Danfoss Oil Pump BFPS II Installation guide

Brand: Danfoss

Model: Oil Pump BFPS II

Type: Installation guide

071R9839

Technical data

Oil types: Fuel #2 or lighter fuel

Pressure: With fuel #2: 100-210 psi

With lighter fuel:

100-210 psi, 2 GPH

100-150 psi, 3 GPH

Factory setting: 100 psi

Strainer capacity: 3 GPH

Revolution 3450 RPM

Coil voltage: 120 V 60 Hz

Connection, g. 1

1-pipe operation:

Remove the

⁄4" plug in one of the two inlet ports.

To remove inlet plug use

⁄4" Allen

wrench. Connect

the inlet line to the inlet port.

2-pipe operation:

Remove the return/bleed plug in the return/bleed

port and the

⁄4" plug in one of the inlet ports. To

remove the return/bleed plug use

⁄4" wrench.

Connect the return line to the return port and con-

nect the inlet line to one of the inlet ports.

Please note: The BFPS II fuel unit has automatic

by pass.

Electrical connecton, g. 2

The coil of the solenoid valve does not have a delay

function built in. Only primary controls with a

valve on delay should be used.

Bleed, g. 3

Bleeding is only necessary for 1-pipe operation. To

bleed use a

/4" wrench and open the return/bleed

plug

/2 a turn. Bleed unit until all air bubbles dis-

appear. To end bleeding tighten the return/bleed

plug securely.

In the case of 2-pipe operation, the unit bleeds the

system automatically through the return line.

Pressure adjustment, g. 3

To adjust pressure use

⁄32" Allen wrench. Pressure

gage port is in the front. To remove the pressure

gage plug use a

⁄32" Allen wrench. To increase

pressure turn CW to decrease the pressure turn

CCW.

Strainer removal, g. 4

To gain access to the strainer use

⁄32" Allen wrench

to remove the 4 screws and remove the cover. If the

alternate suction on the side is used the inlet line

can be disconnected.

Vacuum check

Vacuum gage may be installed in one of the

⁄4" inlet port.

Caution

Disconnect power supply before wiring the sole-

noid valve to prevent electrical shock or equip-

ment damage.

Non-hardening oil pipe dope is recommended for

all thread connections, as teon tape pieces may

cause problems in pump and nozzle. It is suggest-

ed that a quality lter is installed in the supply line.

Maximum pressure on inlet and return line at the

fuel unit must not exceed 30 psi.

A pressure greater than that may cause damage to

the shaft seal.

Do not use check valves or equivalent compo-

nents in oil lines or restrict oil ow back to the

supply tank by any means, (especially not in

gravity feed systems), unless a means of pres-

sure relief is installed. Thermal expansion of the

oil during o-cycle/burner shutdown can create

high pressure within the supply line that can cause

damage to the shaft seal and/or cover of the fuel

unit, or to the piping.

All installations must be in accordance with

National and Local Codes.

Pumps should only be installed by qualied

installers.

INSTRUCTIONS

Fuel unit BFPS II for 3450 RPM

Fig. 1 Fig. 3

Use only primary controls with valve-on delay!

Fig. 2 Fig. 4

071R9839

520F0539 – DKBD.PI.010.B3.22 03-2007

Double-Cut™

One pipe system

Suction line length

Maximum one-pipe

lift = 8 feet

Line length in feet including vertical and horizontal length:

H = Head in feet

Q = Firing rate (Actual nozzle size) in GPH

6 – 0.75H

/8" line length = ––––––––– = feet

0.0086 Q

6 – 0.75H

/2" line length = ––––––––– = feet

0.00218 Q

If tank is above fuel unit change – to +

Two pipe system

Suction line length

Suction line length in feet including vertical and horizontal length

Pump

size

3 GPH

1725 RPM 3450 RPM

Lift

Feet

/8" OD

tubing

/2" OD

tubing

/8" OD

tubing

/2" OD

tubing

0’ 150 150 91 150

2’ 132 150 80 150

4’ 114 150 68 150

6’ 94 150 57 150

8’ 74 150 45 150

10’ 57 150 34 134

12’ 37 150 23 90

14’ 19 75 - 45

Calculation basis:

Viscosity 57 SSU = 9.6 cSt.

Tube wall thickness .035"

Solenoid wiring

Disconnect the power supply before wiring of the BFPS fuel unit.

The BFPS fuel unit can replace other fuel units with separate mounted sole-

noid valve, but only if the primary conrol has a valve on delay (pre-purge).

The lead wires are long enough to reach the junction box on most burner

installations.

Please note!

If the wire length is more than 4 inch between the solenoid valve and the

junction box, a 3/8 inch. exible steel or aluminium conduit type RWFMC must

be tted.

Check the burner manufacturer's installation sheets for correct wiring.

Wiring must be according to the National Electrical Code.

Black: 120 V Line

White: Neutral

Green: Ground

Troubleshooting guide

Cause

No oil at nozzle

Remedy

Check all oil piping and electrical wiring to unit for

proper connections.

Make sure oil is in tank.

Proceed with trouble shooting as follows:

♦ Open the valve on the inlet line.

♦ Bleed the fuel unit in accordance with the

instructions.

♦ Install a pressure gage and vacuum gage in

the pump to check pressure and vacuum.

♦ Check the coupling between motor and fuel

unit.

♦ Start the burner and check the fuel unit

direction of rotation.

♦ Check the fuel unit installation. If there is

still no sign of oil at the nozzle, check:

• To see that the inlet and return lines have

not been swapped over.

• That the solenoid valve operates, or if

appropriate, why it does not operate.

• That the oil nozzle is not clogged.

• That the oil safety valve in the inlet line

is properly installed.

• That the inlet line does not leak and

that it has not been crushed at.

• That the strainer is not clogged.

• That the shut o valve is not clogged.

Pulsating pressure

Nozzle cut-o ineective

Fuel unit pressure variations can produce poor

combustion since the oil volume as well as the

atomizing pattern will change.

Possible reasons are:

♦ Air in the oil as a consequence of leaks or too

high a vacuum in the inlet line, (half-closed

shut-o valve, clogged strainer, blocked check

valve in the inlet line, crushed inlet line, etc.).

♦ Dirt in the fuel unit pressure regulating valve.

♦ Pump/motor coupling slip, i.e. speed

variations.

An oil burner starts and stops about ten or twelve

thousand times a year. If the nozzle cut o is inef-

fective the boiler will accumulate soot.

Fuel units having an electrical cut-o function are

designed to cut o oil to the nozzle at max. revo-

lutions per minute to ensure a soot-free stop.

The reasons for poor cut-o can be as follows:

♦ Air build-up in the nozzle line, or perhaps

in the nozzle or between nozzle and nozzle

holder.

♦ Dirt in the nozzle line solenoid valve.

Pressure cannot

be regulated

If the fuel unit pressure cannot be regulated, or if

the pressure gage deviates, the reason can be.

♦ Coupling between motor and fuel unit

defective, (no pressure reading on the gage).

♦ Pressure gage defective.

♦ Pressure gage incorrectly tted.

♦ Pressure regulating valve defective or clogged

If this is the case, the pressure gage will show

either constant high pressure or constant low

pressure.

♦ Air in the oil. This will produce pulsatin pressure

gage readings.

♦ Wrong type of fuel unit, i.e. capacity too small

in relation to nozzle capacity.

Here, the pressure gage will show too low a

pressure.

Fuel unit will not rotate

Is the fuel unit in fact being driven by the

motor coupling/fan pulley?

The coupling or pulley could be defective or could

have worked itself loose.

Solenoid coil might be disconnected The resistance of the coil is approx 685 Ω at 77 F.

The resistance increases at increasing temperature.

In principle the coil is OK as long as a resistance

can be measured between the two plugs indicated.

Fuel unit whines or makes a crackling noise

When shortly after starting, a gradually

increasing whine comes from the fuel unit the

most probable reason is that a valve in the

inlet line is still closed. This valve will produce

such a high vacuum in the inlet line that air will

separate from the oil and the fuel unit will begin

to shriek in protest.

Depending to some extent on temperature and

viscosity, the fuel unit will begin to whine at about

– 15” HG (vacuum) in the inlet line. This can dam-

age the fuel unit, therefore the valve should be

opened immediately.

A similar condition, with high vacuum and whine

can occur if the oil lter in the inlet line is clogged;

if the oil safety valve in the inlet line has stuck in

its closed position; or if the inlet line has been

crushed at.

Other factors producing fuel unit whine are: an

undersized inlet line (the internal diameter is too

small for the length), also an excesive, suction

height, and perhaps dirt in the inlet line.

Air bubbles from a leaking inlet line can

produce a crackling noise in the fuel unit. Such a

defect can be conrmed by tting a pressure gage

to the fuel unit – air bubbles will cause it to jump

or utter.

In other words: low vacuum and a jittery

pressure gage indicate a leak in the inlet line.

Leaks at shaft seal Problems in the system that result in pressure

build up, can cause leaks at the shaft seal. This can

happen by e.g. thermal expansion of oil or a sup-

ply pump with the supply pressure set too high.

Check the system for:

• Water contamination (risk of ice plugs

and thermal expansion of oil).

• Check valves or other restrictions in the line/

lines without proper pressure relief

back to tank.

• Supply pressure setting in systems with

supply pump.

• Any other restriction that has occurred.

• Ensure that outdoor piping is suciently

insulated.

The system must be corrected for the cause of

pressure build up in oil lines.

Service Kits

Danfoss Oil Pump BFPS II Installation guide

Danfoss Oil Pump BFPS II Installation guide

Danfoss Oil Pump BFPS II Installation guide

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