baltur TBG 45 PV User manual

- TWO STAGE GAS BURNER WITH INVERTER
EN
Manual
instructions for use
РУС
Инструкция по
эксплуатации
ORIGINAL INSTRUCTIONS ARE (IT)
ORİJİNAL KULLANIM KILAVUZU (IT)
ОРИГИНАЛЬНЫЕ ИНСТРУКЦИИ (IT)
0006081445_201011
TR
Kullanım
talimatları kılavuzu.
TBG 45 PV
TBG 60 PV
- İKI KADEMELI INVERTÖRLÜ GAZ BRÜLÖRÜ
- ДВУХСТУПЕНЧАТЫЕ ГАЗОВЫЕ ГОРЕЛКИ С ИНВЕРТОРОМ

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INDEX PAGE
- Warning notes for the user ................................................................................................................................................... 4
- Technical specications .......................................................................................................................................................“ 6
- Connecting the burner to the gas supply .............................................................................................................................“ 9
- Application of the burner to the boiler - ...............................................................................................................................“ 10
- Wiring diagram - Operation description ...............................................................................................................................“ 11
- Combustion head air adjustment .........................................................................................................................................“ 13
- Starting up and regulation with methane gas ......................................................................................................................“ 18
- Gas burner control devices ..................................................................................................................................................“ 20
- Maintenance - Use of the burner .........................................................................................................................................“ 22
- Problem - Cause - Solution ..................................................................................................................................................“ 24
- Electric diagrams .................................................................................................................................................................“
- Before using the burner for the rst time please carefully read the chapter “WARNINGS NOTES FOR THE USER : HOW TO
USE THE BURNER SAFELY” in this instruction manual, which is an integral and essential part of the product. The works
on the burner and on the esystem have to be carried out only by competent people.
- Read carefully the instructions before starting the burner and service it.
- The system electric feeding must be disconnected before starting working on it.
- If the works are not carried out correctly it is possible to cause dangerous accidents.
BALTUR S.p.A.
Via Ferrarese 10 - 44042 CENTO (Ferrara) ITALIA
Tel. [phone] Fax [phone]
(International Tel. ++39.051.684.37.11 - Fax ++39.051.683.06.86)
http://www.baltur.it - http://www.baltur.com - [e-mail]
04/01/2010
Declaration of Conformity
We declare that our products
BPM...; BGN…; BT…; BTG…; BTL…; TBML...; Comist…;
GI…; GI…Mist; Minicomist…; PYR…; RiNOx…; Spark...;
Sparkgas...; TBG...;TBL...; TBML ...; TS…; IBR...; IB...
(Variant: … LX, for low NOx emissions)
Description:
forced air burners of liquid, gaseous and mixed fuels for residential and
industrial use meet the minimum requirements of the European Directives:
90/396/CEE ...............................................(D.A.G.)
89/336/CEE - 2004/108/CE........................(C.E.M.)
73/23/CEE – 2006/95/CE...........................(D.B.T.)
2006/42/CEE .............................................(D.M.)
and conform to European Standards:
UNI EN 676:2008 (gas and combination, gas side)
UNI EN 267:2002 (diesel and combination, diesel side)
These products are therefore marked:
0085 Dr. Riccardo Fava
Managing Director / CEO
!Important / note iInformation IWarning / Attention

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FOREWORD
These warning notes are aimed at ensuring the safe use of the compo-
nents of heating systems for civil use and the production of hot water.
They indicate how to act to avoid the essential safety of the components
being compromised by incorrect or erroneous installation and by improper
or unreasonable use. The warning notes provided in this guide also seek
to make the consumer more aware of safety problems in general, using
necessarily technical but easily understood language. The manufacturer
is not liable contractually or extra contractually for any damage caused
by errors in installation and in use, or where there has been any failure to
follow the manufacturer’s instructions.
GENERAL WARNING NOTES
• The instruction booklet is an integral and essential part of the product
and must be given to the user. Carefully read the warnings in the bo-
oklet as they contain important information regarding safe installation,
use and maintenance. Keep the booklet to hand for consultation when
needed.
• Equipment must be installed in accordance with current regulations,
with the manufacturer’s instructions and by quali ed technicians. By
the term ‘quali ed technicians’ is meant persons that are competent in
the  eld of heating components for civil use and for the production of
hot water and, in particular, assistance centres authorised by the manu-
facturer. Incorrect installation may cause damage or injury to persons,
animals or things. The manufacturer will not in such cases be liable.
• After removing all the packaging make sure the contents are complete
and intact. If in doubt do not use the equipment and return it to the
supplier. The packaging materials (wooden crates, nails, staples, plastic
bags, expanded polystyrene, etc.) must not be left within reach of chil-
dren as they may be dangerous to them. They should also be collected
and disposed on in suitably prepared places so that they do no pollute
the environment.
• Before carrying out any cleaning or maintenance, switch off the equi-
pment at the mains supply, using the system’s switch or shut-off sy-
stems.
• If there is any fault or if the equipment is not working properly, de-ac-
tivate the equipment and do not attempt to repair it or tamper with it
directly. In such case get in touch with only quali ed technicians. Any
product repairs must only be carried out by BALTUR authorised assi-
stance centres using only original spare parts. Failure to act as above
may jeopardise the safety of the equipment. To ensure the ef ciency
and correct working of the equipment, it is essential to have periodic
maintenance carried out by quali ed technicians following the manufac-
turer’s instructions.
• If the equipment is sold or transferred to another owner or if the owner
moves and leaves the equipment, make sure that the booklet always
goes with the equipment so it can be consulted by the new owner and/
or installer.
• For all equipment with optionals or kits (including electrical), only origi-
nal accessories must be used.
IWARNING NOTES FOR THE USER HOW TO USE THE BURNER SAFELY
BURNERS
• This equipment must be used only for its expressly stated use: applied
to boilers, hot air boilers, ovens or other similar equipment and not
exposed to atmospheric agents. Any other use must be regarded as
improper use and hence dangerous.
• The burner must be installed in a suitable room that has ventilation in
accordance with current regulations and in any case suf cient to ensure
correct combustion
• Do not obstruct or reduce the size of the burner’ air intake grills or the
ventilation openings for the room where a burner or a boiler is installed
or dangerous mixtures of toxic and explosive gases may form.
• Before connecting the burner check that the details on the plate corre-
spond to those of the utility supplies (electricity, gas, light oil or other
fuel).
• Do not touch hot parts of the burner. These, normally in the areas near
to the  ame and any fuel pre-heating system, become hot when the
equipment is working and stay hot for some time after the burner has
stopped.
• If it is decided not to use the burner any more, the following actions must
be performed by quali ed technicians:
a) Switch off the electrical supply by disconnecting the power cable from
the master switch.
b) Cut off the fuel supply using the shut-off valve and remove the control
wheels from their position.
c) Render harmless any potentially dangerous parts.
Special warning notes
• Check that the person who carried out the installation of the burner  xed
it securely to the heat generator so that the  ame is generated inside
the combustion chamber of the generator itself.
• Before starting up the burner, and at least once a year, have quali ed
technicians perform the following operations:
a) Set the burner fuel capacity to the power required by the heat ge-
nerator.
b) Adjust the combustion air  ow to obtain combustion yield of at least
the minimum set by current regulations.
c) Carry out a check on combustion to ensure the production of no-
xious or polluting unburnt gases does not exceed limits permitted
by current regulations.
d) Check the adjustment and safety devices are working properly.
e) Check the ef ciency of the combustion products exhaust duct.
f) Check at the end of the adjustments that all the adjustment devices
mechanical securing systems are properly tightened.
g) Make sure that the use and maintenance manual for the burner is
in the boiler room.
• If the burner repeatedly stops in lock-out, do not keep trying to manually
reset but call a quali ed technicians to sort out the problem.
• The running and maintenance of the equipment must only be carried
out by quali ed technicians, in compliance with current regulations.

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ELECTRICAL SUPPLY
• The equipment is electrically safe only when it is correctly connected to an
ef cient ground connection carried out in accordance with current safety
regulations. It is necessary to check this essential safety requirement.
If in doubt, call for a careful electrical check by a quali ed technicians,
since the manufacturer will not be liable for any damage caused by a
poor ground connection.
• Have quali ed technicians check that the wiring is suitable for the
maximum power absorption of the equipment, as indicated in the technical
plate, making sure in particular that the diameter of cables is suf cient
for the equipment’s power absorption.
• Adapters, multiple plugs and extension cables may not be used for the
equipment’s power supply.
• An ominpolar switch in accordance with current safety regulations is
required for the mains supply connection.
• The electrical supply to the burner must have neutral to ground
connection. If the ionisation current has control with neutral not to ground
it is essential to make a connection between terminal 2 (neutral) and the
ground for the RC circuit.
• The use of any components that use electricity means that certain
fundamental rules have to followed, including the following:
- do not touch the equipment with parts of the body that are wet or damp
or with damp feet
- do not pull on electrical cables
- do not leave the equipment exposed to atmospheric agents (such as
rain or sun etc.) unless there is express provision for this.
- do not allow the equipment to be used by children or inexpert
persons.
• The power supply cable for the equipment not must be replaced by the
user. If the cable gets damaged, switch off the equipment, and call only
on quali ed technicians for its replacement.
• If you decide not to use the equipment for a while it is advisable to switch
off the electrical power supply to all components in the system that use
electricity (pumps, burner, etc.).
GAS, LIGHT OIL, OR OTHER FUEL SUPPLIES
General warning notes
• Installation of the burner must be carried out by quali ed technicians
and in compliance with current law and regulations, since incorrect
installation may cause damage to person, animals or things, for which
damage the manufacturer shall not can be held responsible.
• Before installation it is advisable to carry out careful internal cleaning
of all tubing for the fuel feed system to remove any residues that could
jeopardise the proper working of the burner.
• For  rst start up of the equipment have quali ed technicians carry out
the following checks:
• If you decide not to use the burner for a while, close the tap or taps that
supply the fuel.
Special warning notes when using gas
• Have quali ed technicians check the following:
a) that the feed line and the train comply with current law and
regulations.
b) that all the gas connections are properly sealed.
• Do not use the gas pipes to ground electrical equipment.
• Do not leave the equipment on when it is not in use and always close
the gas tap.
• If the user of is away for some time, close the main gas feed tap to the
burner.
• If you smell gas:
a) do not use any electrical switches, the telephone or any other object
that could produce a spark;
b) immediately open doors and windows to create a current of air that
will purify the room;
c) close the gas taps;
d) ask for the help of quali ed technicians.
• Do not block ventilation openings in the room where there is gas
equipment or dangerous situations may arise with the build up of toxic
and explosive mixtures.
FLUES FOR HIGH EFFICIENCY BOILERS AND SIMILAR
It should be pointed out that high ef ciency boilers and similar discharge
combustion products (fumes) at relatively low temperatures into the  ue.
In the above situation, traditional  ues (in terms of their diameter and heat
insulation) may be suitable because the signi cant cooling of the combustion
products in these permits temperatures to fall even below the condensation
point. In a  ue that works with condensation there is soot at the point the
exhaust reaches the atmosphere when burning light oil or heavy oil or the
presence of condensate water along the  ue itself when gas is being burnt
(methane, LPG, etc.). Flues connected to high ef ciency boilers and similar
must therefore be of a size (section and heat insulation) for the speci c use
to avoid such problems as those described above.
IWARNING NOTES FOR THE USER HOW TO USE THE BURNER SAFELY

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TECHNICAL SPECIFICATIONS TBG 45 PV TBG 60 PV
THERMAL CAPACITY MAX kW 450 600
MIN kW 100 120
OPERATION Progressive two stage
NOx EMISSIONS mg/kWh < 80 (Class III according to EN 676)
MOTOR kW 0,50 0,75
r.p.m. 2730 2800
ABSORBED ELECTRICAL POWER* kW 0,71 0,98
line FUSE 230 V 4A 4A
IGNITION TRANSFORMER 26 kV - 40 mA - 230/240 V - 50/60 Hz
VOLTAGE 1N ~ 230 V + 10% - 15% - 50/60 Hz
PROTECTION RATING IP 44
FLAME DETECTOR IONIZATION PROBE
NOISE** dBA 73 75
AMBIENT TEMPERATURE OF OPERATION MAX ° C 40
MIN ° C - 10
WEIGHT kg 42 44
Natural Gas (G 20)
FLOW RATE MAX m³n/h 45,3 60,3
MIN m³n/h 10,1 12,1
PRESSURE MAX mbar 360
STANDARD ACCESSORIES TBG 45 PV TBG 60 PV
BURNER COUPLING FLANGE 2 2
INSULATING GASKET 1 1
STUD BOLTS N° 4 M 12 N° 4 M 12
HEXAGONAL NUTS N° 4 M 12 N° 4 M 12
FLAT WASHERS N° 4 Ø 12 N° 4 Ø 12
*) Total absorption at start with ignition transformer on and fan motor supplied at 50 Hz.
**) Noise levels measured in the laboratory of the manufacturer with burner running on test boiler, at maximum nominal thermal output.
TECHNICAL AND FUNCTIONAL SPECIFICATIONS
• Gas burner with low NOx and CO emissions in accordance
with "Class III" of the European standard EN676
• Two-stage progressive output operation.
• Adjustment of the number of revolutions of the fan according
to the operating stage through a frequency converter to obtain
a noticible reduction in noise and electricity consumption.
• Combustion head with exhaust gas recirculation which allows
extremely low polluting emissions with particular attention to
nitric oxide (NOx).
• Maintenance facilitated by the fact that the mixing unit can be
removed without having to remove the burner from the boiler.
• Combustion air ow adjustment with closure of the shutter when
paused to prevent any heat dispersion to the ue.
• Gas adjustment through the single stage working valve control-
led electromagnetically.
• Possibility to integrate the burner with a kit for valve seal control.
• Equipped with 4 and 7 pole connectors, 1 ange and 1 insulating
seal for xing to the boiler.
• Gas train exit from below.

OVERALL DIMENSIONS
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MODEL A A1 A2 B B1 B6 C D D EFI L L MN
min max Ø Ø min max
TBG 45 PV 550 270 280 435 325 160 920 140 300 137 133 215 200 245 M12 145
TBG 60 PV 550 270 280 455 325 160 920 140 300 156 152 260 225 300 M12 160
CONSTRUCTION CHARACTERISTICS
The burner consists of the following parts:
• Combustion air intake with buttery gate for adjusting the air
ow rate, designed to obtain optimal linear air shutter opening.
• Mounting ange to the sliding generator, to adapt the protuber-
ance of the head to various types of heating generators.
• Air pressure switch to ensure the presence of combustion air.
• Adjustment of air intake for the rst and second stage by means
of electric servomotor.
• Frequency converter to obtain a noticible reduction in noise
and electricity consumption.
• Gas train complete with safety valve and single stage operation,
and electromagnetic functioning, minimum pressure switch,
pressure regulator and gas lter.
• Flame detection by ionisation electrode.
• Automatic command equipment and burner control according
to European regulation EN298.
• Connection to gas train with fail safe connectors.
• 7 pole plugs for the electricity and thermostat supply of the
burner, 4 pole plug for the command of the second stage of
operation.
• Suitable for microammeter connection to the ionisation cable.
• Electrical system with protection rating IP44.
1) Combustion head
2) Insulation Gasket
3) Burner connection ange
4) Combustion head adjustment device
5) Cover
6) Gas train connector ange
7) Electrical panel
8) Motor
9) Air regulation servomotor
10) Air pressure switch
10a) Second stage air control pressure switch
11) Inverter
12) gas throttle strap activation
n° 0002471280

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OPERATING RANGE
ELECTRICAL BOX COMPONENTS
13) Equipment
14) Ignition transformer
17) 7 pole plug
18) 4 pole plug
19) Led burner on
20) Led burner lock-out
21) Reset button
22) ON/OFF switch
23) Inverter fuse
24) Burner fuse
2
0
mbar
0002922650
100
kW
TBG 45P
10
200 300 400 500 600 700
4
6
8
10
3
3
m /h(Metano)
m /h(G.P.L.)
n
n
20 30 40 50 60 70
2 4 6 8 10 12 14 16 18 20 22 24 26 28
TBG 45ME
TBG 60P
TBG 60PN
TBG 45PN
TBG 60ME
TBG 45P-V TBG 60P-V
TBG 45 PV
TBG 45 PNV TBG 60 PV
TBG 60 PNV
The working elds are obtained from test boilers corresponding
to the standard EN676 and are indicatively for the combination
burner-boiler. For correct working of the burner the size of the
combustion chamber must correspond to current regulations; if
not the manufacturers must be consulted.

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Legend
1) Manual shut off valve
2) Anti-vibration joint
3) Gas lter
4) Minimum gas pressure switch
5) Safety valve
6) Pressure regulator
7) Valves seal control device (obligatory for burner with
maximum nominal thermal out-put over 1200 kW)
GENERAL GAS BURNER SYSTEM
8) Slow opening working valve
9) Air shutter servomotor control
10) Air adjustment gate
11) Air pressure switch
11a) Second stage air control pressure switch
12) Combustion head
13) Gas adjustment buttery valve
Gas train supplied by the manufacturer Responsibility of the installer
0002911080
POWER SUPPLY LINE
The gas supply scheme is shown in the diagram below. The gas train
is certied in accordance with regulations EN 676 and is supplied
separately from the burner.
A manual shut off valve and anti-vibration joint must be installed
upstream of the gas valve, as shown in the diagram.
In the case of a gas train with a pressure regulator that is not
incorporated in a monoblock valve,
we consider it useful to give the following practical advice regarding
the installation of accessory components to the gas piping close
to the burner:
1) To prevent severe drops in pres-sure on ignition it is advisble
to have a length of piping of 1.5 to 2 metres between the point
of application of the stabiliser or pressure reducer and the
burner. This pipe must have a diameter equal to or greater
than the connector to the burner.
2) For the better working of the pressure regulator it is advisable to
apply it to the horizontal piping, after the lter. The gas pressure
regulator must be adjusted when working at maximum capacity
and actually used by the burner. The delivery pressure must be
adjusted to a level slightly below the maximum obtainable. (that
which is obtained when the regulation screw is turned almost
to the end); in the specic case, when the regulation screw is
tightened, the output pressure from the regulator increases and
when it is loosened it decreases.

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ASSEMBLING THE GAS TRAIN
There are different ways of assembling the valve train 8 and 8a as
shown in the drawing.
Choose the most rational position for the set-up of the boiler room
and the position in which the gas pipe arrives.
APPLICATION OF BURNER TO BOILER
- Position insulating seal 3 on the sleeve, placing cord 2 between
the ange and the seal.
- slacken screws “6”,
adjust the position of connection ange “5” so that the combu-
stion head penetrates the furnace up to the length recommen-
ded by the generator manufacturer.
- Fasten the burner 4 to the boiler 1 by means of the stud bolts,
washers and the nuts provided 7.
!Competely seal the space between the tube unit of the
burnerandtheholeintherefractorypanelusingsuitable
materials to do so.