Bentone B45-2 RME Technical specifications

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Installation and Maintenance instruction
B45-2 RME

2Bentone B45-2 RME

3
Bentone B45-2 RME
General
Table of Contents
1. GENERAL INSTRUCTIONS _________________________________ 4
1.1 Manual___________________________________________________________ 4
1.2 Safety directions______________________________________________ 4
2. TECHNICAL DATA________________________________________________ 6
2.1 Dimensions_____________________________________________________ 6
2.2 Setting of ignition electrodes and brake plate _______ 6
2.3 Dimension, flange ____________________________________________ 7
2.4 Recommended nozzle and pressure ___________________ 7
2.5 NOZZLE TABLE_______________________________________________ 8
2.6 Description B45-2__________________________________________ 10
3. INSTALLATION___________________________________________________ 12
3.1 Acceptance inspection ___________________________________ 12
3.2 Preparations for installation______________________________ 12
3.3 Distribution of oil____________________________________________ 12
3.4 Electrical connection ______________________________________ 13
3.5 Nozzle selection ____________________________________________ 14
3.6 Setting of brake plate and air flow_____________________ 14
3.7 Burner installation __________________________________________ 14
3.8 Burner installation __________________________________________ 15
3.9 Check oil line seals_________________________________________ 15
4. BASIC SETTINGS ______________________________________________ 16
4.1 Examples of basic setting ______________________________ 16
4.2 Setting values for nozzle assembly B45-2 RME __ 17
4.3 Setting values for air damper B45-2 RME __________ 17
4.4 Nozzle assembly control, brake plate ________________ 18
4.5 Air setting Damper motor ________________________________ 19
5. BURNER SERVICING ________________________________________ 21
5.1 Servicing the combustion assembly _________________ 21
5.2 Servicing air dampers ____________________________________ 22
5.3 Replacement of damper motor ________________________ 23
5.4 Replacement of oil pump ________________________________ 24
5.5 PUMP INSTRUCTION ____________________________________ 26
5.6 Suntec DV67C ______________________________________________ 26
5.7 Components_________________________________________________ 26
6. ELECTRICAL EQUIPMENT _______________________________ 30
6.1 Wiring diagram LMO24.255 ... ________________________ 30
6.2 Component list LMO24.255 ... ________________________ 31
6.3 Function LMO24.255 ...__________________________________ 31
6.4 Technical data LMO24.255...___________________________ 32
6.5 Colour codes ________________________________________________ 33
6.6 Fault codes___________________________________________________ 33
7. FAULT LOCATION ______________________________________________ 34
7.1 Burner will not start ________________________________________ 34
8. DECLARATION OF CONFIRMITY______________________ 35

4Bentone B45-2 RME
General
General rules
This is a burner designed for FAME (RME) fuel. The fuel must meet the
requirements of standard EN 14214 for FAME. The equipment on the burner
is, however, of such a quality that it is possible to use EO1 type oil without
modification, although with appropriate adjustments to the combustion
values after each change of fuel type.
Firing with EO1 should be conducted the last few hours at the end of the
firing season.
The installation of an oil burner should be carried out in accordance with
local regulations. The installer of the burner must therefore be aware of all
regulations relating to oil and combustion.
Only oil suitable for the burner must be used and then in combination with a
suitable oil filter designed for FAME (RME) and installed before the burner’s oil
pump.
If the burner is replacing an existing burner, ensure that the oil filter is
changed to a filter designed for FAME (RME). Installation may only be
performed by qualified personnel.
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.
Burners which are fuelled by FAME (RME) are and must be equipped with
parts designed for this fuel. This applies in particular to oil-related parts such
as the pump, solenoid valve, oil filter and hoses. It is very important when
carrying out a service to replace old parts with new parts of the same quality.
1.1 Manual
• 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.
1.2 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 oil, fire or
personal injury is avoided.
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.
1. GENERAL INSTRUCTIONS

5
Bentone B45-2 RME
General
Adjustment of burner
The burner is from the factory preset to an average value
that must then be adjusted to the boiler in question.
All burner adjustments must be made in accordance with
boiler manufacturers instructions.These must include
the checking of flue gas temperatures, average water
temperature and CO2 or O2 concentration.
To adjust the combustion device, start by increasing the
air volume and the nozzle assembly somewhat. When
the burner starts it is burning with excess air and smoke
number 0. Reduce the nozzle assembly adjustment
until soot occurs, and then increase the adjustment to
make the soot disappear again. Then the volume of air is
reduced until soot occurs and increased again to reach a
combustion free of soot.
By this procedure an optimum adjustment is obtained. If
larger nozzles are used the preadjustment of both the air
volume and the nozzle assembly must be increased.
A whistling sound may be heard which can be
eliminated or reduced as follows: Increase the nozzle
assembly adjustment somewhat. The CO2-content and
consequently the air volume will then be reduced.
Condensation in chimney
A modern burner works with less excess air and often
also with smaller nozzles than older models. This
increases the efficiency but also the risk of condensation
in the chimney. The risk increases if the area of the
chimney flue is too large. The temperature of the flue
gases should exceed 60°C measured 0,5 metres from
the chimney top.
• Measures to raise the temperature:
• Insulate the chimney in cold attics
• Install a tube in the chimney
• Install a draught regulator (dilutes the flue gases
during operation and dries them up during
standstill)
• Increase the oil quantity
• Raise the flue gas temperature by removing
turbulators, if any, in the boiler.
Pump adjustment
See separate description.
Maintenance
The boiler/burner should be examined regularly for any
signs of malfunction or oil leakage. Any boiler/burner that
uses FAME (RME) as fuel must be serviced at least twice
a year.
Firing with EO1 should be conducted the last few hours
at the end of the firing season.
Installation instructions
General installation instructions accompany the burner
and should be left in a prominent place adjacent to the
burner.
Oil supply
The oil line should be dimensioned in accordance with
the pump manufacturer´s instruction. A filter designed for
FAME (RME) that prevents any particles in the oil from
reaching the burner is mounted in the burner’s suction
pipe. If the installation consists of several burners each
one should have its own suction line from the tank or a
circulation system should be used.
The temperature in the oil line should be kept as
constant as possible. Avoid exposing the line to
excessive cold which may cause blockages.
The oil pipe and electric cable should be fitted so that
the burner can be placed on the floor for inspection of
the combustion device.
Oil hoses must be of a quality designed for FAME (RME).

6Bentone B45-2 RME
General
Insertion length,
burner tube
Burner tube,
Dimension B
270 238
370 338
!*NB It is important that
the spark does not strike
against the brake plate or
nozzle
2. TECHNICAL DATA
2.1 Dimensions
2.2 Setting of ignition electrodes and brake plate
a b c d
5,0-6,0 3,5-4,0 7,0-9,0 2,0-3,0
2.2.1 Burner output
8,5 -45,5 kg/h
101 -540 kW
262
515 B480
Ø162
Ø134
252
335
328
a
b
c
d

7
Bentone B45-2 RME
General
2.3 Dimension, flange
2.4 Recommended nozzle and pressure
Nozzle: 45° Solid/semi-solid
60° Solid/semi-solid
80° Solid/semi-solid
Pump pressure 14 bar (8-28 bar)1) !The burner pump is factory set at 14 bar and
test operated using Roadway 80.
Because of the various boiler types with varying furnace geometries and
furnace loads, it is impossible to commit to a certain scattering angle or a
specific distribution pattern.
It should be noted that the scattering angle and distribution pattern changes
with pump pressure.
14
ø134
220
34
B45-2 RME

8Bentone B45-2 RME
General
Gph 8 10 12 14
kg/h kW kg/h kW kg/h kW kg/h kW
1,00 3,33 39 3,72 44 4,08 48 4,40 52
1,10 3,66 43 4,09 48 4,48 53 4,84 57
1,20 3,99 47 4,47 53 4,89 58 5,29 63
1,25 4,16 49 4,65 55 5,10 60 5,51 65
1,35 4,49 53 5,02 59 5,50 65 5,95 70
1,50 4,98 59 5,58 66 6,11 72 6,60 78
1,65 5,49 65 6,14 73 6,73 80 7,27 86
1,75 5,82 69 6,51 77 7,14 85 7,71 91
2,00 6,65 79 7,45 88 8,16 97 8,81 104
2,25 7,49 89 8,38 99 9,18 109 9,91 118
2,50 8,32 99 9,31 110 10,19 121 11,01 131
2,75 9,15 108 10,24 121 11,21 133 12,11 144
3,00 9,98 118 11,16 132 12,23 145 13,21 157
3,50 11,65 138 13,03 15 14,27 169 15,42 183
4,00 13,31 158 14,89 176 16,31 193 17,62 209
4,50 14,97 177 16,75 199 18,35 218 19,82 235
5,00 16,64 197 18,62 220 20,39 242 22,03 261
5,50 18,30 217 20,48 243 22,43 266 24,23 287
6,00 19,97 237 22,34 265 24,47 290 26,43 313
6,50 21,63 256 24,20 287 26,51 314 28,63 340
7,00 23,29 276 26,06 309 28,55 339 30,84 366
7,50 24,96 296 27,92 331 30,59 363 33,04 392
8,00 26,62 316 29,79 353 32,63 387 35,25 418
8,50 28,28 335 31,65 375 34,66 411 37,45 444
9,00 29,95 355 33,59 398 36,71 435 39,65 470
9,50 35,37 419 38,74 549 41,85 496
10,00 37,23 441 40,78 484 44,06 523
Pump pressure bar
2.5 NOZZLE TABLE
The table applies to oil with a viscosity of 4,4 mm2/s (cSt) with density 830 kg/m3.

9
Bentone B45-2 RME
General
Gph 16 18 20 22 24
kg/h kW kg/h kW kg/h kW kg/h kW kg/h kW
1,00 4,71 56 4,99 59 5,26 62 5,53 66 5,77 68
1,10 5,18 61 5,49 65 5,79 69 6,07 72 6,34 75
1,20 5,65 67 5,99 71 6,32 75 6,62 78 6,92 82
1,25 5,89 70 6,24 74 6,58 78 6,90 82 7,21 85
1,35 6,36 75 6,74 80 7,11 84 7,45 88 7,78 92
1,50 7,06 84 7,48 89 7,89 93 8,27 98 8,64 102
1,65 7,77 92 8,24 98 8,69 103 9,11 108 9,51 113
1,75 8,24 98 8,78 104 9,21 109 9,66 115 10,09 120
2,00 9,42 112 9,99 118 10,53 125 11,04 131 11,53 137
2,25 10,60 126 11,24 133 11,85 140 12,43 147 12,98 154
2,50 11,77 140 12,48 148 13,16 156 13,81 164 14,42 171
2,75 12,95 154 13,73 163 14,48 171 15,19 180 15,86 188
3,00 14,13 168 14,98 178 15,79 187 16,18 192 17,30 205
3,50 16,49 196 17,48 207 18,43 218 19,33 229 20,19 239
4,00 18,84 223 19,98 237 21,06 250 22,10 262 23,08 274
4,50 21,20 251 22,47 266 23,69 281 24,85 295 25,96 308
5,00 23,55 279 24,97 296 26,33 312 27,61 327 28,84 342
5,50 25,91 307 27,47 326 28,96 343 30,38 360 31,73 376
6,00 28,27 335 29,97 355 31,59 374 33,14 393 34,62 411
6,50 30,62 363 32,46 385 34,22 406 35,90 426 37,49 445
7,00 32,98 391 34,96 415 36,86 437 38,56 457 40,38 479
7,50 35,33 419 37,46 444 39,49 468 41,42 491 43,26 513
8,00 37,69 447 39,96 474 42,14 499 44,19 524 46,15 547
8,50 40,04 475 42,45 503 44,75 531 46,95 557 4903 581
9,00 42,40 503 44,95 533 47,39 562 49,71 589 51,92 616
9,50 44,75 531 47,45 563 50,02 593 52,47 622 54,80 650
10,00 47,11 559 49,94 592 52,66 624 55,23 655 59,69 684
Pump pressure bar
The table applies to oil with a viscosity of 4,4 mm2/s (cSt) with density 830 kg/m3.

10 Bentone B45-2 RME
General
2.6 Description B45-2
2.6.1 Components
1. Nozzle assembly control
2. Scale, nozzle assembly control
3. Solenoid valve, 1
4. Solenoid valve, 2
5. Measuring nipple, fan pressure
6. Valve block
7. Burner tube
8. Burner flange
9. Pressure outlet pump
10. Pump
11. Return pump
12. Pressure control pump
13. Inlet pump
14. Ignition electrodes
15. Air intake
16. Brake plate
17. Nozzle
18. Contactor for motor
21
10
6
1
2
5
4
3
18
19
7
8
9
11
12
13
14
15
16
17

11
Bentone B45-2 RME
For installers
19. Relay box
20. Ignition transformer
21. Fan wheel
22. Damper motor
23. Switch 0-I
24. Indicator, min. load
25. Switch I-II
26. Indicator lamp, maximum load
27. Inspection glass
28. 4-pole Euro plug (max. load)
29. 7-pole Euro plug (min. load feed)
30. Air damper
31. Air intake
32. Capacitor
33. Motor
34. Fan housing
20
26
25
24
23
33
34 32
27 22
29 28
30 31

12 Bentone B45-2 RME
For installers
1
3. INSTALLATION
3.1 Acceptance inspection
Make sure everything is delivered and the goods have not been damaged
during transit. If something is wrong with the delivery, report it to the supplier.
Transport damage must be reported to the shipping company.
3.2 Preparations for installation
Check that the burner's dimensions and capacity range are suitable for the
boiler in question. The power data on the type sign refers to the burner's
min. and max. power.
3.3 Distribution of oil
In order to achieve good reliability, it is important that the oil distribution
system is designed correctly.
Take the following into account:
- Selection of pipe diameter, pipe length and height difference; see Pump
instruction.
- Pipelines are to be laid with a minimal number of glands.
- The pipes are to be laid so that the oil supply hoses are not subjected to
tensile stresses or are excessively bent when the burner is swung out or
removed for service.
- The oil filter should be installed so that the filter cartridge can easily be
replaced or cleaned.
- Oil-affected parts shall be selected in materials that are capable of
withstanding the medium's physical properties.
- When installing oil hoses, check that the inlet and return hoses are
fitted to the appropriate connection on the oil pump. The hoses shall be
located so that they do not bend or become subject to tensile load.
- Bleed the oil system. The oil pump/oil preheater may be damaged if run
dry. The vacuum should not fall below 0 bar in the suction line during
start-up.
3.3.1 Proposed pipe routing for oil distribution
systems without transport pump
1. Oil filter
!Be sure to fill the burner
oil system before starting
it for the first time.

13
Bentone B45-2 RME
For installers
X3
X4
3
1
2
1 Transport oil pump / Transportoljepump
!If any electrical connection is used other than that recommended by Bentone, there may be a danger of
damage to property and personal injury.
3.3.2 Proposed pipe routing for oil distribution
systems with transport pump
1. Transport oil filter
2. Oil filter
3. Overflow valve 0.5 – 2.0 bar
3.4 Electrical connection
Before electrical installation begins, the main power switch must be turned
off.
If the boiler has a 7-pole, they will usually connect directly to the burner.
Otherwise, use the supplied connectors. See connection under Electrical
equipment.
1. Switch off the main switch.
2. Connect the Euro plugs. (See Electrical equipment)
3. Make sure the burner operations switch (S1) is off.
4. Turn on the main switch.

14 Bentone B45-2 RME
For installers
3.5 Nozzle selection
See under Technical data: Recommended nozzle and Nozzle table.
If, after selecting the nozzle, burner type B45-2 has difficulty starting, this
may in some cases be due to the selection of nozzle made for the first stage.
Selecting a nozzle with a smaller effect in the first stage may solve the
problem.
3.6 Setting of brake plate and air flow
Prior to commissioning, the basic settings of the burner can be set in
accordance with the diagram. See under Basic settings. Note that it is simply
a matter of a basic setting that should be adjusted retrospectively once the
burner has started. You should then conduct a flue gas analysis and soot
quantity measurement.
3.7 Burner installation
3.7.1 Hole pattern
Make sure the hole pattern on the boiler is designed for burner flange.
Combustion
device
d 1d 2d 3
B45-2 Ø 135-(175) 200 M10-M12 Ø (195) 224-260
d1
d2
d3

15
Bentone B45-2 RME
For installers
A
A
3.8 Burner installation
1. Separate the burner body and the flange.
2. Remove the brake plate from the oil pipe.
3. Install the selected nozzle. (See Technical data)
4. Install the brake plate on the oil pipe
5. Remove the burner tube from the flange.
6. Install the flange with gasket on the boiler.
7. Install the burner tube on the flange. Make sure that the hole in the
front of the burner tube pipe is pointing down. This allows any drops of
oil to flow out.
8. Insulate between the burner and boiler door to reduce radiated heat.
9. Slide the burner body on the guides.
10. Lock the burner body using with the nut/nuts.
11. Connect the oil hoses to the pump.
12. Connect burner electrically.
3.9 Check oil line seals
Once the burner has been installed and commissioned, the seals of the
various coupling elements should be checked (A).
When a leak is detected, it is usually sufficient to tighten the coupling
element that is leaking.
!If the burner tube must be installed from the inside the boiler, it
must be possible to open the boiler or have a hinged flange that
is designed so that it can be reconnected with the burner tube
installed.
!Recommended thread sealer.
(Loctite 5188, 5400)

16 Bentone B45-2 RME
For installers
4. BASIC SETTINGS
4.1 Examples of basic setting
The nozzle effect is calculated for two-stage burners with two nozzles
(separately for each nozzle).
Nozzle selection in accordance with the table. (See technical data)
Nozzle selection is based on the selected pump pressure and the desired effect.
According to the nozzle table, this provides the following nozzle.
Burner output Max. 500 kW
Min. 200 kW
Estimated nozzle output min. load 200 kW/10,4 kWh/kg*= 20 kg/h
Estimated nozzle output max. load (500kW-200 kW)/10,4 kWh/kg*= 30 kg/h
Selected pump pressure 25 bar
Nozzle min. load 3.50 gph
Nozzle max. load 5.00 gph
Power in min. load 20.61 kg/h => 20.61 kg/h x 10 kWh/kg*
= 206 kW
Power in max. load 20.61 kg/h + 29.44 kg/h => 50.05 kg/h x
10 kWh/kg* = 501 kW
* ≈10,4 kwh/kg
Basic settings
The setting value for maximum load 500 kW and minimum load 200 kW
according to the basic settings tables. For the correct procedure when
implementing settings, see 4.2 Nozzle assembly control, brake plate B45-2
and 4.3 Air setting B45-2
Damper motor 2-stage (see technical data ...)
Effects and nozzle selection from example
Nozzle assembly Stage 2 = 25
Damper motor Closed = 0° Blue cam
Min. load = 45° Orange cam
MV max. load = 60° Black cam
Max. load = 90° Red cam
Black cam for MV (solenoid valve) max. load shall be placed between the
cams for min. and max. load. The positions of MV max. load are determined
by the boiler's characteristics when switching between stages. By default,
the black cam is placed between the orange and red cams.
Basic settings should only be seen as setting values to get burner to start
and establish a flame. Once the burner has started and established a flame,
it will be necessary to adjust the settings so that they are adapted to the
installation in question and the fuel used at the time.

17
Bentone B45-2 RME
For installers
0
5
10
15
20
25
30
80 120 160 200 240 280 320 360 400 440 480 520 560
0
20
40
60
80
100
120
80 120 160 200 240 280 320 360 400 440 480 520 560
4.2 Setting values for nozzle assembly B45-2 RME
Air, <° Nozzle assembly scale
4.3 Setting values for air damper B45-2 RME

18 Bentone B45-2 RME
For installers
4.4 Nozzle assembly control, brake
plate
The nozzle assembly control is used to achieve the most favourable pressure
drop across the brake plate as possible in the various power stages.
2 nozzles
The nozzle assembly control is manually adjusted in order to
achieve optimal pressure loss for good combustion. Brake plate
position is controlled primarily by the second stage effect.
Set the desired position on the scale (C) using the set screw (D) (left
turn reduces pressure loss, the brake plate is moved outward).
If pulsation occurs, the changed pressure drop over the brake plate
may result in the pulsation stopping
D
C

19
Bentone B45-2 RME
For installers
4.5 Air setting Damper motor
The damper motor turns the damper between three pre-set positions. These
positions are controlled in the motor by a microswitch, whose switching
modes is set using the colour-coded cams. There is also a black cam that
controls the engagement of solenoid valve 2 second stage oil.
When the amount of air needs to be changed:
Remove the hood from the damper motor and change the position of the
cams by turning them using the included tool. In order for the cam to be
inoperative while being turned, we recommend that you switch to a different
stage than the one that is to be adjusted and, after making the change,
returning to pre-check of the outcome.
Adjustment Stage 1
Set the operations switch to Stage 2 (II).
* Reduce the air volume:
Turn the orange cam towards 0°.
* Increase the air volume:
Turn the orange cam towards 90°.
Once the red or orange cam has been moved, check whether the black
cam must be changed. The black cam must be between the orange and red
cam.
Return the operations switch to Stage 1 and check combustion.

20 Bentone B45-2 RME
For installers
Stage 2 (red)
Stage 1 (orange)
Closed damper (blue)
Solenoid valve Stage 2
(black)
Releasing buttonN.B. The
upperposition is thestandard
position
Adjustment Stage 2
Set the operations switch to Stage 1 (I).
* Reduce the air volume:
Turn red cam towards 0°.
* Increase the air volume:
Turn red cam towards 90°.
Once the red or orange cam has been moved, check whether the black
cam must be changed. The black cam must be between the orange and red
cam.
Return the operations switch to Stage 2 and check combustion.
Closed
The blue cam is the limit position for fully closed damper and does not
normally need to be changed.
Disconnection
Damper motor can be disengaged using the white disconnection button.
This function facilitates the replacement of damper motor.
During disconnection. Press the white disconnection button and move
it outwards until it engaged in a milled groove.
During connection. Slide the white release button inwards and
release. Changing the position of the motor until
the gears engage with each other.