Bentone 760000176601, Installation And Maintenance Instruction

Page 1: ...roviding sustainable energy solutions worldwide Installation and maintenance instruction BG 450 M J K IP20 LME22 233C2 MB VEF 412 Translation of the original instructions CR00264 178 125 76 3 2021 06 21 ...

Page 2: ...oaded at www bentone com ecodesign da 1 Manualer på andre sprog 2 www bentone com download eller scan QR koden 3 Indtast brænderens artikelnummer der findes på typeskiltet se billede og vælg dit sprog Detaljerede oplysninger om ecodesign kan downloades på www bentone com ecodesign fr 1 Manuels dans d autres langues 2 www bentone com download ou scannez le code QR 3 Saisir le numéro d article du br...

Page 3: ... 4 9 Leakage control _________________________________ 16 4 10 Gas nozzle______________________________________ 17 4 11 Setting Damper motor modulating operation ________ 18 5 Setting the burner ___________________________________ 19 5 1 Setting the combustion assembly___________________ 19 5 2 Setting the air pressure switch _____________________ 20 5 3 Setting the min gas pressure switch _______...

Page 4: ...a dry environment max 80 relative humidity no condensation Temperature 20 to 60 C Check that the burner is compatible with the boiler s output range All components must be installed without being bent twisted or subjected to mechanical or thermal forces which can affect the components The burner must be installed so that it complies with local regulations for fire safety electrical safety and fuel...

Page 5: ... be put into operation without proper safety and protection devices A Class BE fire extinguisher is recommended It is forbidden to alter thedesign or use accessories which have not been approved by Enertech in writing Prior to operation the following points must be checked fitting and installation work has been completed and approved electrical installation has been correctly performed flue gas du...

Page 6: ...check 1 year 3 000 hrs Filter 1 year replacement at Δp 10 mbar 3 000 hrs replacement at Δp 10 mbar Electrodes Replacement Cleaning 1 year Replacement Cleaning 3 000 hrs Brake disc Replacement Cleaning 1 year Replacement Cleaning 3 000 hrs Motor 1 year 3 000 hrs Fan wheel 1 Year Replacement when cleaning needed imbalance 3 000 hrs Replacement when cleaning needed imbalance The burner and its compon...

Page 7: ...I J BG 450 538 252 328 500 640 262 200 K L M The above dimensions are max measurements Depending on the components used the measurements may vary Min recommended distance to floor K L M BG 450 M12 Ø 210 Ø 255 290 Ø 170 2 1 1 Heat generator connection dimensions Type Length of burner tube Flange measure A Burner tube measure B Burner tube measure C BG 450 1 256 226 ø160 ø162 2 356 326 ø160 ø162 3 4...

Page 8: ...mbar EN676 Grade of gas Natural gas Natural gas Butane Propane Biogas Gas quantity and capacity vary according to grade of gas and connection pressure BG 450 G20 120 550 12 6 57 9 360 G25 120 550 14 6 67 1 360 G30 120 550 3 7 16 9 360 G31 120 550 4 9 22 4 360 kWh Nm3 MJ Nm3 kcal Nm3 G20 9 5 34 02 8126 G25 8 2 29 25 6986 G30 32 5 116 09 27728 G31 24 6 88 00 21019 6 0 21 60 5159 2 3 Appliance catego...

Page 9: ...according to EN 3746 2010 Alt 1 The sound level of the burner can be reduced by equipping the burner with silencer Installation must be done so it does not prevent air supply to the burner Alt 2 The burner s noise level can be reduced by connecting the burner s air intake to the air duct that opens into an appropriate location Installation must be done so it does not prevent air supply to the burn...

Page 10: ...Fan housing 7 Brake plate 8 Ignition electrode 9 Ionisation electrode 10 Motor 11 Gas connection 12 Air intake 13 Air damper 14 Air pressure switch 15 Impulse pipe 16 Gas pressure switch 17 Changeover switch increase decrease 18 Changeover switch manual automatic 19 Indicator lamp operation 20 Switch 0 1 21 Damper motor 22 Relay box 23 Electrical connection 24 MultiBloc 2 6 Description ...

Page 11: ...ion and maintenance The unit must be serviced and maintained at the interval specified in the service schedule If the burner is in a dirty environment service should be done at more frequent intervals than specified 3 5 Start up After the burner has been fitted to the boiler and the electric connection the leakage control the venting and the electric function test have been carried out the burner ...

Page 12: ...icated gas pressure 3 The gas supply system should be installed in accordance with current standards 4 Pipe lines should be run so that service on boiler and burner is facilitated 5 Pipe lines should be run so that eventual contaminants cannot come into contact with the gas components 6 Gas discharge system must be installed prior to local regulations 4 4 Electric connection Before starting the el...

Page 13: ...13 Bentone 4 6 Handling and lifting instruction 4 6 1 BG 450 The lifting aids we use here are available as accessory 172 515 29 2018 01 02 ...

Page 14: ...late from the fan housing 3 Loosen screw D on the nozzle assembly 4 Disconnect the electrical cables to the valve assembly and gas damper motor 5 Undo the screws B on both sides 6 Undo the end stops C on the guides 7 Disconnect the ignition cable ionisation cable and control arm from the gas nozzle 8 Pull out the burner body from the guides and put it in a suitable place After separating the burne...

Page 15: ...e there is enough slack in the electrical cables to the valve assembly and gas damper motor to pull out the burner body in the rear position on the guides If there is not enough slack the cables can be disconnected 6 Undo the screw B on both sides 7 Pull out the burner on the guides 8 Undo the screw s A on the gas flange 9 Take out the gas nozzle 10 See section Gas nozzle Re assemble the burner in...

Page 16: ...utral are not reversed The gas shut off cock should be closed To prevent the gas pressure switch from locking out it should be linked temporarily After the main switch has been switched on and the thermostats have been adjusted the pre purging period begins 30 35sec At the end of this period the pre ignition period starts 0 5 2 5 sec dependent on the design of the gas control The gas valve is ener...

Page 17: ...17 Bentone 4 10 Gas nozzle 45 Natural gas Propan Biogas UV detector ...

Page 18: ...on MIN and if mounted gas pressure switch max in position MAX Start burner If no flame is formed and the manometer does not give a reading adjust the amount of gas by increasing with screw N on the multi block Check combustion values Set high load by pressing control switch increase Adjust the amount of gas with screw V on the multi block and check the combustion values Return to low load check co...

Page 19: ... The best position is among other things dependent on the input power and overpressure in the boiler A general rule of thumb is that the smaller the capacity the smaller the gap should be between the brake plate and the combustion assembly The position of the brake plate also has an impact on the quantity of air supplied for combustion This means that once the brake plate has been adjusted the com...

Page 20: ...tch clockwise until the air pressure switch stops the burner Is the tolerance on the scale for the min air pressure switch approx 15 4 Try to find the pressure at which the burner stops for both the minimum and maximum input power by turning the scale Make a note of the values and then set the air pressure switch on the basis of the highest pressure noted at which the burner stopped 5 The air pres...

Page 21: ...to the burner during normal operation at the highest input power 5 Based on the desired connection pressure set determine the connection pressure at which the gas pressure switch should stop the burner Set the connection pressure at which the burner is stopped at a level where the burner is stopped before poor combustion occurs 6 Set the min gas pressure switch to this value by turning the scale 7...

Page 22: ... wiring diagram Setting the power monitor 1 Remove the protective cover screw Y 2 Open the test socket X and connect a pressure gauge to measure pressure in the connection pipe 3 Start the burner 4 Measure and note the value 5 Using the measured pressure the power monitor can be adjusted so that the burner can be stopped and its output can be limited 6 Adjust the power monitor by tuning the adjust...

Page 23: ...h mini 5b Gas pressure switch maxi 6a Main valve 2 stage When modulaing operation is required this valve is equipped with controls for variable opening 6b Safety valve 7 1 Valve proving system 9 Air pressure switch 10 Gas burner control Pos 5b 7 Components not required according to EN 676 1 Required over 1200 kW according to EN 676 hhh MultiBloc ...

Page 24: ...ion 1 8 before V1 before governor 10 Adjustment screw for zero point adjustment N min load 11 Test point connection 1 8 PF 12 Test point connection 1 8 PBr 13 Flange connection outlet 14 Test point connection 1 8 Pa before V2 after governor 15 Indication of V1 and V2 in operation not standard 16 O ring Check the filter at least once a year It is possible to connect a leakage control VPS 504 and a ...

Page 25: ... 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...

Page 26: ...DN p p a p a Br F pL 3 p e 3 p e 7 8 4 6 1 5 1 3 3 4 2 2 6 8 7 6 5 5 Pressure taps P1 L1 Mp N P1 L1 MP N 2 1 S 10 S 30 1 3 4 5 G 1 8 screwed sealing plug 2 Measuring nozzle 6 7 8 G 1 8 female thread for pL pF pBr pulse lines 6 5 6 Electrical connection ...

Page 27: ...gas 6 0 21 60 5159 6 1 Recommended excess air when using default setting Grade of gas Excess air flue gases Max CO2 O2 CO2 Lambda 1 2 Natural gas 3 5 10 11 9 Propane 3 5 11 5 13 9 Butane 3 5 11 5 14 1 Biogas 3 5 6 2 Determining the gas quantity for the system The heat values indicated are normal values the heat value varies according to the origin of the gas For more exact information on values co...

Page 28: ...19 Nm3 h Hu η 9 5 0 90 Example C V 0C Q 160 19 Nm3 h Hu 0 00116 η 8126 0 00116 0 90 If the barometer reading altitude pressure and temperature of the gas deviate significantly from normal values this must be taken into account as follows Calculation example Q 160 kW HU Example A 34020 MJ Nm3 Example B 9 5 kWh Nm3 Example C 8126 kcal Nm3 η 90 V0 Desired quantity of gas Nm3 h Q Boiler output kW HU G...

Page 29: ...sually to measure how long it takes for the burner to consume a certain quantity of gas To measure t Time for a certain quantity of gas consumed by the burner h M Quantity of gas consumed m3 V Actual gas flow m3 h V V0 f VA V0A f 18 8 0 90 17 m3 h VB V0B f 19 0 90 17 m3 h VC V0C f 19 0 90 17 m3 h This means that the quantity of gas read from the gas meter should actually be read off as 1 11 the ca...

Page 30: ...he Euro plugs from the burner 2 Remove the cover and disconnect the ignition cable ionisation cable and control arm D from the gas nozzle 3 Loosen the nuts B and pull the burner body out of the guides 4 Loosen the screw A this releases the combustion assembly and allows it to be lifted out 5 Check and clean the brake plate and gas inlet If necessary replace the worn parts 6 Check the ignition elec...

Page 31: ...at the air intake 5 Remove the screws G securing the damper motor mounting plate 6 Lift up the damper motor 7 Clean the air damper and the intake Lubricate any damper shaft 8 Re install the damper motor and mounting plate on the air intake Ensure that the damper shaft and control arm are connected correctly 9 Install the intake grille for the air intake 10 Press the burner together and lock using ...

Page 32: ...te 9 Install the new damper motor on the mounting plate 10 Fit the control arm on the damper motor shaft It is important that the screw is perpendicular to the plane of the shaft 11 Re install the damper motor and mounting plate on the air intake Ensure that the damper shaft and control arm are connected correctly 12 Connect the damper motor cable 13 Fit the Euro plugs and turn on the mains power ...

Page 33: ...m vibration level are 5 0 mm s Check all bolts and nuts for correct torque Check fan wheel for damage and contamination Change when dirty unbalanced Check motor bearings If worn change motor bearings Use lid screw for sensor mounting ...

Page 34: ...s made easier by the fact that all gas burners are equipped with a divisible ionisation cable The reason for low ionisation current can be leakage current poor connection to earth fouling or incorrectly positioned ionisation electrode in the combustion head Occasionally an incorrect gas air mix may result in poor ionisation current Technical data For continuous operation Idle voltage at ION termin...

Page 35: ...ry only if a malfunction is suspected 7 5 3 Flame monitoring UV detector QRC Technical data For continuous operation Idle voltage at ION terminals AC 115 230V Protect the ionisation electrode from electric shock Short circuit current Max AC 100 300 mA Max current for flame detection Max DC 5 5 µA Required current to ensure detection Min DC 40 µA Possible detection current Max DC 60 µA Operational ...

Page 36: ...ndent 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 correct...

Page 37: ...es water level pressure temperature and other safety limiters must be installed in safety loop according to process The switch for high gas pressure can be installed for different uses Installation must be carried out pursuant to applicable regulations The switch can be installed so that it reacts either to inlet pressure or pressure according to the multi block pressure regulator The high gas pre...

Page 38: ...38 Bentone 10 2 Wiring diagram LME If there is no Plug in contact X4 X16 on the boiler connect to the contact enclosed ...

Page 39: ...ure switch Y1 Solenoid valve 1 Y3 Solenoid valve 3 10 3 Function LME 1 Operating switch ON Thermostat ON Gas pressure switch ON A check that the air pressure switch does not indicate fan pressure is carried out 2 Burner motor starts A check that the air pressure switch indicates sufficient fan pressure is carried out 3 The ignition spark is created 4 The gas solenoid valve is open The gas is ignit...

Page 40: ...king red Interface diagnostics Red flicking 10 4 1 1 Diagnosing alarm causes After alarm disconnection the red alarm signal light is lit continuously The diagnosing of the alarm cause can be read according to the following sequence Continuous Off Red Yellow Green 10 4 1 2 Limiting of starting repetitions LME 11 has a function with start repetition if the flame is not created at start or disappears...

Page 41: ...ive or fouled flame monitoring Blinking 8 x Free Blinking 9 x Free Blinking 10 x Connection fault or internal fault outgoing contacts or other faults Blinking 14 x CPI contact not closed During the diagnosing of the alarm cause the control outputs are voltage free The burner is disconnected Exception alarm signal AL at board 10 Reconnection of the burner happens after resetting only Press the rese...

Page 42: ...otor faulty Burner control faulty Replace Burner motor running no ignition spark at the end of pre aeration No power in the terminals Check the connector Replace faulty burner controls Ignition electrodes in contact with each other or earth Adjust Ignition electrode porcelain damaged Replace the electrodes Poor connection to cable connectors Adjust connection Ignition cables damaged Replace Transf...

Page 43: ...djust Gas pressure too high Check and adjust using pressure gauge and pressure control valve Flue gas side blocked Check the chimney flue Burner pulsates during operation Burner incorrectly set Adjust Burner dirty Clean the burner Incorrect chimney Check and modify dimensions if necessary Burner functioning properly but with occasional blockage Ionisation current too low Check Must be at least 6 µ...

Page 44: ...supply Check flue gas damper Holes in gas nozzle clogged Clean Poor fresh air intake Check and increase Flame at incorrect angle due to combustion head out of position Check the combustion head and readjust Condensation build up in boiler and chimney Flue gas temperature too low or gas volume too low Raise the flue gas temperature by increasing gas volume Insulate the chimney ...

Page 45: ...ermostats etc are correctly adjusted 10 Read the instructions and follow the directions given for the burner as to starting up and service 12 4 2 Maintenance 1 Switch off the current with the main switch 2 Shut off the gas supply with the shut off cock on the burner Normal operation 1 Ensure that the air supply to the burner is not obstructed by dust and dirt 2 Have the installer make a yearly ove...

Page 46: ...Measu rement C µ A Before After mbar mbar Small Flame Large Flame Measures Date Nm3 gas h Governor CO2 CO Fluegas temp Ionisation current Pressure Efficiency Fire room Chimney Measu rement C µ A Before After mbar mbar Small Flame Large Flame Measures Date Nm3 gas h Governor CO2 CO Fluegas temp Ionisation current Pressure Efficiency Fire room Chimney Measu rement C µ A Before After mbar mbar Small ...

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