Banjo Burners & Propane Problem

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Banjo Burners & Propane Problem

Postby Son of a Kraut » Mon Sep 21, 2009 10:36 am

I'm having a bit of problem with propane flow and my sculpture. I have a Brewtus 10 with two banjos (BK & MT) and then a wok-style jet burner for my HLT. Yesterday, while brewing the gas flow basically stopped. Everything was fine until it tried to fire both the Mash Tun burner while the HLT was fired up. Then the gas went out and I couldn't get it going again. I couldn't even light a single burner by itself.

I'm not really sure what happened, but initially thought it was due to a low tank (lack of pressure). I'm using a 20lb tank. I started with another full tank and it ran for a little while before having the same thing happen. Luckily my mash was over so I pulled out my old turkey and moved my kettle over to that for the boil.

Any ideas as to why the flow would stop? Would something I did trip the OPD and not allow flow through? It seems I used it this way on a previous brew and didn't have any problems.

Anything would help.

Thanks,
Matt
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Re: Banjo Burners & Propane Problem

Postby Wild Bill » Mon Sep 21, 2009 12:40 pm

Well my first thought was that you froze up your propane tank. I don't have it happen to me on a full tank by when the tank gets 2/3 empty I really need to watch out. When this happens the gas pressure will drop gradually until your high pressure burner's flame gets so low that it goes out. The low pressure burner will still run since they are obviously designed to run at lower pressures. The really scary thing is when this happens your high pressure burners spewing unburnt propane a few feet away from your HLT burner. :shock:

Given the fact that you tried a second full tank I don't imagine that is the issue. It sounds more like an OPD or regulator issue to me. To check if it is the OPD in your tank you would want to turn off all your burners, turn off your regulator, and turn off your tank. Then do everything in reverse, open your tank, turn up your regulator, and then try to light a burner.

Also your regulator is rated for a certain number of BTU's but I don't know that it will shut you off if you try to draw more than what it is rated for. I'll leave it to other forum members to chime in there.

At any rate I recommend putting a pressure gauge (that is rated for flammable gas) somewhere in your gas delivery system. I added one after my first experience with a frozen tank. Now I can see it coming and deal with it before it becomes a real safety hazard.

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Re: Banjo Burners & Propane Problem

Postby jward » Mon Sep 21, 2009 7:55 pm

I think pressure regulators can have a safety feature where they restrict or cut off the flow when too much gas flows. It is suppose to detect a cut hose.
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Re: Banjo Burners & Propane Problem

Postby Wild Bill » Tue Sep 22, 2009 5:33 am

Here is a link from the Mosquito Magnet company talking about a regulator reset tool. But I'm not sure if it's just talking about a tank OPD reset...

Matt, Do you have any specs on your regulator or do you have a link to where you bought it? Also when yuou had this problem did all of your burners go out, High and low pressure?

As a last resort you could look at purchasing another regulator. I've never dealt with them but Tejas Smokers has the best selection of regulators that I have seen. (a good selection of burners too) They even have regulators with a built in pressure gauge.
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Re: Banjo Burners & Propane Problem

Postby ValonaBrewingCo » Tue Sep 22, 2009 8:26 am

Propane regulators can be tricky because they have internal safety mechanisms to keep you from blowing out gas without anything connected. Try disconnecting the tank and opening (then closing) the burner valve to relieve any pressure in the line. Then reconnect everything and remember to open the tank valve first, then the burner. If that doesn't work, then the regulator is probably busted. I've had one fail on me on my Banjo Cooker, so it's not unheard of. Remember to get one the right pressure for your burner. My Bayou Classic uses a 10 PSI regulator while the typical BBQ regulator they sell at OSH is 1 PSI.
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Re: Banjo Burners & Propane Problem

Postby hotrod38 » Thu Sep 24, 2009 5:22 am

When ever this happens to me, I will disconnect the regulator from the tank, hold the tank upside down and give it a quick shake.The OPD can get hung up and shut the flow off. Reconnect and slowly turn the valve on followed by the regulator and then burner.
I have also had this happen at the filling station. The attendant told me he couldn't get it to fill. I had showed him the above method and he was able to fill it.
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Re: Banjo Burners & Propane Problem

Postby usmcruz » Thu Sep 24, 2009 3:43 pm

Stop d#$king around and get the 0-30 psi regulator from bayou classic depot.com, and your problems will be over.
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Re: Banjo Burners & Propane Problem

Postby Son of a Kraut » Fri Sep 25, 2009 11:09 am

That's exactly the regulator that I have from Bayou Classic Depot. Everything worked fairly well for my first few batches (all 5-Gallon), but with the last weekend's bath (a 10-gallon) batch I ran into the above problems. At the time when I ran into problems I had propane going to the Banjo, two pilot lights (through an inline low pressure regulator), and the wok/jet burner. I'd hate to think the regulator is already shot as I only have about 4 brews on it.

My neighbor thought the same thing as hotrod, but that didn't seem to do the trick either. I'm really comtemplating switch this to run off two different tanks. One for the two banjos and one for the wok burner and the pilots.

Any other thoughts?
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Re: Banjo Burners & Propane Problem

Postby Wild Bill » Fri Sep 25, 2009 1:17 pm

That's the same regulator I have and I have never triggered the OPD with a banjo and my jet burner running. At times there both running together for a half hour or more.

Matt, again the gas shuts right off, your low pressure burner went out as well right?

Try contacting Bayou Classic to see what they say.
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Re: Banjo Burners & Propane Problem

Postby P-J » Fri Sep 25, 2009 5:26 pm

I don't know if this is part of the problem that you are experiencing but I'll describe something that might shed some light on the issue.

Since the change in propane tank requirements, where they must have an OPD valve assembly (Overfill Protection Device), there was also a change in the propane regulator assembly. The regulators now must have a high flow restrictor in case of sudden failures. We can all thank the turkey fryer business for that one. The flow restrictor will transfer if the hose is cut or burnt and it severely restricts the flow of propane. It can and will transfer if the regulator is set for a high flow and the tank valve is opened quickly.

This image shows the high pressure inlet to the regulator:

Image

There is a ball check valve directly behind the small hole that will transfer with sudden changes in flow and/or high flow rates. The procedure to get around this is to shut the tank valve off and then turn the regulator down so that there is minimal flow when you turn the tank back on. Next, open the tank valve and then adjust the regulator.

There are regulators out there that are rated for high flow that might help eliminate the issue. My way around the issue is different. I do NOT recommend this and you are on your own if you do it - - I drill out the port to the check valve and remove the spring and ball asm. Issue resolved.
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Re: Banjo Burners & Propane Problem

Postby Son of a Kraut » Sat Sep 26, 2009 10:16 am

Wild Bill wrote:Matt, again the gas shuts right off, your low pressure burner went out as well right?



When the banjo went out, the low pressure burner went to small yellow flames. I don't know if there was still enough gas in the lines to keep the yellow flames (not blue as usual) going. I quickly turned off all burners when it first happened as I wasn't sure what was going on.

Wild Bill wrote:
Try contacting Bayou Classic to see what they say.


I just sent them an e-mail describing my problem so we'll see what they say.

I'm going to try and see if I can get the burners going again today, so I'll see if I can narrow this down.
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Re: Banjo Burners & Propane Problem

Postby Son of a Kraut » Sat Sep 26, 2009 10:26 am

P-J wrote:Since the change in propane tank requirements, where they must have an OPD valve assembly (Overfill Protection Device), there was also a change in the propane regulator assembly. The regulators now must have a high flow restrictor in case of sudden failures. We can all thank the turkey fryer business for that one. The flow restrictor will transfer if the hose is cut or burnt and it severely restricts the flow of propane. It can and will transfer if the regulator is set for a high flow and the tank valve is opened quickly.

There is a ball check valve directly behind the small hole that will transfer with sudden changes in flow and/or high flow rates. The procedure to get around this is to shut the tank valve off and then turn the regulator down so that there is minimal flow when you turn the tank back on. Next, open the tank valve and then adjust the regulator.



It's difficult to tell from Bayou Classic's website if this might be the issue with the 0-30 PSI regulator that I am using. I'll take a look at it this afternoon. Since Wild Bill is using this without much problem I'm beginning to wonder if my regulator hasn't already gone bad.

I'll let everyone know what my results are if I can find some time this afternoon or evening.
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Re: Banjo Burners & Propane Problem

Postby Son of a Kraut » Sun Sep 27, 2009 8:59 am

Well, I pulled out the brewstand yesterday to attempt to recreate what happened last weekend. No luck. Everything seemed to run fine. I could run multiple burners and not recreate. I guess I'll just try another batch and see what happens.

Thanks everyone for your help. I'll keep all of this in mind should I run into the same problem again.
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Re: Banjo Burners & Propane Problem

Postby waleeed » Sat Feb 06, 2016 5:32 am

I'm not really sure what happened, but initially thought it was due to a low tank (lack of pressure). I'm using a 20lb tank. I started with another full tank and it ran for a little while before having the same thing happen. Luckily my mash was over so I pulled out my old turkey and moved my kettle over to that for the boil.
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Re: Banjo Burners & Propane Problem

Postby tennee » Wed Apr 20, 2016 9:09 pm

Try contacting Bayou Classic !
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