TeHa BR1000 ECO PLUS Manual de usuario

Owners manual for BR1000 ECO PLUS

valid from 01.01.2013

Table of contents Page

Description................................................................. 1

Assemblies................................................................. 1 - 2

Definition and application........................................... 2

Installation recommendation ...................................... 2 - 4

Service and maintenance ........................................... 4 - 5

Safety advice.............................................................. 5 - 6

Warranty..................................................................... 6

Exploded view combustion chamber, complete.......... 4

Parts list, combustion chamber, complete................... 8 - 9

Parts list, mixing device.............................................. 10

Exploded view, mixing device ..................................... 10

Exploded view, switch box.......................................... 11

Parts list, switch box .................................................. 12

View of burner adjustment settings ............................ 13

Dimensioned drawing, combustion chamber............... 13

Circuit diagram with flame control.............................. 14

Chimney connecting piece.......................................... 15

Diagram to determine the chimney cross-section ...... 15

Enclosure: Trouble shooting guide .............................. 16 - 20

Technical data ............................................................ 20

Digital control............................................................. 21-31

1. Description

Theodor Henrichs’ new boiler technology enables you to achieve less soot discharge at a very high performance level.

The nominal capacity of 90-95kW is well controllable by means of the digital thermostat. If you need high and constant

temperatures, the BR1000 ECO PLUS is what you need.

2. Assemblies

The combustion chambers mainly consist of the following assemblies: (See also exploded view page 7)

Burner Type B90 (See also exploded view page 10)

The BR series of vertical burners have proven themselves over the years and the design is applied unchanged for all types

of combustion chambers. The different capacities are achieved by the fitting of fuel nozzles with different flow rates and

corresponding changes in air flow.

Heating coil (See also exploded view page 7, Pos.37)

An efficient high capacity is achieved by using double wound heating coils. Their tube wall thickness is strongly over

dimensioned, so that normally a long lifetime is guaranteed. Almost all applications can be covered due to the large range

of varieties:

Material: steel, stainless steel 1.4301 and 1.4571

Dimensions: 3/8“ and 1/2“

Range of pressure: up to 500 bar

Casing (See also exploded view page 7, P. 35 + 36)

Between the inner and the outer casing is an integrated ventilator housing building a ring gap.

Through this ring gap the burner is provided with combustion air. The following advantages arise from this method:

a. The outer casing is cooled.

b. The combustion air is preheated.

c. Due to the double casing the construction is very stable and extremely rigid.

Galvanized, powder coated steel sheet and stainless steel 1.4301 are the available materials.

Ventilator motor, ventilator fan and oil pump are the next assembly. (page 7, P. 22, 20 and 24).

A solenoid valve controls the oil supply of the burner thermostatically.

Normally a two step pump with integrated solenoid valves is installed.

The combustion chamber is formed by an extremely heat resistant tube reaching deeply into the flame area. This prevents

the still cold heating coil being sprayed by unburned oil during the start period, thus reducing distortion of the heating coil.

The insulation plate (page 8, P. 34) made from oxide ceramic prevents the combustion chamber from burning out.

It absorbs unburned sprayed heating oil as well as condensation water. During operation of the burner it will evaporate

immediately. The insulating plate will not be damaged by these procedures.

The safety device consists of:

Switch box with switch elements (P. 7, Pos. 19 + S. 16), Temperature limiting safety device (P. 7, Pos. 5 + P.13, Pos.10)

Flame control (P. 10, Pos. 18), Digital thermostat (P. 10 Pos. 20), Safety valve (P. 7 Pos. 30),

Flow switch (P. 7 Pos. 29) and manometric switch (P. 7 Pos. 31).

These safety devices guarantee the safe operation of the burner and regulate the desired water temperature.

The ignition transformer (P. 7, Pos. 18) with 20 mA secondary current ensures high ignition capacity and thus a safe

start even under unfavourable conditions. It is mounted outside the switch box either on the outer casing or at the switch

box support to achieve better heat dissipation and moisture exclusion.

3. Definition and application

The BR series of burners have been designed to provide almost instant heating of water under pressure. The water may be

mixed with cleaning chemicals. However, in this case special attention has to be paid to the choice of material for the wetted

parts and if the chemicals are corrosive, a stainless steel coil material 1.4201 is recommended to be ordered.

The areas of application are primarily in cleaning applications for example:

Car washing in the automobile section,

Cleaning of façades (among others: removal of graffiti),

Floor cleaning (among others: removal of bubble gums),

Renovation of buildings and ships,

Cleaning of food production areas, abattoirs, sterilisation, etc.

4. Recommandations for installation

Mobile installation

Installation sites which are permanently under surveillance do not need a flame control. However, burners used in these

installations have to be provided with a permanent ignition spark. This applies particularly to mobile machines.

Stationary installation

Those installations which are not under permanent surveillance necessarily require a flame control.

Range of pressure

Low pressure range 4 – 20 bar

The normally fitted manometric/pressure switch has a shift point of 20 bar. For use in a low pressure range this switch is

not necessary and has either to be by-passed or to be removed. For low pressure use, the heating coil should be of 1/2“

tubing. Thus the production of steam bulbs which might lead to premature coil failure is avoided.

High pressure range 20 bar and above

Here mainly the 3/8“- heating coils are used, though the 1/2“- heating coils can be installed up to 200 bar depending

on the desired flow rates.

Safety valve (P. 7 Pos. 30)

The operator should never adjust the safety valve.

Before putting into operation the installer should adjust the safelty valve as follows:

1. Bring the machine to the required operating pressure.

2. Loosen the lock nut (the upper nut from the two nuts above the pressure spring).

Loosen the lower of the two nuts by turning slowly to the left until drops come out at the angled bush (P. 7 Pos. 28).

3. Close the nut again until water is no longer dripping out.

4. Then make another half turn to the right and lock the nut by tightening the upper nut tightly against the lower nut.

Wrongly adjusted safety valves may lead to bursted heating coils and hoses as well as danger to the operators.

Installation of the combustion chambers in closed machines or areas.

The following points should always be considered.

- The combustion chamber has to be installed in such a manner that the maintenance of the burner can be carried out at

any time without having to remove parts of the machine or the chimney.

- Air damper (page 7, item 21) and oil pump (page 7, item 24) must be accessable for adjustment.

Enough space should be available to install and read an oil pressure gauge.

- The perforated air intake side of the ventilator housing may not be covered;

otherwise the lack of air leads to building up of soot inside the burner.

- The installation and removal of the combustion chamber should easily be possible

(to enable general cleaning and the exchange of the heating coil).

- In closed areas one has to make sure that sufficient additional ventilation is available.

- The heat emission of pumps, motors, transformers and the combustion chamber has to be removed

by the appropriate ventilator devices.

Exhaust gas control

The German regulations LBauO / FeuVO have to be considered. Please refer to the appropriate authorities during planning.

The clear opening and height of the exhaust systems have to be sized in such a way that the exhaust air will vent into the

open air during all expected operating conditions. There has to be a permanent vacuum of at least 0.5 mbar with respect to

the surrounding rooms.

We recommend a chimney diameter of at least 200 mm.

See also diagram for determination of the chimney diameter on page 15!

Connecting piece for the connection of the chimney see page 15!

The mouth of the chimney has to be at least 40 cm above the roofridge or at least 1m away from the roof surface.

The burner must be fitted with a flame monitor.

The chimney connecting pipe, page 15, makes the chimney connection easier.

The connecting pipe is available either in open or in closed type. However, the open type makes the starting procedure

easier. Please refer to page 21 for examples of some of the connectins available.

When connecting more than one combustion chamber to one chimney please seek expert advice.

Installation rooms and additional air control (German regulations LBauO / FeuVO have to be considered).

Fireplaces with a total heat capacity of more than 50 KW may only be installed in rooms, which are not being used in any

other way. The only exception is the simultaneous installation of heating pumps, engine-based cogenerators and internal

combustion engines.

The heating rooms must have a volume of at least 8m³ and a height of 2 m.

There has to be at least one exit to the open air or to a floor. For the ventilation of the room an upper and a lower opening

for fresh air has to be installed. These openings must have the following dimensions:

For 50 KW –cross section of the opening 300 cm² each + 2.5 cm² for every further KW.

Alternatively outside air suction can be carried out by means of a pipe system.

A suitable ventilator joint is available from the TEHA accessories range.

The nominal diameter of the tube shall be Ø >=110 mm. In case of danger of frost a motor driven lid is recommended.

This lid should be coupled with the burner control in such a way that the burner cannot be startet, if the lid is closed.

Special attention has to be paid to the fact that the burner ventilator should not suck in its own or foreign exhaust gases.

The same applies to dust of all kinds, like for example wheel swarf and lacquer dust in production areas in industry and in

workshops.The following are just two problems likely to be caused by excessive dust in the intake air:

1. The dust particles are polluting the baffle plate, leading to malfunction of the burner.

2. The dust particles will secrete on the heating coil and the inner casing and thus causing corrosion.

Oil pump and fuel filter

The fuel supply should be carried out by means of two caoutchouc hoses reinforced by metal tissue via a two strand fuel filter.

The operator has to mount the fuel filter on the machine.

Attention! The oil pump must always be protected against running dry or being left idle for long periods.

Calcareous water

A decalcifying device has to be installed in case the machine is being operated with calcareous water with a high calcium or

mineral content. The coil might clog irreparably within short notice if the water is extremely calcareous.

5. Service and maintenance

All maintenance should be carried out by well trained professionals only.

The maintenance rate of 400 operating hours should be maintained.

This figure may vary up or down depending on the operating conditions.

Mixing device, (page 7, P. 3 and page 10)

Remove the spark plug sockets (P. 10, Pos.13) Loosen the connection of the fuel tube (P. 10, Pos.12),

Loosen the 3 fastening screws (P.7, Pos. 2) Carefully pull out the entire mixing device (P. 7, Pos. 3),

Loosen the fastening screw (P. 10, Pos. 9) and pull off the centering device ( P. 10, Pos. 5) together with the igniting

electrodes (P. 10, Pos. 8). Thorougly clean all pieces. Replace nozzle (P. 10, Pos. 6) and igniting electrodes (P. 10, Pos. 8)

with new ones, if necessary. Re-assemble everything in reverse order.

Adjust igniting electrodes as shown in drawing MIEIRI/3 (P. 13).

The adjustment of the burner is aimed to achieve the best possible exhaust values, with high effectivity and good

ignition behaviour. The following measured values with the recommended limiting values serve as a guide:

Exhaust gas temperature: < 260 °C

CO2- value: > 11%

Smoke appearance: <= 1

Oil pressure step 1: 8 – 10 bar

Oil pressure step 2: 10 – 14 bar

The following possibilities exist to influence these values:

5.2.1 Changing the quantity of the primary air shifting the air damper (P. 7, Pos. 21)

Air damper upward means more air, air damper downward means less air.

5.2.2 Changing the quantity of the secondary air by shifting the nozzle tube (P. 10, Pos.11)

and (P. 13) This is how the ring gap between the baffle plate and the flame tube is

changed. This leads to a change of the distribution of the air quantities between the

baffle plate on the one hand and the ring gap on the other hand.

Attention! Act very sensitively: the smallest movement shows its effect.

5.2.3 Changing the pump pressure.

First of all connect the suitable pressure gauge to position 8 of the 2-step-oilpump

Suntec AT2. Position 6 as well as 7 are intended to adjust the two pressure levels.

The upper one (6) adjusts the low pressure level, respectively step 1. The lower (7)

adjusts the high pressure level respectively step 2. Turning to the right produces more

pressure, turning to the left produces less pressure.

5.2.4 Adjustment of the regulating devices, 5.2, Pos. 1–3, leads to the following changes:

1) more air: better smoke appearance

lower CO2 – value

higher exhaust gas temperature

worse ignition behaviour

2) pulling out of the nozzle tube: better smoke appearance

lower CO2 – value

better ignition behaviour

3) higher oil pressure: worse smoke appearance

higher CO2 – value

higher exhaust gas temperature

worse ignition behaviour

better heating capacity

By changing the values a compromise has to be found which produce the best possible performance.

Inspection of the burner chamber

Remove the mixing device as described under item 5.1.

Remove outer lid (P. 7, Pos. 6) Pull out the inner lid (P. 7, Pos. 7) with flame tube, inner tube and chimney and remove

possible soot accumulation. Now the inner part of the heating coil can be reached and examined by means of an exterior

source of light (a torch e.g.).

Small layers of soot and corrosion can be loosened by using a scratch brush and removed by using a vacuum cleaner.

(Attention: Avoid damaging the insulating plate (S. 7, P. 34)

Spray the entire heating coil with soot spray as completely as possible before re-assemblance. After correct adjustment

of the burner the soot will burn out, however be prepared for some excessive smoke while the burner clears this soot.

Defective heating coil (entirely sooted, entirely calcified, damaged by frost, excessive pressure or faulty material)

The replacement of the heating coil requires the removal of the entire combustion chamber.

Having removed the combustion chamber the procedure is as follows:

Remove the mixing device as described under item 5.1.

Remove the outer and the inner lid as described under item 5.3.

Turn the combustion chamber from its vertical axis for 180° and place it with its heating coil on a cylinder

with diameter Ø 270mm x height 200 mm ( approx. measurements).

Remove 2 brass nuts (P. 7, Pos. 25) Pull off the outer casing upward (P. 7, Pos. 35) Remove 2 spacer tubes (P. 7, Pos. 33)

Pull off the inner casing upward (P. 7, Pos. 36) Remove remainder of the insulating plate (P. 7, Pos. 34)

Place the new heating coil onto the assistant cylinder. Re-assemble in reverse order.

A new insulating plate absolutely has to be used and make sure that the spacer tubes are not forgotten

(P. 7, Pos. 33) + (P. 7, Pos. 38)

Fuel Filter

- The filter cartridge should be exchanged at least every year or more often depending on use and quality of fuel.

- Every year the cover of the housing has to be removed and the pump has to be cleaned with either cleaning petrol

or compressed air.

- The fuel tubing has to be checked for leaks.

6. Safety Notice

Service and repairs should only be carried out by trained professionals.

Stationary installations (see also 4.1.2!) always have to be equipped with a flame control system. Otherwise the flame might

stop or start off unnoticed. If the flame stops, unburned oil may continue to be injected and the leaking oil may cause severe

damage. In the worst case this might lead to detonations or explosions with damage by fire and/or injuries of the personnel.

For low pressure range use the heating coil should be ½“ tubing.

It has to be made sure that the minimum flow pressure of the water is 4 bars.

Otherwise steam bubbles may build up inside the heating coil, which leads to an intermittent flow. In case of breakdown

of the over temperature relay the combustion chamber may burn out possibly resulting in fire damages and/or injuries of

the operator or on looking personnel.

The safety valve always has to be adjusted precisely to the operating pressure (see 4.3!). Pressure peaks caused by

switching impulses or choked nozzles will not be relieved by an improperly adjusted valve, and this may cause the heating

coil or valves to burst. In the worst case this may lead to serious injuries to the operator or adjacent personnel.

Make sure that the exhaust gas and the additional air venting is appropriate (see 4.5 + 4.6!).

Exhaust gas conduits which are not properly fitted or not sufficiently dimensioned as well as insufficient additional air conduits

may cause damage to buildings and in the worst case cause injuries to persons.

7. Warranty

The machines will be delivered with control system, safety device and flame control.

The manufacturer has no control over the proper installation (adjustment of the safety valves, correct conduit of the additional

air and the exhaust gas (pages 3 + 4).

The manufacturer cannot assume liability for defects or damages resulting from non-expert installation.

Otherwise the legal one-year-warranty is valid in case of correct installation.

In case the product is resold by the dealer from his store after a longer storage period, the one-year-warranty will be exten-

ded only, if the final customer returns to us a copie of the invoice. The manufacturer’s liability is not valid, if the user does not

follow the directions for mounting and operation and uses spare parts that are not covered by warranty.

In all other cases our general conditions for sale and supply shall apply.

BR1000 ECO PLUS, oil heated, since 01.01.2013

List of spare parts for oil heated combustion chamber type 1000 ECO PLUS,

all variations up to 500 bar, application as of 01.01.2013

Pos. Code-No. Pieces Description

1 B10400237 1 Fuel tube BR1000, copper

2 E10400229 3 Fastening screw 4,2x13, galvanised

3 B10400169 1 Mixing device, complete, see separate list of parts, without fotocell

4 E10400155-2 2 Ignition cable with connector plug for transformer, 1100 mm long

4.1 E10400091-1 2 Spark plug socket with rubber caps

5 E10400657-3 1 Temperature limiting safety device, ﬂue gas sensor

5.1 B10400104 1 Support for ﬂue gas sensor

5.2 E10710025 2 Oval head screw M5x8 VA

5.2.1 E10700066 2 Hexagon nut M5 VA

5.3 E10440074 1 Oval head screw M4x6 VA

6 1 Outer lid, green

B1040005902-1 1 Outer lid, stainless steel

7 B10400320-3 1 Inner lid, chimney, ﬂame tube, insulating plate, diffusor 260mm

7.1 E10400763 1 Insulating plate for inner tube Drm 181 (belongs to 7)

7.2 B10400096-4 1 Inner tube, BR1000 ECO PLUS 295mm (belongs to 7)

8 B10400201 4 Eyebolt, complete.8 with countersunk bolt., washer, nut

8.1 E10400252-2 4 Eyebolt M6x50, galvanised

8.2 E10400769 4 Countersunk bolt M6x10, galvanised

9 B10400251 1 Water outlet 3/8“ up to 400bar, Ermeto tube, galvanised

B10400314 1 Water outlet 1/2“ up to 200bar, Ermeto tube, galvanised

10 E10460003 1 Connector GAI 12 PLR, straight, 3/8“i-12, galvanised

E10440049 1 Connector GAI 18 PLR, straight, 1/2“i-18, galvanised

11 E1040020601 2 Hose clamp, Drm 12-22 mm, galvanised

12 B10440037-10 1 Split taper socket for ptc sensor, 3/8“, copper

B10440037-12 1 Split taper socket for ptc sensor, 1/2“, copper

14 E10400126 2 Fastening nut M6, galvanised

14.1 E10400197 2 Washer 6,6, galvanised

15 E10460003-1 2 Connector GAI 12 LRCFX, galvanised

E1044004901 2 Connector GAI 18 LRCFX, galvanised

16 E10850093 2 Connector EW 12 LCF, angle galvanised

E10850060 2 Connector EW 18 LCF, angle, galvanised

16.1 E1046000201 1 Connector GE 12 PLR ED, galvanised

E10850003 1 Connector GE 18 PLR ED, galvanised

18 E10400014-3 1 Ignition transformer, 20 mA 100% ED, 230V, 50/60Hz

E10400013 1 Ignition transformer, 20 mA 100% ED, 110V, 50/60Hz

18.1 B1040008501 1 Transformer support, galvanised

18.2 E10400014-3-1 1 Connecting cable with plug for transformer, 1500 mm long

19 B10400253 1 Switch box, complete (see page 9)

Pos. Code-No. Pieces Description

20 E10400157 1 Ventilating wheel 180x82, left

21 B10400070-2 1 Adjustable damper for air, convex, galvansied

21.1 E10400229 2 Fastening screw 4,2x13, galvanised

21.2 E10400831 5 Washer 12, galvanised

22 E10400246-01 1 Ventilating motor 230V, 50Hz, 150W

E10400143-01 1 Ventilating motor 110V, 50/60Hz, 150W

22.1 B10400317 1 Capacitor for 230 V- Motor, galvanised

23 E10400101 2 Washer 8,4, galvanised

23.1 E10400102 2 Fastening nut M8, galvanised

24 E10400955 1 Suntec 2 step oil pump with solenoid valve and coil, without cable

24.1 E10400326 1 Coupling, diameter 8 mm, palstic

24.4 E10400061 2 Joint cable, solenoid valve, 1050 mm

E10400061-1 2 Joint cable, solenoid valve, 700 mm

24.5 E10400042 Connector GE 04 LLR, 1/8“, galvanised

25 E10400245 2 Brass-nut ﬂat 3/8“

E10400489 2 Brass-nut ﬂat 1/2“

25.1 E10400133 2 Washer 17, galvanised, 3/8“

E10720009 2 Washer 25, galvanised, 1/2“

26 E10400199 2 Double nipple, 3/8“, OT-OT, galvanised

E10710063 2 Double nipple, 1/2“, OT-OT, galvanised

27 E10460022 1 T-piece, 3/8“, IT-IT, stainless steel

E10450012 1 T-piece, 1/2“, IT-IT, stainless steel

28 E10400147 1 Angular joint, Polyamid

29 E104500021 1 Flow switch RMU-B12, G 3/8“

E104500611 1 Flow switch RMU-B12, G 1/2“

30 E10400009 1 Safety valve, 250bar

E104000091 1 Safety valve, 500bar

31 E10400558 1 Manometric switch, 1/4“, 300bar

E10400581 1 Manometric switch, 1/4“, 600 bar

32 B10400252 1 Water inlet 3/8“ up to 400bar, Ermeto tube galvanised

32 B10400314 1 Water inlet 1/2“ up to 200bar, Ermeto tube, galvanised

33 E10400057 2 Spacer

34 E10400166 1 Oxydceramic disk, Ø290 x 8, 2 holes

35 B10400204-ECO 1 Outer casing BR1000 ECO PLUS, galvanised, powder coated, RAL9005

36 B1040016301 1 Inner casing BR1000, stainless steel

37 B10400145-1 1 Heating coil HZ100, steel, 3/8“, 300bar, for BR1000

Heating coils for further nominal Ø, materials and operating pressures upon request

38 E10400161 4 Spacer tube, D 16 x 1 x 23

39 E10400196 4 Cap nut M6, galvanised

39.1 E10400197 4 Washer 6,6, galvanised

Pos. Code-No. Pieces Description

3B10400006 1 Electrode holder, half

5 B10400087 1 Centering device, since 1992

6 E10400570-2 1 Oil nozzle 2,25/60°H

7 E10400118-1 1 Nozzle holder with thread M8, hexagon, brass

8 E10400464-2 CIM 2 Igniting electrode, short. since 2011

9 E10440040 2 Hexagon socket screw M6 x 12, galvanised

11 B10400199 1 Nozzle tube

12 E10400789 1 Connector (for 8mm tube), GR 8/4 - LL, galvanised

12.1 E10400042 1 Connector (1/8“ OT), GE 4 LLR, galvanised

13 E10400091-1 2 Spark plug socket with rubber caps

16 B10400086 1 Support ﬂange, galvanised

17 B10400185 1 Photocell holder with screws, Pertinax

18 E1040045601 1 Photocell, 230V/110V

19 E10400400 1 Glas for photocell, 14,2 x 3 mm

20 E10850036 2 Sheet metal screw, 3,9 x 9,5, galvanised

21 E10440040 1 Hexagon socket screw M6 x 12, stainless steel

22 E10400571 1 Oval head screw M4 x 10, galvanised

List of parts, mixing device BR1000 ECO PLUS

Mixing device

Drawing No.: Mischeinrichtung_BR6-12

21.11.2002

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