at the start of the fuel gas line. Additionally before entering or servicing

the Heater the burner manual isolation valve and pilot line isolation valve should beclosed.

8.1.2 ELECTRICAL ISOLATION

All electric power to the Heater and the remote control station is switched through thelocal isolator. This isolator is fitted with a lock facility to permit it to be locked in theOFF position.

Additionally isolate the power at the Wall Isolator.



8 SERVICING

8.2 ROUTINE MAINTENANCE

The Heater should be routinely serviced at the start of each heating season. Isolate

the Heater as above before servicing. Details of access to individual components aregiven in Section 8.4 of this manual.

1 Remove and clean spark igniter. Check that the gap is correctly set at 2.5 mm. Replace everytwo years.

2 Clean the flame detector lens to ensure freedom from dirt and moisture. If the cell shows anysign of cracks it should be replaced. Routinely replace the cell every two years or after 10,000hours of operation, which ever comes first.

3 Inspect the entire Heater paint system for general damage. Repair as necessary.

4 Every two years brush the burner plates and clear the burner holes carefully with a Size

1.8mm drill for NP II and 2.0mm drill for NP I.WARNING: THE BURNER HOLES MUST NOT BE ENLARGED.

5 Inspect and lubricate all damper linkages to ensure freedom of operation. Wipe off all excesslubricants to prevent dirt build up on linkage parts.

6 Check the fan belt for cracks and splits. Check tension. The correct tension gives 16mmdeflection per metre of span when the belt is centrally loaded with a force of 27N. Adjust asnecessary.

Grease both the fan shaft bearings with Mobilith AW2 grease, or similar.

NEVER use high temperature grease.

NEVER mix two different greases within the bearing, always flush existing grease out.

Note: Removing the cover plate on the end of the Heater gains access to the outboard fanbearing.

AMBIENT CONDITIONS OPERATING CONDITIONSBEARING OPERATING

CONDITIONS

Dirt Moisture Load Speed Low High

SUGGESTEDGREASINGINTERVALS

0 120 2 to 6 monthsClean Dry

Light toMedium

Slow toMedium 120 200 1 to 2 months

0 120 1 to 4 weeksModerate toDirty

DryLight toMedium

Slow toMedium 120 200 1 to 7 days

7

Extreme Dirt DryLight to

Medium

Slow to

Medium0 200

Daily Flushing out

Dirt

8.3 ANNUAL SERVICE CHECKS

After Servicing, test fire the Heater following the Commissioning Procedure detailed inSection 4 of this manual, to ensure correct operation generally. Special attention mustbe paid to the damper system and related controls and interlocks.

Additionally check that the fresh air and recirculation air entry path to the Heater hasbeen kept clear and instruct the User of the need for this, as necessary.



8 SERVICING

8.4 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS

IMPORTANT

Turn off the gas at the appliance service valve and the electricity at the main panel andwall isolator before proceeding.

8.4.1 BURNER

The burner is located inside the Heater casing and is mounted on two brackets fromthe support straps. To remove the burner isolate the Heater as in 8.1 and undo theunion on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew themain and pilot gas feed pipes from the burner rail. Access to the rear of the burner assembly is made by removing the partition plate below the burner, separating the

fresh air inlet to the burner from the return air inlet compartment. This is held in placeby screws which engage in captive nuts on the top side of the partition. Remove theFlame Detector and pull off the ignition plug cap. Disconnect the burner supportbrackets and remove the burner. The burner will easily pass through the access hatchfor further strip down. Replace in the reverse order, soundness test the gas pipework,check the burner operation and duty as described in the commissioning section of thismanual.

8.4.2 FLAME DETECTOR

This is a 240 Volt instrument.

The flame detector is mounted on the end of the burner rail inside the Heater casing.To remove the detector, isolate the panel electric supply and lock off. Push thescanner towards the burner and rotate to release the bayonet fixing and lift thedetector from its mount. Remove the two screws holding the detector cover anddisconnect the supply leads noting the polarity of the connections.

Replace the flame detector in the reverse order ensuring correct polarity of connections. Ensure the access panel is securely closed and the retaining nuts aretightened down. Check operation by inserting a test meter in the points provided in themain control panel and reading the flame signals during start up to full rate burner operation (See 4.3.1). Operate the appliance over six starts for reliability of operationincluding turn off of start and main gas valves to check for lockout operation.

8.4.3 IGNITER SPARK PLUG

This is a high tension spark plug.

The igniter spark plug is mounted on the end of the burner rail inside the Heater casing. To remove the spark plug, isolate the Heater as above. Enter the serviceaccess door. Access to the spark plug is made through the profile plate. To removethe spark plug pull off the high tension lead and unscrew the plug with a plug spanner.

When replacing the spark plug check the plug gap is set at 1.5mm. Check ignitionreliability over six start ups.



8 SERVICING

8.4.4 IGNITER SPARK TRANSFORMER


The ignition transformer is located in a plastic box mounted on the Heater casingadjacent to the main control panel. To remove the transformer, isolate the Heater asabove and unscrew the four retaining screws holding the box lid in place and removethe lid. Disconnect the supply cable at the terminal strip and undo the transformer retaining screws. The transformer may then be ‘unscrewed’ from the High Tensioncable leading to the spark plug.

Replacement is a simple reversal of this procedure.

Check ignition reliability over six start ups.

8.4.5 COMBUSTION AIR PRESSURE SWITCH (DPS)Note: The switch is set and sealed and should be replaced if not operating correctly.

This switch is a 240 Volt instrument.

The air switch is mounted directly on the Heater casing and can be serviced in situ.However, if it is necessary to remove the switch, isolate the Heater as above.Disconnect the supply cable. Break the downstream pipe compression fitting andunscrew the switch housing from its locating fitting. Reverse the procedure to replace,after ensuring switch setting is as specified in Section 1.3 of this manual. Operate theHeater to ensure reliability of operation over six start ups.

8.4.6 HEATER OVERHEAT LIMIT CONTROL


The overheat limit control is mounted directly on the Heater casing and can beserviced in situ. However, if it is necessary to remove the control isolate the Heater asabove and lock off. Remove the switch cover. Disconnect the supply cable andunscrew the control housing from its locating fitting. Reverse the procedure to replace,check the switch is set to 50°C. Test the switch operation as described in section 4.3.6over at least three operations.



8 SERVICING

8.4.7 AIR FAN AND MOTOR

The air fan motor is either a 415 Volt, 3 phase or 240 Volt, single phase motor. Checkthe data badge for type.

The motor and slide rails are easily accessible inside the Heater casing. If it isnecessary to remove the motor, isolate the Heater as above. Slacken the fan-belttension and remove the drive belts. Pull the motor away from the Heater casing tomake access to the motor terminal box and disconnect the supply cable. The motor may now be removed from the unit. Following replacement, the Heater must be fullyre-commissioned as in Section 4.

It is unlikely that the air fan will need replacing or servicing. If required, a full procedureshould be obtained from BMM.

Replacement must be followed by full re-commissioning as in Section 4.

8.4.8 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS


The fuel gas multi-functional control can be serviced in situ. However, if it is necessaryto remove the unit, isolate the Heater as above. Disconnect the Hirschman electrictermination. Unbolt the control from its flanges and remove.

When replacing, care must be taken to ensure the flange ‘O’ rings are undamaged andin the correct location. Following replacement, the Heater must be fully re-commissioned as in Section 4, including tests for soundness prior to start-up.

8.4.9 GOVERNOR AND BLOCK VALVES

The block valves are 240 Volt instruments.

All these items may be serviced in situ. However, if it is necessary to remove any item,isolate the Heater as above. Disconnect the electric termination to the two blockvalves, the pilot block valve and the flow control block valve. Break the two pipe unionsand remove the fuel gas line complete for further strip-down.



8 SERVICING

8.4.10 FUEL GAS FLOW CONTROL VALVE


The fuel gas flow control valve can be serviced in situ. However, if it is necessary toremove the valve, isolate the Heater as above. Disconnect the supply cables to thecontrol valve.

On small Heaters fitted with a multi-functional control, support the multi-functionalcontrol and unbolt its discharge flange. Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down.

On large Heaters fitted with separate block valves, it will be necessary to remove thefuel gas line complete, as Section 8.4.10 above.

Following replacement, re-commission the Heater.

Note: If the fresh air damper is not in the full open position, the heat input must not exceed the maximum heat input at recirculation condition specified in the technicaldata section of this manual.

8.4.11 PILOT GAS GOVERNOR AND BLOCK VALVE

The block valve is a 240 Volt instrument.

Both items may be serviced in situ. However, if it is necessary to remove either item,isolate the Heater as above. Disconnect the electric termination to the solenoid valve.

Undo the upstream pipe union and the compression fitting downstream of the manualblock valve (PV3). Remove the pilot gas line complete for further strip down.

Replace broken or distorted connections and retest for soundness. Ensure the pilotgas pressure is correct and the flame is sensing an output. Ensure reliability over sixstart-ups.



8 SERVICING

8.4.12 BELT TENSIONING PROCEDURE

1 The setting tensions are designed to cover a wide range of drives. A precisesetting force for individual applications can be calculated as detailed in part 2.0.

SETTING FORCES

Setting Force To Deflect Belt16mm per Metre Of Span.Belt

Section

Small Pulley Diameter (mm)

Basic Setting Forces

Newtons (N) Kilograms (kgf)

1.25 x Setting Forces

Newtons (N) Kilograms (kgf)

56 to 71 16 1.6 20 2.0

75 to 90 18 1.8 22 2.2

95 to 125 20 2.0 25 2.5SPZ

Over 125 22 2.2 28 2.8

80 to 100 22 2.2 28 2.8

106 to 140 30 3.0 38 3.8

150 to 200 36 3.7 45 4.6SPA

Over 200 40 4.0 50 5.1

112 to 160 40 4.0 50 5.1

170 to 224 50 5.1 62 6.3

236 to 355 62 6.3 77 7.9SPB

Over 355 65 6.6 81 8.3

224 to 250 70 7.1 87 8.9

265 to 355 92 9.4 115 12.0SPC

Over 375 115 12.0 144 15.0



8 SERVICING

BELT TENSIONING USING FENNER BELT TENSION INDICATOR

1 Calculate the deflection in mm on a basis of 16mm per metre of centre distance. CentreDistance (m) x 16 = Deflection (mm).

2 Set lower marker ring at the deflection distance required in mm on the lower scale.

3 Set upper ring against to bottom edge of the top tube.

4 Place the belt tension indicator on top of the belt at the centre of span, and apply a force at rightangles to the belt defecting it to the point where the lower marker ring is level with the top of theadjacent belt.

5 Read off the force value indicated by the top edge of the upper marker ring.

6 Compare this force to the kgf value shown in the table above.

7 If a Fenner Belt Tension Indicator is not available, a spring balance and rule will be suffice.



8 SERVICING

8.5 MAIN PANEL CONTROLS

All panel controls are readily accessible and may be easily exchanged for replacement

components in the event of failure. Ensure any replacement item is of the same makeand type as the original.

8.5.1 LANDIS & GYR LFL1.335 AUTOMATIC SEQUENCE CONTROLLER

The Landis & Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wiredchassis. To remove the controller, undo the two retaining screws at the top left and lower right corners, and pull the module off the chassis.

Replacement is a simple reversal of the above procedure.

8.5.2 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER

The Controls Circuit Transformer is fixed to the panel back plate by tapped screws. Toremove the transformer, undo the wiring connections after first noting that theconnections are correct to the wiring diagram attached to the panel. Undo the tworetaining screws and remove the unit complete.


8.5.3 CONTROL RELAYS, R1, R2 & R3

The Control Relays are DIN Rail mounted. To remove a relay, undo the wiringconnections after first noting that the connections are correct to the wiring diagram,attached to the panel. Release the DIN rail retaining clip under the relay with ascrewdriver and remove the relay.


8.5.4 6A MCB

The 6A MCB is DIN Rail mounted. To remove the MCB, undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel.Release the DIN rail retaining clip under the MCB with a screwdriver and remove theMCB.


8.5.5 THERMAL OVERLOAD

The thermal overload is attached to the underside of the main contactor. To remove theoverload, undo the wiring connections after first noting that the connections are correct tothe wiring diagram attached to the panel, and that the overload setting is as specified inSection 1.3 of this manual. Unscrew the three connections to the contactor and removethe overload.




8 SERVICING

8.5.6 MAIN CONTACTOR

The Main Contactor is DIN Rail mounted. To remove the contactor, remove the thermal

overload, as 8.5.5 above, and then undo the wiring connections, after first noting that theconnections are correct to the wiring diagram attached to the panel. Release the DIN railretaining clip under the contactor with a screwdriver and remove the contactor.


8.5.7 MOTOR FUSE

To replace a motor fuse pull the fuse carrier off the fuse holder base. The fuse is attachedto the fuse carrier by two screws. Unscrew, remove and replace.

8.6 REMOTE CONTROL STATION

The remote control station contains some serviceable parts, although these items shouldonly be fitted by an approved BMM Heaters.



9 RECOMMENDED SPARES

For two years operation, it is recommended that the following items should be held instock:

ITEM DESCRIPTION PART NO. QUANTITY

1 INDICATOR BULBS W1121 1 PACK

2 SPARK PLUG 023739 1

3 UV DETECTOR QRA10 1

4 ROOM SENSOR DRT.2453 1

5 DUCT SENSOR DDT.1701 1

All replacement parts can be obtained from BMM Heaters. by quoting the Heater serialnumber, the part number and description.



APPENDIX 1

SOUNDNESS TESTING THE FUEL GAS PIPEWORK

This procedure should only be carried out by personnel familiar with the BMM Heater.

The pressure test points and all valves are identified on the Process and InstrumentationDiagram for the Heater included in Section 1 of this manual.

Isolate the Heater electric supply at the main control panel and lock off. Close themanual isolation valves MV1, MV6 and PV3. Ensure the supply pressure is available onthe upstream side of MV1.

A1.1 TESTING THE UPSTREAM PIPEWORK AND BURNER CONTROLS1 Connect a 60 mbar manometer to the pressure test nipple A. Monitor the

pressure for two minutes. Any rise in pressure indicates that valve MV1 isleaking and must be replaced. Remove pressure test points B and F.2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the

first block valve.3 Close MV1. Allow one minute for the temperature to stabilise and then test the

system for 2 minutes and watch for a drop in the pipework pressure. If thepressure falls, open valve MV1 and test the pipework connections and valvesfrom MV1 to MV3, and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray. Turn off MV1, seal any leaks and re-test.

4 If no external leaks are found either the pilot block valve, PV1, or either the firstmain gas block valve, MV3, is letting by.

5 To test this, seal pressure test point A and fit a manometer to pressure testpoint B. Leave for two minutes with MV1 open. A rise in pressure on themanometer confirms a leak on the block valve, MV3. Turn off MV1, exchangethe valve and re-test from point 2 above.

6 Repeat this procedure for the pilot block valve: Seal test point B and fit amanometer to pressure test point F. Leave for two minutes with MV1 open. Arise in pressure on the manometer confirms a leak on the pilot block valve, PV2.Turn off MV1, exchange the valve and re-test from point 1 above. Seal test pointF.



APPENDIX 1

A1.2 TESTING THE DOWNSTREAM BURNER VALVE1 Close MV1 and connect pressure test points A and B with flexible 6 mm bore

tubing teed into the manometer. Remove pressure test point C. Open MV1 topressurise the downstream block valve, MV4.

2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor the pressure for 2 minutes. If the pressure falls, open valve MV1 and leak testthe line between the two block valves MV3 and MV4 with a proprietary leakdetector. Turn off MV1, seal any leaks and re-test.Note: Smaller Heaters in the BMM Series are fitted with multi-functional valvescombining the pressure regulator and two block valves in one component. Theabove procedure still applies, but if a leak is found on either block valve, thewhole control should be replaced. If no external leaks are found, thedownstream block valve is letting by.

3 To confirm this, close MV1, remove the manometer and refit to pressure testpoint C. Connect pressure test points A and B with flexible 6mm bore tubing.Open MV1 and allow one minute for the temperature to stabilise. Monitor thepressure for a further 2 minutes with MV1 still open. A rise in pressure confirmsthat the second block valve MV4 is letting by. Turn off MV1. Replace the valveand re-test from 2 above.

A1.3 TESTING THE DOWNSTREAM BURNER PIPEWORK1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore

tubing teed into the manometer. Open MV1 to pressurise the downstream pilot

pipework.2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor

the pressure for 2 minutes. If the pressure falls, open valve MV1 and leak testthe line between the downstream block valve, MV4 and the manual block, MV6with a proprietary leak detector fluid or spray. If no external leaks are found themanual block valve, MV6, is letting by. Turn off MV1, seal any leakages and re-test from 2 above.

A1.4 TESTING THE DOWNSTREAM PILOT PIPEWORK1 Close MV1 and connect pressure test points A and F with flexible 6mm bore

tubing teed into the manometer. Open MV1 to pressurise the downstream pilotpipework.

2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor thepressure for 2 minutes. If the pressure falls, open valve MV1 and leak test theline between the downstream block valve, PV2 and the manual block, PV3 witha proprietary leak detector fluid or spray. If no external leaks are found, themanual block valve, PV3 is letting by. Turn off MV1, seal any leakages and re-test from 2 above.



APPENDIX 1

A1.5 TESTING THE BURNER CONNECTIONS1 Remove the burner access panel as described in Section 8.4 of this manual.

Remove the burner spark igniter. Slacken the two retaining bolts holding theburner to the burner support straps and unbolt the burner supply endplate fromthe burner casting and mixing plates.

2 Connect pressure test points A and D with flexible 6mm bore tubing teed intothe manometer. Open MV1 and MV6 to pressurise the burner pipework. Leaktest the main gas burner pipework and connections with proprietary leakdetector fluid. Turn off MV6. Seal any leakages and re-test.

3 Connect pressure test points A and F with flexible 6 mm bore tubing teed intothe manometer. Open MV1 and PV3 to pressurise the pilot burner pipework.Leak test the pilot gas burner pipework and connections with proprietary leakdetector fluid. Turn off PV3. Seal any leakages and re-test.

4 Turn off MV1.

5 Replace the spark igniter and profile division plate.



APPENDIX 2

START SEQUENCE

The burner start sequence is controlled by the Landis and Gyr burner management unit.

The timings are pre-set and comply with BS5885. This unit must NOT be tampered with.

A brief description of the start-up sequence is:-

The unit checks:

1 The NO FLAME signal on the UV flame scanner.

Note: If the scanner detects a flame at any time other than in the correct operatingsequence, the flame programmer initiates a lockout.

2 The operation of the combustion air proving switch in the NO AIR position.

3 The Heater discharge high temperature switch.

If the checks are completed, the unit starts the combustion air fan and then checks thecombustion air flow.

Once the air flow is proven, the unit checks that the damper control circuit is functioningcorrectly. After the damper microswitch is made, to prove the fresh air damper is fullyopen, the sequence allows 30 seconds for the combustion air to purge any combustiblegas from the Heater.

After completion of the purge, the spark ignition system is energised, the pilot valve

opened and the spark terminated. If the pilot flame is not proven by the UV scanner, thesystem will initiate a LOCKOUT.

If the flame is proven the main gas valves are opened, the pilot extinguished and themain burner flame proven.



APPENDIX 2

The following flow chart shows the complete start sequence, including the lighting of thevarious indicating lamps:

MANUALPOWER ON

STATUS LIGHT

POWER ON

INITIATE START BY TIMESETTING ON

CONTROLLER

CHECK NO FLAMEVISIBLE

PROVE FAIL LOCKOUT

CHECK RELAY R4 N/CPOSITION

PROVE FAIL NO START

CHECK AIR PRESSURESWITCH N/C POSITION

PROVE FAIL NO START

CHECK RELAY R1 N/CPOSITION

PROVE FAIL NO START

START COMBUSTION AIR BLOWER

CHECK AIR PRESSURESWITCH N/O POSITION

PROVE FAIL NO START

STATUS LIGHT FAN ON

ENERGISE RELAY R1



APPENDIX 2

CHECK OVERHEAT LIMITCONTROL R5

PROVE FAIL NO START

CHECK 5, 4, 14, 12LOOP CLOSED ON

LANDIS & GYR CIRCUIT

PROVE FAIL NO START

COMBUSTION AIRPURGE PERIOD

30 SECONDS

CANCEL NO FLAMECHECK CIRCUIT

ENERGISE SPARK

TIMED PERIOD2.5 SECONDS

ENERGISE PILOT GASVALVE

TIMED PERIOD2.5 SECONDS

TERMINATE SPARK

INTERROGATE UVFLAME SCANNER

PROVE FAIL LOCKOUT

TIMED PERIOD10 SECONDS



APPENDIX 2

ENERGISE MAIN GASVALVES

STATUS LIGHTBURNER ON

TIMED PERIOD5 SECONDS

DE-ENERGISE PILOT

GAS VALVES

CONTINUOUS FROM PILOTINTERROGATE UVFLAME SCANNER

PROVE FAIL LOCKOUT



APPENDIX 3

Please see copy of Standard Service Sheet



APPENDIX 3

BMM “NP”, “RG” & “LV-NP-I” AIRFLO

GAS BURNERS

BMM series “NP, “RG” and “LV-NP-I” AIRFLO line burners are exclusivelydesigned for direct fired fresh air heating applications. They are the standardof the industry for low temperature make up air applications. Their uniquedesign makes it possible to operate the burner without a combustion air blower. The line burner concept allows for great flexibility in application andconfiguration.

1.2

1.3

PRINCIPLE OF OPERATION

“NP”, “RG” AND “LV-NP-I” burners are raw gas burners.They are mounted in the air stream to be heated and a specific velocity iscreated at the burner to provide progressive aeration of the space betweenthe burner mixing plates. As the sketch shows, the fuel gas is thoroughlymixed with the air to be heated which penetrates into the V-shaped spacebetween the plates. The design of the mixing plates provides for completecombustion and a wide range of turndown.

Contrary to the conventional burners which stratified air streams need to bemixed downstream of the burner, the principle of working with a specific air

velocity and a small pressure drop across the burner, ensures good mixing of combustion products with the air stream giving good temperature uniformity,thus shorter lengths of duct are required and no baffles, perforated plates etcneed to be installed.

Optimum performance demands that the air velocities be uniform across theentire burner.

FEATURES

• High turndown, up to 25:1

• To suit this broad range of applications, BMM offers several versionsaccording to the application and the operating conditions:

• Series “NP” is suitable for natural gas, propane or propane/air mixtures,for constant air velocities.

• Series “RG” for natural gas only, for air velocity changes of up to 2:1

• Series “LV-NP-I” is suitable for natural gas, propane or propane/air mixtures, for varying air velocities. Only straight elements available.

• Capacities range from 150kw to 300kw per unit of burner (300mm). Theburners are assembled from a number of these units depending on thecapacity and the available space.



APPENDIX 3• Extremely good, clean combustion, 100% nett thermal efficiency meeting

or exceeding all known standards for direct fired make up air and spaceheating appliances.

• No need for external combustion air blower, mixing equipment, etc.

• Carefully controlled progressive aeration patterns g8ive excellent mixing,

superior cross ignition and flame retention with uniform distribution of temperature.

• High quality materials for long life.

• Simple and static with no moving parts or special maintenancerequirements.

• Operate economically and installs easily.

• Unlimited capacity: burners are assembled for modular units.



APPENDIX 31.4



APPENDIX 3



APPENDIX 3

1.5 APPLICATIONS

Series “NP”, “RG” and “LV-NP-I” AIRFLO line burners are designed for direct

heating of fresh, clean air for high and low temperature air heatingapplications.

Typical low temperature applications include humidity controlled dual stagepaint, spray booth, general make up air applications, packaged units, door heaters, grain drying, malt drying.

Typical high temperature process air applications include spray dryers,chemical dryers, fresh air oven heating, drying, baking and curing operations,

metal parts finishing and all fresh air heating applications up to 650°c.

These burners can also be mounted downstream of a steam or hot water coilthus bringing the air to higher temperature. This can boost the capacity of anexisting installation.



APPENDIX 3



APPENDIX 3

1.5.1 DESIGN AND APPLICATION DETAILS

BMM series “NP”, “RG” and “LV-NP-I” AIRFLO burners consist of rustresistant cast iron bodies (which serve as the gas manifold) drilled todischarge the fuel between diverging stainless steel mixing plates.

The entire burner assembly is mounted directly in the airstream being heated.The fresh air stream passes through the mixing plates and mixes with thefuels as combustion air; thus available heat from the gaseous fuel is releaseddirectly into the airstream.

Air velocities across the burner assemblies (the key to successful operation)are established by the use of profile plates.

Nominal capacities of 6kw per 300mm sections (minimum) to 300kw(maximum) give 25:1 turndown. Fuel used and design velocities may result inhigher or lower turndown. Modular design allows to match burner shape andtotal heat release to the specific application needs.

1.6 BURNER SELECTION

Several variations are offered, each optimized for a specific type of applicationas follows. All are raw gas burners, intended for use in fresh air streams.

• FOR MAKE-UP AIR HEATING:

“NP-I” AND “NP-II” burner types provide a nominal capacity of 150kw per 300mm section.

Turndown of 25:1

With staged burner configuration turndown may exceed 50:1.

Optimum air stream velocity is 15m (st)/s.

“NP-II” burners are selected when “NP-I” burners cannot be used becausegas supply pressure is too low. The NP-II will cover the same applications witha turndown of 20:1.

• FOR PROCESS AIR HEATING:

• “NP-I” and “NP-II” burners may be used if temperature rise does notexceed 450°c.



APPENDIX 3

“NP-III” burners provide a nominal capacity of 300kw per 300mm section anoptimum air stream velocity of 20m (st)/s for temperatures up to 650°c with aturndown of 7:1.

Special aluminium body “NP-I” AIRFLO burner can be supplied having allstainless steel fasteners and aluminium back-up bars for applications wherecorrosion is determined.

“LV-NP-I” burner may be used where air floes can vary between 5 to 25m(st)/s for a nominal capacity of 175kw per 300mm section at 15m/s and aturndown of 25:1.

• FOR 2 SPEED AIR HANDLING SYSTEMS:Usually make up air applications.

“RG-IV” burners (for natural gas only) may be used for a nominal capacity of 150 kw per 300mm section at an optimum velocity of 15m (st)/s or 75kw per 300mm section at a velocity of 7.5m (st)/s.

1.7 GENERAL CONSIDERATIONS

• Air velocity: the burner will perform properly within a given range of air velocity. The higher the velocity at a given gas pressure, the shorter theflame length. A higher velocity will obviously create a higher pressure dropof the process air.

• Gas Pressure: the burner capacity will depend upon the differential gaspressure burner to duct. A satisfactory performance can be expectedwithin a given range of gas pressures but here again, for a given air velocity, a higher gas pressure will result in a higher heat release and alonger flame.

Optimum performancedemands that air velocities beuniform across the entireburner.

Nominal capacities and pressure required for various burner types



APPENDIX 3NP- I [1] NP-II [1] NP-III [1] RG-IV [2] LV-NP-I [3]

Maximum capacity per unit – kw 150 150 300 75/150 175

Minimum capacity per unit – kw [4] 6 7 50 7 9

Natural gas pressure required – mbar

[5]

12-14 6-7 12-14 12-14 30-32

Flame length –mm 250-300

250-300

700-800 300-350 150-600

Air velocity required – m/s 15 15 20 8-16 5-15

Pressure drop process air – mbar 1.4 1.4 2.5 0.3-1.4 0.5-1.5

Turndown 25:1 20:1 6:1 20:1 25:1



APPENDIX 3

SPECIFIC INSTALLATION INSTRUCTIONS FOR BMM SERIES“NP”, “RG” & “LV-NP-I” BURNER SYSTEM

Instructions provided by the company responsible for the manufacture of acomplete system incorporating BMM burners take precedence over theinstallation and operating instructions provided by BMM. If any of theinstructions provided by BMM are in conflict with local codes or regulations,please contact our head office or representative.

Before reading following “installation instructions” please refer to the “generalinstructions” on burner system installation, piping lay out, pipe size andmanifolding, electrical installation and burner installation.

IMPORTANT: Do not discard packing material until all loose items areaccounted for.

Series “NP”, “RG” and “LV-NP-I” AIRFLO line burners are used only for heating of fresh air in motion. They should be mounted so as to direct their flames parallel to and in the same direction as the movement of the air (see sketch below).

Do not mount the AIRFLO assembly so that the movement of air is across theface of the line burner, nor should it be mounted too near to a turn in the ductwhich may cause air to be directed at an angle over the burner.

Velocity and flow of air at operating temperature must be uniform andnot less than specified for the application.

Install adjustable profile plates to attain this velocity. Minimum silhouetteprofile plates of 150mm should be installed in duct to completely surroundburner assembly.

Install a differential pressure switch across the profile plate to make sure theburner can only operate when air velocity is correct.

Wiring to electrical components as spark ignitors and flame rods of inductburners, should be designed to withstand the maximum expected returntemperature and radiation heat from burner.



APPENDIX 3



APPENDIX 3

SPECIFIC INSTALLATION INSTRUCTIONS FOR BMMSERIES “NP”, “RG” & “LV-NP-I” BURNER SYSTEM



APPENDIX 3

SPECIFIC START-UP INSTRUCTIONS AIRFLO LINE BURNERS – SERIES“NP”, “RG” “LV-NP-I”

Instructions provided by the company responsible for the manufactureof a complete system incorporating BMM burners take precedence over the installation and operating instructions provided by BMM. If any of the instructions provided by BMM are in conflict with local codes or regulations, please contact our head office or representative.

Before initiating the following start-up and adjustment procedure, IT ISIMPORTANT that a check can be made to verify that all of the equipmentassociated with and necessary to the operation of the AIRFLO burner systemhas been installed and piped in accordance with the “specific installation

instructions”. If the burner system is part of a complete incinerator or other heating unit which has been purchased as a complete prepiped and prewiredpackage, it may be assumed that these instructions have already been carriedout by the company responsible for the overall installation.

Initial adjustment and light-off should be undertaken only by trained andexperienced personnel familiar with combustion systems, with control/safetycircuitry with knowledge of the overall installation.

1.8 INTRODUCTION

“NP”, “RG” AND “LV-NP-I” are raw gas burners. There is no flammable air-gasmixture in the feeder line and, therefore, a flash-back will not occur. However,the burner depends completely on the process air to supply the oxygen for combustion. A correct air velocity is therefore very important and the processair must be fresh air.

1. Close all burner fuel valves and/or cocks. Make preliminaryadjustments to fuel regulators.

2. Check all electric circuitry. Verify that all safety devices and interlocksare operable and functioning within their respective settings/ranges. Besure all manifolds are tight and that test ports are plugged if not beingused.

3. Check that all duct and chamber dampers are properly positioned andlocked into operating positions.

4. Start main process fans; check whether system has been purged.



APPENDIX 3

5. Check ΔP or velocity over the burner!

Do not bypass control panel timers typically controlling sequential

operations.



APPENDIX 3

6. Disconnect the automatic control motor linkage from your BMM controlvalve by loosening the control motors connecting rod from the valvestoggle linkage. Initial start-up adjustment should only be accomplishedduring a “manual” control mode. Manually set and secure control valve inits “minimum” position.

7. To light and adjust gas pilot: pilot gas regulator should initially be set atapproximately midpoint of its adjustment range. With pilot gas solenoidvalve closed, open main fuel gas and pilot gas cock. Energize spark ignitor and open pilot gas solenoid. Turn adjustable orifice screw out (counter clockwise) several turns from its fully seated position. Observe pilot ignitionthrough a sight port by viewing micro amp signal metered from flamesafeguard relay circuit.

8. Prepare to ignite main burner by adjusting main gas regulator toapproximately midpoint of its adjustment range. Linkage arrangement for the use of series “CV” gas control valve is illustrated for a typical controlmotor. Arrange accordingly.

9. With control valve at “minimum”, ignite main burner by operating main fuelshut off valve. Adjust main gas regulator to give the desired outletpressure. Refine pilot adjustment if it has been affected. Adjust burner “minimum” by turning in on the minimum stop screw of the gas controlvalve until stable flame appears in the narrow zipper channel at the base

of burner mixing plates.



APPENDIX 3

1.8.1 MAINTENANCE INSTRUCTIONS

Periodic maintenance will ensure continued trouble free operation of your

series “NP”, “RG” or “LV-NP-I” AIRFLO burner system.

Inspection annually, at least, is recommended for make up air heatinginstallations and more frequently for process applications in regular operation.Your own experience is the best guide in determining frequency of inspection,but as a minimum the following procedure should be followed:

1. Shut the system down totally, disconnecting or locking out power supply sothere can be no accidental start-up during inspection.

2. Inspect the burners carefully, including upstream and downstream side of the mixing plates as well as burner body face. Any accumulation of scaleor foreign material on either side of the mixing plates should be removedwith a wire brush. Check visually that no holes in the mixing plates areblocked.

Burner type NP-I NP-II NP-III RG-IV LV-NP-I

Rows of gas ports 1 2 2 1 1

Drill size in mm 1.9 1.8 1.9 1.9 1.9

If any burner ports are blocked (even partially) clear them with a piece of wireor a drill bit matching the drill size for your appropriate burner type (see tableabove)

WARNING: DO NOT ENLARGE BURNER PORTS OR PERFORMANCE

MAY BE DRASTICALLY AFFECTED.

If any mixing plates are loose or fasteners are missing, tighten/replace asnecessary. Always use zinc plated or stainless steel fasteners.

3. Put system back into operation and, if possible view from downstream sidewhile cycling burner through full firing range. This will give a visual checkfor blocked burner ports.

4. Observe flame patter and, if necessary take steps to correct velocityand/or air distribution problems.



APPENDIX 3

1.8.2 REPAIR/REPLACEMENT PROCEDURES

If adverse operating conditions or accidental damage make it necessary toreplace either individual mixing plates or complete burner sections, follow thisprocedure:

1. Identify necessary replacement parts. Consider carefully the economics of installing a complete replacement burner instead of replacing individualparts. Once exposed to actual flame temperatures, burner castings hardenand the removal and replacing of fasteners can be time consuming anddifficult. Accessibility may also be severely limited thus requiring removalof the complete assembly.

2. When necessary parts have been received, remove damaged mixingplates or burner sections, taking care not to damage remaining portion of burner. If new burner bodies are being installed, apply thin coat of keygraphite paste to the mating flanges of loose cast iron bodies. (This isnecessary to provide a gas-tight seal after assembly). Insert new sectioninto place, making sure that both flanges are square and flush, then boltsections together.

3. Install new mixing plates, back-up bars and plate support brackets to the

new body castings. Be careful not to damage gaskets that go betweenmixing plates and burner body. They are cut to overlap approximately 2mm for tight air seal.

4. If end plate sets must be installed, apply key paste to both sides of endplate at the areas that will contact the cast iron body and end flange or pilot. Then put in position between mixing plates and insert fastenersloosely. Do not tighten at this time.

5. Tighten burner body bolts making sure that mating cast iron flanges

remain square and flush.

6. Align mixing plates and check that gaskets are in position and properlyaligned, then tighten all mixing plate mounting screws and bolts.

7. Double check that all fasteners are secure.

8. Return burner to operation, observing flame carefully at all firing rates.



APPENDIX 3

1.8.2.1



APPENDIX 3PERFORMANCE SELECTION DATA “NP” AIRFLO BURNERS

Airstream Velocity across and through the burner’s mixing plates must bekept uniform and within desired limits by use of a silhouette profile plate

through which the burner fires. A 150mm (minimum) profile plate should beinstalled surrounding the interior duct walls at the leading edge of your burners mixing plates.

Optimum design ranges for the various types are shown in the abovegraphs. Velocities (m³ (st)h) are measured with a velometer directly in the ductat the plane of the profile plate and leading edge of burner mixing plates.

Table 1: burner displacement(cm²/section)

Section NP

150mm straight section 232


300mm back inlet section 465

300 x 300 x 300mm H-back inlet section 1115300 x 150 mm T-section 557

150 x 150mm elbow section 418

To determine profile opening areas, add burner displacement areas(cm²/section) from table 1 for complete burner assembly to “Net Free Area” of duct:

“Net Free Area” of duct (cm²) =

Fan volume m³ (st) h

_________________ x 10,000 = …….. cm²

Velocity (m/s x 3600)

Various duct size/profile area relationships may give slightly different field sitedata than is shown in table 2. Velocities should always be confirmed andestablished by use of a velometer on actual field site installation.



APPENDIX 3Inlet Feed limitations:

NP-I NP-II NP-III

1 ¼” end inletflange

≤ 4 sections ≤ 4 sections ≤ 2 sections

1 ½” back inlets ≤ 5 sections ≤ 5 sections ≤ 4 sections

* Note: for 300 x 300 x 300mm back inlet sections, not more than 150mmsection off any one leg.

Pilot capacities: nominally rated at 7.3 kw with natural gas differentialpressures of 10-15 mbar.

1.9 Table 2: velocity factors

Velocity m/s (15°c 8 9 10 11 12 13 14 15 16 17 18 19 20

Pressure drop inmbar

0.39

0.50

0.61

0.74

0.88

1.04

1.20

1.38

1.57

1.77

1.99

2.21

2.45



APPENDIX 3

PERFORMANCE SELECTION DATA “RG” AIRFLOWBURNERS

Airstream velocity across and through the burner’s mixing plates must bekept uniform and within desired limits by used of a silhouette profile platethrough which the burner fires. A 150mm (minimum) profile plate should beinstalled surrounding the interior duct walls at the leading edge of your burners mixing plates.

Optimum design ranges for the various types are shown in the abovegraphs. Velocities (m³)st(h) are measured with a velometer directly in the ductat the plane of the profile plate and leading edge of burner mixing plates.

To determine profile opening areas, add burner displacement areas(cm²/section) from table 1 for complete burner assembly to “Net Free Area” of duct:

“Net Free Area” of duct (cm²)

Fan volume m³ (st) h

_________________ x 10,000 = ….. cm²

Velocity (m/s x 3600)

Net free area (cm²) + burner displacement (cm²)

= profile area (cm²)



APPENDIX 3

Various duct size/profile area relationships may give slightly different field datathan is shown in table 2. Velocities should always be confirmed andestablished by use of a velometer on actual field site installation.



APPENDIX 3

Table 1: burner displacement

(cm²/section)Section RG



300mm back inlet section 613

300 x 300 x 300mm back inlet section 1394

300 x 150mm T-section 697

150 x 150mm elbow section 557

Inlet Feed Limitations:

RG-IV

1 ¼” end inlet flange ≤ 4 sections

1 ½” back inlets ≤ 5 sections

* Note: for 300 x 300 x 300mm back inlet sections, not more than 150mmsection off any one leg.

Pilot capacities: nominally rated at 7.3 kw with natural gas differentialpressures of 10-15 mbar.

1.10 Table 2: Velocity factors

Velocity m/s (15°c) 8 9 10 11 12 13 14 15 16 17 18 19 20

Pressure drop inmbar

0.39

0.50

0.61

0.74 0.88 1.04

1.20

1.38

1.57

1.77

1.99

2.21

2.45

NOTE: for applications on butane or other gases than natural gas, propane or

manufactured gas, contact BMM Head Office.



APPENDIX 3

Equipments Bmm Heaters Direct Fired Manual

Documents