Bentone BG 300-2 Installation And Maintenance Instruction

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178 001 72-4 2018-03-23

Installation- and maintenance instruction

BG 300-2

Bentone

3 Bentone

General

Table of contents

1. General Information _____________________________________________ 4

2. Technical data __________________________________________________ 7

2.1 Burners are intended for use at: ________________________________ 7

2.2 Dimensions _________________________________________________ 7

2.3 Description BG 300 _________________________________________ 10

3. General instruktions ____________________________________________ 11

3.1 General instructions _________________________________________ 11

3.2 Installation and maintenance instructions _______________________ 11

3.3 Instructions ________________________________________________ 11

3.4 Inspection and maintenance __________________________________ 11

3.5 Start up ___________________________________________________ 11

3.6 Commissioning of installation _________________________________ 11

4. Installation ____________________________________________________ 12

4.1 Delivery check ______________________________________________ 12

4.2 Preparations for installation ___________________________________ 12

4.3 Gas supply _________________________________________________ 12

4.4 Electric connection __________________________________________ 12

4.5 Skeleton diagrams __________________________________________ 13

4.6 Mounting on the boiler _______________________________________ 14

4.7 Inspection of gas nozzle before commissioning __________________ 15

4.8 Gas nozzle _________________________________________________ 16

4.9 Setting Air damper __________________________________________ 17

4.10 Air adjustment ______________________________________________ 17

4.11 Low load: __________________________________________________ 17

4.12 Full load ___________________________________________________ 17

5. Setting the burner ______________________________________________ 18

5.1 Adjustment of brake plate ____________________________________ 18

5.2 Control of burner head _______________________________________ 18

5.3 Setting the air pressure switch ________________________________ 20

5.4 Setting the min. gas pressure switch ___________________________ 21

5.5 Multiblock MB-ZRDLE 405-412 _______________________________ 22

5.6 Recommended excess air when using default setting _____________ 25

5.7 Determining the gas quantity for the system _____________________ 25

5.8 Calculating the quantity of gas supplied ________________________ 27

6. Service ________________________________________________________ 28

6.1 Servicing the combustion assembly ____________________________ 28

6.2 Replacement of damper motor, air _____________________________ 29

6.3 Flame monitoring and ionisation current check ___________________ 30

6.4 UV-Detector ________________________________________________ 31

7. Handing over of the installation __________________________________ 32

8. Fault location, functional troubles ________________________________ 32

9. Electric equipment _____________________________________________ 33

9.1 Safety system ______________________________________________ 33

9.2 Wiring diagram LME _________________________________________ 34

9.3 List of components __________________________________________ 35

9.4 Control program at faults; fault mode indicator LME .... ___________ 36

10. Troubleshooting _____________________________________________ 38

11. EU Declaration of conformity _________________________________ 41

13. General instructions for gasburners ____________________________ 42

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1. General Information

This Installation and Maintenance manual:

• is to be regarded as part of the burner and must always be kept near the installation site

• is intended for use by authorised personnel

• must be read prior to installation

• must be observed by all who work with the burner and associated system components

• work with the burner may only be carried out by certiﬁ ed installers/ personnel

Enertech AB is not liable for any typographical errors and reserves the right to make design changes without prior notice.

Safety instructions

• The burner may only be used for its intended purpose in accordance with the product’s technical data.

• The burner may only be installed and operated by authorised personnel.

• The product is packaged to prevent damage from occurring during handling. Handle the product with care. Lifting equipment must be used to lift larger packages.

• The products must be transported/stored on a level surface in a dry environment, max. 80% relative humidity, no condensation. Temperature -20 to +60 °C.

• Check that the burner is compatible with the boiler’s output range.

• All components must be installed without being bent, twisted or subjected to mechanical or thermal forces which can affect the components.

• The burner must be installed so that it complies with local regulations for ﬁ re safety, electrical safety, and fuel distribution.

• The gas outlet from the pressure regulator shall be conﬁ gured in accordance with applicable regulations and lead to a safe area.

• Make sure when installing the equipment that there is enough space to service the burner.

• Permitted temperature during operation -10 to +60 °C. Max 80% relative humidity, no condensation.

• The installer must ensure that the room has adequate air supply.

• The room must comply with local regulations pertaining to its intended use.

• The installation site must be free of chemicals.

• Burner pipes, fan wheels and air dampers may contain sharp edges.

• The surface temperature of the burner’s components can exceed 60 °C.

• Caution: The burner has moving parts, and there is risk of crushing injuries.

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• The electrical installation must be professionally carried out in accordance with applicable high voltage regulations, as per Enertech’s recommendations.

• Before servicing, shut off the fuel supply and turn off the power to the burner.

• Seal inspections must be performed during installation and servicing to prevent gas leakage.

• Care should be taken by the installer to ensure that no electrical cables or fuel lines are crushed or otherwise damaged during installation or servicing.

• If the boiler is equipped with an access hatch, this must be equipped with a hatch opening switch connected to the burner's safety system.

• When in operation, the burner’s noise level can exceed 85 dBA. Use hearing protection.

• The burner must not be put into operation without proper safety and protection devices.

• A Class BE ﬁ re extinguisher is recommended.

• It is forbidden to alter thedesign or use accessories which have not been approved by Enertech in writing.

• Prior to operation, the following points must be checked:

- ﬁ tting and installation work has been completed and approved

- electrical installation has been correctly performed

- ﬂ ue gas ducts and combustion air ducts are not blocked

- all actuators and control and safety devices are in working order and correctly set

Actions to take if you smell gas

Turn off the equipment and the boiler. Open windows and doors. Prevent open ﬂ ames or sparking, e.g. do not turn lights on or off, do not use any electrical appliances, do not use mobile phones. Open windows and doors. Close the gas ball valve. Warn residents; do not use doorbells. Evacuate the building. Notify the installer or gas supplier once the building has been evacuated.

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Control system 10 years 250,000 starts

Valve control system 10 years 250,000 starts

Pressure switch 10 years 250,000 starts

Ignition system with ﬂame guard 10 years 250,000 starts

UV ﬂame sensor 10000 hrs N/A

Gas pressure regulators 15 years N/A

Gas valve without seal testing 10 years 250,000 starts

Gas valve with seal testing Replacement upon fault detection N/A

Gas pressure switch 10 years 250,000 starts

Safety blow-off system 10 years N/A

Damper motor N/A 500,000 starts

Contactor 10 years 500,000 starts

Burner 1 year 3000 hrs

Inspection of electrical installation 1 year 3000 hrs

Leakage check 1 year 3000 hrs

Filter 1 year replacement at ∆p>10 mbar 3000 hrs replacement at ∆p>10

mbar

Electrodes Replacement/Cleaning 1 year Replacement/Cleaning 3000 hrs

Brake disc Replacement/Cleaning 1 year Replacement/Cleaning 3000 hrs

Motor 1 year 3000 hrs

Fan wheel 1 Year

Replacement when cleaning needed/ imbalance

3000 h Replacement when cleaning needed/ imbalance

The burner and its components must be recycled according to applicable regulations.

Burner servicing schedule

Servicing must be carried out once a year or after 3000 hours of operation

Component replacement intervals

Delivery check

• Make sure everything is delivered and the goods have not been damaged during transit.

• If something is wrong with a delivery, report it to the supplier.

• Transport damage must be reported to the shipping company.

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1.2.1 Heat generator connection dimensions

Type

Length of burner

tube

Flange

measure A

Burner tube

measure B

Burner tube

measure C

BG 300

Standard 1 145 125 ø120 ø110

Standard 2 245 225 ø120 ø110

K L M

BG 300

M10 Ø 175-240 ø125 (***115)

D E F G H I J

BG 300

372 220 100 *380 *460 170 **200

2. Technical data

2.1 Burners are intended for use at:

• Hot water boilers in intermittent operation

2.2 Dimensions

• Gas connection ¾-2”

* The above dimensions are max. measurements. Depending on the

components used, the measurements may vary.

** Min. recommended distance to ﬂoor.

***Dimensions when installing blast tubes from the inside of the boiler

**J

Dimensions stated in mm

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2.2.1 Gas categories, approved gases

Only dry gas is permitted for use

2.2.2 Capacity range

Gerätekategorien

Appliance categories

Versorgungsdrücke

Supply pressures

Besimmungsländer

Countries of desinaion

2R/3R

20-360mBar BG, CZ, DE, EE, ES, FR, GR, HU, IS,

IT, LU, LV, NO, PT, SI, All countries

2H3B/P

20-360mBar AT, CH, CY, DK, FI, LT, RO, SE,

2H3P

20-360mBar GB, IE,

2L3B/P

20-360mBar NL, RO

2E3B/P

20-360mBar PL

2E(R)B

20-360mBar BE

Capacity kW Gas quantity

at min. power

Nm3/h 1)

Gas quantity

at max. power

Nm3/h 1)

Max.

connection

pressure

mbar

Min connection

pressure mbar

See data plate

Lower heat value Hu at normal state 15°C and 1013.25 mbar EN676

Grade of gas

Natural gas

Butane

Propane

BG 300

G20 50-200 5.2 21 360

G25 50-180 6,1 21.9 360

G30 65-200 2.6 8.1 360

G31 50-200 1.5 6,1 360

kWh/Nm

MJ/Nm

kcal/Nm

G20 9.5 34.02 8126

G25 8.2 29.25 6986

G30 32.5 116.09 27728

G31 24.6 88.00 21019

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2.2.3 Electric Speciﬁcation EN 60335-2-102

Burner correspond to IP20

Type BG 300

Motor

180W 230V 1,3A 50Hz

The recommended main fuse

motor

C10A

Control power

230V 2,1A 50Hz

Sound

82 dBA ± 0,5 dBA

2.2.4 Working ﬁeld

BG 300

G20,G31 50-200 kW

BG 300

G30 65-200 kW G25 50-180 kW

-1

40 60 80 100 120 140 160 180 200 220

G20, G31

mbar

-1

40 60 80 100 120 140 160 180 200 220

G30, G25

mbar

Do not exceed working ﬁeld

Measurements according to EN 3746: 2010

Alt.1 The sound level of the burner can be reduced by equipping the burner

with silencer. Installation must be done so it does not prevent air supply to the burner.

Alt.2 The burner’s noise level can be reduced by connecting the burner’s air

intake to the air duct that opens into an appropriate location. Installation must be done so it does not prevent air supply to the burner.

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2.3 Description BG 300

Components

1. Switch 0-1

2. Switch I-II

3. Cover, inspection glass

4. Reset button

5. Air pressure switch

6. Damper motor

7. Inner assembly adjustment (not town gas)

8. Flame cone

9. Connection gas ﬁttings

10. Air damper

11. Air intake

12. Ignition electrode

13. Electric panel

14. Indicating lamp Stage 2

15. Indicating lamp Stage 1

16. Fan wheel

17. Motor

18. Ionization electrode

19. Transformer

20. Inner assembly

21. Nozzle

22. Brake plate

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3. General instruktions

3.1 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.

3.2 Installation and maintenance

instructions

The maintenance instructions supplied with the burner must be kept at an easily accessible location in the boiler room.

3.3 Instructions

The user should be thoroughly in-structed in the function of the gas burner and the whole installation. The supplier must instruct the user.

3.4 Inspection and maintenance

See service schedule.

3.5 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.

3.6 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 efﬁciency. Check also the actual gas volume on the gas meter so that the correct input is achieved.

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4. Installation

4.1 Delivery check

Check that all has been delivered and that the goods have not been damaged during transport. If that is not the case, please notify the delivery company. Transport damages should be reported to the forwarding agency.

4.2 Preparations for installation

Check that the measurements and capacity range of the burner are compatible with the boiler. The power ratings on the type plate refer to the min. and max. power of the burner.

4.3 Gas supply

For good operating safety, it is important that the gas supply system is installed correctly. Consider the following:

1. Check that the burner is approved for the gas quality of the installation. If not, please contact the supplier.

2. Check that the gas components of the burner are approved for indicated gas pressure.

3. The gas supply system should be installed in accordance with current standards.

4. Pipe lines should be run so that service on boiler and burner is facilitated.

5. Pipe lines should be run so that eventual contaminants cannot come into contact with the gas components.

6. Gas discharge system must be installed prior to local regulations.

4.4 Electric connection

Before starting the electric installation, the main switch must be turned off. If the boiler has a 7-pole and a 4-pole Eurostecker connector, these usually ﬁt directly to the burner. If not, use the connectors included. (Refer to connection under Electric equipment)

If an electric connection other than the one recommended by Enertech is used, a risk of damage and injury can arise.

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4.5 Skeleton diagrams

1. Ball valve

2. Filter

3. Governor

4. Pressure gauge with shut-off cock

5a. Gas pressure switch, mini

5b. Gas pressure switch, maxi

6a. Main valve, 2 -stage. When modulaing operation is required this

valve is equipped with controls for variable opening.

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.hhh

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4.6 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.

Remove the screws (A). Swing out the fan housing. Remove the ionisation and ignition wires from the electrodes. Remove the bolt (B) on the spectacle ﬂange. Lift away the fan housing.

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.

Check the gas tightness.

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4.7 Inspection of gas nozzle before

commissioning

General rules

Care should be taken by the installer to ensure that no electrical cables or fuel/gas pipes are trapped or damaged during installation or service/ maintenance.

Gas nozzle

Check that the ignition and ionisation electrodes are correctly set. In the ﬁgure (see the gas nozzle chapter), the dimensions are speciﬁed for adjustment of the ignition and ionisation electrodes.

Gas quality

Ensure that the burner head is meant for the gas quality to be used (see capter gas nozzle).

De-aerating

De-aerating of the gas line is conducted, for example, by unscrewing the screw on the measuring nipple for the connection pressure. Connect a plastic hose and release the gas in a safe place. Once de-aerating is completed, be sure to reﬁt the screw on the measuring nipple.

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.

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 on 2-stage and modulating burners that during the pre-purging period the damper opens to the set value for air on stage 2 and just before the end of the pre-purging period it goes down to the air setting for stage 1. On some burners under 350kW the pre-purging mainly takes place with the air damper set for stage 1.

If the burner is directly connected, ensure that all components on the burner are without power.

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4.8 Gas nozzle

Natural gas

Propan

Biogas (UV detector)

2,5

8,0

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4.9 Setting Air damper

4.10 Air adjustment

The damper motor turns the damper between three pre-set positions: fully closed, low load, full load. These positons are controlled in the motor by cams of different colours. The black cam controls the gas valve for full load. If the air volume needs changing: Remove the cover of the damper motor and change the position of the cams by turning them with the tools accompanying the burner.

4.11 Low load:

Adjust the operating switch to full load (ll).

- * Reduce the air volume: Turn orange cam towards 0°

- * Increase the air volume: Turn orange cam towards 90°

Adjust the operating switch back to low load and check the air volume.

4.12 Full load

Adjust the operating switch to low load.

- Reduce the air volume: Turn red cam towards 0°

- Inrease the air volume: Turn red cam towards 90°

If the red cam is moved, change the black cam as much. Adjust the operating switch to low load and check that the correct air volume has been obtained.

Note! The blue cam is the limit position for fully closed damper and it is normally not necessary to change it.

Releasing button

By pressing the button and snapping it down, the motor will be released and the damper can easily be turned. This function facilitates an exchange of damper motor.

Releasing button

N.B! The upper position is the standard positiont

High capacity (red)

Low capacity (orange)

Closed damper (blue)

Solenoid valve High capacity (black)

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5. Setting the burner

5.1 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.

5.2 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.

Control of burner head

Adjustment of inner assembly

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General instructions

Operating instructions

The installation and maintenance instructions supplied with the burner must be kept at an easily accessible location in the boiler room.

Instructions

The user should be thoroughly in-structed in the function of the gas burner and the whole installation. The supplier must instruct the user.

Inspection and maintenance

Inspection as needed, preferably daily. Maintenance per service schedule.

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 po si tion of the brake plate in the burner head. This is used to adjust the cor rect pressure drop over the com bus tion device in order to obtain a good pulsation free combustion.

Which position to use depends on input and overpressure in the boiler.

A general rule is that the lower capacity the smaller the opening between brake plate and combustion device.

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 efﬁciency. Check also the actual gas volume on the gas meter so that the correct input is achieved

Service

Service should only be carried out by qualiﬁed personnel. Replacement parts should be of the same make and approved by the same authorities 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).

Gas quality CO2%

lambda 1,2

02% max. CO2%

Natural gas 10,0 3,5 11,9

LPG 11,5 3,5 13,9

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Be careful when adjusting the air pressure switch; it contains a live component.

Inställningsområde ca: LGW 10 1-10 mbar LGW 50 2,5-50 mbar

5.3 Setting the air pressure switch

The air pressure switch should block the burner if the air quantity supplied for combustion is insufﬁcient. The air pressure switch must be set so that, if there is a defective air supply at the burner’s max. or min. capacity, it reacts before the monitored pressure falls so much that it results in poor combustion.

Setting for air pressure switch

1. Remove the protective cover, screw (Y).

2. Start the burner.

3. Carefully turn the scale on the air pressure switch clockwise until the air pressure switch stops the burner. Is the tolerance on the scale for

the min. air pressure switch approx. ±15%?

4. Try to ﬁnd the pressure at which the burner stops for both the minimum and maximum input power by turning the scale. Make a note of the values and then set the air pressure switch on the basis of the highest pressure noted at which the burner stopped.

5. The air pressure switch should be set to a pressure approx. 10–15% lower than the highest noted pressure at which the burner stopped.

6. After setting the air pressure switch, perform repeated starts and run through the burner’s set output range several times. This is to ensure the reliable function of the burner. If breakdowns or interruptions occur, the air pressure switch is probably set to a too narrow position.

7. Fit the protective cover, screw (Y).

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5.4 Setting the min. gas pressure

switch

The min. gas pressure switch should react to a burner connection pressure that is too low and in such cases prevent the burner from starting. If the connection pressure to the burner is too low during operation, the min. gas pressure switch should stop the burner. The burner can start again once the connection pressure has risen above the pressure set for the min. gas pressure switch.

Setting for min. gas pressure switch

1. Remove the protective cover, screw (Y).

2. Open the pressure outlet (X) and connect a manometer to measure the connection pressure.

3. Start the burner.

4. Measure and make a note of the connection pressure to the burner during normal operation at the highest input power.

5. Based on the desired connection pressure set, determine the connection pressure at which the gas pressure switch should stop the burner. Set the connection pressure at which the burner is stopped at a level where the burner is stopped before poor combustion occurs.

6. Set the min. gas pressure switch to this value by turning the scale.

7. Check the setting by carefully closing the ball valve while measuring the connection pressure.

8. When the min. gas pressure switch stops the burner, the value measured should then approximately correspond to the setting on the min. gas pressure switch. The tolerance on the scale for the min. gas pressure switch is approx. ±15%.

9. Open the ball valve.

10. Remove the pressure gauge and close the pressure outlet (X).

11. Fit the protective cover, screw (Y).

Check the gas tightness.

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All gasline components shall be assembled and mounted without bending, torque and outher mechanical or thermal stress.

1. Gas pressure switch

2. Inlet pressure

3. Governor with pressure adjustment

4. Hydraulic device, adjustment of stage 2

5. Protective cover, start gas adjustment

6. Lock screw for ﬂ ow adjustment

7. Main valve

8. Knob for adjustment of stage 1

9. Test nipple, pressure after governor

10. Test nipple for nozzle pressure

11. Filter

12. Fixing ﬂ ange

13. Ball valve

5.5 Multiblock MB-ZRDLE 405-412

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, stage 1 and stage 2.

Turn to the left = the start gas ﬂ ow is increased.

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Flow adjustment 2-stage design

For stage 1, loosen the lock screw a. Turn the hydraulic device e:

to the right = the gas ﬂow is reduced

to the left = the gas ﬂow is increased

For stage 2, 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 lock screw again.

Adjustment of governor

Adjust outlet pressure from governor by means of a screw driver. Min. and max. outlet pressures correspond 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

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

Multi-bloc MB-ZRDLE 405-420

Flow adjustment

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5.5.1 Pressure taps

1,2,3,4,5 1/8 screwed sealing plug

5.5.2 Electrical connection

S 20/S 50

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Lower heat value Hu at normal state 15°C and 1013.25 mbar EN676

Grade of gas kWh/Nm

MJ/Nm

kcal/Nm

Natural gas G20 9.5 34.02 8126

Natural gas G25 8.2 29.25 6986

Propane G31 24.6 88.00 21019

Butane G30 32.5 116.09 27728

5.6 Recommended excess air when

using default setting

Grade of gas Excess air ﬂue gases Max. % CO

% O

% CO2 Lambda 1.2

Natural gas 3–5 ≈10 11.9

Propane 3–5 ≈11.5 13.9

Butane 3–5 ≈11,5 14,1

Liqueﬁed petroleum gas (LPG)

3–5 ≈11 13,8

5.7 Determining the gas quantity for

the system

The heat values indicated are normal values; the heat value varies according to the origin of the gas. For more exact information on values, contact the gas distributor.

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T = Temperature of gas at the gas meter [°C]

B = Barometer reading [mbar]

P = Pressure of gas at the gas meter [mbar]

f = Factor calculated for multiplication with ﬂow in Nm

/h to

arrive at actual ﬂow in Nm

/h.

V = Actual ﬂow [m

/h]

f =

273

B+P

273+T 1013.25

Example A V

= Q . 3600

160 · 3600

≈ 18.8 Nm

· η

34020 · 0.90

Example B V

= Q

≈

160

≈ 19 Nm

· η

9.5 · 0.90

Example C V

160

≈ 19 Nm3/h

· 0,00116 · η

8126 · 0.00116 · 0.90

If the barometer reading (altitude), pressure and temperature of the gas deviate signiﬁcantly from normal values, this must be taken into account as follows:

Calculation example:

Q = 160 kW

= Example A: 34020 MJ/Nm

Example B: 9.5 kWh/Nm3

Example C: 8126 kcal/Nm

η = 90%

V0 = Desired quantity of gas [Nm3/h]

Q = Boiler output [kW]

= Gas heat value [kWh/Nm3] or [MJ/Nm3] or [kcal/

Nm3]

η=

Boiler efﬁciency [%]

5.7.1 Example of how to calculate the gas quantity

(natural gas G20):

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M = 330 = 0.33 m

1000

t = 1 + 10 = 0.0194 h

60 3600

V = M = 0,33 ≈ 17 m

t 0.0194

Calculation example:

t = 1 min 10 s

M = 330 dm

(litre)

V = M

/h]

5.8 Calculating the quantity of gas

supplied

The quantity of gas supplied can be calculated if the system is equipped with a gas ﬂow meter of some type. The procedure here is usually to measure how long it takes for the burner to consume a certain quantity of gas.

To measure:

t = Time for a certain quantity of gas consumed by the burner. [h]

M = Quantity of gas consumed. [m

]

V = Actual gas ﬂow [m

/h]

V = V

. f

= V

. f = 18.8 . 0.90 ≈ 17 m3/h

. f = 19 . 0.90 ≈ 17 m3/h

This means that the quantity of gas read from the gas meter should actually be read off as 1.11 . the calculated ﬂow in a normal state.

f = 273

945+15

≈ 0.90 Nm

273+15 1013.25

Calculation example:

T = 15°C

B = 945 mbar

P = 15 mbar

Bentone

172 615 08 2018-01-03

6. Service

Whoever carries out service and maintenance on the burner must be authorised to do so. If components need to be replaced, the replacements must be of the same make and type and be approved by the authorities. If the burner is to be used for a different grade of gas, a new adjustment must be carried out. If town gas is to be used, it is also necessary to convert the combustion assembly; in some cases the multi-block or valves and gas train may also need to be changed to a larger type.

6.1 Servicing the combustion assembly

Removal and installation

1. Switch off the main power supply and disconnect the Euro plugs from the burner.

2. Remove the screws (A), turn off the burner Remove the ignition and ionisation cables

3. Check the combustion device’s position. Remove the screw (B) to remove the adjustment device.

4. Remove the screw (C), remove the combustion device.

5. Check and clean the brake plate and gas inlet. If necessary, replace the worn parts.

6. Check the ignition electrode (see chapter Gas nozzle). Replace if necessary.

7. Check the ionisation electrode (see chapter Gas nozzle). Replace if necessary.

8. Fit the combustion assembly in reverse order.

9. Press the burner together and lock using the nuts (B).

10. Fit the Euro plugs and turn on the main power supply.

11. Check/adjust the combustion.

If the burner is directly connected, ensure that all components on the burner are without power.

29 Bentone

6.2 Replacement of damper motor, air

Removal and installation

1. Break the main current and disconnect the Euro plugs from the burner.

2. Note the connection position of the cables on the damper motor.

3. Disconnect the damper motor cable from the damper motor.

4. Loosen the screws (G) to the damper motor mounting plate.

5. Decouple the damper motor and rotate to approx. 70°.

6. Lift up the damper motor.

7. Loosen the screw (H) and remove the damper from the motor shaft

8. Remove the screws (I) securing the damper motor to the mounting plate.

9. Remove the damper motor from the mounting plate (I).

10. Install the new damper motor on the mounting plate.

11. Mount the damper to the damper motor’s shaft. Ensure that the screw is perpendicular to the plane of the shaft.

12. Re-install the damper motor and mounting plate on the air intake. Ensure that the damper shaft and control arm are connected correctly.

13. Connect the damper motor cable.

14. Fit the Euro plugs and turn on the mains power.

15. Check/adjust the combustion.

If the burner is directly connected, ensure that all components on the burner are without power.

- Releasing button

By pressing the button and snapping it down, the motor will be released and the damper can easily be turned. This function facilitates an exchange of damper motor.

Bentone

7.5 Flame monitoring and ionisation

current check

The standard version of the burner is monitored according to the ionisation principle. The ionisation current should be checked on initial start-up and at each service visit. The reason for low ionisation current can be leakage current, poor connection to earth, fouling or incorrectly positioned ionisation electrode in the combustion head. Occasionally, an incorrect gas/air mix may result in poor ionisation current. Ionisation current is measured using a micro ammeter (µA) connected in series with the ionisation electrode and gas burner control. Connect the µ ammeter according to the diagram. The minimum required ionisation current is shown in the table. In practice, this current must be signiﬁcantly higher, preferably more than 10µA. Connection of the µA instrument is made easier by the fact that all gas burners are equipped with a divisible ionisation cable.

Technical data

For continuous operation!

Idle voltage at ION-terminals AC 115-230 V

Protect the ionisation electrode from electric shock!

Short-circuit current Max. AC 100-300 mA

Min. current for ﬂame detection Min. DC 1.5 µA

Required current to ensure detection

Min. DC 3 µA

Possible detection current Max. DC 20 µA

Operational indicator lamp ﬂashes green

<5 µA DC

Operational indicator lamp shines green

>5 µA DC

172 615 02 2018-01-02

31 Bentone

DC current detector signals with ﬂame detector QRQ...

Min. required Max. possible

Measurement at the ﬂame detector QRA… 200 A 500 A

In connection with burner controls LMExx.xxxx2, use of UV ancillary unit AGQ3...A27 is mandatory. Correct functioning of aged UV cells can be checked as UV test with a higher supply voltage across the UV cell after controlled shutdown until terminal 3 ON.

Ancillary unit AGQ3...A27

7.6 UV-Detector

Connection diagram Measuring circuit for measuring the

UV ﬂame current

Measurement made at the ﬂame detector QRA…

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172 615 04 2018-01-02

7. Handing over of the

installation

• 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 be carried out by authorized personnel.

8. 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.

Review and service should be performed by authorised personnel only

33 Bentone

9. Electric equipment

9.1 Safety system

Safety systems must be installed in accordance with regulations that are applicable for the appliance. This may differ according to the process burner are installed in to. Se local regulations for information.

Safety system cables must be run in separate cables outgoing signal must not come in same cable as incoming signal. Signals must be in different harnesses for safety reasons.

Safety system as door switches, water level, pressure, temperature and other safety limiters must be installed in safety loop according to process.

172 615 13 2018-01-12

Bentone

9.2 Wiring diagram LME

If there is no Plug-in contact (X4,X6) on the boiler, connect to the contact enclosed.

If S6 is missing connect T6 and T8.

1N~50/60Hz 230V

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9.3 List of components

A1 Gas burner control

B1 Ionization electrode

F1 Operating fuse

H1 Lamp, low capacity

H2 Lamp, high capacity

H3 Alarm signal 230 V

M1 Burner motor

M2 Damper motor, L&S

SQN75.254.A21B

P1 Time meter, total operating

time

P2 Time meter, high capacity,

total operating time

S1 Operating switch

S2 Operating switch, stage 2

S3 Control thermostat

S4 Temperature limiter

S5 Micro switch for hinged door

S6 Control thermostat, stage 2

S7 Main switch

S8 Air pressure switch

S9 Gas pressure switch

T1 Ignition transformer

X1 Connection terminal board

X2 Earth terminal

X3 Plug-in contact, burner

X4 Plug-in contact, boiler

X5 Plug-in contact, stage 2,

burner

X6 Plug-in contact, stage 2,

boiler

Y1 Gas solenoid valve 1

Y2 Gas solenoid valve 2

9.3.1 Function LME...

1. Operating switch ON-Thermostat ON-Gas pressure switch ON

A check that the air pressure switch does not indicate fan pressure is carried out

2. Burner motor starts

A check that the air pressure switch indicates sufﬁcient fan pressure is carried out

3. The ignition spark is created

4. The gas solenoid valve is open

The gas is ignited. The ionisation electrode now indicates a ﬂame

5. The safety time expires

The ignition spark ceases. The safety period ceases. If the spark is missing or it disappears after this time limit, the gas burner control is blocked

6. Operating position

7. Stop

The operation of the burner can now be stopped with the control switch or thermostat

If the gas burner control is blocked

Red light in the gas burner control is lit. The burner is restarted by pushing the reset button

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Light period (waiting period ≥ 10 s)

Blinking code

Pause

Blinking code

Press the reset button > 3 s

9.4 Control program at faults; fault

mode indicator LME ....

9.4.1 Colour codes

Table colour codes for multi-coloured signal light (LED)

Status Colour codes Colours

Waiting period «tw», other waiting periods

○…………………

Off

Ignition phase, ignition controlled

•○ •○ •○ •○ •○ •

Blinking yellow

Normal operation

□…………………

Green

Operation, poor ﬂame signal

□○□○□○□○□○

Blinking green

Illegal ﬂame signal during start-up

□▲□▲□▲□▲□▲

Green-Red

Undervoltage

●▲●▲●▲●▲●▲

Yellow-Red

Fault, alarm

▲…………………

Red

Blinking code for fault codes

▲○ ▲○ ▲○ ▲○

Blinking red

Interface diagnostics

▲▲▲▲▲▲▲▲

Red ﬂicking

9.4.1.1 Diagnosing alarm causes

After alarm disconnection, the red alarm signal light is lit continuously. The diagnosing of the alarm cause can be read according to the following sequence:

……

Continuous

○

Off

▲

Red

●

Yellow

□

Green

9.4.1.2 Limiting of starting repetitions

LME 11... has a function with start repetition if the ﬂame is not created at start or disappears during operation.. LME 11... allows max. three repetitions during continuous starting cycle.

37 Bentone

9.4.1.3 Alarm code table

Red blinking code on signal lamp (LED)

Possible causes

Blinking 2 x

No ﬂame creation at End of “TSA”

- defective or fouled ﬂame monitoring

- defective or fouled fuel valves

- poor burner setting

- defective ﬁring device

Blinking 3 x

...

“LP” defective

- No air pressure switch signal after “t10”

- “LP” is welded in open position

Blinking 4 x

....

Illegal ﬂame signal during start-up

Blinking 5 x

.....

Time out “LP”

- “LP” is welded in open position

Blinking 6 x

......

Free

Blinking 7 x

.......

Too many ﬂame disappearances during operation

- poor burner setting

- defective or fouled fuel valves

- defective or fouled ﬂame monitoring

Blinking 8 x

........

Free

Blinking 9 x

.........

Free

Blinking 10 x

..........

Connection fault or internal fault, outgoing contacts or other faults

Blinking 14 x

..........

....

CPI contact not closed

During the diagnosing of the alarm cause, the control outputs are voltagefree.

• The burner is disconnected

• Exception, alarm signal «AL» at board 10

• Reconnection of the burner happens after resetting only.

• Press the reset button 0.5...3 s

9.4.1.4 Interface diagnostics

To change to interface mode, press and hold the reset button longer than 3 s. To go back to the normal position, press and hold the reset button longer than 3 s. If the gas burner control is in the alarm position, it is reset by pressing the reset button 0.5...3 s.

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172 615 06 2018-01-10

10. Troubleshooting

Gas Burner

Conditions favourable to disruption-free operation of the system can only be guaranteed through the interaction between three factors – electricity, gas ﬂow and combustion air. A change in any of these factors may cause disruptions.

It has been shown that a large proportion of disruptions can be attributed to relatively small things. Therefore, before requesting servicing, you should ascertain the following:

1. Are the system’s gas taps open?

2. Are the fuses intact and is the power on?

3. Are control devices (room thermostat, boiler thermostat, etc.) correctly set?

4. Is gas pressure to the burner sufﬁcient?

5. Are the burner controls on standby and not locked?

6. Is air supply to the burner adequate?

To facilitate troubleshooting, we have created a table of the most common faults that may arise in a gas burner system and how they should be rectiﬁed.

Cause of fault Action

Burner does not start

No gas Make sure all gas taps are open

No power Check the fuse, thermostat and electrical

connections

Burner motor does not start Motor protection has tripped. Motor faulty.

Burner control faulty Replace

Burner motor running, no ignition spark at the end of preaeration

No power in the terminals Check the connector. Replace faulty burner

controls

Ignition electrodes in contact with each other or earth Adjust

Ignition electrode porcelain damaged Replace the electrodes

Poor connection to cable connectors Adjust connection

Ignition cables damaged Replace

Transformer damaged, no power to secondary winding Replace the transformer

Ignition cable and ionisation cable swapped around Reconnect

No ﬂame propagation

Gas solenoid valve faulty Replace

Gas solenoid valve does not open despite having power Replace solenoid valve terminals, or entire

valve

No power to solenoid valve Check the connection

No electrical connection through air pressure gauge Check the air pressure gauge’s settings and

functions

Ignition load incorrectly set Increase/decrease gas supply Reduce

airﬂow

39 Bentone

Cause of fault Action

Burner control faulty Replace

Air pressure gauge incorrectly set or faulty Check the settings and reset, or replace

No acknowledgement signal due to incorrect adjustment or misalignment of the control motor cams.

Check the settings and realign.

Burner trips after safety time limit despite ﬂame propagation

No ionisation current or UV cell incorrectly positioned Adjust ionisation electrode and UV cell

Check cables and connectors

Burner control monitor faulty Replace burner control

Voltage lower than 185 V Contact an electrician

Ignition electrodes disrupting ionisation current Adjust ignition electrodes. Re-polarise the

transformer

Poor earth connection Ensure adequate earth connection

Phase and neutral swapped around Check wiring diagram and change

accordingly

Burner trips during pre-aeration.

Air sensor faulty or incorrectly set Increase/decrease air setting. Reduce air

volume

Ignition load incorrectly set Increase/decrease gas supply Reduce

airﬂow

Gas pressure too low Increase pressure. If necessary, contact gas

supplier

Pulsations at start-up

Ignition electrodes incorrectly set Adjust

Gas pressure too high Check and adjust using pressure gauge and

pressure control valve

Flue gas side blocked Check the chimney ﬂue

Burner pulsates during operation

Burner incorrectly set Adjust

Burner dirty Clean the burner

Incorrect chimney Check and modify dimensions if necessary

Burner functioning properly but with occasional blockage

Ionisation current too low Check. Must be at least 6 µA, but should

ideally lie between 8 and 20 µA

UV cell incorrectly positioned Adjust

Voltage drop at certain times Must not drop below 15% of rated voltage.

Contact an electrician if necessary

Incorrectly set or faulty air sensor Check the settings and reset, or replace

Ignition electrode overload Replace

Burner control ambient temperature too high Insulate for heat, Max. 60 °

Ignition spark too weak Check the transformer

Poor combustion

Poor draught conditions Check the chimney

Bentone

Cause of fault Action

Flue gas temperature too high Boiler overloaded Decrease the gas volume,

sweep the chimney if necessary

content too low Choke the air supply. Check the boiler for

any leakages. Choke the draught if too high

CO content too high

Surplus air when using natural gas and liqueﬁed petroleum (propane, butane)

Choke the air supply

Poor air supply Open the air supply. Check ﬂue gas damper

Holes in gas nozzle clogged. Clean

Poor fresh air intake Check and increase

Flame at incorrect angle due to combustion head out of position Check the combustion head and readjust

Condensation build up in boiler and chimney

Flue gas temperature too low or gas volume too low Raise the ﬂue gas temperature by increasing

gas volume Insulate the chimney

172 905 04 2018-02-15

11. EU Declaration of conformity

Bentone Gasburners

172 615 07 2018-01-04

13. General instructions for gasburners

13.3.1 Installation

1. Press the reset button of the relay

2. Check that the max. thermostat has not cut out

3. Check other thermostats for example room ther mostat, if any

4. Check that the gas pressure to the burner is sufﬁcient

5. Check that the electric fuses have not blown

6. Make a new attempt to start the burner and check the counter of the gas meter to ﬁnd out whether the solenoid valve opens

7. If the burner does not start in spite of repeated starting attempts call the installer

1. Follow standards and instructions applicable to the installation of gas burners

2. Ensure that the electric installation is made in accordance with existing regulations

3. Check that the fresh air intake of the boiler room is sufﬁciently dimensioned

4. Check by studying the data plate that the efﬁciency of the burner is adapted to the boiler output

5. Check that the burner is adapted to the gas quality in question

6. Check that the input pressure of the gas is correct

7. Check that the dampers of the boiler are open

8. Check that there is water in the system

9. Check that thermostats etc. are correctly adjusted

10. Read the instructions and follow the directions given for the burner as to starting-up and service

13.3.2 Maintenance

1. Switch off the current with the main switch

2. Shut-off the gas supply with the shut-off cock on the burner

Normal operation

1. Ensure that the air supply to the burner is not obstructed by dust and dirt

2. Have the installer make a yearly overhaul of the installation so that safety is not jeopardized

3. Have the installer at the yearly overhaul also adjust the burner to ensure optimal combustion economy

4. Check periodically that there is water in the system ( ﬁll up if necessary ) and that thermostats etc. are normally adjusted

5. Ensure that there is no water or dampness in contact with the burner

General instructions

1. Keep the boiler room clean

2. Ensure that the fresh air intake of the boiler room is not restricted

3. Switch off the current and shut off the gas supply if the burner must be withdrawn from the boiler

4. Do not use the boiler for burning paper and waste if there is no special arrangement ( ﬁre room ) for this

1(2)

13.3.3 If the burner has stopped 13.3.4 Shut-Off

13.3.5 Warning

1. Never keep your face in front of the ﬁre room door when starting up the burner

2. Do not use naked ﬂame when inspecting the ﬁre room

Authorized installer::

Address:

Telephone:

172 615 07 2018-01-04

Service- and inspection card

Installation Boiler

Name: Type: Efﬁciency kW:

Address: Burner

Type: Efﬁciency kW:

Installed by: Date:

Date

Nm3 gas/h Governor CO

CO Fluegas

temp

Ionisation current

Pressure Efﬁciency

Fire

room

Chimney

Measurement % % °C µ ABefore After mbar mbar

Small

Flame Large

Flame

Measures

Date

Nm3 gas/h Governor CO

CO Fluegas

temp

Ionisation current

Pressure Efﬁciency

Fire

room

Chimney

Measurement % % °C µ ABefore After mbar mbar

Small

Flame Large

Flame

Measures

Date

Nm3 gas/h Governor CO

CO Fluegas

temp

Ionisation current

Pressure Efﬁciency

Fire

room

Chimney

Measurement % % °C µ ABefore After mbar mbar

Small

Flame Large

Flame

Measures

Enertech AB. P.O Box 309, SE-341 26 Ljungby.

www.bentone.se, www.bentone.com

Bentone BG 300-2 Installation And Maintenance Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual