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

178 005 82-2 2016-05-10

Providing sustainable energy solutions worldwide

Installation- and maintenance instruction

BG 550 CN, BG 650 CN

Model 2, M

BG 550 LN CN

Contents

1. DESCRIPTION ______________________________________________________________________________________________________________________ 5

1.1 Warning __________________________________________________________________________________________________________________________ 5

2. DESCRIPTION ______________________________________________________________________________________________________________________ 6

2.1 2-Stage___________________________________________________________________________________________________________________________ 6

2.2 Modulating ______________________________________________________________________________________________________________________ 7

3. TECHNICAL DATA ________________________________________________________________________________________________________________ 8

3.1 Dimensions _____________________________________________________________________________________________________________________ 8

3.2 Output range ___________________________________________________________________________________________________________________ 9

3.3 Working field _________________________________________________________________________________________________________________ 10

4. SKELETON DIAGRAMS _____________________________________________________________________________________________________ 11

4.1 2-stage or modulating burners ________________________________________________________________________________________ 11

5. MOUNTING OF THE BURNER __________________________________________________________________________________________ 12

5.1 Inspection of gas assembly _____________________________________________________________________________________________ 12

5.2 Adjustment of the position of the shrouded disc in the blast tube ________________________________________ 13

6. ELECTRIC EQUIPMENT ___________________________________________________________________________________________________ 14

6.1 Wiring diagram LGB22/LMG22/LME22 (BG550/BG650) 2-Stage _______________________________________ 14

6.2 Wiring diagram LMG22/LME22 (BG550/BG550LN/BG650) Modulating _______________________________ 15

6.3 Wiring diagram LMG22/LME22 (BG550/BG550LN/BG650) Modulating with R316 _______________ 16

6.4 List of components LMG22/LME22 (BG550/BG550LN/BG650) __________________________________________ 17

6.5 Function LGB/LMG22/LME22 _________________________________________________________________________________________ 18

6.6 Control diagnosis under fault conditions and lockout indication Gas burner control: LGB ... __ 19

6.7 Control diagnosis under fault conditions and lockout indication Gas burner control: LMG ... __ 21

6.8 Control program when disruption; disruption display Gas burner control: LME.... ________________ 23

6.9 Wiring diagram LFL1... (BG550/BG650) 2-Steg _________________________________________________________________ 25

6.10 Wiring diagram LFL1... (BG550/BG550LN/BG650) Modulating ___________________________________________ 26

6.11 Wiring diagram LFL1... (BG550/BG550LN/BG650) Modulating with R316 ___________________________ 27

6.12 Wiring diagram LFL1... (BG550/BG650) 2-stage _______________________________________________________________ 28

6.13 List of components LFL1... (BG550/BG650) _____________________________________________________________________ 29

6.14 Funktion LFL1... _____________________________________________________________________________________________________________ 30

6.15 Control programme under fault conditions and lockout indication LFL1.... ____________________________ 31

7. MEASURES AND CHECKS BEFORE START-UP ___________________________________________________________32

7.1 2-Stage or modulating burners ________________________________________________________________________________________ 32

7.2 Inner assembly BG 550LN ______________________________________________________________________________________________ 34

8. DETERMINATION OF GAS VOLUME FOR THE INSTALLATION ___________________________________ 35

8.1 Example how to calculate the gas volume (natural gas) ______________________________________________________ 35

9. GAS SOLENOID VALVE MVD ____________________________________________________________________________________________36

10. OPERATION AND ASSEMBLY INSTRUCTIONS______________________________________________________________ 37

10.1 Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11 ____________________________________________ 37

11. Gas pressure regulator Type FRS ____________________________________________________________________________________ 41

12. MULTI-BLOC, MB-ZRDLE 405-420 __________________________________________________________________________________ 44

12.1 Flow adjustment 2-stage design ______________________________________________________________________________________ 45

12.2 Adjustment of governor __________________________________________________________________________________________________ 45

12.3 Adjustment of start gas flow ____________________________________________________________________________________________ 45

13. MULTI-BLOC, MB-VEF 412-425 B01 _______________________________________________________________________________ 46

13.1 Technical data________________________________________________________________________________________________________________ 47

13.2 Mounting instruction - impulse lines PL, PF och P

13.3 Adjustment possibilities __________________________________________________________________________________________________ 47

______________________________________________________________________________________________________________

Br

47

Bentone BG550/650

3

14. DAMPER MOTOR 2-STAGE ______________________________________________________________________________________________ 48

14.1 Air adjustment _______________________________________________________________________________________________________________ 48

14.2 Releasing button: ___________________________________________________________________________________________________________ 48

15. DAMPER MOTOR MODULATING _____________________________________________________________________________________ 49

15.1 Air adjustment _______________________________________________________________________________________________________________ 49

15.2 Releasing button: ___________________________________________________________________________________________________________ 49

16. GENERAL INSTRUCTIONS _______________________________________________________________________________________________50

16.1 Adjustment of burner ______________________________________________________________________________________________________ 50

16.2 Service__________________________________________________________________________________________________________________________ 50

16.3 Flame monitoring and measurement of ionisation current ___________________________________________________ 51

16.4 UV-detector ___________________________________________________________________________________________________________________ 51

16.5 Adjustment of air pressure switch ____________________________________________________________________________________ 52

16.6 Adjustment of min. gas pressure switch____________________________________________________________________________ 52

16.7 Adjustment of max. gas pressure switch ___________________________________________________________________________ 52

17. LEAKAGE CONTROL, DUNGS VPS 504 SERIES 2_________________________________________________________53

17.1 Technical data________________________________________________________________________________________________________________ 53

17.2 Programme sequence ____________________________________________________________________________________________________ 53

17.3 Program sequence schedule ___________________________________________________________________________________________ 54

17.4 Electrical connection VPS 504 ________________________________________________________________________________________ 54

18. HANDING OVER OF THE INSTALLATION ________________________________________________________________________55

18.1 Fault location, functional troubles _____________________________________________________________________________________ 55

19. FAULT LOCATION GUIDE __________________________________________________________________________________________________ 57

20. GENERAL INSTRUCTIONS FOR GASBURNERS ___________________________________________________________60

20.1 Installation _____________________________________________________________________________________________________________________ 60

20.2 Maintenance __________________________________________________________________________________________________________________ 60

Bentone BG550/650

4

1. DESCRIPTION

1.1 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 qualified 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 fitter is to ensure that the boiler room is supplied with fresh air
ventilation that is sufficient 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.

General

!

Varning

Safety directions

• 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, fire 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.

Acceptance inspection

• 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.

Preparations for installation

• 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.

Bentone BG550/650

5

General

2. DESCRIPTION

2.1 2-Stage

Components

1. Flame cone

2. Connection flange

3. Guide bar

4. Fan wheel

5. Fan house

6. Shrouded disc

7. Ignition electrode

8. Nozzle

9. Ionisation electrode

Bentone BG550/650

6

10. Motor

11. Connection gas fittings

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

2.2 Modulating

General

Components

1. Flame cone

2. Connection flange

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 fittings

12. Ignition transformer

13. Air damper

14. Air damper motor

15. Air pressure switch

16. Fuse holder

17. Change-over switch increase­decrease

18. Change-over switch manually­automatically

19. Indicating lamp

20. Switch 0-l

21. Time meter

22.

23. Contactor with thermal
overload protection

24. Control box

25. Gas train

26. MultiBloc

Bentone BG550/650

7

General

3. TECHNICAL DATA

Type designation BG550/BG550LN/BG650

3.1 Dimensions

D



C



290*

690*

321

B

658

321

400

660*

BG550 BG550LN

Length of

burner tube

Standard 1 256 226 162 162 252 222 162 162
Standard 2 356 326 162 162 352 322 162 162
Standard 3 456 426 162 162 452 422 162 162

Standard 1 316 286 185 162
Standard 2 416 386 185 162
Standard 3 516 486 185 162

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

components used, the measurements may vary.

Flange

Measure

Length of

burner tube

B

Burner

tube

Measure

C

Flange

Measure B

BG650

Burner tube

Measure C

Burner

tube

Measure

D

Length of

burner tube

Burner tube

Measure D

Flange

Measure

B

M12

Burner

tube

Measure

C

ø190

Burner

Measure

tube

D

(ø210)ø254-280

Bentone BG550/650

8

3.2 Output range

General

Capacity kW Gas volume at a

min. output Nm3/h

1)

Gas volume at a

max output Nm3/h

1)

Max. inlet

pressure mbar

Rated inlet pressures

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

Typ 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)

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

2)

Dimension and capacity depending on gas quality and available pressure

Armatur

BG550/BG550LN

Natural gas LPG

1 1/2”-2”

2)

Motor Tändtransformator

0,75 kW

230/400V 50 Hz

3,1/1,8A

Prim. 230 V, 0,25A

50-60Hz 60VA

Sek. 11kV Ampl

50 mA rms

33% ED in 3 min

BG650

Natural gas LPG

1 1/2”-2”

230/400V 50 Hz

1,5 kW

5,7/3,3A

Prim. 230 V, 0,25A

50-60Hz 60VA

Sek. 11kV Ampl

50 mA rms

33% ED in 3 min

Bentone BG550/650

9

General

3.3 Working field

BG550

140-640 kW
BG550
BG550 (G25)

Measured (test)

BG550LN

140-620 kW
BG550LN
Measured (test)

14
12

10

8
6
4
2

Pressure in fire place

0

-2
100 200 300 400 500 600 700

Capacity kW

14
12

10

8
6
4
2

Pressure in fire place

0

-2

100 200 300 400 500 600 700

Capacity kW

BG650

200-1125 kW

BG650

Measured (test)

Unbroken line is the approved working
field as per EN 676.

Bentone BG550/650

10

16
14

12
10

8
6
4
2

Pressure in fire place

0

-2
200 300 400 500 600 700 800

900 1000 1100 1200

Capacity kW

4. SKELETON DIAGRAMS

4.1 2-stage or modulating burners

General

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

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.

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

!

Bentone BG550/650

11

General

5. MOUNTING OF THE BURNER

Fit the burner to the boiler by means of 4 bolts M12. For flange and bolt
dimensions see technical data.
If for some reason you want to separate the burner from the gas flange with
burner head and valve package you can do so.

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
assembly.

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

When the burner head and the gas flange have been fitted to the boiler it is
easy to lift up the burner to where it belongs.

5.1 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 flange.

• Withdraw the gas assembly.

Ensure that the O-ring between the gas assembly and the gas flange will be
in the correct position when the gas assembly is fitted again

!

Bentone BG550/650

12

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).

5.2 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.

General

Service position

Bentone BG550/650

13

General

6. ELECTRIC EQUIPMENT

6.1 Wiring diagram LME22 (BG550/
BG650) 2-Stage

Bentone BG550/650

14

General

6.2 Wiring diagram LME22 (BG550/BG550LN/BG650)
Modulating

Design without A3

Bentone BG550/650

15

General

6.3 Wiring diagram LME22 (BG550/BG550LN/BG650)
Modulating with R316

Design without A3

Bentone BG550/650

16

General

6.4 List of components LME22 (BG550/BG550LN/BG650)

A1 Gas burner control
A2 Power control
A3 Valve, leak tester, Dungs VPS 504
A6 Power control R316
A6(2) PT 100-sensor, Thermocouple, current/voltage
B1 Ionization electrode
F1 Operation fuse
F2 Operation fuse
F3 Operation fuse
F4 Operation fuse 1A
H1 Lamp, low capacity
H2 Lamp, high capacity (Optional)
K1 Motor contactor with thermal overload protector
M1 Burner motor
M2 Damper motor, L&S SQN75.624.A21B
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

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

sliding)
S20 Main switch 1-phase
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 boler
X7 Plug-in contact, 3-phase, burner
X8 Plug-in contact, 3-phase, boiler
X9 Plug-in contact, power controller R316, burner
X10 Plug-in contact, power controller R316
X15 Plug-in contact, power controller, burner
X16 Plug-in contact, power controller
S9 Gas pressure switch
Y1 Gas solenoid valve 1
Y2 Gas solenoid valve 2
Y3 Safety solenoid valve2

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

Bentone BG550/650

17

General

6.5 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.

1. Air damper motor opens.

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

2. Air damper motor closes.

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

3. Main and safety valves open

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

4. 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.

5. 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.

6. 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.

Bentone BG550/650

18

General

6.6 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
Ignition phase, ignition checked
Normal operation
Operation, poor flame signal
Prohibited flame signal during start up
Undervoltage
Disruption, alarm
Flashing code for fault codes
Interface diagnostics

○…………………

•○ •○ •○ •○ •○ •

□…………………

□○□○□○□○□○

□▲□▲□▲□▲□▲

●▲●▲●▲●▲●▲
▲…………………
▲○ ▲○ ▲○ ▲○
▲▲▲▲▲▲▲▲

Off
Flashing yellow
Green.
Flashing green
Green-Red
Yellow-Red
Red.
Flashing red
Red flickering

Continuous

Off

▲

●

□

Red

Yellow

Green

Diagnostics alarm trigger

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:

Press reset­button > 3 s

FS

lights red

AL

Light period (waiting time 10 s)

Limit on start attempts

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.

Flash code

Paus

c:a 3 s

Flash code

Bentone BG550/650

19

General

Alarm control table

Red flashing code
on signal lamp (LED)

Flashing 2 x

••

Flashing 3 x

•••

Flashing 4 x

••••
Flashing 5 x

•••••
Flashing 6 x

••••••
Flashing 7 x

•••••••

Possible causes

No flame at End of «TSA»

- Defective or obscured flame monitor -

- Defective or obscured fuel valves

- Poor burner installation

- Defective ignition unit

«LP» defective

- No air monitor signal after «t10»

- «LP» is welded in the open position

Prohibited flame signal during start up

Time out «LP»

- «LP» is welded in the closed position

Free

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

••••••••••

Flashing 14 x

Connection fault or internal fault, outgoing
contacts or other fault

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 con-
nection block 10

- The burner is only to be reconnected
after it is reset -

Connecting signal amplifier

A1 = LME

- 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.

GP
R/W

11112 2

br bl rt sw

sw rtQ1 = AGQ 3...

Bentone BG550/650

20

L N

QRA

6.7 Wiring diagram LFL1... (BG550/BG650) 2-Steg

General

DAMPER POSITION

Design without A3

Design without S10

Bentone BG550/650

21

General

6.8 Wiring diagram LFL1... (BG550/BG550LN/BG650)
Modulating

DAMPER POSITION

Design without A3

Design without S10

Bentone BG550/650

22

General

6.9 Wiring diagram LFL1... (BG550/BG550LN/BG650)
Modulating with R316

DAMPER POSITION

Design without A3

Design without S10

Bentone BG550/650

23

General

6.10 Wiring diagram LFL1... (BG550/BG650) 2-stage

DAMPER POSITION

Design without A3

Design without S10

Bentone BG550/650

24

1(2)

6.11 List of components LFL1... (BG550/BG650)

A1 Gas burner control
A2 Power control
A3 Valve, leak tester,,

Dungs VPS 504
A6 Power control R316
A6(2) PT 100-sensor, Thermocouple, current/voltage
R1 UV-Detector
B1 Ionization electrode
F1 Operation fuse
F2 Operation fuse
F3 Operation fuse
F4 Operating fuse 1A
H1 Lamp, low capacity
H2 Lamp, high capacity (optional))
K1 Motor contactor with thermal overload protector
K2 Auxiliary relay
M1 Burner motor
M2 Damper motor,

L&S SQN75.294A21B
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
S10 Gas pressure switch, max
S11 Change-over switch, Aut.-man.
S12 Change-over switch, Increase-Reduce
S20 Main switch 1-phase
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
X7 Plug-in contact, 3-phase, burner
X8 Plug-in contact, 3-phase, boiler
X9 Plug-in contact, power controller R316, burner
X10 Plug-in contact, power controller R316
X15 Plug-in contact, power controller, burner
X16 Plug-in contact, power controller

S9 Gas pressure switch
Y1 Gas solenoid valve 1
Y2 Gas solenoid valve 2
Y3 Safety solenoid valve

General

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

Bentone BG550/650

25

General

6.12 Funktion LFL1...

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 sufficient 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 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
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.

Bentone BG550/650

26

General

6.13 Control programme under fault conditions and lockout

indication LFL1....

In the event of fault conditions the fuel supply is always interrupted immedia-tely and, simultaneously, the sequence
switch stops and thus the lockout indicator. The symbol appearing above the reading mark indicates the kind of fault:

No start,, because, e.g., the CLOSE signal has not

◄

been supplied to terminal 8 or a contact has not
been closed between terminals 12 and 4 or 4 and 5.

Interruption of the start-up sequence, because

▲

the OPEN signal has not been supplied to terminal
8 from dam-per motor to switch «max.». Terminals
6, 7and 14 are under tension until the fault has been
remedied.

Lockout because the air pressure signal has not

P

been received at the start of the air pressure check.

Any air pressure failure after this point in time
also causes the control to go to lockout!

Lockout

■

due to a fault in the flame supervision circuit

Interruption of the start-up sequence, because

▼

the position signal for the low-flame position has not
been supplied to terminal 8 by the damper motor.
Terminals 6, 7 and 14 are under tension until the
fault has been remedied.

Lockout because no flame signal has been

1

received on completion of the 1st safety time.

Any flame signal failure after completion of
the first safety time also causes the control
to go to lockout!

Lockout because no flame signal has been

2

received on completion of the 2nd safety time
(flame signal of the main flame with interrupted
pilot burners).

Lockout because the flame signal has been lost

▌

during burner operation or air pressure failure has
occured.

Lockout on completion of control

◄

programme sequence due to extraneous light
(e.g. flame not extinguished, leaking fuel valves)
or due to a faulty flame signal

a - b

Start-up sequence

b - b´

”idle steps” up to the self

shut-down of the sequence switch

b ( b´) - a

Post-purge sequence

a

b´

b

Technical data LFL1.....

Pre-purge time with full air volume: 31,5 s
Pre-iginition time: 6 s
Safety time: 3 s
Post-ignition time: 3 s
Reset after lock-out Omedelbart
Time of re-start: 18 s
Ambient temperature: -20°C till +60°C
Protective standard: IP 40

Supervision of ionization current

Voltage at the detector electrode operation: 330V ±

10%

test: 380V ± 10%
Short circuit current max. 0,5 mA
Min. required ionization current 6 µ A
Recommended range of measuring device 0...50 µ A

Bentone BG550/650

27

General

7. MEASURES AND CHECKS BEFORE
START-UP

7.1 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.

Leakage control

When making a leakage control of the gas supply
system, the solenoid valve should be closed. Connect
a pressure gauge to the test nipple Pa, see fig. The
test pressure in the system should be 1,5x max. inlet
pressure or min. 150 mbar. If any leakage, locate the
source by means of soapy water or a leak location spray.
After tightening repeat the test.

Electric function test:

Ensure that phase and neutral are not reversed. The
gas shut-off cock should be closed.To prevent the gas
pressure switch from locking out, it should be linked
temporarily.
After the main switch has been switched on and the
thermostats have been adjusted, the pre-purging period
begins (30-35sec.). At the end of this period the pre­ignition 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 pre­purging 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.

Bentone BG550/650

28

Multibloc Gas train

Inner assembly

Town gas

Inner assembly

Natural gas, LPG

General

Inner assembly

Biogas ((UV-detector)

Bentone BG550/650

29

General

7.2 Inner assembly BG 550LN

A

B

A = 10 mm Front edge Brake plate

B = 3 mm

A = Position Ionisation detector

B = Position Ignition electrode

A B

Bentone BG550/650

30

General

8. 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

3

kJ/Nm

3

kcal/Nm

3

8.1 Example how to calculate the gas volume (natural gas)

V = Gas volume Nm3/h

Q = Boiler output 120 kW

H

η

Ex. A v=

Ex. B v=

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 . 1013,25

t = Temperature of the gas at the gas meter (15°C)

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

u

= Expected efficiency 90%

Q .3 600

H

· η 37 144 . 0,90

u

120

10,3 · 0,90

273 B+P

=

≈

12,9 Nm3/h

u

120 . 3 600

12,9 Nm3/h

≈

3

B = Barometer height (945 mbar)

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

f = 273+15 . 1013,25

273 945+15

f = 11,1

The gas volume read on the gas meter actually reads1,11 . 12,9 = 14,4 m3/h.

Bentone BG550/650

31

General

9. GAS SOLENOID VALVE MVD

MVD:

1-step valve fast opening with max.
flow adjustment.

1. Protection cover

2. Flow adjustment

3. Lock nut

Bentone BG550/650

32

Flow adjustment MVD/5

Remove protection cover 1. Loosen
lock nut 3. Turn the flow adjustment
screw 2 to the right = gas flow
decreases or to the left = gas flow
increases. Tighten the lock nut.

General

10. OPERATION AND ASSEMBLY
INSTRUCTIONS

10.1 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
sys-tem accessories.

Bentone BG550/650

33

General

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

3. Remove double solenoid
valve between the
threaded flanges. Figs 3
and 4

4. After mounting, perform
leakage and functional
tests.

1.

3.

2.

4.

Bentone BG550/650

34

525/11 Main flow setting only possible at V1!

Set main volume on open valve. Set valve
V1 during operation. Check setting values
continuously. Smallest setting volume flow:

7. DMV-DLE
Rapid stroke adjustment V°start Factory
setting DMV-DLE: Rapid stroke not adjusted

7.1 Unscrew the adjustment cap E from the hydraulic
brake.

7.2 Turn the adjustment cap and use as a tool.

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

6.6. DMV - D 507/11 - 525/11 DMV-DLE 507/11 -

° °

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

General

7.

Bentone BG550/650

35

General

8. Replacing hydraulic brake unit

or adjustment plate

8.1 Switch off firing system.

8.2 Remove locking varnish from
countersunk screw A.

8.3 Unscrew countersunkscrew A.

8.4 Unscrew socket headscrew B.

8.5 Raise adjustment plate C or hy­draulic brake D.

8.6 Remove sealing plug E

8.7 Exchange adjustment plate C or
hydraulic brake D

8.8 Screw in countersunk and socket
head screw. Only tighten socket
head screw so that hydraulic
brake can just be turned.

8.9 Coat countersunk screw A with
locking varnish.

8.10 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.

8.11 Perform functional test.

8.12 Switch on firing system.

8.

9. Replacing the solenoid

Versions with adjusting plate
DMV-D 5.../11or hydraulic
brake DMV-DLE 5../11

9.1 Remove hydraulic brake or adjus­ting plate as described on page
8:1-5 ”Replacing the hydraulic
brake or adjusting disk”, steps 1 -5

9.2 Replace solenoid.

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

9.3 Remount hydraulic brake or
adjusting plate as described on
page 8:7-11.
”Replacing the hydraulic brake or
adjusting plate”, steps 7 -11.

Bentone BG550/650

36

9.

3(3)

11. Gas pressure regulator Type FRS

Nominal diameters

Rp 3/8 - Rp 2 1/2

DN 40 - DN 150

1. Never close vent nozzle!

2. Pressure taps

2.1 Vent plug

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

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

1.
Vent plug

Vent nozzle

2.

2.1

General

2.2

2.3

Max. operating pressure 500 mbar
Pressure regulator Klass 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

h

DN

c

d

b

e

h

d

DN

c

f

a

e

f

a

Bentone BG550/650

37

General

Typ Order

number

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

p

[mbar] [kg]

Rp / DN Dimensions

max.

a b c d e f g h

Do not use unit as lever.

Weight

[mm]

!

DN 40 50 65 80 100 125 150
Rp 3/8 1/2 3/4 11 1/2 2 2 1/2 -- -- -- -­M

max.

(Nm)
T

max.

(Nm)

≤

≤

70 105 225 340 610 1100 1600 2400 5000 6000 7600

10s

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

10s

Bentone BG550/650

38

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)

3. Check setpoint

4. Screw on protective cap A.

General

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
type-plate.

3. 4.

B

A

B

C/D

E

Bentone BG550/650

39

General

12. MULTI-BLOC, MB-ZRDLE 405-420

1. Ball valve

2. Fixing flange

3. Gas pressure switch

4. Governor with pressure
adjustment

5. Protective cover, start gas
adjustment

6. Hydraulic device, adjustment of
stage 2

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.

7. Lock screw for flow 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

Bentone BG550/650

40

12.1 Flow adjustment 2-stage design

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

to the left = the gas flow is increased
For stage 2, turn the hydraulic device b:
to the right = the gas flow is reduced
To the left = the gas flow is increased
Do not forget to tighten the lock screw again.

12.2 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

General

Flow adjustment

12.3 Adjustment of start gas flow

Remove the protective cover c.
Turn the adjustment knob d (use the protective cover as a tool) to the desired
start gas flow.

Turn to the right = the start gas flow is reduced
Turn to the left = the start gas flow is increased

Adjustment of governor

Multi-bloc
MB-ZRDLE 405-420

Adjustment of start gas flow

Bentone BG550/650

41

General

201379

19

8

6

5

4

3

1

17 2

16 10 11 18

14

15

12

13. MULTI-BLOC, MB-VEF 412-425 B01

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 filter)

7. Data plate

8. Connection 1/8" P

9. Adjustment screw V for ratio P

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

11. Connection M4 for measurement of burner
pressure after V

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

L

2

1

: PL (max. load)

Br

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

13. Test point connection 1/8” P

14. Test point connection 1/8” PBr(after V2 burner)

15. Flange connection, outlet

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

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

18. Impulse flange PBr (gas pressure)

19. Impulse line PL (air pressure)

20. Impulse line (fire room)

F

Bentone BG550/650

42

{

13.1 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

General

• 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

13.2 Mounting instruction - impulse lines PL, PF och 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

13.3 Adjustment possibilities

Adjustment range

!

P

∆

!

∆ PL = PL-P

Effective burner
pressure

= PBr - P

Br

F

Effective fan pressure

F

∆ PBr

N=+2

N=-2

{

∆pL, min =0,4 mbar

V = 3:1

V = 1:1

V = 0,75:1

∆pBr, min =0,5 mbar

PL, max. = 100 mbar

P

Br, max. =100 mbar

∆PL

Br

∆ P

Br

+ N

V = 3:1

V = 1:1

V

V = 0,75:1

- N

∆PL

Bentone BG550/650

43

General

14. DAMPER MOTOR 2-STAGE

14.1 Air adjustment

The damper motor turns the damper between three
pre-set positions: fully closed, low load, full load. These
positons are controlled in the motor by cams of different
colours. The black cam controls the gas valve for full
load.

If the air volume needs changing: Remove the cover of
the damper motor and change the position of the cams
by turning them with the tools accompanying the burner.

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.

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

!

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.

14.2 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))

Bentone BG550/650

44

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

15. DAMPER MOTOR MODULATING

15.1 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

General

Gas valve (black)

Max. load (red)
Min. load (orange)

Closed damper (blue)

• Before the burner starts vent the lines to make sure
that there is gas vailable at the multibloc. Use an
allen key size 2,5 mm for adjusting N and V

• Connect a pressure gauge for measuring 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.

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

• 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.

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

!

adjustment, see special instructions

15.2 Releasing button:

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

Bentone BG550/650

45

General

16. GENERAL INSTRUCTIONS

16.1 Adjustment of burner

The burner is from the factory pre-set to an average
value that must then be adjusted to the boiler in
question. All burner adjustments must be made in
accordance with boiler manu-facturers instructions.
These must include the checking of flue gas
temperatures, average water temperature and CO2 or
O2 concentration.

General instructions

The installation of the gas burner must be carried out in
accordance with current regulations and standards. The
installers of gas burners should therefore be acquainted
with all regulations and ensure that the installation
complies with the requirements. The installation,
mounting and adjustment should be made with the
greatest care and only the correct gas should be used..

Operating instructions

The operating instructions accompanying the burner
should be left in a prominent position in the boiler room.

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.

Adjustment of burner head

The burner is equipped with an adjustment device
changing the position of the brake plate in the burner
head. This is used to adjust the correct pressure drop
over the combustion device in order to obtain a good
pulsation free combustion.

Which position to use depends on input and
overpressure in the boiler. A general rule is that the lower
capacity the smaller the opening between brake plate
and combustion device.

Commissioning of installation

Control of the combustion. The combustion quality is
checked by means of a flue gas analysis device. Adjust
the burner to appr. 20% excess air in accordance with
the table. Check the flue gas temperature. Calculate the
efficiency. Check also the actual gas volume on the gas
meter so that the correct input is achieved.

16.2 Service

Service should only be carried out by qualified personnel.
Replacement parts should be of the same make and
approved by the same authorities as the original. If the
burner is converted to fire another gas quality it must
be re-commissioned. If town gas is to be fired the
combustion head must be converted and the gas train
adjusted to suit (e.g.a larger gas armature or a different
spring in the governor may be required).

Start up

After the burner has been fitted to the boiler and the electric
connection, the leakage control, the venting and the electric
function test have been carried out, the burner will be ready
for start-up.

Howerer, study the sections dealing with adjustments
of multi-bloc, combustion air and combustion head.
Open the ball valve and switch on the main switch. If the
burner starts the actual adjustment can be made.

Gas quality CO2%

lambda 1,2
Natural gas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

02% max. CO2%

Bentone BG550/650

46

General

16.3 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 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

Min. ionisation
current required

16.4 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

Flame monitoring

Control box

Bentone BG550/650

47

General

16.5 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

16.6 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.

16.7 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%.

Gas pressure switch, air pressure switch

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

Bentone BG550/650

48

General

17. LEAKAGE CONTROL, DUNGS VPS
504 SERIES 2

17.1 Technical data

Test volume ≤ 4,0 l
Pressure increase using motor pumps ≈ 20 mbar
Backup (customer supply) 10A fast or 6.3A slow
Fuse integrated in housing, replaceable T6,3L 250V (IEC 127-2/111) (DIN41662)

Switching capacity Operating outputs SO1, SO2, SO4: 4A

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

Release time ≈ 10 - 30 s

Depending on test volume and input pressure.
Sensitivity limit 50 l/h
Max. number of test cycles 20/h

17.2 Programme sequence

Idle state: Valves 1 and 2 are closed. Pressure build-up:
The internal motor pump increases the gas pressure
Pe in the section by approx. 20 mbar compared with
the input pressure at valve V1. During the test time, the
integrated differential pressure sensor monitors the test
section for leaks. When the test pressure is attained,
the motor pump switches off (end of test 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 the control 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 not attained 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 (heat
requirement).

After a short voltage drop during testing or during burner
operation, an automatic restart is performed.

Bentone BG550/650

49

General

Pressure buildup OperationProgrammer Idle state

17.3 Program sequence schedule

VPS 504 ”TIGHT” TEST =0,31

Controller

Motor pump

Solenoid valve

Differential pressure sensort

Release signal

Controller

Motor pump

Solenoid valve

Differential pressure sensor

Release signal

Controller

Motor pump
Solenoid valve
Solenoid valve

Differential pressure sensor

Release signal

VPS 504 "TÄTHETSTEST"=0,31

VPS 504 ”TIGHT” TEST=41

VPS 504 "TIGHT" TEST=41

VPS 504 ”NOT TIGHT”

17.4 Electrical
connection
VPS 504

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

untight

Lock-out Operation

Plug

(S)

tight

Operating voltage
~(AC) 230V 50Hz

Bentone BG550/650

50

18. 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.

General

18.1 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.

Bentone BG550/650

51

General

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.

Bentone BG550/650

52

Håkan Lennartsson

172 905 95 14-01

19. 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.

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 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?

General

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 flame 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

Bentone BG550/650

53

General

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 flame 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 flue gas side is blocked Check the chimney flue.

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.

Bentone BG550/650

54

General

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 flue 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 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 the burner head is out of

position

Condensation in boiler and chimney

The flow gas temperature is too low or the quantity of gas is not
sufficient

Check the burner head and readjust.

Increase the flue gas temperature by

increasing the gas supply. Insulate the

chimney

Bentone BG550/650

55

General

20. GENERAL INSTRUCTIONS FOR
GASBURNERS

20.1 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

sufficiently dimensioned

4. Check by studying the data plate that the efficiency

of the burner is adapted to the boiler output

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

in question

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

7. Check that the dampers of the boiler are open

8. Check that there is water in the system

9. Check that thermostats etc. are correctly adjusted

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

20.2 Maintenance

General instructions

1. Keep the boiler room clean

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

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

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

Om brännaren har stannat

1. Tryck in återställningknappen på reläet

2. Kontrollera att max. termostaten inte löst ut

3. Kontrollera andra termostater ex. rumstermostat
om sådan finns

4. Kontrollera att tillräckligt gastryck finns till brännaren

5. Undersök att de elektriska säkringarna är hela

6. Kontrollera vid nytt startförsök genom att iakttaga
på gasmätarens räkneverk att magnetventilen
öppnar

5. Om brännaren inte startar trots upprepat startför­sök meddela då installatören

Normal operation

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

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

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

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

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

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 fire room door
when starting up the burner

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

Authorized installer

____________________________________________________________________________________________________

Adres:______________________________________________________________________________________________

Tel:______________________________________________________________________________________________

Bentone BG550/650

56

SERVICE AND INSPECTION CARD

Installation Boiler

Namn: Typ: Efficiency kW:

Adres:

Burner

Type: Efficiency kW:

Installed by: Date:

Date

Measure­ment

Measures
Date

Measure­ment

Measures
Date

Measure­ment

Measures

Nm3 gas/h Governor CO2CO Flue gas -

temp

Before

Small
flame

Large
flame

Nm3 gas/h Governor CO2CO Flue gas -

Before

Small
flame

Large
flame

Nm3 gas/h Governor CO2CO Flue gas-

Before

Small
flame

Large
flame

After % % °C µ A mbar mbar %

temp

After % % °C µ A mbar mbar %

temp

After % % °C µ A mbar mbar %

Ionisa-

tion-

current

Ionisa-

tion-

current

Ionisa-

tion-

current

Pressure Efficiency

Fire room Chimney

Pressure Efficiency

Fire room Chimney

Pressure Efficiency

Fire room Chimney

General

Bentone BG550/650

57

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

www.bentone.se, www.bentone.com