Bentone bg 300 User Manual

Page 1
BG 300
172 601 83 98-01
Page 2
178 002 71
Page 3
DESCRIPTION
COMPONENTS
1. Cover,inspection glass
2. Air pressure switch
4. Inner assembly adjustment (not town gas)
5. Flame cone
6. Connecting pipe
7. Air damper
8. Air intake
9. Ignition electrode
10. Control box
11. Reset button
12. Fan wheel
13. Motor 14 Ionization electrode
15. Transformer
16. Inner assembly
17. Nozzle
18. Brake plate
172 205 31 97-01
Page 4
TECHNICAL DATA
Type designation BG 300
DIMENSIONS
B
ø108
170
460
A
100
Length of burner tube Measure A Measure B
Standard 145 125 ø120 Long design 245 225 ø120 Town gas 172 155 ø140
The above dimensions are max. measurements. Depending on the compo­nents used, the measurements may vary.
OUTPUT RANGE
380
220
372
Type Capacity Gas volume at a min. Gas volume at a max Max. Inlet Rated inlet pressures
kW ouput Nm3/h 1) output Nm3/h 1) pressure mbar mbar
Natural gas/LPG Natural gas LPG Natural gas LPG Natural gas LPG
300 60-190 6 2,3 19 7,3 100 20 20
(4,6 kg/h) (14,8 kg/h)
2
) Town gas2) Town gas
Gas fittings2) Motor Ignition transformer
Natural gas, LPG Town gas 1-phase, 0,18 kW, Primary 230 V, 1, A
1" 1½" 2 800 r/m, 230 V Secondary 8 000 V
2
) Town gas
2
) Town gas
1
) Calorific value:
Natural gas 10 kWh/Nm LPG 26 kWh/Nm
2
) Dimension and capacity depen-
3
3
ding on gas quality and availa­ble pressure
CAPACITY CHART ACCORDING TO EN 676
172 215 11 00-02
Page 5
TECHNICAL DATA
DIMENSIONS OF FLANGE
M10
ø175-240
ø120
172 215 29 95-01
Page 6
SKELETON DIAGRAMS, 1-STAGE BURNER
10
9
4
5a
5b
6b
6a
3
1
2
Incorporated in the MultiBloc
7
1. Ball valve
2. Filter
3. Governor
4. Pressure gauge with shut-off cock
5a. Gas pressure switch, mini 5b. Gas pressure switch, maxi
When Bio gas is used, Bentone shall always be contacted.
6a. Main valve 6b. Safety valve
1)
7. Valve proving system
9. Air pressure switch
10. Gas burner control
Pos. 5b, 7: Components not required according to EN 676.
1)
Required over 1200 kW according to EN 676.
172 415 04 03-01
Page 7
MOUNTING ON THE BOILER
Remove the combustion unit from the burner. Fit the enclosed flange and gasket to the boiler.If new fixing holes must be drilled, use the fixing flange as a pattern.
REMOVAL OF VALVE UNIT FROM BURNER
Remove the plug-in contact from the multi-bloc. Loosen the union nut.
REMOVAL OF FAN HOUSE UNIT FROM BURNER.
Loosen the screws. Swing out the fan house. Remove the ionisation and igni­tion cables from the electrodes. Rem­ove the bolt on the flange.
INSTALLATION EXAMPLE
Connect the gas to the burner by means of the ball valve. Ensure that the union nut, ball valve and tubing make it easy to remove the burner for in­spection and service.
172 205 36 93-01
Page 8
ELECTRIC EQUIPMENT
GAS BURNER CONTROL: LGB21/LMG21 WIRING DIAGRAM
If there is no plug-in contact (X2) on the boiler, connect to the contact enclosed. In case the twin thermostat is in series on incoming phase L1, a loop between the terminals T1 and T2 is necessary.
COMPONENT LIST A1 Gas burner control A2 Twin thermostat B1 Ionization electrode F1 Fuse H1 Alarm, 220 V
M1 Burner motor S3 Main switch S8 Air pressure switch S9 Gas pressure switch T1 Ignition transformer
X1 Plug-in contact, burner X2 Plug-in contact, boiler Y1 Gas solenoid valve
172 425 16 99-02Mains connection in accordance with local regulations.
Page 9
ELECTRIC EQUIPMENT
CONTROL DIAGNOSIS UNDER FAULT CONDITIONS AND LOCKOUT INDICATION GAS BURNER CONTROL: LMG ...
Operating concept
Diagnosis of cause of fault
Red LED on
FS
AL
During the time the cause of the fault is diagnosed, the control outputs are deacti­vated.
- The burner remains shut down
- Exception: fault status sig­nal «AL» at terminal 10
The burner is switched on only after a reset is made.
- Press lockout reset button for 0.5...3 seconds
• Burner control has initiated lockout • Reset > Red fault LED on Press lockout reset button for 0.5 ...3 s
• Diagnosis of cause of fault
- Wait >10 s
- Press lockout reset buttonj for >3 s
- Read blink code of red fault LED
AL
>«Error code table»
After lockout, the red fault LED is steady on. For reading the cause of fault, refer to the blink code given in the following table:
LED on (waiting time 10 s)
Fault
Press lockout reset button for > 3 s
Blink code
Off
Approx. 3 s
Blink code
Error code table
Blink code Possible cause 2 x • No establishment of flame at the end of «TSA»
•• - Faulty or soiled detector electrode
- Faulty or soiled fuel valves
- Poor adjustment of burner
3 x • Air pressure monitor does not close
••• - «LP» faulty
- «LP» incorrectly adjusted
- Fan motor does not run
4 x • Air pressure monitor does not open or extraneous light on
burner startup
•••• -«LP» faulty
- «LP» incorrectly adjusted
5 x • Extraneous light during pre-purging
••••• - Or internal device fault 7 x • Loss of flame during operation
••••••• - Poor adjustment of burner
- Faulty or soiled fuel valves
- Short-circuit between detector electrode and ground
8...17 x • Free
••••••••
..................
••••••••••
••••••• 18 x • Air pressure monitor opens during pre-purging or operation
•••••••••• - «LP» incorrectly adjusted
•••••••• - Four time s loss of fla me dur ing op erati on (LMG25) 19 x • Faulty output contact
•••••••••• - Wiring error
••••••••• - External power supply on output terminal 20 x • Internal device fault
••••••••••
••••••••••
172 425 57 01-01
Page 10
MEASURES AND CHECKS BEFORE START-UP, 1-STAGE BURNER
INNER ASSEMBLY
Ensure that the ignition and ionisa­tion electrodes are correctly adjus­ted. The sketch shows the correct measurements.
GAS QUALITY
Ensure that the burner head is meant for the gas quality to be used (see fig.).
VENTING
The gas line is vented by loosening the screw on the test nipple for the inlet pressure. Connect a plastic hose and conduct the gas into the open. After having vented the gas line tigh­ten the screw again.
LEAKAGE CONTROL
When making a leakage control of the gas supply system the solenoid valve should be closed. Connect a pressu­re gauge to the test nipple Pa, see fig. The test pressure in the system should be 1,5x max. inlet pressure or min. 150 mbar. If any leakage, locate the source by means of soapy water or a leak location spray. After tightening repeat the test.
LEAKAGE CONTROL
ELECTRIC FUNCTION TEST:
Ensure that phase and neutral are not reversed. The gas shut-off cock should be closed.To prevent the gas pressure switch from locking out it should be linked temporarily. After the main switch has been swit­ched on and the thermostats have been adjusted the pre-purging period begins (30-35sec.). At the end of this period the pre-ignition period starts (0,5-2,5 sec. dependent on the de­sign of the gas control). The gas valve is energized and opens and flame is established. At the end of the safety time (2-3 sec.) the gas control locks out. The solenoid valve and the motor will be "dead". Remove the link from the gas pressure switch after the test is finished.
NOTE! APPLIES ONLY TO GAS BURNER CONTROL LFL1.
When using LPG (Propane) the bur­ner should be connected for post­purge. Move connection to terminal 6 to terminal 7 in the base of LFL1.
172 205 33 97-02
Page 11
MEASURES AND CHECKS BEFORE START-UP
INNER ASSEMBLY
Town gas
INNER ASSEMBLY
Natural gas, LPG
LGP
INNER ASSEMBLY
Biogas (UV-detector)
2,5
Natural gas
8
172 205 78 98-01
Page 12
DETERMINA TION OF GAS VOLUME FOR THE INST ALLA TION
Specifications on natural gas, town gas and bio gas vary. For more exact information please contact the gas distributor.
Gas quality kWh/Nm
Net calorific value
Natural gas 10.3 37 144 8 865 Propane 26.0 93 647 22 350 Butane 34.3 123 571 29 492 Town gas 4.9 17 653 4 213 Bio gas 7.0 25 219 6 019
EXAMPLE HOW TO CALCULATE THE GAS VOLUME (NATURAL GAS)
V = Gas volume Nm3/h Q = Boiler output 120 kW Hu= Calorific value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm
= Expected efficiency 90%
Ex. A
.
Q 3 600
V =
H
u
=
.
.
120 3 600 12,9 Nm3/h 37 144 0,90
.
3
3
kJ/Nm
3
kcal/Nm
3
Ex. B
120 12,9 Nm3/h
V =
10,3 0,90
.
If the barometer height, pressure and temperature of the gas deviate very much from the normal values this must be taken into account as follows:
f = 273 + t . 1013,25
273 B + P
u
t = Temperature of the gas at the gas meter (15°C) B = Barometer height (945 mbar) Pu= Pressure of the gas at the gas meter (15,0 mbar) f = 273 + 15 1013,25
.
273 945 + 15 f 1.11 The gas volume read on the gas meter actually reads 1,11 . 12,9 = 14,4 m3/h.
172 205 16 98-01
Page 13
ADJUSTMENT OF MUL TI-BLOC, MB-DLE 405-420
Max. inlet pressure: 360 mbar. Adjustable governor pressure: 405 - 412 S50 = 4 - 50 mbar 415 - 420 S20 = 4 - 20 mbar 415 - 420 S50 = 20 - 50 mbar Solenoid valve: Slow opening valves with adjustable start load and max. flow.
1. Protective cover start load ad­justment
2. Hydralic damping
3. Fixing screw
4. Test nipple (inlet pressure)
5. Test nipple (pressure after go­vernor)
6. Test nipple (pressure in inner assembly)
7. Governor
8. Filter
9. Gas pressure switch
10. Solenoid valve
FLOW ADJUSTMENT
Loosen the fixing screw a. Turn the hydraulic device b: to the right = the gas flow is reduced to the left = the gas flow is increased Do not forget to tighten the fixing screw again. The flow adjustment can also be made by means of the governor. Adjust the outlet pressure to a value giving the desired gas flow on the fully open valve. At small capacities (gas flows) it is also necessary to adjust as abore.
ADJUSTMENT OF GOVERNOR
Adjust outlet pressure from governor by means of a screw . Min. and max. outlet pressures corresponds to appr. 60 turns of the spring. It is not possible to change pressure springs in order to change the outlet pressure.
Turn to the right = the outlet pressure is increased Turn to the left = the outlet pressure is reduced
FLOW ADJUSTMENT
ADJUSTMENT OF START GAS FLOW
Remove the protective cover c. Turn the adjustment knob d (use the protective cover as a tool) to the desi­red start gas flow.
Turn to the right = the start gas flow is reduced Turn to the left = the start gas flow is increased
ADJUSTMENT OF GOVERNOR
ADJUSTMENT OF START GAS FLOW
172 505 02 97-02
Page 14
GENERAL INSTRUCTIONS
ADJUSTMENT OF BURNER
The burner is from the factory pre-set to an average value that must then be adjusted to the boiler in question. All burner adjustments must be made in accordance with boiler manu-facturers instructions.These must include the checking of flue gas temperatures, average water temperature and CO2 or O2 concentration.
GENERAL INSTRUCTIONS
The installation of the gas burner must be carried out in accordance with current regulations and standards. The installers of gas burners should there­fore be acquainted with all regulations and ensure that the installation comp­lies with the requirements. The instal­lation, mounting and adjustment should be made with the greatest care and only the correct gas should be used.
OPERATING INSTRUCTIONS
The operating instructions accompanying the burner should be left in a prominent position in the boiler room.
SERVICE
A general rule is that the lower capa­city the smaller the opening between brake plate and combustion device.
Service should only be carried out by qualified personnel. Replacement parts should be of the same make and approved by the same authoriti-
COMMISSIONING OF INSTALLA­TION
Control of the combustion. The com­bustion quality is checked by means of a flue gas analysis device. Adjust the burner to appr. 20% excess air in accordance with the table. Check the flue gas temperature. Calculate the
es as the original. If the burner is converted to fire another gas quality it must be re-commissioned. If town gas is to be fired the combustion head must be converted and the gas train adjusted to suit (e.g.a larger gas ar­mature or a different spring in the governor may be required).
efficiency. Check also the actual gas volume on the gas meter so that the correct input is achieved.
Gas quality CO2%0
% max. CO2%
2
lambda 1,2
Natural gas 10,0 3,5 11,9 LPG 11,5 3,5 13,9
INSTRUCTIONS
The user should be thoroughly in­structed in the function of the gas burner and the whole installation. The supplier must instruct the user.
INSPECTION AND MAINTENANCE
Daily inspection is advisable.
START UP
After the burner has been fitted to the boiler and the electric connection, the leakage control, the venting and the electric function test have been car­ried out, the burner will be ready for start-up.
Howerer, study the sections dealing with adjustments of multi-bloc, com­bustion air and combustion head. Open the ball valve and switch on the main switch. If the burner starts the actual adjustment can be made.
ADJUSTMENT OF BURNER HEAD
The burner is equipped with an ad­justment device changing the position of the brake plate in the burner head. This is used to adjust the correct pres­sure drop over the combustion device in order to obtain a good pulsation free combustion.
Which position to use depends on input and overpressure in the boiler.
172 305 28 97-01
Page 15
GENERAL INSTRUCTIONS, 1-STAGE BURNER
AIR ADJUSTMENT
Loosen the stop screw and turn the knob along the scale to the desired position and tighten the screw. Check the air adjustment by making a flue gas analysis.
ADJUSTMENT OF BRAKE PLATE
- Loosen the screw on the adjust­ment device.
- To reduce the opening: turn the knob to the left.
- To increase the opening: turn the knob to the right.
The adjustment of the position of the brake plate affects the air flow. It is therefore always necessary to make a fine adjustment of the air by means of the adjustment device of the bur­ner.
CONTROL OF BURNER HEAD
To check the burner head, brake pla­te and electrodes proceed as follows: Loosen the nuts a. Swing out the burner. Remove the screw b and the knob for adjustment of burner head. Loosen the screw c so much so that the inner assembly can be pulled out.
AIR ADJUSTMENT
CONTROL OF BURNER HEAD
ADJUSTMENT OF INNER ASSEMBLY
172 305 31 94-01
Page 16
GENERAL INSTRUCTION
FLAME MONITORING AND MEASU­REMENT OF IONISATION CURRENT
The burner is monitored according to the ionisation principle. Check the io­nisation current on start-up and on each service call.
The reason for a low ionisation current may be leaking currents, bad connec­tion to earth, dirt or a faulty position of the flame electrode in the burner head. Sometimes also a faulty gas/air mixtu­re may cause too weak a ionisation current.
The ionisation current is measured by means of a microampere meter (µA) connected in series with the flame electrode and the gas burner control.
Connect the µA-meter, see figure. Min. required ionisation current ac­cording to table. In practice this cur­rent must be considerably higher, pre­ferably more than 10 µA. All the gas burners are equipped with a ionisation cable that can be slit which facilitates the connection of the µA-device.
ADJUSTEMNT OF MAX. GAS PRES­SURE SWITCH
The burner is equipped with a max. gas pressure switch only on request. It should stop the burner if the gas pres­sure exceeds the set value. The burner can then only be re-started manually (gas burner control or overpressure switch). Remove the protective cover. Connect a pressure gauge for measuring the rated gas pressure. Decide on pres­sure at which the gas pressure switch should switch off. Turn the adjustment knob to this value. Tolerance on the scale ±15%.
Gas control Connection to terminal Min. ionisation
in gas control current required
LMG 1 2 µ A LGB 1 10 µ A LFL 24 10 µ A MMI 810 2 5 µ A TMG 740-3 1 5 µ A
ADJUSTMENT OF AIR PRESSURE SWITCH
The air presure switch should stop the burner if the air volume is reduced. The air proving device shall be adjus­ted in such a way that if there is insufficient air supply at the highest or lowest burner operating stage, the device operates before the supervised pressure is less than 80% of the pres­sure at the controlled stage and the CO content of the combustion products exceeds 1% by volume.
AIR PRESSURE SWITCH:
Adjustment range ca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50
GAS PRESSURE SWITCHES:
Adjustment range:
2,5-50 mbar GW 50
5-150 mbar GW 150
ADJUSTMENT OF MIN. GAS PRES­SURE SWITCH
The min. pressure switch should react if the gas pressure is too low and prevent the burner from starting. Too low a gas pressure during operation should stop the burner. The burner may start again when the rated gas pressure has been reached. Remove the protective cover. Connect a pressure gauge for measuring the rated pressure. Decide on pressure at which the gas switch should switch off. Set this pressure by means of the valve. Carefully turn the knob (see figure) until the gas pressure switch switches off. The value shown on the scale should then approximately cor­respond with the value shown on the pressure gauge. Tolerance on scale appr. ± 15 %. Open the ball valve.
FLAME MONITORING
GAS PRESSURE SWITCH, AIR PRESSURE SWITCH
172 305 25 00-01
Page 17
HANDING OVER OF THE INST ALLA TION
- Make repeated start attempts to ensure that the adjustments func­tion.
- Close the ball valve during opera­tion to check that the gas switch switches off at the set value.
- Remove the hose for the air pressu­re switch to check that the burner locks out.
- Check that all protective covers and measurement nipples are mounted and fastened.
- Fill out necessary test reports.
- Instruct the persons in charge of the operation on the service and main­tenance of the installation and what to do should any troubles occur.
- Inspection and service must only be carried out by authorized people.
FAULT LOCATION, FUNCTIONAL TROUBLES
Trouble free operation is dependent on three factors: electricity, gas and air supply. Should there be any changes in the ratio between these three factors there is a risk of break downs. It has been proved that most break downs are caused by simple faults. Before calling the service engineer, the following should therefore be checked:
- Is the gas cock open?
- Are all fuses in order and the cur­rent switched on?
- Are the thermostats correctly set?
- Are pressostats, overheating pro­tection etc. in operating position and not locked-out?
- Is the gas pressure sufficient?
- Is the gas burner control in start position?
- Has the gas control or the motor protector locked out? - Reset.
- Is the circulation pump in opera­tion?
- Is there a supply of fresh air to the installation?
If integral components are of a diffe­rent make from what is stated in this manual, see the enclosed loose-leaf.
172 305 17 93-01
Page 18
FAUL T LOCA TION GUIDE
Gas burner
The basis for trouble free operation can only be ensured by the correct combined effect of the three factors: electricity, gas flow and combustion air. Should any of these factors change troubles may arise.
It has been proved that many troubles have rather simple causes. Before calling the serviceman the following checks should be made:
1. Are the gas cocks of the installation open?
2. Are the fuses in order and the current switched on?
3. Are the controls (room thermostat, boiler thermostat etc.) correctly adjusted?
4. Is the gas pressure to the burner sufficient?
5. Is the gas relay of the burner ready for start and not locked out?
6. Is the air supply to the burner sufficient?
CAUSE
To facilitate fault location we have drawn up a scheme showing the most frequent faults in a gas burner instal­lation and the remedies.
REMEDY
The burner does not start
No gas No voltage The burner motor fails to start The gas relay is defective
Burner motor is running but no ignition after the pre­purge time has elapsed
No voltage on the terminals The ignition electrodes in contact with each other or with
earth The porcelain of the electrodes is broken
Check that all gas cocks are open. Check fuses, thermostats and electrical connections. The thermal protection has locked out. Motor defective. Replace
Check the contact. Replace faulty relay Adjust
Replace the electrodes
1(4)
170 091 16 97-01
Page 19
CAUSE
REMEDY
The cable shoes have bad contact The ignition cables are damaged The ignition transformer is damaged, no voltage on the
secondary side The ignition cable and the ionisation cable have been
transposed.
No flame establishment in spite of a trouble free start
The gas solenoid valve defective The gas solenoid valve does not open in spite of its
obtaining voltage No voltage to the solenoid valve No electrical connection through the air pressure switch
The starting load is not correctly adjusted
Improve the contact Replace Replace the transformer
Change
Replace Replace coil or the whole valve if necessary.
Check the contact Test the adjustment and the function of the air pressure
switch. Reduce or increase the gas supply, reduce the quantity
of air. Gas relay defective Air pressure switch incorrectly adjusted or defective No reponse as the cams of the servomotor are not
correctly adjusted or out of position.
The burner locks out after the safety time has elapsed in spite of flame establishment
No ionisation current or the UV-cell in wrong position
The supervision part of the gas relay is defective
Replace
Check the adjustment and readjust.
Adjust the ionisation electrode and the UV-cell, examine
cables and connections.
Replace the relay
2(4)
Page 20
CAUSE
REMEDY
Voltage lower than 185 V The ignition electrodes are disturbing the ionisation
current Bad earthing Phase and neutral transposed
The burner locks out during pre-purge
Air pressure switch defective or incorrectly adjusted. The starting load is not correctly adjusted
The gas pressure is too low
Pulsations at start
The ignition electrodes are wrongly adjusted The gas pressure is too high
Contact the electricity authorities. Adjust the ignition electrodes, repole the ignition transfor-
mer if necessary. Arrange for proper earthing. See wiring diagram and change.
Reduce or increase the gas supply. Reduce the quantity of air.
Increase the pressure. Contact the gas supply company if necessary.
Readjust. Check and adjust by means of a pressure gauge and a
pressure adjustment valve.
The flue gas side is blocked
Pulsations during operation
The burner is not correctly adjusted The burner is dirty Defective chimney
The burner is operating correctly but locking out now and then
The ionisation current is too low
The UV-cell is in a wrong position Voltage drop at certain times
Air pressure switch defective or incorrectly adjusted
Check the chimney flue.
Readjust Clean the burner. Check and change the dimensions if necessary.
Check. Must be at least 4 µ A according to the relay manufacturer but should be 8-20 µ A.
Adjust. Must not drop more than 15% of the rated current. Contact
the electricity authorities if necessary.
Spark-over in ignition electrodes
Replace the electrodes
3(4)
Page 21
CAUSE
REMEDY
The ambient temperature of the gas relay is too high The ignition spark is too weak
Bad combustion
Bad draught conditions The flue gas temperature is too high The CO
The CO-content is too high
Excess air when using natural gas and gasoil (propane, butane
Air shortage The holes in the gas nozzle are clogged The fresh air intake is too small
-content is too low
2
Heat insulate, max. 60° C.
Check the transformer
Check the chimney
The boiler is overloaded. Reduce the quantity of gas.
Check the boiler with regard to leaks. Choke the draught
if it is too high.
Choke the air.
Open the air supply. Check the flue gas damper.
Clean.
Check and enlarge.
The flame is not burning straight because the burner head is out of position
Condensation in boiler and chimney
The flow gas temperature is too low or the quantity of gas is not sufficient
Check the burner head and readjust.
Increase the flue gas temperature by increasing the
gas supply. Insulate the chimney.
4(4)
Page 22
DECLARATION OF CONFORMITY
We (supplier´s name)
BENTONE
.................................................................
(address)
P.O. Box 309, S-341 26 Ljungby, Sverige
.................................................................
declare under our sole responsibility that the product (name, type or model, batch or serial number, possibly sources and number of items)
BG 100, BG 150, BG 200, STG 120, STG 146, BG 300,BG 300LN, BG 400, BG 400LN BG 450,BG 450LN,
..........................................................................................................................................................................................
BG 500, BG550, BG550LN, BG 600,BG 600LN, BG650, BG 700,BG 700LN and BG 800,BG 800LN
....................................................................................................................................................................................................
all fan gas burners
...........................................................................................................................................................................
to which this declaration relates is in conformity with the following standard(s) or the normative socument(s) (title and/or number and date of issue of the standard(s) or other normative document(s)
EN 676, DIN 4788
...................................................................................................................................................................................................
following the provisions of Directive (if applicable)
Gas directive 90 / 396 / EEC, EMC directive 89 / 336 / EEC och Low voltage directive 73 / 23 / EEC
..........................................................................................................................................................................................
............................................................................................................................................................................................
Ljungby, 031201
...........................................................
(Place and date of issue)
BENTONE
Sven-Olov Lövgren
..........................................................................................................................
(name and signature of equivalent marking of authorized person)
172 905 95 03-02
Loading...