Forced draught burner PBG..

EE

Technical Information · GB
7 Edition 04.12

• Robust burner design for applications in industry

• Easy to install thanks to compact design, complete pre-
assembly and pre-wiring
• Electronic actuator permits easy integration into existing
control systems
• Wide control range > 1:20
• Large temperature range thanks to excess air operation
• Direct ignition and monitoring
• 4 sizes from 70 – 1100 kW

www.lbe-online.de
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Contents
Forced draught burner PBG..EE . . . . . . . . . . . . . . . . . . . . . . 1 6.3.1 Installation in open combustion chambers . . . . . . . . . . . . 12
6.3.2 Installation in heat exchangers . . . . . . . . . . . . . . . . . . . . . 12
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6.3.3 Installation with protective flame tubes . . . . . . . . . . . . . . . 13
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6.4 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 4 6.5 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.1 Direct heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Indirect heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6.6 Control signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.3 Continuous control with pneumatic ratio control system . . 5 7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1.4 Continuous control with linear flow control . . . . . . . . . . . . . 5 7.1 Burner size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7.2 Dimensions of PBG 300 – 1000 . . . . . . . . . . . . . . . . . . . 15
2.1 Declaration of Incorporation pursuant to 7.3 Dimensions of PBG 2000 – 5000 . . . . . . . . . . . . . . . . . . 16
the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9.1 Protective flame tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9.2 Measuring orifice VMO . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Gas safety and control system . . . . . . . . . . . . . . . . . . . 8 9.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Burner control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 PBG..EE with air/gas ratio control . . . . . . . . . . . . . . . . . 9
4.2 PBG..EE with linear flow control . . . . . . . . . . . . . . . . . . . 9
5 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Burner size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Burner type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Gas types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Project planning information . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Combustion chamber conditions . . . . . . . . . . . . . . . . . 11
6.2 Standard installation positions . . . . . . . . . . . . . . . . . . . 11
6.2.1 PBG..EE with air/gas ratio control . . . . . . . . . . . . . . . . . . . . . 11
6.2.2 PBG..EE with linear flow control . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PBG..EE · Edition 04.12 t = To be continued

Application 3

1 Application
Completely pre-assembled and pre-wired burner unit with
mounted fan, gas safety and control system and burner control
unit for applications in industry. Typical applications include
drying systems, hot-air generators, flue air purification or pro-
cess gas heating.
Thanks to its compact design, both conversion of existing
systems and initial installation can be implemented within a
very short time.
Control is carried out using constant excess air (air/gas ratio
control) or using linear flow control LFC in the gas circuit with
a constant air volume.
PBG..EE with air/gas ratio control
The air/gas ratio control VAG ensures a constant gas/air pres-
sure ratio with excess air. The pressure is preset by the air
PBG..EE with air/gas ratio control
control line.
PBG..EE with linear flow control
The gas flow rate can be adjusted continuously using the
linear flow control LFC with actuator IC 20. The air flow rate
remains constant.

PBG..EE with linear flow control

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1.1 Examples of application

PBG 1.1.1 Direct heating
The forced draught burner PBG fires into a combustion cham-
ber which is directly connected to the process chamber. Thanks
to this direct firing system, optimal utilization of the heat gener-
ated is possible, e.g. in directly heated drying systems.
Combustion Process chamber
chamber

Exhaust gas
Fresh air

1.1.2 Indirect heating

PBG
The forced draught burner PBG fires into a combustion cham-
ber which heats the process medium indirectly via a heat
Process medium exchanger. For applications in which combustion gases must
be kept separate from the product, e.g. for hot-air generation
or process gas heating.
Flue gas

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1.1.3 Continuous control with

pneumatic ratio control system
VAS VAG The burner capacity is controlled in mod-
ulating mode by adjusting the butterfly
AKT VMF PZL valve BVA. An impulse line on the air/
gas ratio control VAG ensures constant
PZH
air and gas pressures. The ratio of the
PZL gas volume is kept constant.
M
BCU
DL BVA

1.1.4 Continuous control with linear

M flow control
VAS
The burner capacity is controlled in
modulating mode by adjusting the linear
AKT VMO VMF PZL LFC flow control LFC in the gas circuit with a
constant air volume.
PZH

PZL

BCU
DL BVA

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2 Certification
2.1 Declaration of Incorporation pursuant to the
Machinery Directive
The forced draught burner PBG..EE complies with the require-
ments of EN 746-2 and the Machinery Directive 2006/42/
EC. This is confirmed by the manufacturer’s Declaration of
Incorporation.

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3 Mechanical construction Burner insert

The forced draught burner PBG..EE is a completely pre-as-
sembled and pre-wired burner unit. With its mounted fan, gas
safety and control system and burner control unit, the burner
constitutes a coordinated system.
Thanks to its compact design, both conversion of existing
systems and initial installation can be implemented within a
very short time.
The ignition and ionization electrodes are screwed into the
3.1 Burner connection flange and can be replaced without removing
The burner is composed of 3 modules: burner housing, burner the burner insert.
insert and burner tube. Gas and air are only mixed once they are in the burner head
and are then ignited. This prevents explosive gases from be-
ing generated in the pipelines.

3.2 Fan

The entire burner unit can be easily mounted using the burner
On the PBG..EE, the fan is flange-mounted directly onto the
flange on the burner housing. The solid burner housing made
burner housing air connection. No other complex pipework
of cast iron accommodates the burner insert and the burner
is required. A pressure switch fitted to the fan housing acts
tube, and routes the combustion air.
as the air deficiency cut-out in accordance with the require-
ments of EN 746-2.
An air filter is available separately, see page 18 (Air filter).

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3.3 Gas safety and control system 3.5 Actuator

Air/gas ratio control
The PBG..EE is available with two different types of gas train:
an air/gas ratio control line with capacity control via the com-
bustion air or a control line with linear flow control at constant
air volume.
Both gas trains include a high gas pressure protection de-
vice (PZH), a low-pressure cut-off (PZL) and a double shut-off
valve, in accordance with the requirements of EN 746-2.
Actuator IC 20..E for precise, controlled rotary movement be-
tween 0° and 90° is mounted on the butterfly valve or on the
linear flow control depending on the type of control selected.
The actuator can be controlled by a 4 – 20 mA, 0 – 20 mA or
0 – 10 V signal as desired.
You can find further information on actuators at:
www.docuthek.com.

3.4 Burner control unit

The burner control unit BCU 370 controls, ignites and monitors
forced draught burners of unlimited capacity in intermittent or
continuous operation.
You can find further information on burner control units at:
www.docuthek.com.

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4 Function
VAS VAG
Air
AKT VMF PZL
PZH

PZL
Ignition electrode M
BCU
Burner tube DL BVA

Burner insert PBG..EE with air/gas ratio control

Gas
VAS M

AKT VMO VMF PZL LFC

PZH
Burner head
PZL

Ionization electrode BCU

DL BVA

Burner housing
4.1 PBG..EE with air/gas ratio control
The burner control unit BCU 370 actuates the fan and pre-purge
is carried out in the combustion chamber. After pre-purge, the
air valve moves back to the ignition position. The gas can be
released and the gas control element comprising gas solenoid
valve VAS and solenoid valve with pressure regulator VAG
opens. The gas flows through the burner insert and the air
flows through the burner housing as far as the burner head.
The combustible gas/air mixture is produced downstream of
the burner head and is electrically ignited directly by an ignition
electrode. The resulting flame is controlled by the ionization
electrode. After pre-purge and burner start, the controller en-
able signal is issued to an external controller which positions
the butterfly valve in accordance with the capacity demand.
The pressure for the air/gas ratio control is preset by the air
control line. A gas orifice limits the maximum burner capacity.
PBG..EE with linear flow control
4.2 PBG..EE with linear flow control
The burner control unit BCU 370 actuates the fan and pre-
purge is carried out in the combustion chamber. After pre-
purge, the linear flow control LFC moves back to the ignition
position. The gas can be released and the safety solenoid
valves VAS open. The gas flows through the burner insert to
the burner head. Here, it mixes with the air which is supplied
via the burner housing. The combustible gas/air mixture is
produced downstream of the burner head and is electrically
ignited directly by an ignition electrode. The resulting flame
is controlled by the ionization electrode. Once the controller
enable signal has been issued, the linear flow control is posi-
tioned in accordance with the capacity demand. The air flow
rate remains constant. A maximum capacity can be pre-set
using the adjusting cock which is situated on the gas insert.

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5 Selection 5.3 Gas types

The choice of forced draught burner depends on the capacity Calorific value
Gas type Code letter range Density ρ
and process conditions. The desired operating mode deter- [kg/m3]
[kWh/m3(n)]
mines which type of control (air/gas ratio control or control Natural gas L
using linear flow control) is most suitable. B 8 – 12 0.7 – 0.9
and H quality
If near-stoichiometric burner operation is required, air/gas Propane, pro-
ratio control is the more suitable option because it allows a pane/butane, G 25 – 35 2.0 – 2.7
control range of 1:10. butane

If a maximum thermal control range is to be achieved, op-

eration using a linear flow control and a constant air supply 5.4 Selection table
is recommended. This type of control allows a control range -EE- V F B G M 2 F
of > 1:20. PBG 300D ● ●  ●   ● ●
PBG 500D ● ●  ●   ● ●
5.1 Burner size PBG 750D ● ●  ●   ● ●
PBG 1000E ● ●  ●   ● ●
Capacity PBG 2000C ● ●  ●   ● ●
Burner
[kW]* PBG 3000C ● ●  ●   ● ●
PBG 300D 70 PBG 5000C ● ●  ●   ● ●
PBG 500D 110 ● = Standard,  = lieferbar
PBG 750D 170 Bestellbeispiel
PBG 1000E 230 PBG 1000E-EE-VB2F
PBG 2000C 450 5.4.1 Type code
PBG 3000C 660
Code Description
PBG 5000C 1100
PBG Forced draught burner
* The capacity values given apply for operation at 50 Hz and 300 – 5000 Burner size
at atmospheric pressure. C, D, E Construction stage
-EE- European market
5.2 Burner type V Gas train with VAG
F LFC
Burner Size Gas train Air valve
B Gas type: Natural gas
Air/gas ratio G LPG
PBG..EE-V..2F 300 – 5000 Actuator
control
M Air control: manual
Linear flow 2 IC 20
PBG..EE-F..MF 300 – 5000 Manual valve
control F Flame control with ionization electrode

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6 Project planning information 6.2 Standard installation positions

The entire burner unit can be easily mounted using the burner
6.1 Combustion chamber conditions
flange on the burner housing.
PBG..EE can be used in a wide temperature range – the maxi-
The burner flange seal is included in the delivery.
mum combustion chamber temperature is 900°C. In low tem-
perature applications, higher CO values are to be expected 6.2.1 PBG..EE with air/gas ratio control
which can be reduced by secondary measures such as using
the optionally available protective flame tube, see page 18
(Protective flame tube).
The PBG..EE can be operated in combustion chamber pres-
sures of between -3 mbar and +2 mbar. Higher reverse
flow pressures lead to reduced performance and should be
checked on an individual basis.

6.2.2 PBG..EE with linear flow control

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6.3 Installation options 6.3.1 Installation in open combustion chambers

When installing in a refractory combustion chamber, the burner
Installation in systems with positive pressure must not protrude from the refractory lining into the combus-
In systems with positive pressure in the combustion chamber: tion chamber.
furnace wall diameter ≥ burner tube diameter + 25 mm. Fill
the resulting annular gap with temperature-resistant insula-
tion material.

≥ 12,5 mm

6.3.2 Installation in heat exchangers

When used in heat exchangers in the low temperature range,
the burner can be installed directly in the combustion chamber
without refractory lining.
Installation in systems with negative pressure
In systems with negative pressure in the combustion chamber,
spacers can be mounted between the burner flange and the
furnace wall so that secondary air can be supplied along the
burner tube.

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6.3.3 Installation with protective flame tubes 6.5 Power supply

For flow velocities of > 3 m/s, we recommend using a protec- The central power supply is provided via the main terminals
tive flame tube to protect the flame from being cooled, see of the pre-wired burner control unit BCU.
page 18 (Protective flame tube).
Burner size Voltage Frequency Phases
PBG 300 – 1000 230 V 50 Hz 1
PBG 2000 – 5000 400 V 50 Hz 3
For burner sizes 300 – 1000, local protection is to be provided.
We recommend using one slow-acting 10 A fuse per burner.
For burner sizes 2000 – 5000, the central power supply of
400 V/50 Hz for all components is provided via the switch box
additionally mounted on the burner control unit BCU.

6.6 Control signal

Actuator IC 20 is set to be controlled by a continuous 4 – 20 mA
6.4 Gas connection signal on delivery.
A gas pressure of between 50 and 100 mbar is required at Details on the control options are given in the burner con-
the gas connection of the PBG..EE. trol unit BCU 370 and actuator IC 20 documentation, see
www.docuthek.com.
The burner insert can be rotated in 90° steps if necessary. Here,
note the installation position of the controls in the gas train.
Installation of the air/gas ratio control VAG in vertical pipelines
requires an inlet pressure of > 80 mbar. For documentation on
the installation position of the gas safety and control system,
see www.docuthek.com.
Install flexible tubes or bellows units to prevent mechanical
stress or transmission of vibration.
To ensure optimum burner adjustment, it is necessary to meas-
ure the flow rates or flue gas. We recommend using measuring
orifice VMO to measure the flow rate in the gas train with air/
gas ratio control, see page 18 (Measuring orifice VMO). This
is already included in the gas train with linear flow control.

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7 Technical data 7.1 Burner size

Gas inlet pressure pu: 50 – 100 mbar. Capacity Flame length
Gas types: natural gas, LPG. Burner Weight [kg]
[kW]* [mm]**
Mains voltage: PBG 300 70 75 300
PBG 300 – 1000: 230 V AC, ± 10%, 50 Hz, PBG 500 110 75 360
PBG 2000 – 5000: 400 V AC, ± 10%, 50 Hz. PBG 750 170 75 610
Electrical power consumption: PBG 1000 230 80 810
PBG 300 – 1000: 0.4 kW in ongoing operation, PBG 2000 450 114 1520
PBG 2000 – 5000: 1.7 kW in ongoing operation. PBG 3000 660 114 1680
Control type: modulating or staged. PBG 5000 1100 140 1830
Control: three-point step, 0 – 10 V, 0(4) – 20 mA. * The capacity values given apply for operation at 50 Hz and
Control range: at atmospheric pressure.
1:10 (air/gas ratio control), ** The length of the flame is significantly influenced by the
1:20 (linear flow control). ambient conditions and can thus only be given as a general
Flame control: direct ionization control. guide value.
Ignition: direct spark ignition.
Combustion chamber pressure: -3 to +2 mbar.
Maximum combustion chamber temperature: 900°C.

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7.2 Dimensions of PBG 300 – 1000

H
D2
D1
GA

A L

Connection Dimensions
Type
[mm]
GA A ∅ D1 ∅ D2 L H B
PBG 300D-EE-VB2F Rp ½ 464 95 300 232 726 380
PBG 300D-EE-FBMF Rp ½ 800 95 300 232 726 380
PBG 500D-EE-VB2F Rp ½ 464 95 300 232 726 380
PBG 500D-EE-FBMF Rp ¾ 800 95 300 232 726 380
PBG 750D-EE-VB2F Rp ½ 464 95 300 232 726 380
PBG 750D-EE-FBMF Rp 1 816 95 300 232 726 380
PBG 1000E-EE-VB2F Rp ¾ 489 138 300 241 726 380
PBG 1000E-EE-FBMF Rp 1 816 138 300 241 726 380

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7.3 Dimensions of PBG 2000 – 5000

H
D2
D1
GA

A L

Connection Dimensions
Type
[mm]
GA A ∅ D1 ∅ D2 L H B
PBG 2000C-EE-VB2F Rp 1½ 603 190 362 438 934 456
PBG 2000C-EE-FBMF Rp 1½ 995 190 362 438 934 470
PBG 3000C-EE-VB2F Rp 1½ 603 222 362 438 934 456
PBG 3000C-EE-FBMF Rp 1½ 995 222 362 438 934 470
PBG 5000C-EE-VB2F Rp 1½ 603 263 362 438 993 456
PBG 5000C-EE-FBMF Rp 1½ 1068 263 362 438 993 470

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8 Maintenance
Twice per year, but if the media are highly contaminated, this
interval should be reduced.

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9 Accessories 9.3 Air filter

9.1 Protective flame tube

Straight or curved protective flame tube to protect the flame

from cross flows in direct heating systems. The air filter is secured to the fan housing using a mounting
bracket and a butterfly nut.
The protective flame tube is installed between the burner flange
and the furnace wall. Available on request.
The furnace wall seal is included in the delivery.
Available on request.

9.2 Measuring orifice VMO

Measuring orifice for flow rate measurements. The appropriate

differential pressure can be checked using two pressure test
points upstream and downstream of the orifice.
Available on request.

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10 Legend
Manual valve
Measuring orifice
Filter module
PZH
Pressure switch for maximum pressure
PZL
Pressure switch for minimum pressure
M
Butterfly valve with actuator
M
Linear flow control with actuator
Butterfly valve with manual adjustment
Gas solenoid valve

Air/gas ratio control with solenoid valve

Burner control unit

Fan

Burner

PBG..EE · Edition 04.12

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Kromschröder AG

Michael Rehkamp
m.rehkamp@kromschroeder.com

Osnabrück

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PBG..EE · Edition 04.12