Bentone BFG 1 H1, Installation And Maintenance Instruction

Page 1: ...Providing sustainable energy solutions worldwide CR00249 178 051 35 7 2021 02 01 Installation and maintenance instruction BFG 1 Translation of the original instructions ...

Page 2: ...KS 76 24 1234567 1 230V 1 0A 50Hz IP 20 Man Year 2019 Cap Min Max Manualer på övriga språk www bentone com download or scan QR code Enter the burner s article number on your data plate see picture and select language Manuals in other languages www bentone com nedladdning eller scanna QR koden Skriv in brännarens artikelnummer som finns på din typskylt se bild och välj ditt språk www bentone com do...

Page 3: ...________________________ 22 4 4 3 Air quantity setting procedure__________________ 22 4 4 4 Inlet cone air control _________________________ 23 4 4 5 Rotation of air intake _________________________ 23 4 4 6 Air duct ____________________________________ 23 5 Burner service ______________________________________ 24 5 1 Service _________________________________________ 24 5 1 1 Combustion device ser...

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: ...ical data BFG 1 2 1 Burners are intended for use at Hot water boilers in intermittent operation 2 2 Dimensions The above mentioned measurements are maximum measurements They can vary depending on which components are used Flange 1 BFG 1 H1 and BFG1 H2 Flange 2 BFG 1 H1 and BFG1 H2 Flange 3 BFG 1 H3 172 525 25 ...

Page 8: ...0 61 2 45 BFG 1 H2 15 65 kW G 20 1 59 6 88 G 25 1 86 8 06 G 30 0 47 2 02 G 31 0 61 2 66 BFG 1 H3 25 100 kW G 20 2 65 10 58 G 25 3 10 12 41 G 30 0 75 3 10 G 31 1 02 4 09 MB Block Max connection pressure mbar Min connection pressure mbar GB LD 055 65 See data plate MBC 65 200 MBC 120 360 MB 403 200 MB 405 360 MB 407 360 Lower heat value Hu at normal state 15 C and 1013 25 mbar EN676 Grade of gas Nat...

Page 9: ...Gas categories approved gases Only dry gas is permitted for use Gerätekategorien Appliance categories Versorgungsdrücke Supply pressure Bestimmungsländer Countries of destination II2R 3R 20 mBar AT BE BG CH CZ CY DE DK EE ES FI FR GB GR HR HU IE IS IT LT LU LV MK MT NL NO PL PT RO RS SE SI SK TR II2H38 P 20 mBar AT CH CY DK FI LT RO SE SK II2H3P 20 mBar GB IE II2L38 P 20 mBar NL RO II2E38 P 20 mBa...

Page 10: ...50 60 0 0 2 0 4 0 6 0 8 0 10 0 12 0 14 0 16 0 18 0 15 20 25 30 35 40 45 50 55 60 Air setting Nozzle assembly setting 2 4 Model BFG 1 H1 2 4 1 Burner output Basic settings 15 60 kW Blast tube length mm Blast tube Dimension A mm Flange Dimension B ø 108 79 90 140 111 90 The above mentioned measurements are maximum measurements They can vary depending on which components are used Do not exceed workin...

Page 11: ... 60 65 70 0 0 2 0 4 0 6 0 8 0 10 0 12 0 14 0 16 0 18 0 20 0 22 0 15 20 25 30 35 40 45 50 55 60 65 Natural gas LPG Air setting Nozzle assembly setting 2 5 Model BFG 1 H2 Blast tube length mm Blast tube Dimension A mm Flange Dimension B ø 115 86 90 147 118 90 The above mentioned measurements are maximum measurements They can vary depending on which components are used 2 5 1 Burner output Basic setti...

Page 12: ...0 50 60 70 80 90 100 0 2 4 6 8 10 12 14 16 18 20 22 24 25 35 45 55 65 75 85 95 Natural gas LPG Air setting Nozzle assembly setting 2 6 Model BFG 1 H3 Blast tube length mm Blast tube Dimension A mm Flange Dimension B ø 145 120 110 245 220 110 The above mentioned measurements are maximum measurements They can vary depending on which components are used 2 6 1 Burner output Basic settings 25 100 kW Do...

Page 13: ...13 Bentone BFG1 4 3 5 1 6 2 10 16 9 15 14 13 7 8 22 11 12 2 7 Description ...

Page 14: ...ch 9 Test point for the air pressure switch on the low pressure side 10 Air intake 11 Air regulation 12 Electric connection 13 Gas burner control 14 Reset button 15 Nozzle assembly adjustment 16 Screw for division of burner in front and rear part 17 Nozzle assembly 18 Brake plate 19 Ignition electrode 20 Ionisation electrode 21 Nozzle 22 Air flow indicator indicates the air setting ...

Page 15: ...valve 2 Filter 3 Pressure regulator 4 Outlet for gas pressure measuring 5a Gas pressure switch min 5b Gas pressure switch max 6a Main valve 6b Safety valve 7 1 Leakage control 9 Air pressure switch 10 Gas burner control Pos 5b Components not required acc to EN 676 1 Required above 1200 kW acc to EN 676 ...

Page 16: ...r are approved for indicated gas pressure 3 The gas supply system should be installed in accordance with current standards 4 Pipe lines should be run so that service on boiler and burner is facilitated 5 Pipe lines should be run so that eventual contaminants cannot come into contact with the gas components 3 5 Electric connection Before starting the electric installation the main switch must be tu...

Page 17: ...s connections 1 Check the gas pipe dimensions According to local regulations 2 Connect the gas pipe to the gas flange of the multiblock 3 A manual gas valve should be installed in the vicinity of the burner 4 No mechanical stresses forces should exist in the gas connection 5 Check the sealing of the gas connections including the multiblock and flanges NOTE If the gas connection is via a hose the s...

Page 18: ...he pre ignition is started 0 5 2 5 secs depending on the design of the gas burner control The ignition spark should then be able to operate faultlessly at the required quantity of air for combustion The gas valve is energized and opens After the end of the safety period 2 3 secs the gas burner control blocks The solenoid valve and motor become de energized Remove the bridge after completed testing...

Page 19: ... 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 Liquefied petroleum gas LPG 3 5 11 13 8 4 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 contact...

Page 20: ... 8 Nm3 h Hu η 9 5 0 90 Example C V 0C Q 50 5 9 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 50 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 Ga...

Page 21: ...1 11 the calculated flow in a normal state f 273 945 15 0 90 Nm3 h 273 15 1013 25 Calculation example T 15 C B 945 mbar P 15 mbar 4 4 Calculating the quantity of gas supplied The quantity of gas supplied can be calculated if the system is equipped with a gas flow meter of some type The procedure here is usually to measure how long it takes for the burner to consume a certain quantity of gas To mea...

Page 22: ...r regulation device of the burner 4 4 2 Air intake adjustment The air setting is very important to get good combustion with neither too much nor too little air The air flow for combustion is adjusted by turning the air adjusting screw with an Allen key How open the air control should be is determined by the fired in effect and overpressure in the boiler as well as other settings on the burner such...

Page 23: ...urner into different environments The intake can be rotated into various positions not just the ones shown to the left To rotate the air intake loosen the three screws securing the air intake and the two screws fastening the air pressure switch Then rotate the air intake to the desired position and tighten the screws The air intake position does somewhat affect the air flow through the burner The ...

Page 24: ... any electric cables or gas pipes during installation or service 5 1 1 Combustion device service 1 Switch off the main current disconnect the Eurostecker from the burner and turn off the gas 2 Remove the gas pipe after ensuring that the gas is turned off 3 Remove the burner from the burner flange Pull out the burner Disconnect the blast tube and remove it 4 If necessary clean the brake plate and n...

Page 25: ... electrical bracket 6 Remove the cable conduit for the ignition electrode and ionisation electrode 7 Loosen the screws H holding the motor flange 5 pcs 8 Lift off the motor 9 Disconnect and remove the fan wheel 10 Install the fan wheel on the new motor and tighten the locking screw The fan wheel should be installed in the bottom position against the motor shaft 11 Fit in the motor flange against t...

Page 26: ... Be careful when installing the inlet cone install it in the same position as it was before being removed 11 Fit the O ring in the groove between the fan housing and inlet cone Ensure that it is properly located in the groove and is not damaged when the air intake is fitted 12 Install the Eurostecker switch on the main current and open the gas flow 13 Start the burner and check the combustion 5 1 ...

Page 27: ...olding the air intake 3 pcs 5 Remove the air intake 6 Loosen the screw J holding the inlet cone and note the inlet cone position 7 Remove the inlet cone from the fan housing 8 Clean the fan wheel If necessary disconnect and remove the fan wheel for more thorough cleaning of the fan and fan housing 9 Install the fan wheel and tighten the screw The fan wheel should be installed in the bottom positio...

Page 28: ...essure switch and disconnect the cables Note how the air pressure switch is connected 6 Loosen the screw holding the electrical bracket 7 Disconnect the ignition electrode and ionisation electrode cables from the electrical package 8 Attach the new electrical package 9 Connect the ignition electrode and ionisation electrode in the new electrical package 10 Install the screws in the electrical brac...

Page 29: ...om the front piece and pull it backwards until the cables to the ignition electrode and ionisation electrode can be loosened 4 Remove the gas burner control 5 Remove the cable of components to be replaced Disconnect the cable in the terminal board 6 Insert the new cable 7 Check that all wires enter the terminal board and that they are securely fastened 8 Switch on the gas burner control 9 Assemble...

Page 30: ...nipple for regulator pressure 5 Test nipple for nozzle pressure 6 Quantity setting via gas throttle 7 Gas pressure switch min 8 Electric connector gas pressure switch 9 Setting of pressure regulator 10 Screw for coil 4 mm Allen key 11 Screw gas pressure switch All gasline components shall be assembled and mounted without bending torque and other mechanical or thermal stress 172 525 29 ...

Page 31: ... regulator can be required if for instance the quantity setting is max open and the factory setting 10 mbar is not sufficient The regulator pressure can be changed with a 2 mm Allen key on the adjustment screw 9 Adjustment clockwise gives higher pressure Adjustment counter clockwise gives lower pressure 6 1 1 3 Coil replacement Loosen screw 10 Remove the coil 2 Install a new coil Attach the coil w...

Page 32: ... regulator pressure 5 Test nipple for nozzle pressure 6 Quantity setting via gas throttle 7 Gas pressure switch min 8 Electric connector gas pressure switch 9 Setting of pressure regulator 10 Screws for coil 11 Screw gas pressure switch 12 Cover adjustment control All gasline components shall be assembled and mounted without bending torque and other mechanical or thermal stress ...

Page 33: ...ged with a 2 mm Allen key on the adjustment screw 9 Adjustment clockwise gives higher pressure Adjustment counter clockwise gives lower pressure 6 2 1 3 Replacement of coil Loosen screw 10 Remove the cover Remove the circuit board Disconnect the solenoid valve from the valve with a hexagonal screw Install and fasten the new coil Install and fasten the circuit board and cover 6 2 1 4 Replacement of...

Page 34: ...essure 5 Quantity setting via gas throttle 6 Gas pressure switch min 7 Electric connector gas pressure switch 8 Setting of pressure regulator 9 Screw for cover over coil 10 Screw gas pressure switch 11 Cover adjustment control 12 Quantity setting of start gas via gas throttle All gasline components shall be assembled and mounted without bending torque and other mechanical or thermal stress ...

Page 35: ... can be changed with a 2 mm Allen key on the adjustment screw 8 Adjustment clockwise gives higher pressure Adjustment counter clockwise gives lower pressure 6 3 1 3 Setting start gas flow The multiblock is set with the slow opening at start The start gas flow can be changed with a 2 mm Allen key on the adjustment screw 12 For quicker opening turn counter clockwise For slower opening turn clockwise...

Page 36: ...e two screws 10 Carefully remove the gas pressure switch Install a new gas pressure switch Attach the gas pressure switch with the two screws 10 6 3 1 6 Important When replacing gas pressure switches inspecting filters via the gas connection etc ensure that the O rings and gaskets are positioned correctly and that leak testing is performed after each operation Also check the function of the gas pr...

Page 37: ...sure MB DLE 403 200 mbar Adjustable governor pressure 4 50 mbar Solenoid valve Slow opening valves with adjustable start load and max flow 1 Protective cover start load adjustment 2 Hydralic damping 3 Fixing screw 4 Test nipple inlet pressure 5 Test nipple pressure after go vernor 6 Test nipple pressure in inner assembly 7 Governor 8 Filter 9 Gas pressure switch 10 Solenoid valve ...

Page 38: ...ustment 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 start gas flow is reduced Turn to the left start gas flow is increased Adjustment of governor Adjust outlet pressure from governor by means of a screw Min and max outlet pressures corresponds to appr 60 turns of the spring It is not p...

Page 39: ...ssible 8 Test point connection G 1 8 downstream of valve 1 possible on both sides 9 Output flange 10 Gas flow direction 11 Test point connection G 1 8 upstream of V1 possible on both sides 12 Vent nozzle regulator 13 Filter below flange 14 Input flange 15 Pressure switch 16 Electrical connection for valves DIN EN 175 301 803 connector 16 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 172 515 12 Max inlet pre...

Page 40: ...ust as above Adjustment of governor Adjust outlet pressure from governor by means of a screw Min and max outlet pressures corresponds to appr 60 turns of the spring It is not possible to change pressure springs in order to change the outlet pressure Turn to the right the outlet pressure is increased Turn to the left the outlet pressure is reduced Adjustment of start gas flow Remove the protective ...

Page 41: ...41 Bentone Pressure taps 1 3 4 5 Screwed sealing plug G 1 8 2 Measuring nozzles Electrical connection 1 4 pa 3 pe 2 3 pe 4 pa 5 1 2 4 4 3 1 5 5 P1 L1 MP N 2 1 P1 L1 Mp N S 20 S 50 ...

Page 42: ...rent for different gas control units is indicated in the table below In reality this current must be significantly higher preferable more than 15 µA The connection of the µA instrument is facilitated by the fact that all gas burners are equipped with a detachable ionisation cable Gas burner control Connection to the board in gas burner control Min required ionisation current Normal ionisation curr...

Page 43: ...n the air pressure switch clockwise until the air pressure switch stops the burner 4 Try to find the pressure at which the burner stops for both the minimum and maximum input power by turning the scale Make a note of the values and then set the air pressure switch on the basis of the highest pressure noted at which the burner stopped 5 The air pressure switch should be set to a pressure approx 10 ...

Page 44: ...uring normal operation at the highest input power 5 Based on the desired connection pressure set determine the connection pressure at which the gas pressure switch should stop the burner Set the connection pressure at which the burner is stopped at a level where the burner is stopped before poor combustion occurs 6 Set the min gas pressure switch to this value by turning the scale 7 Check the sett...

Page 45: ... Remove the hoses for the air pressure switch to check that the burner goes into blocking Check the gas installation for leaks Check that all protective covers and test nipples are installed and tightened Fill out required test protocols Instruct operating staff in the care and maintenance of the system and how to react in case of breakdown Review and service should be performed by authorized pers...

Page 46: ... the rules and regulations that apply The cables of the safety system must be separated so that the outgoing signal is not placed in the same cable as the incoming signal These signals must be laid in two different cables The safety system such as safety switches for doors doors water level pressure temperature and other safety devices must be installed in the safety circuit according to the rules...

Page 47: ...47 Bentone BFG1 Alt 1 Acc to DIN 4791 Alt 2 Alt 3 8 2 Wiring diagram ...

Page 48: ...ed 6 Operating position 7 Stop The operation of the burner can now be stopped with the control switch or thermostat If the gas burner control is blocked Red light in the gas burner control is lit The burner is restarted by pushing the reset button 8 2 1 List of components A1 Gas burner control A3 Valve leak tester Dungs VPS504 optional A7 RC circuit B1 Ionisation electrode U2 UV sond QRC LME23 F1 ...

Page 49: ...nking green Illegal flame signal during start up Green Red Undervoltage Yellow Red Fault alarm Red Blinking code for fault codes Blinking red Interface diagnostics Red flicking 8 3 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 8 3 ...

Page 50: ...ting defective or fouled fuel valves defective or fouled flame monitoring Blinking 8 x Free Blinking 9 x Free Blinking 10 x Connection fault or internal fault outgoing contacts or other faults Blinking 14 x CPI contact not closed During the diagnosing of the alarm cause the control outputs are voltage free The burner is disconnected Exception alarm signal AL at board 10 Reconnection of the burner ...

Page 51: ...tor 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 Transfo...

Page 52: ...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 53: ...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 ...

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Page 55: ...ermostats etc are correctly adjusted 10 Read the instructions and follow the directions given for the burner as to starting up and service 10 3 2 Maintenance 1 Switch off the current with the main switch 2 Shut off the gas supply with the shut off cock on the burner Normal operation 1 Ensure that the air supply to the burner is not obstructed by dust and dirt 2 Have the installer make a yearly ove...

Page 56: ...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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Page 60: ...Enertech AB P O Box 309 SE 341 26 Ljungby www bentone se www bentone com ...