Bentone BG 550, BG 550 LN, BG 650 Installation And Maintenance Instruction

178 015 82-2 2016-12–07

Providing sustainable energy solutions worldwide

Installation- and maintenance instruction

BG 550,BG 650

Model 2, M

BG 550 LN

Contents

Description _____________________________________________________________ 5

Warning __________________________________________________________________________________________ 5
2-stage ___________________________________________________________________________________________ 6
Modulating________________________________________________________________________________________ 7

TECHNICAL DATA _______________________________________________________ 8

Dimension ________________________________________________________________________________________ 8
Output range ______________________________________________________________________________________ 9
Working field _____________________________________________________________________________________ 10

SKELETON DIAGRAMS _________________________________________________ 11
MOUNTING OF THE BURNER ___________________________________________ 12

Inspection of gas assembly ________________________________________________________________________ 12
Adjustment of the positiion of the shrouded disc in the blast tube _____________________________________ 12

ELECTRIC EQUIPMENT ________________________________________________ 13

Wiring diagram LME22 (BG550/BG650) 2-Stage _____________________________________________________ 13
List of components _______________________________________________________________________________ 14
Function LME22 __________________________________________________________________________________ 14
Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating _________________________________________ 15
List of components _______________________________________________________________________________ 16
Function LME22 __________________________________________________________________________________ 16
Control diagnosis under fault conditions and lockout indicatio ________________________________________ 17
Gas burner control: LMG ... _______________________________________________________________________ 17

MEASURES AND CHECKS BEFORE START UP ___________________________ 18

2-Stage or modulating burners _____________________________________________________________________ 18
Inner assembly ___________________________________________________________________________________ 19
Inner assembly BG 550LN _________________________________________________________________________ 20

DETERMINATION OF GAS VOLUME FOR THE INSTALLATION ______________ 21
GAS SOLENOID VALVE DUNGS MVD ____________________________________ 22
OPERATION AND ASSEMBLY INSTRUCTIONS ____________________________ 23

Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11 _________________________________________ 23
DMV 525/11 ______________________________________________________________________________________ 24
Gas pressure regulator Type FRS ___________________________________________________________________ 26

MULTI-BLOC, MB-ZRDLE 405-420 BO1 __________________________________ 28

Flow adjustment 2-stage design ___________________________________________________________________ 29

MULTI-BLOC, MB-VEF 412-425 B01 _____________________________________ 30

view _____________________________________________________________________________________________ 30

MULTI-BLOC, MB VEF 412-425 B01 ______________________________________ 31

Technical data ____________________________________________________________________________________ 31
Mounting instruction-impulse lines _________________________________________________________________ 31
Adjustment possibilities ___________________________________________________________________________ 31

MULTI-BLOCK VDG20...SKP75/15 _______________________________________ 32

Technical data ____________________________________________________________________________________ 33
Mounting of impulse lines _________________________________________________________________________ 33

2

DAMPER MOTOR 2- STAGE _____________________________________________

Air adjustment____________________________________________________________________________________ 34
Releasing button _________________________________________________________________________________ 34

34

DAMPER MOTOR MODULATING ________________________________________ 35

Air adjustment____________________________________________________________________________________ 35
Releasing button _________________________________________________________________________________ 35

GENERAL INSTUCTION_________________________________________________ 36

Adjustment of burner _____________________________________________________________________________ 36
Service __________________________________________________________________________________________ 36
Flame monitoring and measurement of ionisation current _____________________________________________ 37
UV- detektor _____________________________________________________________________________________ 38
Adjustment of air pressure switch __________________________________________________________________ 39
Adjustment of min. gas pressure switch ____________________________________________________________ 39
Adjustment of max. gas pressure switch ____________________________________________________________ 39

LEAKAGE CONTROL, DUNGS VPS 504 SERIE 2___________________________ 40

Technical data ____________________________________________________________________________________ 40
Programme sequence _____________________________________________________________________________ 40
Program sequende schedule ______________________________________________________________________ 41
Electrical connection VPS 504 Series 2 _____________________________________________________________ 41

HANDING OVER OF THE INSTALLATION _________________________________ 42

Fault location, functional troubles __________________________________________________________________ 42

DECLARATION OF CONFORMITY _______________________________________ 43
FAULT LOCATION GUIDE _______________________________________________ 44

Gas burner _______________________________________________________________________________________ 44

3

4

Description

DESCRIPTION

Warning

Warning

!

Warning

- Read the manual before assembling or commissioning.



- The contents of this manual are to be observed by all who work for
any reasoN on the unit and its appertaining system parts.

- This manual is intended especially for authorised personnel.

- This manual is to be regarded as part of the burner and shall always
be available near the place of installation.

- The burner is only to be installed by qualifi ed personnel

- Check that the burner is suitable for the boiler´s power range.

- The burner is to be installed such that it complies with any local re­gulations relating to electrical safety, boilers and fuel distribution.

- Check that the burner is approved for the gas quality intended used.

- No burner safety systems are to be disengaged.

- The fi tter is to ensure that the boiler room is supplied with fresh air
ventilation that is suffi cient in accordance with local standards.

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

- The outer temperature of the boiler´s components can exceed 60 °C.

- Check that the guide stop is installed before servicing.

- Take great care when servicing. Trap and pinch risks can be present.

- The boiler´s sound level can exceed 85 dBA during operation. Use
ear protectors when present in the boiler room.

Safety directions

Acceptance inspection

Preparations for installation

- The electrical installation shall be made according to valid regulations
for heavy current and in a professional way, so that the risk of leaking

gas, fi re or personal injury is avoided.

- If another electrical connection is used than the one recommended
by Enertech, there might be a risk of material damage or personal

injury.

- Notice should be carefully taken by the installer that no electrical
cables or gas pipes get squeezed or damaged when installing or at
service

- If the boiler is provided with an opening door, this should be interlocked
with a door switch.

- Ensure that everything is delivered and that there is no transport
damage.

- If there is anything wrong with the delivery, please report it to the
supplier.

- Ensure that the size and capacity range of the burner are suitable for
the boiler.

- Power data on the data plate refer to the minimum and maximum
power of the burner.

5

2-stage

DESCRIPTION

2-Stage

Components

1. Flame cone

2. Connection fl ange

3. Guide bar

4. Fan wheel

5. Fan house

6. Shrouded disc

7. Ignition electrode

8. Nozzle

9. Ionisation electrode

10. Motor

11. Connection gas fi ttings

12. Ignition transformer

13. Air damper

14. Air damper motor

15. Air pressure switch

16 Fuse holder

17. Indicating lamp Stage 2

18. Switch I-II

19. Indicating lamp Stage I

20. Switch 0-l

21. Time meter, stage 1

22. Time meter, stage 2

23. Contactor with thermal
overload protection

24. Control box

25. Gas train

26. MultiBloc

6

DESCRIPTION

Modulating

Modulating

Components

1. Flame cone

2. Connection fl ange

3. Guide bar

4. Fan wheel

5. Fan house

6. Shrouded disc

7. Ignition electrode

8. Nozzle

9. Ionisation electrode

10. Motor

11. Connection gas fi ttings

12. Ignition transformer

13. Air damper

14. Air damper motor

15. Air pressure switch

16. Fuse holder

17. Change-over switch
increase-decrease

18. Change-over switch
manually-automatically

19. Indicating lamp

20. Switch 0-l

21. Time meter

23. Contactor with thermal
overload protection

24. Control box

25. Gas train

26. MultiBloc

7

TECHNICAL DATA

TECHNICAL DATA

Dimension

Type designation BG550/BG550LN/BG650

Dimensions



C



321

290*

 



690*



 



D





B



658









660*

400

321







Standard 1

Standard 2

Standard 3

Standard 1

Standard 2

Standard 3

Standard 1

Standard 2

Standard 3

Length of
burner tube

Flange
Measure B

Burner tube
Measure C

Burner tube
Measure D

BG550

256 226 162 162

356 326 162 162

456 426 162 162

Length of
burner tube

Flange
Measure B

Burner tube
Measure C

Burner tube
Measure D

BG550LN

252 222 162 162

352 322 162 162

452 422 162 162

Length of
burner tube

Flange
Measure B

Burner tube
Measure C

Burner tube
Measure D

BG650

316 286 185 162

416 386 185 162

516 486 185 162

M12

(ø210)ø254-280

ø190

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

components used, the measurements may vary.

8

TECHNICAL DATA

Output range

Output range

Capacity Gas volume at a min. Gas volume at a max Max. inlet Rated inlet pressures
kW output Nm3/h 1) output Nm3/h 1) pressure mbar mbar

BG550
G20 140-640 14,8 67,7 360 40
G25 140-600 17,4 74,4 360 40
G30 140-620 4,3 19,2 360 30-50
G31 140-620 5,7 25,4 360 30-50

BG550LN
G20 140-620 14,8 35,6 360 40
G25 140-620 17,4 76,9 360 40

BG650
G20 200-1125 21,2 119,0 360 40
G25 200-1125 24,8 139,6 360 40
G30 200-1125 6,2 34,9 360 30-50
G31 200-1125 8,2 46,0 360 30-50

Type kWh/m

3 1)

kWh/kg

G20: Natural gas H 9,45
G25: Natural gas L 8,06
G30: Butane 32,24 12,68

G31: LPG 24,44 12,87

1)

Calorifi c value: kWh/m3 15°C 1013.25 mbar (according to EN676)

2)

Dimension and capacity depending on gas quality and available pressure

Connection

BG550/BG550LN
Natural gas LPG 1
1/2”-2”

2)

Motor Ignition transformer

0,75 kW

230/400V 50 Hz

3,1/1,8A

Primary 230 V,

0,25A 50-60Hz 60VA

Sec. 11kV Ampl
50 mA rms
33% ED in 3 min

BG650
Natural gas LPG 1
1/2”-2”

1,5 kW

230/400V 50 Hz

5,7/3,3A

Primary 230 V,

0,25A 50-60Hz 60VA

Sec. 11kV Ampl
50 mA rms
33% ED in 3 min

9

TECHNICAL DATA

Working field

Working fi eld

BG550

140-640 kW

BG550
BG550 (G25)
Measured (test)

14
12

10

8
6
4
2
0

Pressure in fi re place

-2
100 200 300 400 500 600 700

Capacity kW

BG550LN

140-620 kW

BG550LN
Measured (test)

BG550 LPG 60Hz

150-820 kW

14
12

10

8
6
4
2
0

Pressure in fi re place

-2
100 200 300 400 500 600 700

Capacity kW

Pressure in fi re place

Capacity kW

BG650

200-1125 kW

BG650
Measured (test)

Unbroken line is the approved wor-

king fi eld as per EN 676.

16
14

12
10

8
6
4
2
0

-2

Pressure in fi re place

200 300 400 500 600 700 800

10

900 1000 1100 1200

Capacity kW

SKELETON DIAGRAMS

SKELETON DIAGRAMS

2-stage or modulating burners

Incorporated in the MultiBloc

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
6b. Safety valve

8. Air damper motor

9. Air pressure switch

10. Gas burner control

1)

7. Valve proving system

Pos. 5b, 7: Components not required according to EN 676.

1)

Required over 1200 kW according to EN 676.



When Bio gas is used, Bentone shall always be contacted.

!

11

MOUNTING OF THE BURNER

MOUNTING OF THE BURNER

Inspection of gas assembly

Fit the burner to the boiler by means of 4 bolts M12. For fl ange and bolt

Adjustment of the positiion of the shrouded disc in the blast tube

If for some reason you want to separate the burner from the gas fl ange

Do like this: - Remove the cover of the fan housing.

- Loosen the nut D of the gas assembly package.

- Loosen the electric cables to the valve package.

- Loosen the screws B on both sides.

- Loosen the stop bolt C on the pull rods.

- Loosen the ignition cable and the ionisation cable from the gas

- Pull out the burner on the pull rods and put it in a suitable place.

When the burner head and the gas fl ange have been fi tted to the boiler

Inspection of gas assembly

If the gas assembly needs to be inspected the pull rods are very useful.

Do like this: - Remove the cover of the fan housing.

- Loosen the nut D of the gas assembly package.

- Loosen ignition cable and ionisation cable of gas assembly.

- Loosen the screw A on both sides.

- Pull out the burner on the pull rods.

- Loosen the screws B on the gas fl ange.

- Withdraw the gas assembly.

Ensure that the O-ring between the gas assembly and the gas fl ange will

dimensions see technical data.

with burner head and valve package you can do so.

assembly.

it is easy to lift up the burner to where it belongs.

be in the correct position when the gas assembly is fi tted again.

Adjustment of the position of the shrouded disc in the blast tube

Sometimes it is necessary to adjust the position of the shrouded disc in

the blast tube. This can be done with the screw E (can be adjusted when

the burner is in operation). If you turn the screw to the left the shrouded
disc will move forward (+), to the right it will move backward.

NOTE!

For maintenance of the brake plate, nozzles, electrodes etc, when using a

long design of the burner tube, you have to remove the nozzle assembly
from the connecting pipe and move the assembly backwards in the
fan housing (from the boiler).

Service position

12

ELECTRIC EQUIPMENT

ELECTRIC EQUIPMENT

Wiring diagram LME22 (BG550/BG650) 2-Stage

Wiring diagram LME22 (BG550/BG650) 2-Stage

13

1(5)

172 445 12 16-01

ELECTRIC EQUIPMENT

List of components

Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating

Function LME22

14

2(5)

172 445 12 16-01

ELECTRIC EQUIPMENT

Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating

List of components LME22 (BG550/BG650)

A1 Gas burner control
A2 Power control
B1 Ionization electrode
F1 Operation fuse
F2 Operation fuse
F3 Operation fuse

H1 Lamp, low capacity
H2 Lamp, high capacity (optional)

K1 Motor contactor with thermal overload protector

M1 Burner motor
M2 Damper motor
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 3-phase
S8 Air pressure switch

If S6 is missing, connection between T6 and T8.
Mains connection and fuse in accordance with local regulations.
Max loading K1

Connection A1,A2 / 95, 96 / 97, 98 Max 0,2A/15W

S9 Gas pressure switch
S11 Change-over switch, Aut.-man.
S12 Change-over switch, Increase Reduce
S15 Control thermostat, 3-pole (only for 2-stage

sliding)

S16 High pressure switch

S20 Main 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
X15 Plug-in contact, power controller, burner
X16 Plug-in contact, power controller
Y1 Gas solenoid valve 1
Y2 Gas solenoid valve 2
Y3 Safety solenoid valve

Function LME22

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 full load. A control is made

that the air pressure switch indicates suffi cient fan pressure.

3. Air damper motor closes.
The air damper motor closes to low load . Then the ignition spark is

formed.

4. Main and safety valves open

The gas is ignited. The ionization electrode indicates a fl ame.

5. The safety time expires.

The ignition spark goes out. The safety time expires. If there is no fl ame

or if for some reason the fl ame 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 full load

if the operating switch and the thermostat for full load are in positon ON.
The burner can alternate between full and low load depending on set
temperature.

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.

15

172 445 12 16-01

3(5)

ELECTRICAL EQUIPMENT

to normal mode, hold the reset button depressed for more than 3 s. If the fi ring unit is

Connecting signal amplifi er

Red fl ashing code on Possible causes

Flashing 2 x No fl ame at End of «TSA»

•• - Defective or obscured fl ame monitor

Flashing 4 x Prohibited fl ame signal during start up

Flashing 7 x Too many loss of fl ame during operation

- Defective or obscured fl ame monitor

List of components
Function LME22

Control program when disruption; disruption display

Gas burner control: LME....

Colour codes

Status Colour codes Colours

Waiting time «tw», other waiting times Off

Ignition phase, ignition checked Flashing yellow

Normal operation Green

Operation, poor fl ame signal Flashing green
Prohibited fl ame signal during start up Green-Red

Undervoltage Yellow-Red

Disruption, alarm Red

Flashing code for fault codes Flashing red

Interface diagnostics Red fl ickering

Diagnostics alarm trigger

lights red

FS

AL

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

Continuous

Off

The red alarm signal lamp lights continuously after the alarm is disconnected.

Diagnostics for alarm triggers can be read as specifi ed by the following sequence:

Light period (waiting time 10 s)

Press the reset
button > 3 s

Red
Yellow
Green

Flash code Pause Flash code

Approx. 3 s

Limit on start attempts

LME 11 … limits the number of start attempts if the fl ame 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.

16

4(5)

172 445 12 16-01

ELECTRICAL EQUIPMENT

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

Control program when disruption; disruption display

Gas burner control: LME....

Alarm control table

Red fl ashing code on Possible causes

signal lamp (LED)

Flashing 2 x No fl ame at End of «TSA»

•• - Defective or obscured fl ame 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 fl ame 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 fl ame during operation

••••••• - Poor burner installation

- Defective or obscured fuel valves

- Defective or obscured fl ame 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 fi ring unit is

in the alarm mode, it is reset by pressing the reset button 0.5...3 s.

Connecting signal amplifi er

GP
R/W

L N

A1 = LME

17

11112 2

br bl rt sw

sw rtQ1 = AGQ 3...

QRA

5(5)

172 445 12 16-01

MEASURES AND CHECKS BEFORE START-UP

MEASURES AND CHECKS BEFORE START UP

2-Stage or modulating burners

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 fi g.).

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 fl ame

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 fi nished.

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 fi g. 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

18

MEASURES AND CHECKS BEFORE START-UP

Inner assembly

Inner assembly

Town gas

Inner assembly

Natural gas, LPG

Inner assembly

Biogas ((UV-detector)

19

MEASURES AND CHECKS BEFORE START-UP

Inner assembly BG 550LN

Inner assembly BG 550LN

A = 10 mm Front edge Brake plate
B = 3 mm

A

B

A = Position Ionisation detector
B = Position Ignition electrode

A B

20

DETERMINATION OF GAS VOLUME FOR THE INSTALLATION

DETERMINATION OF GAS VOLUME FOR THE INSTALLATION

Specifi cations on natural gas, town gas and biogas vary. For more exact

information please contact the gas distributor.

Net calorifi c value

Gas quality kWh/Nm

3

kJ/Nm3 kcal/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

H

η

= Calorifi c value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm

u

= Expected effi ciency 90%

3

3

Ex. A v=

Ex. B v=

Q .3 600

H

· η 37 144 . 0,90

u

120

10,3 · 0,90

=

≈

12,9 Nm

120 . 3 600

3

/h

≈

12,9 Nm

3

/h

If the barometer height, pressure and temperature of the gas deviate consi-

derably 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)

P

= Pressure of the gas at the gas meter (15,0 mbar)

u

f = 273+15 . 1013,25

273 945+15

f = 11,1

The gas volume read on the gas meter actually reads

.

1,11

12,9 = 14,4 m3/h.

21

MANUAL FOR ADJUSTMENT OF GAS SOLENOID VALVE DUNGS MVD

GAS SOLENOID VALVE DUNGS MVD

MVD:

1-step valve fast opening with max.

fl ow adjustment.

1. Protection cover

2. Flow adjustment

3. Lock nut

Flow adjustment MVD/5

Remove protection cover 1. Loosen

lock nut 3. Turn the fl ow adjustment
screw 2 to the right = gas fl ow decrea­ses or to the left = gas fl ow increases.

Tighten the lock nut.

22

OPERATION AND ASSEMBLY INSTRUCTIONS

OPERATION AND ASSEMBLY INSTRUCTIONS

Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11

Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11

Nominal widths
Rp 1/2 - Rp 2
Electrical connection IEC 730-1 (VDE 0631 T1)

Volt U n ~(AC) 230 V

Valve 2 x Class A

Ambient temperature -15 °C … +60 °C

IP 54

Family 1 + 2 + 3

Max. operating pressure 500 mbar

DMV 505-520/11
Pressure taps 1, 2, 3, 4 Sealing
plug

Screw plugs 1,2,3 may also be
replaced by a measuring socket
G 1/8 DIN ISO 228.

Concealed connecting bore for sys­tem accessories.

23

OPERATION AND ASSEMBLY INSTRUCTIONS

DMV 525/11

DMV 525/11

Pressure taps 1, 2, 3, 5 Sealing plug

Screw plugs 1,2,3 and 5 may also be
replaced by a measuring socket
G 1/8 DIN ISO 228.

1. Loosen screws A and B do not

remove. Figs 1 and 2

2. Remove screws C and D. Figs

1 and 2

1.

2.

3. Remove double solenoid valve

between the threaded fl anges.

Figs 3 and

4. After mounting, perform lea-

kage and functional tests.

5. Lead seal

Lead seal eye 2 in 1.5 mm dia.
sealing valve.
Lead seal eye 3 in 1.5mm cap
stand headed screw.
After setting the requested

pressure setpoint:

1. Close protective valve 1.

2. Route wire through 2 and 3, Fig. 2.

3. Press lead around wire ends,
keep wire loop short.

6. DMV - D 507/11 - 525/11 DMV-

DLE 507/11 - 525/11 Main fl ow

setting only possible at V1! Set
main volume on open valve.
Set valve V1 during operation.
Check setting values continu­ously. Smallest setting volume

fl ow:

3.

4.

5. 6.

° °

Vmin. / mini.> 0.1 x Vmax. / maxi.

24

OPERATION AND ASSEMBLY INSTRUCTIONS

7. DMV-DLE Rapid stroke ad­justment V start

Factory setting DMV-DLE:
Rapid stroke not adjusted

1. Unscrew the adjustment cap E
from the hydraulic brake.

2. Turn the adjustment cap and
use as a tool.

3. Turn a-clockwise = increase
rapid stroke (+).

8. Replacing hydraulic brake
unit or adjustment plate

1. Switch off fi ring system.

2. Remove locking varnish from
countersunk screw A.

3. Unscrew countersunkscrew A.

4. Unscrew socket headscrew B.

5. Raise adjustment plate C or hy-
draulic brake D.

6. Remove sealing plug E

7. Exchange adjustment plate C
or hydraulic brake D

8. Screw in countersunk and
socket head screw. Only
tighten socket head screw so

that hydraulic brake can just be

turned.

9. Coat countersunk screw A with
locking varnish.

10. Leakage test: Pressure tap at

sealing plug 2:

DMV 507-520/11 Pressure tap

at sealing plug 3: DMV 525/11

p max. = 500 mbar.

11. Perform functional test.

12. Switch on fi ring system.

7.

8.

9. Replacing the solenoid
Versions with adjusting plate
DMV-D 5.../11or hydraulic
brake DMV-DLE 5../11

1. Remove hydraulic brake or

adjusting plate as described on
page 6: ”Replacing the hydrau­lic brake or adjusting disk”,

steps 1 - 5.

2. Replace solenoid

Important: Make sure that the
solenoid no. and voltage are
correct!

3. Remount hydraulic brake or

adjust- ing plate

as described on page 6. ”Re­placing the hydraulic brake or

adjusting plate”, steps 7 -11.

9.

25

Weight Number [mbar] [mm] [kg]

OPERATION AND ASSEMBLY INSTRUCTIONS

2. Adjustment (+) Setting spindle B

Adjustment (-)

adjustment spindle B counter

Unscrew complete adjustment

Assemble complete adjustment
device and adjust desired off-

Gas pressure regulator Type FRS

Gas pressure regulator Type FRS

Nominal diameters
Rp 3/8 - Rp 2 1/2
DN 40 - DN 150

Never close vent nozzle!

2. Pressure taps

1. Vent plug

2. Connection for external pulse
G 1/4 screw plug ISO 228, on
both sides, optional.

3. G 1/4 screw plug ISO 228, in
inlet pressure range, on both
sides

1.

Vent plug

Vent nozzle

2.

Max. operating pressure 500 mbar

Pressure regulator Class A

Ambient temperature -15 °C … +70 °C

Inlet pressure range 5 - 500 mbar

Family 1 + 2 + 3

Outlet pressure range 2,5 - 200 mbar

Dimensions [ mm]

b

e

h

d

DN

c

f

a

h

d

b

e

DN

c

f

a

Type Order p

a b c d e f g h

FRS 507 070 391 500 Rp 3/4 100 130 28 165 G1/4 G1/4 G1/8 245 1,00

Rp / DN Dimensions

max.

FRS 510 070 409 500 Rp 1 110 145 33 190 G1/4 G1/4 G1/8 310 1,20

FRS 515 058 446 500 Rp 1 1/2 150 195 40 250 G1/2 G1/4 G1/4 365 2,50

FRS 520 058 628 500 Rp 2 170 250 47 310 G1/2 G1/4 G1/4 450 3,50

FRS 525 083 303 500 Rp 2 1/2 230 285 60 365 G1/2 G1/4 G1/4 550 6,00

FRS 5065 058 792 500 DN 65 290 285 95 405 G1/2 G1/4 G1/4 590 7,50

FRS 5080 079 681 500 DN 80 310 285 95 405 G1/2 G1/4 G1/4 590 10,00

26

OPERATION AND ASSEMBLY INSTRUCTIONS

Do not use unit as lever.

DN 40 50 65 80 100 125 150
Rp 3/8 1/2 3/4 11 1/2 2 2 1/2 -- -- -- -­ M
(Nm) _ 10s
T
(Nm) _ 10s

Adjustment of outlet pressure
(setpoint adjustment)
Factory setting: Standard
spring p 2 10-30 mbar

1.

1. Unscrew protective cap A.

2. Adjustment (+) Setting spindle B

”Turn counter-clockwise” =
Increasing outlet pressure
(setpoint)

or

2.

Adjustment (-)

Setting spindle B
”Turn clockwise” =
Reducing outlet pressure
(setpoint)

4. Check setpoint

5. Screw on protective cap A.

6. Attach lead seal (Page 5).

70 105 225 340 610 1100 1600 2400 5000 6000 7600

max.

<

35 50 85 125 200 250 325 400 -- -- --

max.

<

2.1.

B

A

B

Replace setting spring
3-4

1. Remove protective cap.
A.Release spring by turning

adjustment spindle B counter

clockwise. Turn spindle to stop.

2. Unscrew complete adjustment
device B and remove spring C.

3. Insert new spring D.

4. Assemble complete adjustment

device and adjust desired off-

set.

5. Screw on protective cap A.Stick
adhesive label E onto typplate.

6. Attach lead seal.

3. 4.

B

A
B

C/D

E

27

MULTI-BLOC, MB-ZRDLE 405 - 420 B01

MULTI-BLOC, MB-ZRDLE 405-420 BO1

1. Ball valve

2. Fixing fl ange

3. Gas pressure switch

4. Governor with pressure adjustment

5. Protective cover, start gas adjustment

6. Hydraulic device, adjustment of stage 2

7. Lock screw for fl ow adjustment

8. Main valve

9. Knob for adjustment of stage 1

10. Test nipple, inlet pressure

11. Test nipple, pressure after governor

12. Test nipple, before governor

13. Filter

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.

28

MULTI-BLOC, MB-ZRDLE 405 - 420 B01

Flow adjustment 2-stage design

Flow adjustment 2-stage design

For stage 1, loosen the lock screw a. Turn the hydraulic device e:
to the right = the gas fl ow is reduced
to the left = the gas fl ow is increased

For stage 2, turn the hydraulic device b:
to the right = the gas fl ow is reduced
Åt vänster = the gas fl ow 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 fl ow

Remove the protective cover c.

Turn the adjustment knob d (use the protective cover as a tool) to the

desired start gas fl ow.

Turn to the right = the start gas fl ow is reduced
Turn to the left = the start gas fl ow is increased

Adjustment of governor

Adjustment of start gas fl ow

Flow adjustment

Multi-bloc MB-ZRDLE 405-420

29

MULTI-BLOC, MB-VEF 412 - 425 B01

201379

19

8

6

5

4

3

1

17 2

16 10 11 18

14

15

12

:P 0,75:1-3:1

- Zero point adjustment N ±2 mbar

can fl ow back into the multibloc.This is especially important

V = 3:1

V = 1:1

V = 0,75:1

V = 3:1

V = 1:1

V = 0,75:1

MULTI-BLOC, MB-VEF 412-425 B01

view

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

6. Filter (on Multi-Bloc 425 external fi lter)

7. Data plate

8. Connection 1/8” P

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 pressure after V

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

13. Test point connection 1/8” P

(after V2 burner)

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)

19. Impulse line PL (air pressure)

20. Impulse line (fi re room)

14. Test point connection 1/8” P

18. Impulse fl ange PBr (gas pressure)

L

F

Br

1

2

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

30

MULTI-BLOC, MB-VEF 412 - 425 B01

MULTI-BLOC, MB VEF 412-425 B01

Technical data
Mounting instruction-impulse lines

Technical data

Adjustment possibilities

- 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 fl ow 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 = 3:1

Br

V = 1:1

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

31

V = 1:1

PL, max. = 100 mbar

+ N

- N

V = 0,75:1

MULTI-BLOC VDG20… SKP75/15

MULTI-BLOCK VDG20...SKP75/15

View

26 12 2

7

9

8

21

20

3

10

11

25

14

19

18

24

1617

1

5

6

13

22

154

1. Protective cover, adjustment of V och N

2. Adjustment screw V for ratio pG : pA (max. load)

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

4. Stroke indication

5. Connection ¼” pA

6. Impuls tube pA

7. Connection ¼” pG

8. Impuls tube pG

9. Test nippel pG (measurement of nozzle pressure after V2)

10. Connection ¼” pC

11. Impuls tube pC

12. Test nippel pC (measurement of combustion chamber pressure)

13. Electrical connection gas valve V1

14. Electrical connection gas valve V2

15. Indication of V1 and V2 in operation

16. Electrical connection gas pressure switch min

17. Pressure switch min

18. Electrical connection gas pressure switch max (option)

19. Pressure switch max (option)

20. Flange connection inlet

21. Test point connection 1/4" before V1

22. Data plate

23. VPS 504 leakage control (option under 1200kW)

24. Flange connection, outlet

25. Display for N

26. Display for V

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

32

MULTI-BLOC VDG20… SKP75/15

Technical data
Mounting of impulse lines

Technical data

Mounting of impulse lines pA, pC OCH pG

- 220 V-15%...240 V+10%, 50-60 Hz,13,5 VA

- Adjustment range Gas/Air, 0,4-9

- Max. permissible inlet pressure 600 mbar

- Differansce pressure pG-pA 0,8…120 mbar

- Min. air pressure 0,5 mbar

- Min. period of time required when load changes from min. load to
max. load 5 s.

- Permissible test pressure 1 bar.

- Permissible vacuum 200 mbar.

- Closing time in the event of voltage failure < 1 sek.

- Mounting position. Avoid mounting the valves upside down.

- Protection class IP54

- Ambient temperature -10 - +60°C, with heater AGA63.5 -20 - +60°C.

- Impulse lines are mounted from factory

- Should any of the impulse lines be changed should it be made of steel.
Inner diameter > ø 8 mm (steel tube ø 10/8)

- Impulse lines must be mounted so that condensate cannot enter into
the multi-bloc. This especially applies to pC.

- Impulse lines must be mounted so that they are protected against rupture
and damage.

- Impulse lines shall be as short as possible.

Adjustment possibilities

Adjustment range

p

p

G

(max.)

953

10

9

8

7
6
5
4

3

2

1

0

2345678910

1

0

45°

G

p

A

1.5

2

bzw.

1.25

p -p

GC

p -p

AC

1

0.8

0.6

0.4

(min.)

-

p -p

GA

bzw.

AC

p -p

p

GA

AS IR

/p

0.4

2

p

A

9

+

+

-

p

G

+

^

-

0

0

+

0

0

0=

-

p

A

33

23

2(2)

172 505 35-1 12-01

DAMPER MOTOR 2-STAGE

DAMPER MOTOR 2- STAGE

Air adjustment

Air adjustment

Releasing button

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.

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.

Full load

Adjust the operating switch to low load (l).
* 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.

Solenoid valve

High capacity (black)

High capacity (red)

Low capacity (orange)

Closed damper (blue))

Releasing button
N.B. The upper po­sition is the stan­dard position

34

DAMPER MOTOR MODULATING

DAMPER MOTOR MODULATING

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

Air adjustment

vailable at the multibloc

Releasing button

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

- Connect a pressure gauge for measur-ing PBr, (advisable to fi nd 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. adjust-

ment.

- Start the burner, observe the pressure gauge, if no fl ame is esta­blished and the pressure gauge needle does not fl icker, increase N.
When the fl ame is established adjust the gas fl ow by means of the
screw N. Use a fl ue gas instrument.

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

- Adjust the gas fl ow with V and check at the same time the combus-

tion values.

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

cessary.

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

and max.load(V)

- The desired gas fl ow on min. and max. has now been adjusted by
changing the orange and the red cams. Check the gas fl ow on the

gas meter available on the installation.

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

adjustment, see special instructions

Air adjustment

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

Releasing button

By pressing the button and snapping it down, the motor will be relea-

sed 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)










35

Releasing button
N.B. The upper po­sition is the stan­dard position

GENERAL INSTRUCTIONS

GENERAL INSTUCTION

Adjustment of burner

Adjustment of burner

Service

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 fl ue 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.

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 Daily inspection is advisable.

Start up After the burner has been fi tted 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 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 fl ue gas analysis device. Adjust the burner to appr. 20% excess air
in accordance with the table. Check the fl ue gas temperature. Calculate
the effi ciency. 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 qualifi ed personnel. Replacement

parts should be of the same make and approved by the same authori-

ties as the original. If the burner is converted to fi re another gas quality
it must be re-commissioned. If town gas is to be fi red 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% 02% max. CO2%
lambda 1,2

Natural gas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

36

GENERAL INSTRUCTION

Flame monitoring and measurement of ionisation current

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 fl ame 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 fl ame electrode and the gas burner control.
Connect the µA-meter, see fi gure. Min. required ionisation current accor-

ding 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

in gas control

LME 1 5 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

Flame monitoring

Min. ionisation

current required

37

GENERAL INSTRUCTION

UV- detektor

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

38

GENERAL INSTRUCTION

Adjustment of air pressure switch

Adjustment of air pressure switch
Adjustment of min. gas pressure switch
Adjustment of max. gas pressure switch

Adjustment of min. gas pressure switch

Adjustment of max. gas 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
insuffi cien 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

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 fi gure 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.

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

39

LEAKAGE CONTROL, DUNGS VPS 504 SERIE 2

LEAKAGE CONTROL, DUNGS VPS 504 SERIE 2

Technical data

Technical data

Programme sequence

Programme sequence

Test volume ≤ 4,0 l
Pressurre increase using motor pumps ≈ 20 mbar
Backup (customer supply) 10A fast or 6.3A slow
Fuse integrated in

housing, replaceable
Switching capacity Operating outputs SO1, SO2, SO4: 4A Faul

Release time ≈ 10 - 30 s

Sensitivity limit 50 l/h
Max. number of test cycles 20/h

Idle state: Valves 1 and 2 are closed. Pressure build-up: The internal

motorpump increases the gas pressure Pe in the section by approx.
20 mbarcompared with the input pressure at valve V1. During the test
time, theintegrated differential pressure sensor monitors the test section
for leaks.When the test pressure is attained, the motor pump switches
off (end oftest period). The release time (10-30 s) is depending on the
test volume(max. 4.0 l). If the test section has no leaks, the contact is
released to thecontrol box after approx. 30 s and the yellow LED lights
up.If the test section is leaky or if the pressure increase by + 20 mbar is
notattained during the test period (max. 26 s), the VPS 504 generates a
fault.The red LED is lit as long as the contact is released by the regulator
(heatrequirement).
After a short voltage drop during testing or during burner operation, an­automatic restart is performed.

T6,3L 250V (IEC 127-2/111) (DIN41662)

Faul output SO4 1, 2, 3, T7: 1A

Dependent on test volume and input pressure.

output T7: 1A

Programmer Idle state Pressure buildup Operation

40

LEAKAGE CONTROL

Program sequende schedule
Electrical connection VPS 504 Series 2

Program sequende schedule

VPS 504 ”TIGHT” TEST =00,31,31

Controller

Pump motor

Solenoid valve

Differential pressure sensor

Release signal

Controller

Pump motor

Solenoid valve

Differential pressure sensor

Release signal

Controller

Pump motor

Solenoid valve

Differential pressure sensor

Release signal

Fault signal

VPS 504 ”TIGHT” TEST =41

VPS 504 ”NOT TIGHT”

Electrical connection VPS 504 Series 02

The VPS 504 is connected in series between the temperature regu­latorand the control box via a 7-pole plug connector.See the Bentone
wiring diagram.

(S)

tight

untight

Lock-out Operation

Plug

Outlet

Operating voltage

~(AC) 230V 50Hz

41

FINAL TEST OF THE INSTALLATION

HANDING OVER OF THE INSTALLATION

Fault location, functional troubles

Fault location, functional troubles

Trouble free operation is depending on three factors: electricity, gas and

- 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.

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 suffi cient?

- 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.

42

DECLARATION OF CONFORMITY

Declaration of conformity

Gas burner
Zertifi kat TÜV Süddeutschland

Certifi cate No Burner Certifi cate No Burner
CE-0085 BT 0064 BFG1 CE-0085 BP 0352 BG550
CE-0085 AO 0230 BG100 CE-0085 BP 0353 BG550LN
CE-0085 AP 0623 BG150 CE-0085 AO 0084 BG600LN
CE-0085 AP 0624 BG200 CE-0085 BP 0354 BG650
CE-0085 AT 0192 STG120, STG146 CE-0085 AT 0313 BG700
CE-0085 AP 0625 BG300 CE-0085 AT 0314 BG800
CE-0085 AP 0626 BG400 CE-0085 BR 5754 BG950
CE-0085 AU 0156 BG450

Enertech AB declares that the above-mentioned products
comply with the following standards or other normative
documents and meet applicable sections of the EU directive.

Enertech AB försäkrar under eget ansvar att ovannämnda
produkter är i överensstämmelse med följande standarder eller
andra regelgivande dokument och uppfyller tillämpliga delar i EU
direktiv.

Document: EN 676

DIN EN 60335-2-102

EU Directive 90 / 396 / EEC Gas Directive

2004 / 108 / EC EMC Directive
2006 / 95 / EC Low voltage Directive

By conforming to the above-mentioned standards and
directives, the burner will receive the CE marking.

Genom att brännaren uppfyller ovannämnda standarder och
direktiv erhåller brännaren CE - märkningen.

Enertech AB Bentone Division is quality certifi ed according
to SS-EN ISO 9001

Enertech AB Bentone Division är kvalitetscertifi erat enligt
SS-EN ISO 9001

Enertech AB erklärt hiemit, dass oben genannten Produkte mit
den folgenden Normen oder anderen normativen Dokumenten
übereinstimmen und die anwendbaren Teile der EU-Richtlinie
erfüllen.

Enertech AB déclare que les produits ci-dessus mentionnés sont
conformes aux normes ou autres documents normatifs suivants,
et répondent aux sections applicables de la directive EU.

Durch Übereinstimmung mit den oben genannten Normen und
Richtlinien erhalt der Brenner die CE-Kennzeichnung.

De par sa conformité aux normes et directives mentionnées ci­dessus, le brûleur recevra le marquage CE de conformité.

Ljungby, Sweden, 141127 (27/11/14)

ENERTECH AB Bentone Division
Box 309
SE-341 26 Ljungby Sweden

Enertech AB Bentone Division ist nach SS-EN ISO
9001qualitätszertifi ziert.

Enertech AB Bentone Division a reçu la certifi cation
d’assurance qualité SS-EN ISO 9001qualitätszertifi ziert.

Håkan Lennartsson

43

FAULT LOCATION GUIDE

Gas burner

1. 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 fl ow and combustion air. Should any of these factors change,
troubles may arise.

t has been proved that many troubles have rather simple causes. Before
calling the serviceman, the following checks should be made:

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

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 suffi cient?

5. Is the gas relay of the burner ready for start and not locked out?

6. Is the air supply to the burner suffi cient?

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 with each other or with earth Adjust
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 on the secondary

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

No fl ame establishment despite a trouble free start

The gas solenoid valve defective Replace
The gas solenoid valve does not open despite its obtaining voltage Replace coil or the whole valve if necessary.
No voltage to the solenoid valve Check the contact

Replace the transformer

44

1(3)

170 091 16 15-01

Cause Remedy

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

air pres-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 el-apsed in
spite of fl ame establishment

No ionisation current or the UV-cell in wrong position Adjust the ionisation electrode and the UV-

cell, 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 current Adjust the ignition electrodes, repole the

ignition 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 Reduce or increase the gas supply. Reduce

the quantity of air.
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.

Pulsations at start

The ignition electrodes are wrongly adjusted Readjust
The gas pressure is too high Check and adjust by means of a pressure

gauge and a pressure adjustment valve.
The fl ue gas side is blocked Check the chimney fl ue.

Pulsations during operation

The burner is not correctly adjusted Readjust
The burner is dirty Clean the burner.
Defective chimney Check and change the dimensions if

necessary.

45

2(3)

170 091 16 15-01

Cause Remedy

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. Contact the electricity authorities if

necessary.
Air pressure switch defective or incorrectly adjusted
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 transformern

Bad combustion

Bad draught conditions Check the chimney
The fl ue gas temperature is too high The boiler is overloaded. Reduce the

quantity of gas.
The CO2-content is too low Check the boiler with regard to leaks. Choke

the draught if it is too high.

The CO-content is too high

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

damper.
The holes in the gas nozzle are clogged Clean
The fresh air intake is too small Check and enlarge.
The fl ame is not burning straight because the burner head is out of

position

Condensation in boiler and chimney

The fl ow gas temperature is too low or the quantity of gas is not
suffi cient

Check the burner head and readjust.

Increase the fl ue gas temperature by

increasing the gas supply. Insulate the

chimney

46

3(3)

170 091 16 15-01

Cause Remedy

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. Contact the electricity authorities if

necessary.
Air pressure switch defective or incorrectly adjusted
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 transformern

Bad combustion

Bad draught conditions Check the chimney
The fl ue gas temperature is too high The boiler is overloaded. Reduce the

quantity of gas.
The CO2-content is too low Check the boiler with regard to leaks. Choke

the draught if it is too high.

The CO-content is too high

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

damper.
The holes in the gas nozzle are clogged Clean
The fresh air intake is too small Check and enlarge.
The fl ame is not burning straight because the burner head is out of

position

Condensation in boiler and chimney

The fl ow gas temperature is too low or the quantity of gas is not
suffi cient

Check the burner head and readjust.

Increase the fl ue gas temperature by

increasing the gas supply. Insulate the

chimney

47

3(3)

170 091 16 15-01

48

GENERAL INSTRUCTIONS FOR
GASBURNERS

Installation

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
suffi ciently dimensioned

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

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

Maintenance

General instructions

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

Normal operation

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 ( fi re room ) for
this

If the burner has stopped

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
suffi cient

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 fi nd out whether
the solenoid valve opens

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

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
( fi ll up if necessary ) and that thermostats etc. are
normally adjusted

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

Shut-Off

1. Switch off the current with the main switch

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

Warning

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

2. Do not use naked fl ame when inspecting the fi re
room

Authorized installer:

____________________________________________________________________________________________________

Address:_____________________________________________________________________________________________

Tel:_________________________________________________________________________________________________

170 025 05 2015-05-25

49

SERVICE AND INSPECTION CARD

Installation Boiler

Name: Type: Effi ciency kW:

Address:

Burner

Type: Effi ciency kW:

Installed by: Date:

Date

Measure­ment

Measures

3

gas/h Governor O2CO

Nm

Before After % ppm °C µ A mbar mbar %

Small
fl ame

Large
fl ame

Flue gas

temp

Ionisa­tion
current

Pressure Effi ciency

Fire room Chimney

Date

Measure­ment

Measures

Date

Measure­ment

Measures

3

gas/h Governor O2CO

Nm

Before After % ppm °C µ A mbar mbar %

Small
fl ame

Large
fl ame

3

gas/h Governor O

Nm

Before After % ppm °C µ A mbar mbar %

Small
fl ame

Large
fl ame

Flue gas

temp

Ionisa­tion

Pressure Effi ciency

current

Fire room Chimney

CO

2

Flue gas

temp

Ionisa­tion

Pressure Effi ciency

current

Fire room Chimney

50

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

www.bentone.se, www.bentone.com