Bentone BG 450-2 Technical specifications

Providing sustainable energy solutions worldwide
178 057 76-7 P93783 2023-02-23
Installation- and maintenance instruction
BG 450-2 Biogas
LME22.232C2E
DMV-DLE 520/11
MVD 220/5
VPS 504
FRS 520
Translation of the original instructions.

2Bentone
example Beispielexempel
352011030141
Designation
Type
Model
Serial no.
Motor supply
Main supply
MADE IN SWEDEN BY
LIGHT OIL 35-90kW 1,25-6,0 cSt 7-14bar
BF 1 KS 76-24
BF 1
BF 1 KS 76-24
1234567
1~230V 1,0A 50Hz IP 20
Man.Year 2019
Cap. Min-Max
3
?
1
-sv
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QR-koden.
3. Skriv in brännarens
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ditt språk.
Detaljerad ecodesign
information kan laddas ner
på: www.bentone.com/
ecodesign.
-en
1. Manuals in other languages
2. www.bentone.com\
download or scan QR-code.
3. Enter the burner`s article
number on your data plate
(see picture) and select
language.
Detailed ecodesign
information can be
downloaded at:
www.bentone.com/
ecodesign.
-da
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2. www.bentone.com\
download eller scan
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-fr
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2. www.bentone.com\
download ou scannez le
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3. Saisir le numéro d’article
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-de
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download oder scannen Sie
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3. Geben Sie die
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Detaillierte Informationen
zum Ecodesign können unter
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heruntergeladen werden.
2

3Bentone
Table of contents
1. General Information............................................................4
1.1 Delivery inspection........................................................................ 4
1.2 Safety ............................................................................................... 4
1.3 What to do if you smell gas......................................................... 5
2. Technical data.......................................................................6
2.1 Dimensions BG 450-2 .................................................................. 6
2.2 Capacity range............................................................................... 7
2.3 Gas categories, approved gases................................................ 7
2.4 Technicalspecication ................................................................. 7
2.5 Workingeld.................................................................................. 7
2.6 Components................................................................................... 8
2.7 Skeleton diagram, biogas 2-stage burner............................... 9
2.8 Adjusting the gas train................................................................. 9
3. Electric equipment.............................................................10
3.1 Safety system .............................................................................. 10
3.2 Wiring diagram............................................................................ 10
3.3 Function ........................................................................................ 11
3.4 Control program at faults; fault mode indicator LME .... .... 12
4. Leakage control VPS 504 ..................................................14
4.1 Technical data .............................................................................. 14
4.2 Program sequence ..................................................................... 14
4.3 Electrical connection ................................................................. 15
5. Installation..........................................................................16
5.1 General instructions................................................................... 16
5.2 Instructions .................................................................................. 16
5.3 Inspection and maintenance.................................................... 16
5.4 Preparation for assembly ......................................................... 16
5.5 Gas supply .................................................................................... 16
5.6 Electric connection ..................................................................... 16
5.7 Handling and lifting instruction ............................................... 17
6. Mounting ............................................................................18
6.1 Gas nozzle..................................................................................... 19
6.2 De-aerating................................................................................... 20
6.3 Leakage control........................................................................... 20
6.4 Calculationofgasow.............................................................. 21
7. Settings ...............................................................................22
7.1 Setting the combustion assembly........................................... 22
7.2 Startup........................................................................................... 22
7.3 Control of combustion .............................................................. 22
7.4 Settingtheairpressureswitch ................................................ 23
7.5 Settingthegaspressureswitch,min...................................... 24
7.6 Settings Damper motor, 2-stage ............................................. 25
8. Gas pressure regulator .....................................................26
9. Double Solenoid Valve ......................................................28
10. Gas solenoid valve MVD 210/5 / MVD 215/5...................30
11. Service .................................................................................32
11.1 Burner Service Schedule, Gas .................................................. 32
11.2 Component replacement intervals.......................................... 32
11.3 Combustion device ..................................................................... 33
11.4 Air damper.................................................................................... 34
11.5 Replacement, Damper motor air............................................. 35
11.6 Fan ................................................................................................. 36
11.7 Vibrations...................................................................................... 37
11.8 Controlofamemonitoringandionizationcurrent ........... 38
11.9 Replacement of electrical components.................................. 40
12. Handing over of the installation ......................................41
13. Troubleshooting.................................................................42
14. Service- and inspection protocol .....................................44

4Bentone
172 515 01-2 2021-10-05
1. General Information
The burner may only be used for its intended purpose in accordance with the
product’s technical data.
We reserve the right to make design changes and cannot be held liable for any
misprints or typographical errors.
Modifying the design or using accessories or components that have not been
approved by Enertech in writing is strictly prohibited.
This Installation and Maintenance manual:
• is to be regarded as part of the burner and must always be kept near
the installation site.
• must be read prior to installation.
• is intended for use by authorised personnel.
1.1 Delivery inspection
• Make sure everything is delivered and the goods have not been
damaged during transit. Transport damage should be reported to the
shipping company.
• If something is wrong with a delivery, report it to the supplier.
1.2 Safety
- before installation:
• Installation and work on the burner and associated system
components may only be carried out by persons who have undergone
relevant training.
• The product is packaged to prevent damage from occurring when
handled – Handle the product with care! Lifting equipment must be
used to lift larger packages.
• The products must be transported/stored on a level surface in a dry
environment, max. 80% relative humidity, no condensation.
Temperature -20 to +60 °C.
- installation:
• The burner must be installed in accordance with local regulations for
fi re safety, electrical safety, and fuel distribution.
• The premises must comply with local regulations pertaining to use of
the burner and must have adequate air supply.
• The installation site must be free of chemicals.
• Fire extinguisher with Class BE recommended.
• Make sure when installing the burner that there is enough space to
service the burner.
• The electrical installation must be professionally carried out in
accordance with current mains electricity regulations and in a
professional manner.
• Make sure that the burner is suitable for the application (see Technical
Data).
• All components must be installed without being bent, twisted or
subjected to mechanical or thermal forces that affect components.

5Bentone
• Care must be taken by the installer to ensure that no electrical cables
or fuel lines are pinched or otherwise damaged during installation or
service.
• Sharp edges can occur on, for example:  ame tube, fan wheel and air
damper.
• The gas outlet from the pressure regulator must be confi gured in
accordance with applicable regulations and lead to a safe area.
- before  rst start:
• The burner must not be put into operation without proper safety and
protection devices.
• Permitted ambient temperature during operation -10 to +60 °C. Max.
80% relative humidity, no condensation.
• The surface temperature of the burner’s components may exceed
60 °C.
• Handle with caution – the burner has moving parts, and there is risk
of crushing injuries.
• Seal inspections must be performed during installation and servicing
to prevent leakage.
• Fitting and installation work has been completed and approved.
• Electrical installation has been correctly performed.
• Flue gas ducts and combustion air ducts are not blocked.
• All actuators and control and safety devices are in working order and
correctly set.
• If the boiler is equipped with an access hatch, this must be equipped
with a hatch opening switch connected to the burner’s safety system.
• When in operation, the burner’s noise level can exceed 85 dBA – use
hearing protection!
- Operation:
• Carry out all stipulated settings, service and inspection work within
the set time.
1.3 What to do if you smell gas
• Turn off the fuel supply.
• Turn off the device and remove the boiler from operation.
• Open windows and doors.
• Prevent open  ames or sparking, e.g. do not turn lights on or off, do
not use any electrical appliances or mobile phones.
• Evacuate the building.
• Notify the installer or gas supplier of the problem so that it can be
rectifi ed.

6Bentone
2. Technical data
The burner is intended for:
• Operation in installations according to EN 303 and EN 676.
Fuels:
• Natural gas H, E, L, LL.
• Dry biogas max 0.1 Vol% H2S and min 50% CH4.
2.1 Dimensions BG 450-2
172 535 70 2023-02-20
Length of
ame tube
Flame tube
measure A
Flame tube
measure B
Flame tube
measure C
256 226 ø159 ø162
356 326 ø159 ø162
456 426 ø159 ø162
** Min. recommended distance to oor.
K
L
M
2.1.1 Measurements for connection to the boiler
K L M
12 (Ø 210) Ø 255-290 ø170
I
øC
AG
E
D
øB
F
**J
160303-688
H
D E F G H I **J
528 255 152 227 316 491 200

7Bentone
2.3 Gas categories, approved gases
Components are approved for dry biogas with a maximum content of 0.1% H2S.
BG 450
G20 120 - 550 12.7 58.2 360
G25 120 - 550 14.8 67.7 360
G30 120 - 550 3.7 17.1 360
G31 120 - 550 4.9 22.5 360
160303-681-2
Capacity
kW
Gas quantity
at min. power
Nm3/h
Gas quantity
at max. power
Nm3/h
Max.
connection
pressure mbar
Min
connection
pressure mbar
See data plate.
Gas quantity and capacity vary according to grade of gas and connection pressure.
2.2 Capacity range
!Do not exceed working
eld.
2.5 Working eld
2.4 Technical specication
Measurements according to EN 15036-1:2006
Alt.1 The noise 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 burner.
BG 450-2
Main supply 230V, 1~, 5.6A, 50Hz, IP20
Max fuse rating 10A
NOX-class 3
Noise level 88dBA
-1
0
1
2
3
4
5
6
7
8
9
100 150 200 250 300 350 400 450 500 550 600
mbar
kW
120-550 kW
160303-250
Category Country of destination Supply pressure
II2R3R AT, BE, BG, CH, CY, CZ, 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
20 mbar
II2H3B/P AT, CH, CY, DK, FI, LT, RO, SE, SK 20 mbar
II2H3P GB, IE 20 mbar
II2L3B/P NL, RO 20 mbar
II2E3B/P PL 20 mbar
I2E(R)B BE 20 mbar
I3P BE 20 mbar
160302-239-3

8Bentone
2.6 Components
1. Flame tube
2. Brake plate
3. Nozzle
4. Inner assembly
5. Fixing  ange
6. Transformer
7. Burner control
8. Contactor
9. Connection, gas
10. Cover, inspection glass
11. Electrical connection
12. Fan wheel
13. Motor
14. Nozzle control
15. Damper motor
16. Reset button
17. Switch 0-I
18. Indication lamp, operation
19. Changeover switch, man-auto
20. Changeover switch, increase-
decrease
21. Air pressure switch
22. Air damper
23. Ball valve
24. Air intake
25. Gas pressure switch, min
26. Gas valve (MultiBloc)
27. Leakage contro VPS
28. Impulse line PL
29. Impulse line PF
30. Ignition electrode
31. Ionization electrode
1 3 4
10
12
5
160303-689
2 6 7 8
13
9
11
30 31
160303-682
16 15
21 22 262523 24
29
28
160303-690
19 201817
27
14

9Bentone
172 515 72 2018-02-19
2.7 Skeleton diagram, biogas 2-stage burner
VPS: Standard on burners with an output ≥ 1200 kW. Optional on burners with an output < 1200 kW.
1. Safety valve on-off
2. Gas pressure switch
3. Governor FRS shall be be
fitted with separate filter
4. Twin solenoid valve
5. Governor pressure
6. Valve proving system (VPS)
Pe Pressure before valve
Pa Pressure between valves
Adjusting points:
a. Main ow restrictor stage 2
(max load)
b. Gas pressure adjustment
c. Main ow restrictor stage
1(min load)
d. Hydraulic brake stage 1 to 2
2.8 Adjusting the gas train
The burner is test-run with propane prior to delivery.
During operation, the safety valve (1) must be fully open.
When adjusting Stage 1 on the burner, valve 2 must
be opened using the adjustment screw (c). When this is
screwed in, the ow of gas to the burner increases by
lifting the valve. During initial setting, the valve must have
been lifted by the adjustment screw after 1-2 turns. This
valve is always open and this opening is what determines
the minimum load.
When adjusting Stage 2 is done using the adjustment
screw (a) which controls the opening of valve 1.
At start-up, the safety valve opens and valve 1 gas ows
through valve 2, which was opened using adjustment
screw C. The burner now receives gas for the minimum
load. Increase the load to Stage 2 and set the output on
the burner.
Output is adjusted at Stage 2 by opening valve 1 using
adjustment screw A and adjusting the gas pressure on
pressure regulator screw B. The air damper must also
be adjusted to ensure that the correct volume of air is
obtained. Once the correct output and pressure are set in
Stage 2, move on to Stage 1. Stage 1 is now adjusted using
adjustment screw C to ensure that the correct volume
of gas is obtained. Adjust the air damper for correct
combustion.
a
b
4
1 c2 3
5
d
6
a
b
4
1 c 3Pa Pe
d

10 Bentone
E106019
3. Electric equipment
3.1 Safety system
The safety system (safety switch for hatches, doors, water level, pressure,
temperature and other safety devices) must be installed in the safety circuit in
accordance with current regulations for the system.
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.
3.2 Wiring diagram
172 615 38-2
Bn Brown
Bu Blue
Gn Green
Ye Yellow
Gn/Ye Green/Yellow
Bk Black
Gy Grey
Rd Red
Wh White
Og Orange
Vt Violet

11Bentone
3.2.1 Components
A1 Burner control
A3 Leakage control, VPS 504
F1 Operating fuse
H1 Lamp, low capacity
H2 Lamp, high capacity
H3 Alarm signal 230V
K1 Contactor
M1 Motor
M2 Damper Motor
P1 Time counter,
total operating time
P2 Time counter, high capacity,
total operating time
Q1 Signal amplifier AGQ
R1 UV-Detector
S1 Operating switch
S2 Operating switch, Stage 2
S3 Control thermostat
S4 Temperature limiter
S5 Safety switch for hinged door
S6 Control thermostat, Stage 2
S7 Main switch
S8 Air pressure switch
S9 Gas pressure switch, min
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
Y1 Solenoid valve 1
Y2 Solenoid valve 2
Y3 Safety solenoid valve
!Mains connection and
fuse in accordance with
local regulations.
3.2.2 Technical data
LME22.232C2E
3 s
20 s
2.5 s
< 3 s
< 1 s
< 1 s
5 µA
20 µA
160303-325
Preiginition time
Prepurge time
Postignition time
Safety lockout time
Reset time after lockout
Reaction time on  ame failure
Min. ionisation current at  ame
Max. ionisation current
3.3 Function
1. Operating switch ON-Thermostat ON-Gas pressure switch ON-Air
damper closed.
Check that the air pressure switch does not indicate fan pressure,
then the motor starts.
2. Damper motor opens.
The damper motor opens the damper to the maximum load position.
Check that the air pressure switch indicates sucient fan pressure.
3. Damper motor closes.
The damper motor closes to the minimum load position, then the
ignition spark is produced.
4. Main and safety valves open.
The gas ignites and the ionisation electrode indicates ame.
5. The safety time ends.
Ignition spark and safety time cease. If the spark is missing or it
disappears after this time limit, the gas burner control is blocked.
6. Operating position.
The burner is in operating mode and can now switch to the capacity
controlled by the controller.
7. Stop.
The burner operation can be stopped with the operating switch or the
thermostat.
If the gas burner control is blocked
The red light in the gas burner control comes on. The burner is restarted by
pressing the reset button.

12 Bentone
Light period
(waiting period ≥ 10 s)
Blinking
code Pause Blinking code
Press the reset
button > 3 s
3.4 Control program at faults; fault mode
indicator LME ....
3.4.1 Colour codes
3.4.2 Diagnosting 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:
3.4.3 Limiting of starting repetitions
LME 11... has a function with start repetition if the ame is not created at start
or disappears during operation.. LME 11... allows max. three repetitions during
continuous starting cycle.
Table colour codes for multi-coloured signal light (LED)
Status Colour codes Colours
Waiting period «tw», other waiting periods ○………………… O
Ignition phase, ignition controlled ●○●○●○●○●○● Blinking yellow
Normal operation □………………… Green
Operation, poor ame signal □○□○□○□○□○ Blinking green
Illegal ame signal during start-up □▲□▲□▲□▲□▲ Green-Red
Undervoltage ●▲●▲●▲●▲●▲ Yellow-Red
Fault, alarm ▲………………… Red
Blinking code for fault codes ▲○ ▲○ ▲○ ▲○ Blinking red
Interface diagnostics ▲▲▲▲▲▲▲▲ Red icking
…… Continuous
○Off
▲Red
●Yellow
□Green

13Bentone
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 reset button 0.5...3 s.
3.4.4 Interface diagnostics
To change to interface mode, press and hold the reset button longer than 3 s.
To go back to the normal position, press and hold the reset button longer than
3 s. If the gas burner control is in the alarm position, it is reset by pressing the
reset button 0.5...3 s.
3.4.5 Alarm code table
Red blinking code on
signal lamp (LED)
Possible causes
Blinking 2 x
••
No ame creation at End of “TSA”
–defective or fouled ame monitoring.
–defective or fouled fuel valves.
–poor burner setting.
–defective firing device.
Blinking 3 x
•••
“LP” defective
–No air pressure switch signal after “t10”.
–“LP” is welded in open position.
Blinking 4 x
••••
Illegal ame signal during start-up.
Blinking 5 x
•••••
Time out “LP”
–“LP” is welded in open position.
Blinking 6 x
••••••
Free
Blinking 7 x
•••••••
Too many ame disappearances during operation.
–poor burner setting.
–defective or fouled fuel valves.
–defective or fouled ame 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.

14 Bentone
172 615 10 2018-01-15
4. Leakage control VPS 504
4.1 Technical data
Test volume ≤4,0 l
Pressurre increase using motor
pumps
≈20 mbar
Backup (customer supply) 10A fast or 6.3A slow
Fuse integrated in housing,
replaceable
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
Dependent on test volume and input
pressure.
Sensitivity limit 50 l/h
Max. number of test cycles 20 /h
4.2 Program sequence
Idle state: Valves 1 and 2 are closed. Pressure buildup: 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 diffferential 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 dependent 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.
Pressure buildup OperationProgrammer Idle state

15Bentone
4.2.1 Program sequende schedule
Controller
Pump motor
Solenoid valve
Differential pressure sensor
Release signal
Controller
Pump motor
Solenoid valve
Differential pressure sensor
Release signal
Controller
Pump motor
Solenoid valve
Differential pressure sensor
Release signal
Fault signal
VPS 504 "Not TIGHT"
VPS 504 "TIGHT"=41
VPS 504 "TÄTHETSTEST"=0,31
VPS 504 "TIGHT" TEST=41
VPS 504 "TIGHT" =0,31
4.3 Electrical connection
The VPS 504 is connected in series between the temperature regulator and the
control box via a 7-pin plug connector.
See wiring diagram!
Plug
Untight
Tight
Outlet
Lock-out Operation
Operating voltage
~(AC) 230V 50Hz

16 Bentone
172 535 09-2
5. Installation
5.1 General instructions
Installation must be carried out in accordance with current regulations and
instructions.
The supplier/installer of the facility is obliged to familiarize himself with
all regulations so that the installation meets the requirements of the local
authorities.
Installation, assembly and settings must be performed to obtain the best
possible function. Only gas intended for the gas burner may be used.
5.2 Instructions
It is the installer’s responsibility to instruct the user in detail in the functions of
the gas burner and the entire system.
5.3 Inspection and maintenance
The system must be 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.
5.4 Preparation for assembly
Check that the burner’s dimensions and capacity range match the current
boiler. The power information on the type plate refers to the burner model’s
min. and max. effect.
5.5 Gas supply
In order to obtain good operational safety, it is important that the installation
of the gas distribution system is carried out correctly, considering the
following:
• Check that the burner is approved for the gas quality of the
installation.
• Check that the burner gas components are approved for the specified
gas pressure, see type plate.
• Installation must be carried out in accordance with current standards.
• Pipe lines should be assembled so that service can easily be
performed on the boiler and burner.
• Pipe lines should be assembled so that any contaminants do not come
into contact with the gas components.
5.6 Electric connection
• Before work on the electrical connection, the current must be
disconnected so that the installation is isolated.
• Connection must be done in accordance with the applicable
regulations.
• Connection must conform to the wiring diagram.
!If any electrical connection other than that recommended
by Enertech is used, there is a risk of property damage and
personal injury.

17Bentone
172 515 29 2018-02-21
5.7 Handling and lifting instruction
iThe lifting aid are available as
accessories.

18 Bentone
172 515 30-2 2022-09-21
6. Mounting
Mount the fi xing  ange with  ame tube, nozzle assembly and gas fi tting on the
boiler. If new fi xing holes need to be drilled, use the fi xing  ange as a template
and install with M8-M10 screws (A).
Separate the fi xing  ange from the fan housing as follows:
1. Remove cover of fan housing (A), disconnect ignition and ionizing
cables and the control arm (B) from nozzle assembly.
2. Disconnect the electrical cable to the gas valve.
3. Loosen nuts on both sides of the fi xing  ange.
4. Loosen end stop (C) for guides.
5. Pull the fi xing  ange with  ame tube, nozzle assembly and gas fi tting
out of the fan housing.
6. Check that the ignition electrodes are correctly set, see chapter Gas
nozzle.
7. Fit the enclosed gasket to the  ame tube.
8. Screw the fi xing  ange and the enclosed gasket onto the boiler, lift
the fan housing onto the guides and mount in reverse order.
9. Connect the gas line, connect the supply cable, operating and safety
circuits.
!Before obtaining access to electrical and fuel line components
all supply circuits must be disconnected.
B
C
A

19Bentone
6.1 Gas nozzle
Check that the ignition electrodes are correctly set before mounting on the
boiler.
45°
Natural gas Propane
Biogas (UV detector)

20 Bentone
6.2 De-aerating
De-aerating the gas line by closing the tap to the gas connection and
unscrewing the screw on the measuring nipple for the connection pressure.
Connect a plastic hose, open the tap and drain the gas in a safe place. When
the de-aerating is completed, be sure to refit the screw on the measuring
nipple.
6.3 Leakage control
When checking for leakage, the solenoid valve must be closed. A pressure
gauge is connected to the measuring nipple ”Pa”, see picture. The test
pressure in the system must not be higher than max. connection pressure,
see data plate. If leaks are found during measurement, locate the source
using soapy water or leak detection spray. After sealing: check the leakage of
the gas fixture again.
!Check for leaks in the gas line.
Pa