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Burner start-up and maintenance

Buderus Blue Flame Burner BE 1.3 - 2.3 - Specifications subject to change without notice.

7.11 Inspections and maintenance protocol

The Inspections and Maintenance Protocol provides a
complete overview of all necessary maintenance steps
for the burner.

Complete this schedule with every annual service work.

Check off, date and sign all performed service steps.

Inspections and Maintenance Steps

before

after

before

after

Stack measurements

Page 24

a) Stack Temperature

Page 24

_____ °F

b) Room Air Temperature

Page 24

_____ °F

c) Net Stack Temp. (Stack – Ambient)

Page 24

_____ °F

d) CO

-% measured

Page 24

_____ %

e) CO-ppm measured

Page 24

____ ppm ____ ppm ____ ppm ____ ppm

f) Draft at breeching connection

Page 21

___

h) Perform Smoke Test

Page 21

____*

Check Burner Cover and Burner

Page 24

Check Functionality of Fan Motor

Page 25

Placing Burner out of Operation

Page 25

Clean/Replace Oil Pump Filter

Page 25

Check/Replace Shut Off Valve of Oil Preheater

Page 26

Check Blower Wheel for Debris/Damage

Page 26

Check Ignition Electrodes, Mixing System/Diffuser Plate, Gasket,
Nozzle and Burner Tube

Page 27

Tighten Burner Door Bolts

Page 30

10.

Check Electrical Connections

Page 30

11.

Start-up Procedure for the Burner

Page 17

12.

Re-tighten Burner Door Bolts

Page 30

13.

Record Test Values and Possible Adjustment of Burner

Page 24

14.

Perform Safety Procedure Test

Page 31

15.

Confirm Professsional Maintenance

Company name/sig-

nature/date

Company name/sig-

nature/date

Содержание Logatop BE 1.3

Страница 1: ...ed technician equipped with the proper tools and mea surement equipment Improper installation adjustment alter ation service or maintenance can cause property damage personal injury or loss of life Refer to this manual For assistance or additional information consult a Buderus trained installer ser vice agency or oil company CAUTION The operating manual is part of the docu mentation that is delive...

Страница 2: ...ivery 11 5 Conducting service work on the automated primary burner controller LMO 12 5 1 Program sequence 12 5 2 Operating automated burner controller LMO 13 5 3 Repairing faults in the automated burner controller LMO 14 6 Initial burner start up 15 6 1 Checking electrical plug connections 15 6 2 Establishing combustion air pipe connection 15 6 3 Checking and connecting oil lines 15 6 4 Bleeding o...

Страница 3: ...ecking the shut off valve in the oil pre heater 29 7 7 5 Inspecting the burner tube 29 7 7 6 Burner installation and checking of burner gasket 30 7 8 Securing boiler door bolts 30 7 9 Check electrical connections 30 7 10 Conducting the safety test 31 7 11 Inspections and maintenance protocol 32 8 Additional service tests 34 8 1 Measurement of the flame sensor current 34 8 2 Verifying tightness of ...

Страница 4: ...s of all residential properties to install and maintain carbon monoxide CO alarms 1 1 3 Canadian Installations Burner appliance installations in Canada must comply with the latest revision of CSA B139 Installation Code for Oil Burning Equipment CSA standard C22 Part 1 Canadian Electrical Code and all applicable local codes NOTICE It is the installer s and service personnel s responsibility to foll...

Страница 5: ...es with the specifica tions of UL 296 burner and UL 726 boiler The burner is heat tested at the factory and preset for the specified nominal boiler output see label on burner This means that it is only necessary to verify the burner settings at initial start up and adjust for the local condi tions if necessary 2 3 Notes structure Two danger levels are identified and signified by the fol lowing ter...

Страница 6: ...oiler CAUTION BURNER DAMAGE from contaminated combustion air z Prevent excessive dust levels CAUTION SYSTEM DAMAGE from blocked oil filters Filters that clog up immediately after filling a tank may indicate that residue from the bottom was stirred up z In such cases it is recommended to shut down the heating system while fill ing the tank and wait several hours be fore restarting the system Instru...

Страница 7: ...of the heating system must be disposed of according to local regulations WARNING DANGER TO LIFE from neglecting ones own safety in case of emergency z Safety first Never risk your life CAUTION SYSTEM DAMAGE From insufficient maintenance z Perform maintenance annually Check the complete heating system for de fects and malfunction z Mitigate defects immediately to avoid larger scale system damage ...

Страница 8: ...d the oil in the nozzle is heated to approximately 150 F From a cold start the process may take a maxi mum of three minutes After the oil has been heated the fan and pump are energized the solenoid valve is opened and power supplied to the igniter A blue flame is visible immediately after ignition This combustion system vaporizes the oil using recir culation of hot gases mixing them homogenously w...

Страница 9: ...f the burner 4 1 Burnertypes Fig 2 Mixing system Ø A B C Item 1 Stamp Fig 3 Mixing system dimension X Fig 4 Ignition electrode dimension in inches 1 Mixing system Boiler Burner Stamp 4 A 4 B 4 C X in inches in inches in inches in inches Logano G125 BE 1 3 21 1 1 21 1 3 32 15 32 15 64 5 64 BE 2 3 28 1 1 28 1 9 32 31 64 9 32 5 64 BE 2 3 34 2 1 34 1 9 32 31 64 5 16 5 64 Table 2 Technical data mixing ...

Страница 10: ...650 ft elevation see Chapter 6 7 2 Mea suring CO2 value page 19 Settings nozzle installation1 G125 BE atmospheric combustion Burner type BE 1 3 21 BE 2 3 28 BE 2 3 34 Output MBtu h 72 96 116 Mixing system 1 1 21 1 1 28 2 1 34 Nozzle1 Danfoss 0 45 gph 80 HFD Danfoss 0 55 gph 60 HFD Danfoss 0 65 gph 80 HFD Oil pressure psi 189 290 218 334 218 334 Oil gph 0 58 0 76 0 95 Air intake setting estimated 4...

Страница 11: ...8 334 218 334 Oil gph 0 58 0 76 0 95 Air intake setting 4 5 5 5 5 5 Static air pressure W C inch H2O 3 8 4 4 3 8 4 4 3 8 4 5 Combustion chamber pressure 0 0 15 0 0 16 0 0 24 Min draft required draft 2 0 0 0 Available draft 0 12 0 12 0 12 CO2 without hood Fig 16 page 20 CO2 with hood Fig 16 page 20 CO value ppm 50 50 50 Table 5 Settings and nozzle installation for G125 BE with sealed combustion 1 R...

Страница 12: ... DANGER TO LIFE from electric shock z Never open the automated burner con troller LMO and never attempt repair or modifcations z Never operate the unit after the LMO has been dropped or taken a hit Safety functions may be affected even if there is no visible damage Fig 7 Automated burner controller program sequence control signals required input signals allowed input signals yellow yellow gleaming...

Страница 13: ... red indicates the current operating status Operating status Color code Color Oil preheater heating wait time Yellow Preventilation ignition on yellow off Operation flame signal OK green Operation flame signal weak green off Wait time before fault red off Fault alarm see page 14 red Foreign light at burner start green red Low voltage yellow red Fault code output see Table 8 page 14 The LED flashes...

Страница 14: ...use Correction 2 x flash no flame formed during safety time Troubleshooting see Chapter 10 Troubleshooting burner failures page 39 4 x flash Stray light at burner start 7 x flash Flame goes out during operation 8 x flash oil pre heater time monitoring First check electrical connections Next step replace oil pre heater 10 x flash Internal error Unlock LMO Wiring fault Press reset button for one sec...

Страница 15: ...n installations the flexible hose is connected to the air intake in the blower housing z Attach the flexible hose using the supplied hose clamp 6 3 Checking and connecting oil lines Before connecting the oil supply to the burner check that all oil lines and the oil filter are clean and tight z Inspect the oil lines including all components and clean or replace if necessary z Check oil filter repla...

Страница 16: ...automated burner controller Fig 10 Item 2 from its base z Plug burner tester Fig 11 Item 1 into the base z Switch ON power to the heating system z Switch on control mode switch The LED red lights Fig 11 Item 2 z Switch on burner tester with the mode switch Fig 11 Item 5 Both LEDs red and green light Fig 11 Item 2 and 3 z Switch on oil preheater Fig 11 Item 4 switch z Check that the oil in the Tige...

Страница 17: ...13 z Check oil connections for leaks If the burner does not start z Press reset button Fig 12 Item 1 If the burner does not start after pressing the reset but ton three 3 times the cause of the problem must be found with the assistance of the functional diagram see Chapter 10 1 Functional diagram page 39 Fig 12 Reset button and indicator light Item 1 Reset button Item 2 Automated burner controller...

Страница 18: ...e measurements are taken in the exhaust pipe Fig 13 The measurement port coupling Fig 13 Item 2 should be located distance A approx 2 the diameter of exhaust pipe D from the boiler rear section Fig 13 If the exhaust system is connected to an elbow immedi ately after the boiler the measurement must be made before the elbow z Make sure that the exhaust pipe is properly sealed between the exhaust con...

Страница 19: ...r has reached steady state condition z Insert temperature probe in the combustion air hose near the back of the boiler and measure combustion air temperature while the burner is running z Insert combustion analyzer probe Fig 13 Item 4 in flue gas pipe and position near center highest tem perature z Compare measurements with Fig 15 Example Combustion air 77 F with combustion air piped in from outsi...

Страница 20: ...cause the oil pressure would end up outside of range Tab 9 you will need to adjust the amount of combustion air manually z Loosen the screw on the blower housing Fig 17 Item 1 z Slightly adjust the static plenum pressure by moving the air lever along the scale z Adjust the oil pressure as needed see Adjusting the oil pump pressure page 20 until the CO2 value reaches the target If this is not possi...

Страница 21: ... 0 SMOKE 0 z In case of deviations from the specified value correct fault see Chapter 10 Troubleshooting burner fail ures page 39 NOTICE If an excessive CO value is measured on initial start up gas generated from organic matter e g burner door insulation may be the reason z Therefore run the burner for at least 20 30 minutes before measuring the CO content CAUTION SYSTEM DAMAGE from clogged vent p...

Страница 22: ...or against a light source Fig 18 Item 1 It must shut off immediately then lock out af ter restarting z Insert flame sensor again after the shutoff z After waiting for about 30 seconds reset the auto matic burner controller by pressing the reset button Fig 18 Item 2 z Run through function sequence see Chapter 6 5 Starting the Burner page 17 Fig 18 Check function of flame sensor Item 1 Flame sensor ...

Страница 23: ...15 2 Checking and connecting oil lines page 15 3 Bleeding oil line page 16 4 Initial burner start up page 15 5 Tightening burner door retaining screws page 18 6 Adjusting the burner page 18 d Measuring CO2 value page 19 _______________ e Measuring CO content carbon monoxide page 21 _______________ ppm f Measuring chimney draft page 21 _______________ W C inch H2O 7 Run smoke test page 21 8 Carryin...

Страница 24: ... burner performance testing near a boiler water temperature of 140 F and operate the burner for a minimum of 5 minutes z Insert the flue gas analyzer probe Fig 19 Item 4 into the main flue gas flow at the vent connection Drill hole in flue pipe if necessary z Record CO2 CO and flue gas temperatures in start up protocol report see Chapter 6 9 Installation pro tocol page 23 z If deviations are detec...

Страница 25: ...witch or the heating system circuit breaker z Remove burner front cover z Remove electrical cable from burner 7 5 Clean oil pump z Loosen 4 Allen head screws Fig 20 Item 1 z Remove pump cover Fig 20 Item 2 z Remove filter Fig 20 Item 3 z Visually check the condition of the gasket Fig 20 Item 4 for damage Replace gasket annually z Clean filter Fig 20 Item 3 with gasoline replace if excessive residu...

Страница 26: ...dust or contamination z Clean air intake housing with a brush 7 6 2 More significant contamination z Loosen and remove blower wheel Fig 23 Item 1 with an Allen head wrench Fig 23 Item 2 from the spindle z Clean blower wheel and housing with water and mild detergent z Reassemble blower wheel and air intake housing Fig 23 Item 1 z Re install the air intake housing Fig 22 and air in take muffler Fig ...

Страница 27: ...ve ignition cables Fig 26 Item 4 z Remove ignition electrodes Fig 26 Item 5 7 7 2 Check the mixing system replace as needed A slight dark residue build up on the mixing system dif fuser plate is normal and does not affect burner perfor mance Clean the mixing system diffuser plate in case of significant build up Observe the technical character istics of the mixing system diffuser see Chapter 4 Tech...

Страница 28: ...g 28 Item 1 Fig 27 Revmocal of oil nozzle 1 NOTICE The oil nozzle must be replaced as part of the annual service Use the correct nozzle as specified see Chapter 4 Technical data and scope of delivery page 9 NOTICE Replace the shut off valve in the oil pre heater when it is defective see Chapter 7 7 4 Checking the shut off valve in the oil pre heater page 29 and possi bly replace Fig 28 Assembly of...

Страница 29: ... the burner tube z Open the boiler door z Visually inspect the burner tube Carefully clean the burner tube and replace damaged Replacement of burner tube z Pull the burner tube from support collar z Note the part number of the existing burner tube and replace with the proper model Refer also to technical data see Chapter 4 2 Burner tubes page 10 z Place the new burner tube into the locking collar ...

Страница 30: ...er is installed z Pull out the oil line about 1 4 Fig 31 Item 1 z Verify proper placement of the gasket Fig 32 Item 1 with the burner door open Fig 32 Item 2 7 8 Securing boiler door bolts z Close boiler door Fig 32 Item 1 and secure with two bolts Torque to 35 ft lbs 7 9 Check electrical connections z Reconnect electrical connections z Check all electrical connections for proper fit and placement...

Страница 31: ...t mode z Clean flame sensor with a clean rag z Install the flame sensor after burner shut off z Wait for 30 seconds until the primary burner control ler went into lockout Then press the burner reset but ton and restart the burner Fig 33 Item 2 z Check and verify that the flame is visible for the flame sensor Clean the burner if necessary To test flame sensor see Chapter 8 1 Measurement of the flam...

Страница 32: ...____ _____ _____ e CO ppm measured Page 24 ____ ppm ____ ppm ____ ppm ____ ppm f Draft at breeching connection Page 21 ___ ___ ___ ___ h Perform Smoke Test Page 21 ____ ____ ____ ____ 2 Check Burner Cover and Burner Page 24 3 Check Functionality of Fan Motor Page 25 4 Placing Burner out of Operation Page 25 5 Clean Replace Oil Pump Filter Page 25 6 Check Replace Shut Off Valve of Oil Preheater Pag...

Страница 33: ...F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ F _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ____ ppm ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Company name signa ture date Company n...

Страница 34: ...ble flame signal sensor current 45 micro Amp is also shown on the LED of the LMO blinking green light see Table 7 page 13 The sensor current during operation must be at least 80 microAmp no flame 5 microAmp When the sensor current is less than 80 microAmp the flame sensor must be cleaned and the opening to the combustion chamber must be checked for contamina tion z Remove flame sensor during burne...

Страница 35: ... z Increase the oil pressure until CO reaches 100 to 200 ppm z Record the corresponding CO2 value If the measured CO2 value is below 14 3 Deviation of more than 0 5 in CO2 there is likely an air leak be tween the burner combustion and the test location z Find and close off the air leak path Repeat the above test to confirm that 14 8 CO2 can be reached as above 8 2 2 Performing tests in the combust...

Страница 36: ...ure 14 5 psi Maximum Suction Pressure Drop Vacuum 5 8 psi Table 10 Technical data for oil supply system NOTICE Do not add oil additives to the oil as they will not improve the combustion character istics Nozzle Size gph Filter Size Microns 0 40 0 60 10 or less 0 6 10 or less Table 11 Recommended filter types CAUTION SYSTEM DAMAGE from plugged nozzles z Routinely inspect the Tigerloop vacu um gauge...

Страница 37: ...e The oil supply line must be terminated sufficiently close to the burner that the furnished flexible oil lines can be connected without undue strain Use approved materials for the oil line Use only metallic flared connections when using copper supply lines Maximum supply lengths L with inner diameter 3 8 for suction lines 9 3 Testing for oil line vacuum The maximum vacuum negative gauge pressure ...

Страница 38: ...apsed due to high suction pressure or plugged 9 4 Testing Integrity of oil supply line Use a transparent hose dia 1 2 accessory to verify that there are no air leaks in the burner supply loop z Connect hose Fig 36 Item 1 in suction line be tween the TigerLoop Fig 36 Item 2 and the oil line z Form a loop as shown Fig 36 z Start burner and run for at least 3 minutes z Shut burner OFF z Verify if air...

Страница 39: ...ment in oil lines Burner firing control defective Solenoid valve defec tive Oil pump defective Motor defective con denser defective Oil pump clutch de fective Oil filter or nozzle plugged Shut off valve in pre heater defective Air in oil supply line filter or oil line plugged No oil in tank suc tion line plugged quick connect valve proper Flame sensor defec tive or dirty Flame instable or sooting ...

Страница 40: ...uits in control panel Check boiler control panel Defective oil pre heater thermostat Replace oil pre heater Caution After longer shut off times the burner start up time can be 2 to 3 minutes In case of excessively long start up delays check burner pri mary controller check burner motor Replace if necessary Burner starts oil level at sight glass of oil filter re mains empty Incorrect connections at...

Страница 41: ... Correct oil pressure Defective oil nozzle Replace oil nozzle Loose connections between oil pump oil line oil pre heater and oil nozzle Check all connections for leaks Dripping nozzle uncontrolled oil vapors Solenoid does not close Replace solenoid possibly oil pump Shut off in oil pre heater defective Replace Air in nozzle discharge Check entire oil delivery system for air leaks Draft regulator c...

Страница 42: ...are part listing The following spare parts are available via your Buderus wholesaler or BBT North America Corp In case one po sition refers to several boiler models the corresponding numbers are shown in the Table In addition the num ber of components is listed Fig 37 Burner models BE 1 3 2 3 0 1 2 3 4 6 5 10 11 12 ...

Страница 43: ...ons subject to change without notice 43 Catalog 7747100486 Designation Burner Models BE 1 3 2 3 Fig 37 Item Description Part Number 10 Oil Burner BE 1 3 21 7747005758 11 Oil Burner BE 1 3 28 7747005757 12 Oil Burner BE 2 3 34G 7747005756 Table 14 Burner models BE 1 3 2 3 ...

Страница 44: ... 3 2 3 Specifications subject to change without notice 44 Fig 38 Burner housing assembly BE 1 3 2 3 US 0 1 2 3 4 6 5 7747100487 01 Brennergehäuse BE 1 3 2 3 10 20 30 30 40 70 60 80 100 105 110 120 130 140 90 160 161 170 180 220 230 171 190 191 50 200 180 ...

Страница 45: ...47015963 100 100 distribution cup for BE 21kW 34 kW 63006876 105 Distribution cup for BE 28kW 63032532 110 O ring 63002998 120 Gasket 128 x 2 63025160 130 Burner flange HG A 63038318 140 Gasket 143 x 143 x 6 Set V3 7747000719 160 Blower wheel 133 x 38 4 mm for BE 21 kW 63003779 161 Blower wheel 133 x 59 4 mm for BE 28 34 kW 63003780 170 Blower wheel housing HG A size 1 for 21 kW 63006885 171 Blowe...

Страница 46: ...g 11 Buderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 46 Fig 39 Burner Control BE 1 3 2 3 US 7747100488 00 Brennersteuerung BE 1 3 2 3 50 80 80 120 70 90 100 110 10 30 20 40 30 90 50 ...

Страница 47: ...e mounting base assembly HG A 1 stage V5 no partial components 63045082 Single Components 30 Screw M4x16 7747015963 40 Cover component for HG A 1 stage 63029996 50 Screw M4x8 7747015963 70 Ignition assembly Beru EZG 120V 60Hz 7747010786 80 Screw M4x50 7747015963 90 Ignition cables BE BE A 63006890 100 Mounting pipe HG V4 63045054 110 Mounting pipe extension BE 3 RLU 63032472 120 UV flame sensor QR...

Страница 48: ...are part listing 11 Buderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 48 Fig 40 Oilpump BE1 3 2 3 US 7747100489 00 Ölpumpe Suntec OLE55C BE 1 3 2 3 20 10 60 70 40 30 50 ...

Страница 49: ...rt Number 10 Suntec oil pump OLE35C Rev 6 NA for BE 1 3 21 and BE 2 3 28 7747010779 10 Suntec oil pump OLE55C Rev 6 NA for BE 2 3 34 7747010781 Single available components 20 Coil assembly Suntec 120V 60Hz 7747010782 30 Filter A70 rev 3 for oil pump Suntec AS47 05883218 40 Cover gasket 63016667 50 Hose set straight BE SE complete 63031508 60 Nipple XGE 4LLR 1 8 straight 05883224 70 Oil tubing comp...

Страница 50: ...uderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 50 Fig 41 Complete Nozzle BE1 3 2 3 US 7747100490 01 Düsenstock BE 1 3 2 3 10 20 40 30 50 70 80 51 52 60 61 62 90 110 120 130 110 100 101 102 ...

Страница 51: ...D 28 kW 7747009739 52 Danfoss nozzle 65 gph 80 GR HFD 34 kW 7747009741 60 Mixing system diffuser plate assembly BE BE A 1 1 21 kW 63006902 61 Mixing system diffuser plate assembly BE BE A 1 1 28 kW 63006903 62 Mixing system diffuser plate assembly BE BE A 1 2 34 kW 63006904 70 Ignition electrode assembly BE BE A Typ4 L34 63018295 80 Screw DIN 912 M4x10 7747015963 90 Gasket D81 63037931 100 Burner ...

Страница 52: ...4 Disposal 7 F Flame sensor 8 I Inspections and maintenance protocol 32 L LMO 11 M Measure CO2 19 Measuring CO 21 Measuring CO content carbon monoxide 21 Measuring CO2 value 19 Messsonde 19 Mixing system 9 10 11 O Oil connection 38 Oil Delivery System 36 Oil delivery system 38 Oil nozzle 28 Oil pressure 10 20 Oil pump 8 15 16 Oil supply lines 37 Original spare parts 6 P Performance values 24 Progr...

Страница 53: ...Notizen Buderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 53 ...

Страница 54: ...Notizen Buderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 54 ...

Страница 55: ...Notizen Buderus Blue Flame Burner BE 1 3 2 3 Specifications subject to change without notice 55 ...

Страница 56: ...053 Tel 603 552 1100 Fax 603 584 1681 www buderus net Products manufactured by BBT Thermotechnik GmbH D 35573 Wetzlar www buderus de BBT North America Corporation reserves the right to make changes without notice due to continuing engineering and technological advances ...

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