Bentone BG 300LN, BG 400LN Installation And Maintenance Instruction

Installation- and maintenance instruction

BG300LN

1

172 115 07 05-01

178 026 72

DESCRIPTION BG300/400LN

178910

2

3

45

6

11

12

13

14

15

16

17

18

19

20

1. Switch man-aut

2. Switch 0-1

3. Change -over switch
increasedecrease

4. Indicating lamp Stage 1

5. Reset button

6. Air pressure switch

7. Damper motor

8. Connection flange

9. Blast tube

10. Gas nozzle

11. Connection gas fittings

12. Multibloc

13. Air intake

14. Shut-off cock

15. Cover, inspection glass

1

16. Transformer

17. Gas burner control

18. Electric panel

19. Electrical connection

20. Motor

172 205 99 03-01

TECHNICAL DATA

Type designation BG 300LN

ø108

485

ø100

245185

A

Length of Measure A

345

M10

330

220

ø175-240

ø110

Standard 230 217

The above dimensions are max. measurements. Depending on the com
ponents used, the measurements may vary.

1/2

1

172 215 53 03-01

TECHNICAL DATA

Type designation BG 300LN

Output range

Capacity Gas volume at a min.Gas volume at a max Max. inlet Rated inlet pressure

kW output Nm3/h 1) output Nm3/h 1) pressure mbar mbar

G20 51-120 kW

1)

G20 5,1 G20 12 360 20

G25 45-120 kW G25 5,5 G25 14,6

Connection 3) Motor Ignition transformer

Natural gas

1-fas, 0,18 kW Primary 230 V, 1 A

1" 2 800 r/m, 230 V Secondary 8 000 V

1,3 A

1

) G20 = Natural gas Calorific value 10 kWh/Nm

G25 = Natural gas Calorific value 8,2 kWh/Nm

2

) Dimension and capacity depending on gas quality and

available pressure

Capacity chart according to EN 676

3

3

2/2

2

172 215 53 03-01

SKELETON DIAGRAM

2-stage or modulating burners

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 modulating operation is required,

this valve is equipped with controls for variable opening.

6b. Safety valve

1)

7. Valve proving system

8. Air damper motor

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.

9

8

10

4

5a

5b

6b

6a

3

2

1

Incorporated in the MultiBloc

7

When biogas is used, Bentone shall always be contacted.

6

172 415 05 03-01

MOUNTING ON THE BOILER

Fit the burner to the boiler by means of 4 bolts M10 (do not forget the
flange gasket). For flange and bolt dimensions see Technical Data or use
the fixing flange as a pattern. If for some reason you want to separate the
combustion part from the fan housing part to mount the burner on the
boiler, see General Instructions.

Mounting of the multi-bloc on the burner

Connect the multi-bloc to the burner head. Connect PL to the fan housing.
Connect the two cables by means of the plug-in contact to the multi-bloc.
Do not mix up the cables to the valves and to the gas switch.
IMPORTANT! The burner cannot start, if these cables have been mixed
up. Do not forget to connect the plug-in contact to the leakage control,
if any.

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.

a

P

L

7

172 155 01 03-01

ELECTRIC EQUIPMENT

Gas burner control: LMG22/LME22

Wiring diagram

connect to the contact enclosed.

* If there is no Plug-in contact (X4,X16) on the boiler,

*

1(2)

8

172 425 51 08-01

ELECTRIC EQUIPMENT

List of components

A1 Gas burner control S12 Change-over switch, Increase­A2 Power control Reduce
B1 Ionization electrode S15 Control thermostat, 3-pole
F1 Operating fuse (only for 2-stage sliding)
H1 Operating lamp T1 Ignition transformer
H3 Alarm signal 230 V X1 Connection terminal board
M1 Burner motor X2 Earth terminal
M2 Damper motor, X3 Plug-in contact, burner

L&S SQN75.624A21B X4 Plug-in contact, boiler

P1 Time meter, X15 Plug-in contact, power

total operating time controller, burner
S1 Operating switch X16 Plug-in contact, power
S3 Control thermostat controller
S4 Temperature limiter S9 Gas pressure switch
S5 Micro switch for hinged door Y1 Gas solenoid valve 1
S7 Main switch Y3 Safety solenoid valve
S8 Air pressure switch
S11 Change-over switch, Aut.-Man.

Mains connection in fuse in accordance with local regulations.

Gas burner control: LMG22/LME22
Function

1.Operating switch ON-Thermostat ON-Gas pressure switch ON-Air
damper closed.

A control is made that the air pressure switch does not indicate fan
pressure. Then the burner motor starts.

2.Air damper motor opens.

The air damper motor opens the damper to max. position. A control is
made that the air pressure switch indicates sufficient fan pressure.

3.Air damper motor closes.

The air damper motor closes to min. load position. Then the ignition spark
is formed.

4.Main and safety valves open.

The gas is ignited. The ionization electrode indicates a flame.

5.The safety time expires.

The ignition spark goes out. The safety time expires. If there is no flame or
if for some reason the flame disappears after this time limit, the burner
control locks out.

6.Operating position.

The burner is in operating position and can now change over to the capa­city controlled by the regulator.

7.Stop. The operation of the burner can now be interrupted by means of

the operating switch or the thermostat.

The control locks out. The red lamp in the control is lit. Restart the burner by pressing the reset

button.

2(2)

9

172 425 51 08-01

ELECTRIC EQUIPMENT

Control diagnosis under fault conditions and lockout indication
Gas burner control: LMG ...

Diagnosis of cause of fault After lockout, the red fault LED is steady on. For reading the cause of fault,

Red LED on

FS

AL

Error code table

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

refer to the blink code given in the following table:

Press lockout reset button

LED on (waiting time 10 s)

Fault

for > 3 s

Blink code

Off

Approx.
3 s

Blink code

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 times loss of flame during operation (LMG25)
19 x • Faulty output contact

•••••••••• - Wiring error

••••••••• - External power supply on output terminal
20 x • Internal device fault

••••••••••

••••••••••

Connecting signal amplifier

A1 = LMG

GP
R/W

LN

21

11112 2

br bl rt sw

sw r tQ1 = AGQ 2...

QRA

172 425 57 08-01

ELECTRICAL EQUIPMENT

Control program when disruption; disruption display

Gas burner control: LME....

Colour codes

Colour code table for multi-coloured signal lamps (Light diodes)

Status Colour codes Colours
Waiting time «tw», other waiting times Off
Ignition phase, ignition checked Flashing yellow
Normal operation Green
Operation, poor flame signal Flashing green
Prohibited flame signal during start up Green-Red
Undervoltage Yellow-Red
Disruption, alarm Red
Flashing code for fault codes Flashing red
Interface diagnostics Red flickering

Diagnostics alarm trigger

lights red

FS

AL

Limit on start attempts

Continuous

Off

Yellow
Green

The red alarm signal lamp lights continuously after the alarm is disconnected.
Diagnostics for alarm triggers can be read as specified by the following sequence:

Red

Light period (waiting time 10 s)

Press the reset
button > 3 s

Flash code Pause Flash code

Approx. 3 s

LME 11 … limits the number of start attempts if the flame does not ignite on start-up
or goes out during operation. LME 11 … permits a maximum of three start attempts
if the start cycle is uninterrupted.

22

1(2)

172 445 02 08-01

ELECTRICAL EQUIPMENT

Control program when disruption; disruption display

Gas burner control: LME....

Alarm control table

Red flashing code on Possible causes
signal lamp (LED)

Flashing 2 x No flame at End of «TSA»

•• - Defective or obscured flame monitor

- Defective or obscured fuel valves

- Poor burner installation

- Defective ignition unit

Flashing 3 x «LP» defective

••• - No air monitor signal after «t10»

- «LP» is welded in the open position

Flashing 4 x Prohibited flame signal during start up

••••
Flashing 5 x Time out «LP»

••••• - «LP» is welded in the closed position
Flashing 6 x Free

••••••
Flashing 7 x Too many loss of flame during operation

••••••• - Poor burner installation

- Defective or obscured fuel valves

- Defective or obscured flame monitor

Flashing 8 x Free

••••••••
Flashing 9 x Free

•••••••••
Flashing 10 x Connection fault or internal fault,

•••••••••• outgoing contacts or other fault
Flashing 14 x CPI contact not closed

••••••••••

••••

During alarm trigger diagnostics, control outputs are to be disconnected from all power.

- The burner is disconnected

- Exception, the «AL» alarm signal at connection block 10
The burner is only to be reconnected after it is reset

- Press the reset button 0.5...3 s.

Interface diagnostics

To switch to interface mode, hold the reset button depressed for more than 3 s. To return
to normal mode, hold the reset button depressed for more than 3 s. If the firing unit is in
the alarm mode, it is reset by pressing the reset button 0.5...3 s.

Connecting signal amplifier

A1 = LME

GP
R/W

LN

23

11112 2

br bl rt sw

sw r tQ1 = AGQ 3...

QRA

2(2)

172 445 02 08-01

MEASURES AND CHECKS BEFORE START-UP

2-Stage or modulating burners

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.

Inner assembly Ensure that the ignition and ionisation electrodes are correctly adjusted.

The sketch (see separate page) 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 air.

After having vented the gas line tighten the screw again.

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. depending 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.

NOTE! Applies only to gas burner control LFL1.

When using LPG (Propane) the burner should be connected for post-purging.
Move the connection on terminal 6 to terminal 7 in the base of LFL1.

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.

Gas train Multibloc

33

172 205 34 07-01

EASURES AND CHECKS BEFORE START-UP

BG300 / 400LN
Gas nozzle assembly

Natural gas

4-5

12-14

14

2

172 155 05 01- 01

DETERMINATION OF GAS VOLUME FOR THE INSTALLATION

Specifications on natural gas, town gas and biogas vary. For more exact
information please contact the gas distributor.

Net calorific value

Gas quality kWh/Nm

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
Biogas 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

η = Expected efficiency 90%

Ex. A

Ex. B

Q .3 600

=

V

Hu · η

120

=

V

10,3 · 0,90

120 . 3 600

=

37 144 . 0,90

≈ 12,9 Nm3/h

3

≈ 12,9 Nm3/h

kJ/Nm

3

kcal/Nm

3

3

If the barometer height, pressure and temperature of the gas deviate con­siderably from the normal values this must be taken into account as follows:

f=

273+t

273

1013,25

.

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

273

1013,25

.

945+15

f ≈ 1.11

The gas volume read on the gas meter actually reads 1,11 . 12,9 = 14,4 m3/h.

36

172 205 16 03-01

DUNGS COMBI BLOC WITH RATIO ADJUSTMENT

MB-VEF BO1, 407
View

1. Electrical connection gas pressure switch mini

2. Electrical connection gas valve

3. Pressure switch mini

4. Flange connection inlet

5. Test point connection 1/8" before V

1

6. Filter

7. Data plate

8. Connection 1/8" P

L

9. Adjustment screw V for ratio PBr: PL (max. load)

10. Test point connection 1/8" before V1 (before governor)

11. Connection M4 for measurement of burner presssure after V

2

12. Adjustment screw for zero point adjustment N (min. load)

13. Test point connection 1/8" P

14. Test point connection 1/8" P

F

Br

15. Flange connection, outlet

16. Test point connection 1/8" Pa before V2 (after governor)

17. Indication of V1 and V2 in operation (not standard)

1)

18. Impulse line PBr (gas pressure)

19. Impulse line PL (air pressure)

20. Impulse line (fire room)

It is possible to connect a leakage control VPS 504 and a gas pressure
switch maxi.

1)

NOTE!

The impulse line PBr can be replaced by an impulse flange on
the multiblock.If so, the impulse line PBr is placed included in the flange.

16

172 205 43 03-01

MULTI-BLOC, MB-VEF 412 - 425 B01

Technical data

- Max inlet pressure 360 mbar

- Valves V1+V2 class A group 2 in accordance with EN 161

- Governor class A group 2 in accordance with EN88

- Ratio V PBr:PL 0,75:1-3:1

- Filter according to DIN 3386

- Ambient temperature -15°C- +70°C

- Protection standard type IP54 (according to IEC 529, DIN 40050)

- Gas family 1 +2 +3

- Outlet pressure 0,5 - 100 mbar

- Zero point adjustment N ±2 mbar

- Pressure switch DIN3398 TI

- Fan pressure PL0,4-100 mbar

- Fire room pressure PF -2 -+5mbar

- Burner pressure PBr 0,5 - 100 mbar

Mounting instruction - impulse lines PL, PF and P

- Impulse lines should preferably be made of steel. Inside diametre
>ø 4 mm (steel tube ø 6/4)

- For PL other material can be used.

- Impulse lines PL and PBR are ready from factory

- Impulse lines shall be mounted in such a way that no conden sate
can flow back into the multibloc.This is especially important
when PF is concerned.

- Impulse lines shall be mounted in such a way that they are
protected against rupture and damage.

- Impulse lines shall be as short as possible

Adjustment possibilities

Adjustment range

pL, min =0,4 mbar

V = 1:1

V = 3:1

Br

V = 0,75:1

pBr, min =0,5 mbar

P

, max. = 100

Br

!

Effective burner pressure

P

= PBr - P

Br

!

Effective fan pressure

PL = PL-P

F

F

V = 3:1

V = 1:1

V

46

PL, max. = 100 mbar

+ N

- N

V = 0,75:1

172 215 16 03-01

ADJUSTMENT OF GAS FLOW

- Before the burner starts vent the lines to make sure that there is gas

available at the multibloc

- Use an allen key size 2,5 mm for adjusting N and V.

- Connect a pressure gauge for measur-ing PBr, (advisable to find out if

the valves are open)

- Set the switch in position MAN.

- Set the gas pressure switch min. and air pressure switch on min.

adjustment. Set the gas pressure switch max, if any, on max.
adjustment.

- Start the burner, observe the pressure gauge, if no flame is established

and the pressure gauge needle does not flicker, increase N. When the
flame is established adjust the gas flow by means of the screw N. Use
a flue gas instrument.

- Change over to max. load, press the switch “increase”

- Adjust the gas flow with V and check at the same time the

combustion values.

- Go back to min. load and check the combustion value. Adjust if

necessary.

- If necessary repeat the controls of the adjustment made on min. (N)

and max .load(V)

- The desired gas flow on min. and max. has now been adjusted by

changing the orange and the red cams. Check the gas flow on the gas
meter available on the installation.

Damper motor, air volume

Releasing button

Note! Do not forget to set the air and gas pressure switches after the

adjustment, see special instructions.

Adjust the orange cam for min. load (about 5-10 on scale)
Adjust the red cam for max. load (90° )
The blue cam is factory set for closed position during standstill
The black cam has no function at modulating operation

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..

Gas valve (black)
Max. load (red)

Min. load (orange)
Closed damper (blue)








1

o

Releasing button N.B.
The upper position is

172 305 68 03-01

GENERAL INSTRUCTIONS

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.

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

Commissioning of installation

Service

Important

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.

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 should 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 (i.e. larger
gas armature or a different spring in the governor may be required).

To get as low emissions as possible, the burner, the boiler and the
chimney must be adapted to each other.

Gas quality CO2%0

lambda 1,2

Natural gas 10,0 3,5 11,9

18

% max CO2%

2

172 305 61 03-01

GENERAL INSTRUCTIONS

Adjustment of shrouded disc and burner head

The burner head is firm adjusted and there are no possibilities of
settings besides the adjustment and the inspection of the ignition
electrode and the ionisation electrode.

Inspection of burner head when multi-bloc MB...407

The burner head, the shrouded disc and the electrodes can be inspected
by following the instructions below:
Loosen the nut a, the nut b to the impulse line PL , the plug-in contacts c
and the screws d. Pull out the fan housing part. Loosen carefully the
ionisation and ignition cables. When the fan housing part is separated
from the fixing flange, the combustion unit can be checked as follows:
Loosen the screws e and pull out the combustion unit.

Note! Greatest caution at this working moment.

When making service to the burner,

switch off the electric current and the gas supply. Do not forget the gaskets
and O-rings and to check the density after the service.

abce

d

This screw should be loosen when pulling out the blast tube. When re­mounting the blast tube, push the blast tube so far into the flange that the
ring in the blast tube fits tight to the combustion head.

20

172 305 62 03-01

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.

Gas control Connection to terminal Min. ionisation

in gas control current required

LMG Serie A 1 2 μ A
LMG Serie B 2 10 μA
LGB 1 10 μ A
LFL 24 10 μ A
MMI 810 2 5 μ A
TMG 740-3 1 5 μ A

Flame monitoring

50

1(3)

172 305 25 05-01

GENERAL INSTRUCTION

UV-detector

This should not be exposed to temperatures exceeding 60°C. The current
passing through the UV-detector, when it is being illuminated, should be at
least 70 μ A for LFL1.. This current can be measured by means of a
moving coil instrument. Checks should only be made if a fault is suspected.

The capacitor, which sould be placed between the terminals on the moving
coil instrument, must be of 100 μ F 10-25 V.

Flame monitoring

Control box LFL1

UV-detector

μ A

22

1

2

23

51

2(3)

172 305 25 05-01

GENERAL INSTRUCTION

Adjustment of air pressure switch

The air pressure 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.
On adjustment, turn the scale on the air pressure switch in clockwise
direction. When the switch-off point has been reached and the burner stops
read off the value on the scale. Then turn the scale in anti-clockweise
direstion to desired value. Make repeated start attempts to ensure that the
air pressure switch is not too closely set.

Adjustment range ca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50

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.

Adjustment 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%.

Adjustment range:
2,5-50 mbar GW 50
5-150 mbar GW 150

Gas pressure switch, air pressure switch

52

3(3)

172 305 25 05-01

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.

Fault location, functional troubles

Trouble free operation is depending 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 sheet.

57

172 305 17 03-01

FAULT LOCATION GUIDE

Gas burner

The basis for a 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?

To facilitate fault location we have drawn up a scheme showing the most
frequent faults in a gas burner installation and the remedies.

Cause Remedy

The burner does not start

No gas Check that all gas cocks are open.

No voltage Check fuses, thermostats and

electrical connections.

The burner motor fails to start The thermal protection has locked out.

Motor defective.

The gas relay is defective Replace

Burner motor is running but no
ignition after the pre-purge time has elapsed

No voltage on the terminals Check the contact. Replace faulty relay

The ignition electrodes in contact Adjust
with each other or with earth

The porcelain of the electrodes is broken Replace the electrodes

The cable shoes have bad contact Improve the contact

The ignition cables are damaged Replace

The ignition transformer is damaged, no voltage Replace the transformer
on the secondary side

The ignition cable and the ionisation cable Change
have been transposed.

59

1(3)

170 091 16 03-01

Cause Remedy

No flame establishment despite a trouble free start

The gas solenoid valve defective Replace

The gas solenoid valve does not open despite Replace coil or the whole valve if necessary.
its obtaining voltage

No voltage to the solenoid valve Check the contact

No electrical connection through Test the adjustment and the function of the air pres­the air pressure switch sure switch.

The starting load is not correctly adjusted Reduce or increase the gas supply, reduce the quanti

ty of air.

Gas relay defective Replace

Air pressure switch incorrectly adjusted or defective Check the adjustment and readjust.

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 Adjust the ionisation electrode and the UV-cell,
position examine cables and connections.

The supervision part of the gas relay is defective Replace the relay

Voltage lower than 185 V Contact the electricity authorities.

The ignition electrodes are disturbing the ionisation Adjust the ignition electrodes, repole the ignition
current transformer if necessary.

Bad earthing Arrange for proper earthing.

Phase and neutral transposed See wiring diagram and change.

The burner locks out during pre-purge

Air pressure switch defective or incorrectly adjusted

The starting load is not correctly adjusted Reduce or increase the gas supply. Reduce

. the quantity of air.

The gas pressure is too low Increase the pressure. Contact the gas supply

company if necessary.

Condensation in boiler and chimney

The flow gas temperature is too low or the Increase the flue gas temperature by increasing
quantity of gas is not sufficient the gas supply. Insulate the chimney.

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170 091 16 03-01

2(3)

Cause Remedy

Pulsations at start

The ignition electrodes are wrongly adjusted Re-adjust.

The gas pressure is too high Check and adjust by means of a pressure gauge

and a pressure adjustment valve.

The flue gas side is blocked Check the chimney flue.

Pulsations during operation

The burner is not correctly adjusted Re-adjust

The burner is dirty Clean the burner.

Defective chimney Check and change the dimensions if necessary.

The burner is operating correctly but locking out now and then

The ionisation current is too low Check. Must be at least 4 μ A according to the

relay manufacturer but should be 8-20 μ A.

The UV-cell is in a wrong position Adjust.

Voltage drop at certain times Must not drop more than 15% of the rated current.

Air pressure switch defective or incorrectly adjusted Contact the electricity authorities if necessary.

Spark-over in ignition electrodes Replace the electrodes

The ambient temperature of the gas relay is too high Heat insulate, max. 60° C.

The ignition spark is too weak Check the transformer

Bad combustion

Bad draught conditions Check the chimney

The flue gas temperature is too high The boiler is overloaded. Reduce the quantity of gas.

The CO

-content is too low Check the boiler with regard to leaks. Choke

2

the draught if it is too high.

The CO-content is too high

Excess air when using natural gas and Choke the air.
gasoil (propane, butane)
Air shortage Open the air supply. Check the flue gas damper.

The holes in the gas nozzle are clogged Clean.

The fresh air intake is too small Check and enlarge

The flame is not burning straight because Check the burner head and readjust.
the burner head is out of position

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170 091 16 03-01

3(3)

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, possible 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,BG 500LN, BG550, BG550LN, BG 600,BG 600LN, BG650, BG 700,BG 700LN, BG 800,BG 800LN

....................................................................................................................................................................................................

and BG950 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)

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172 905 95 09-01