Bentone BG550 Series Technical specifications

Providing sustainable energy solutions worldwide
178 015 82-2 2016-12–07
Installation- and maintenance instruction
BG 550,BG 650
Model 2, M
BG 550 LN

2
Contents
Description _____________________________________________________________ 5
Warning __________________________________________________________________________________________ 5
2-stage ___________________________________________________________________________________________ 6
Modulating________________________________________________________________________________________ 7
TECHNICAL DATA _______________________________________________________ 8
Dimension ________________________________________________________________________________________ 8
Output range______________________________________________________________________________________ 9
Working field _____________________________________________________________________________________ 10
SKELETON DIAGRAMS _________________________________________________ 11
MOUNTING OF THE BURNER ___________________________________________ 12
Inspection of gas assembly________________________________________________________________________ 12
Adjustment of the positiion of the shrouded disc in the blast tube _____________________________________ 12
ELECTRIC EQUIPMENT ________________________________________________ 13
Wiring diagram LME22 (BG550/BG650) 2-Stage _____________________________________________________ 13
List of components _______________________________________________________________________________ 14
Function LME22 __________________________________________________________________________________ 14
Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating_________________________________________ 15
List of components _______________________________________________________________________________ 16
Function LME22 __________________________________________________________________________________ 16
Control diagnosis under fault conditions and lockout indicatio ________________________________________ 17
Gas burner control: LMG ... _______________________________________________________________________ 17
MEASURES AND CHECKS BEFORE START UP ___________________________ 18
2-Stage or modulating burners_____________________________________________________________________ 18
Inner assembly ___________________________________________________________________________________ 19
Inner assembly BG 550LN _________________________________________________________________________ 20
DETERMINATION OF GAS VOLUME FOR THE INSTALLATION ______________ 21
GAS SOLENOID VALVE DUNGS MVD ____________________________________ 22
OPERATION AND ASSEMBLY INSTRUCTIONS ____________________________ 23
Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11 _________________________________________ 23
DMV 525/11______________________________________________________________________________________ 24
Gas pressure regulator Type FRS___________________________________________________________________ 26
MULTI-BLOC, MB-ZRDLE 405-420 BO1 __________________________________ 28
Flow adjustment 2-stage design ___________________________________________________________________ 29
MULTI-BLOC, MB-VEF 412-425 B01 _____________________________________ 30
view_____________________________________________________________________________________________ 30
MULTI-BLOC, MB VEF 412-425 B01______________________________________ 31
Technical data____________________________________________________________________________________ 31
Mounting instruction-impulse lines _________________________________________________________________ 31
Adjustment possibilities ___________________________________________________________________________ 31
MULTI-BLOCK VDG20...SKP75/15 _______________________________________ 32
Technical data____________________________________________________________________________________ 33
Mounting of impulse lines _________________________________________________________________________ 33

3
DAMPER MOTOR 2- STAGE_____________________________________________ 34
Air adjustment____________________________________________________________________________________ 34
Releasing button _________________________________________________________________________________ 34
DAMPER MOTOR MODULATING ________________________________________ 35
Air adjustment____________________________________________________________________________________ 35
Releasing button _________________________________________________________________________________ 35
GENERAL INSTUCTION_________________________________________________ 36
Adjustment of burner _____________________________________________________________________________ 36
Service __________________________________________________________________________________________ 36
Flame monitoring and measurement of ionisation current_____________________________________________ 37
UV- detektor _____________________________________________________________________________________ 38
Adjustment of air pressure switch __________________________________________________________________ 39
Adjustment of min. gas pressure switch ____________________________________________________________ 39
Adjustment of max. gas pressure switch ____________________________________________________________ 39
LEAKAGE CONTROL, DUNGS VPS 504 SERIE 2___________________________ 40
Technical data____________________________________________________________________________________ 40
Programme sequence_____________________________________________________________________________ 40
Program sequende schedule ______________________________________________________________________ 41
Electrical connection VPS 504 Series 2 _____________________________________________________________ 41
HANDING OVER OF THE INSTALLATION _________________________________ 42
Fault location, functional troubles __________________________________________________________________ 42
DECLARATION OF CONFORMITY _______________________________________ 43
FAULT LOCATION GUIDE _______________________________________________ 44
Gas burner_______________________________________________________________________________________ 44

4

5
Description
Warning
DESCRIPTION
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 qualifi ed 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 re-
gulations 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 fi tter is to ensure that the boiler room is supplied with fresh air
ventilation that is suffi cient 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.
- 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, fi re 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.
- 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.
- 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.

!
Warning
Safety directions
Acceptance inspection
Preparations for installation

6
2-stage
Components
DESCRIPTION
2-Stage
1. Flame cone
2. Connection fl ange
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 fi ttings
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

7
Modulating
Components
DESCRIPTION
Modulating
1. Flame cone
2. Connection fl ange
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 fi ttings
12. Ignition transformer
13. Air damper
14. Air damper motor
15. Air pressure switch
16. Fuse holder
17. Change-over switch
increase-decrease
18. Change-over switch
manually-automatically
19. Indicating lamp
20. Switch 0-l
21. Time meter
23. Contactor with thermal
overload protection
24. Control box
25. Gas train
26. MultiBloc

8
TECHNICAL DATA
Dimension
Length of
burner tube
BG550
Flange
Measure B
Burner tube
Measure C
Burner tube
Measure D
Standard 1 256 226 162 162
Standard 2 356 326 162 162
Standard 3 456 426 162 162
Length of
burner tube
BG550LN
Flange
Measure B
Burner tube
Measure C
Burner tube
Measure D
Standard 1 252 222 162 162
Standard 2 352 322 162 162
Standard 3 452 422 162 162
Length of
burner tube
BG650
Flange
Measure B
Burner tube
Measure C
Burner tube
Measure D
Standard 1 316 286 185 162
Standard 2 416 386 185 162
Standard 3 516 486 185 162
TECHNICAL DATA
Type designation BG550/BG550LN/BG650
Dimensions
* The above dimensions are max. measurements. Depending on the
components used, the measurements may vary.
D
(ø210)ø254-280
ø190
M12
660*
400
658
B
C

290*
690*
321
 


  



321 






9
Output range
Capacity Gas volume at a min. Gas volume at a max Max. inlet Rated inlet pressures
kW output Nm3/h 1) output Nm3/h 1) pressure mbar 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
Output range
TECHNICAL DATA
1) Calorifi c value: kWh/m315°C 1013.25 mbar (according to EN676)
2) Dimension and capacity depending on gas quality and available pressure
Type kWh/m3 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
Connection 2) Motor Ignition transformer
BG550/BG550LN
Natural gas LPG 1
1/2”-2”
0,75 kW
230/400V 50 Hz
3,1/1,8A
Primary 230 V,
0,25A 50-60Hz 60VA
Sec. 11kV Ampl
50 mA rms
33% ED in 3 min
BG650
Natural gas LPG 1
1/2”-2”
1,5 kW
230/400V 50 Hz
5,7/3,3A
Primary 230 V,
0,25A 50-60Hz 60VA
Sec. 11kV Ampl
50 mA rms
33% ED in 3 min

10
Working field
TECHNICAL DATA
Working fi eld
BG550
140-640 kW
BG550
BG550 (G25)
Measured (test)
BG550LN
140-620 kW
BG550LN
Measured (test)
BG650
200-1125 kW
BG650
Measured (test)
Unbroken line is the approved wor-
king fi eld as per EN 676. Capacity kW
200 300 400 500 600 700 800
-2
0
6
8
10
12
14
4
2
Pressure in fi re place
16
900 1000 1100 1200
Pressure in fi re place
Capacity kW
100 200 300 400 500 600 700
-2
0
6
8
10
12
14
4
2
Capacity kW
2
Pressure in fi re place
100 200 300 400 500 600 700
-2
0
6
8
10
12
14
4
BG550 LPG 60Hz
150-820 kW
Pressure in fi re place
Capacity kW

11
SKELETON DIAGRAMS
SKELETON DIAGRAMS
2-stage or modulating burners
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.

!
Incorporated in the MultiBloc

12
MOUNTING OF THE BURNER
Inspection of gas assembly
Adjustment of the positiion of the shrouded disc in the blast tube
MOUNTING OF THE BURNER
Fit the burner to the boiler by means of 4 bolts M12. For fl ange and bolt
dimensions see technical data.
If for some reason you want to separate the burner from the gas fl ange
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 fl ange have been fi tted to the boiler
it is easy to lift up the burner to where it belongs.
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 fl ange.
- Withdraw the gas assembly.
Ensure that the O-ring between the gas assembly and the gas fl ange will
be in the correct position when the gas assembly is fi tted again.
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.
NOTE!
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).
Service position

13
ELECTRIC EQUIPMENT
Wiring diagram LME22 (BG550/BG650) 2-Stage
172 445 12 16-01
ELECTRIC EQUIPMENT
Wiring diagram LME22 (BG550/BG650) 2-Stage
1(5)

14
List of components
Function LME22
172 445 12 16-01
ELECTRIC EQUIPMENT
Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating
2(5)

15
Wiring diagram LME22 (BG550/BG550LN/BG650) Modulating
172 445 12 16-01
ELECTRIC EQUIPMENT
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
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.
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 suffi cient 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 fl ame.
5. The safety time expires.
The ignition spark goes out. The safety time expires. If there is no fl ame
or if for some reason the fl ame 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.
3(5)
A1 Gas burner control
A2 Power control
B1 Ionization electrode
F1 Operation fuse
F2 Operation fuse
F3 Operation fuse
H1 Lamp, low capacity
H2 Lamp, high capacity (optional)
K1 Motor contactor with thermal overload protector
M1 Burner motor
M2 Damper motor
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
S9 Gas pressure switch
S11 Change-over switch, Aut.-man.
S12 Change-over switch, Increase Reduce
S15 Control thermostat, 3-pole (only for 2-stage
sliding)
S16 High pressure switch
S20 Main switch
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
X15 Plug-in contact, power controller, burner
X16 Plug-in contact, power controller
Y1 Gas solenoid valve 1
Y2 Gas solenoid valve 2
Y3 Safety solenoid valve
List of components LME22 (BG550/BG650)

16
List of components
Function LME22
172 445 12 16-01
ELECTRICAL EQUIPMENT
Control program when disruption; disruption display
Gas burner control: LME....
Diagnostics alarm trigger
Colour codes
Limit on start attempts
LME 11 … limits the number of start attempts if the fl ame 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.
The red alarm signal lamp lights continuously after the alarm is disconnected.
Diagnostics for alarm triggers can be read as specifi ed by the following sequence:
Colour code table for multi-coloured signal lamps (Light diodes)
Status Colour codes Colours
Waiting time «tw», other waiting times Off
Ignition phase, ignition checked Flashing yellow
Normal operation Green
Operation, poor fl ame signal Flashing green
Prohibited fl ame signal during start up Green-Red
Undervoltage Yellow-Red
Disruption, alarm Red
Flashing code for fault codes Flashing red
Interface diagnostics Red fl ickering
Continuous
Off
Red
Yellow
Green
Light period (waiting time 10 s)
AL
FS
Flash code Pause Flash code
Approx. 3 s
lights red Press the reset
button > 3 s
4(5)
to normal mode, hold the reset button depressed for more than 3 s. If the fi ring unit is
Connecting signal amplifi er
Red fl ashing code on Possible causes
Flashing 2 x No fl ame at End of «TSA»
•• - Defective or obscured fl ame monitor
Flashing 4 x Prohibited fl ame signal during start up
Flashing 7 x Too many loss of fl ame during operation
- Defective or obscured fl ame monitor

17
Control diagnosis under fault conditions and lockout indicatio
Gas burner control: LMG ...
172 445 12 16-01
Alarm control table
ELECTRICAL EQUIPMENT
Control program when disruption; disruption display
Gas burner control: LME....
During alarm trigger diagnostics, control outputs are to be disconnected from all power.
- The burner is disconnected
- Exception, the «AL» alarm signal at connection block 10
The burner is only to be reconnected after it is reset
- Press the reset button 0.5...3 s.
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 fi ring unit is
in the alarm mode, it is reset by pressing the reset button 0.5...3 s.
Interface diagnostics
Connecting signal amplifi er
Red fl ashing code on Possible causes
signal lamp (LED)
Flashing 2 x No fl ame at End of «TSA»
•• - Defective or obscured fl ame monitor
- Defective or obscured fuel valves
- Poor burner installation
- Defective ignition unit
Flashing 3 x «LP» defective
••• - No air monitor signal after «t10»
- «LP» is welded in the open position
Flashing 4 x Prohibited fl ame signal during start up
••••
Flashing 5 x Time out «LP»
••••• - «LP» is welded in the closed position
Flashing 6 x Free
••••••
Flashing 7 x Too many loss of fl ame during operation
••••••• - Poor burner installation
- Defective or obscured fuel valves
- Defective or obscured fl ame monitor
Flashing 8 x Free
••••••••
Flashing 9 x Free
•••••••••
Flashing 10 x Connection fault or internal fault,
•••••••••• outgoing contacts or other fault
Flashing 14 x CPI contact not closed
••••••••••
••••
A1 = LME
GP
R/W
L N
br bl rt sw
sw rtQ1 = AGQ 3...
QRA
11112 2
5(5)

18
MEASURES AND CHECKS BEFORE START UP
2-Stage or modulating burners
172 205 34-1 12-01
MEASURES AND CHECKS BEFORE START-UP
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 fi g.).
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.
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 pre-ignition period starts (0,5-2,5 sec. depending on the
design of the gas control). The gas valve is energized and opens and fl ame
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 fi nished.
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 pre-purging 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.
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 fi g. 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.
Gas train Multibloc

19
Inner assembly
MEASURES AND CHECKS BEFORE START-UP
Inner assembly
Biogas ((UV-detector)
Inner assembly
Town gas
Inner assembly
Natural gas, LPG
172 155 13 04-01

20
Inner assembly BG 550LN
MEASURES AND CHECKS BEFORE START-UP
Inner assembly BG 550LN
A = 10 mm Front edge Brake plate
B = 3 mm
172 155 14 04-01
A = Position Ionisation detector
B = Position Ignition electrode
A B
A
B