Bentone STG 146 User manual

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178 008 26-2 2016-02-01
Installation- and maintenance instruction
STG 146

172 205 80 07-01
DESCRIPTION
Components
1. Reset button
2. Gas burner control
3. Transformer
4. Fixing ange
5. Connection MultiBloc
6. Ionisation electrode
7. Inner assembly
8. Brake plate
9. Burner tube
10. Ignition electrode
11. Air damper
12. Front part fan housing
13. Rear part fan housing
14. Air pressure switch
15. Shielding arrangement
fan housing
16. Fan wheel
17. Air adjustment
18. Inner assembly adjustment
19. Motor
20. Electric connection
21. MultiBloc

TECHNICAL DATA
172 215 43 07-01
Capacity chart according
to EN 676
1) Caloric value:
Natural gas 10 kWh/Nm3
2) Depending on gas quality and
available pressure
Out range
The above dimensions are max. measurements. Depending on the compo-
nents used, the measurements may vary.
Type Capacity Nm3/h at min.
output of burner 1)
Nm3/h at max
output of burner 1)
Rated inlet pressures
mbar
STG 146 Natural gas
23,5-65
Natural gas
2,35
Natural gas
6,5
Natural gas
20
Connection 2) Motor Ignition transformer
Natural gas
½"
220/240V,2800r/m,
50Hz, 70-90 W, 0,65A
Electronic
230/11000V, Ampl.
Length of
burner tube
Flange A
Measure A
Standard 108 81
Long design 140 113
Type designation STG 146 Burner head 1
in accordance with RAL UZ 80
Dimensions
A
ø 89
20261192
139
290
244
10
145,0
23,5
109,5

TECHNICAL DATA
172 215 44 07-01
Capacity chart according to
EN 676
1) Caloric value:
Natural gas 10 kWh/Nm3
LPG 26 kWh/Nm3
2) Depending on gas quality and
available pressure
Out range
The above dimensions are max. measurements. Depending on the compo-
nents used, the measurements may vary.
Length of
burner tube
Flange A
Measure A
Standard 145 121,5
Long design 245 221,5
Type Capacity Nm3/h at min.
output of burner 1)
Nm3/h at max
output of burner 1)
Rated inlet pressures
mbar
STG 146 Natural gas
41-133
LPG
47-144
Natural gas
4,1
LPG
1,8
Natural gas
13,3
LPG
5,5
Natural gas
20
LPG
30
Connection 2) Motor Ignition transformer
Natural gas, LPG
½"
220/240V,2800r/m,
50Hz, 70-90 W, 0,65A
Electronic
230/11000V, Ampl.
Type designation STG 146
Burner head 2
Dimensions
LPGNatural gas
A
ø 89
20261
192
139
290
244
10
145,0
23,5
109,5

172 415 11 07-01
SKELETON DIAGRAMS
1. Ball valve
2. Filter
3. Governor
4. Pressure gauge with shut-off
cock
5a. Gas pressure switch, mini
5b. Gas pressure switch, maxi
Incorporated in the Multibloc
6a. Main valve
6b. Safety valve
1)7. Valve proving system
9. Air pressure switch
10. Gas burner control
Pos. 5b, 7: Components not required
according to EN 676.
1) Required over 1200 kW according
to EN 676.
When Bio gas is used, Bentone shall always be contacted.
Incorporated in the MultiBloc

The gas armature is from the factory
mounted in a horizontal position. The
connection of the incoming gas line
is made from the right side. Should
it for some reason be necessary to
make the gas connection in any other
direction the armature can be turned
180° to the left and upwards. It is also
possible to connect the gas to the
multi-bloc straight backwards. The
armature can also be extended so
that it comes outside the boiler if there
is not enough room. Ensure that the
distance between the inner asembly
and the gas armature is not too long.
If the distance is too long there will not
be time for the burner to light.
Fit the enclosed ange and gasket to
the boiler.If new xing holes must be
drilled, use the xing ange as a pat-
tern. Use xing screws M8-M10.
Push the burner into the ange and
x it by means of the screws in the
ange. Ensure that the burner is tted
absolutely straight.
MOUNTING ON THE BOILER
Installation example
Connect the gas to the burner by
means of the ball valve. To facilitate
service a union nut is used between
the gas supply system and the ball
valve. Ensure that the union nut,
ball valve and tubing make it easy
to remove the burner for inspection
and service.
172 205 81 07-01

172 425 16 08-01
ELECTRIC EQUIPMENT
Component list
A1 Gas burner control
A2 Twin thermostat
B1 Ionization electrode
F1 Fuse
H1 Alarm, 230 V
If there is no plug-in contact (X2) on the
boiler, connect to the contact enclosed.
In case the twin thermostat is in series
on incoming phase L1,
a loop between the terminals T1 and
T2 is necessary.
Mains connection in accordance with local regulations.
M1 Burner motor
S3 Main switch
S8 Air pressure switch
S9 Gas pressure switch
T1 Ignition transformer
X1 Plug-in contact, burner
X2 Plug-in contact, boiler
Y1 Gas solenoid valve
Gas burner control: LGB21/LMG21/LME11/LME21
Wiring diagram
1(5)

172 425 16 08-01
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
Gas burner control: LGB
Lock-out and Control Programme Indication
The position of the cam can be read through the sight-glass. Under fault condition
the programme is stopped and thus also the lock-out indicator. The symbol visible on
the cam indicates both the position in the programme run and the type of fault. The
symbols are explained below:
No start because the control loop is interrupted
Waiting for the pre-purge to start
Air damper open (LGB22)
Fault condition due to absence of air pressure signal (LGB21),
air damper not open (LGB22)
Pre-purge period
Fuel release (LGB22)
Fault condition because no ame signal available after elapse of the 1st
safety time
Release of the 2nd fuel valve (LGB21)
Release of the load controller LR (LGB22)
Partial or full load operation (or return to the operating position)
Control Programme in Case of Faults
Basically, the fuel supply is stopped immediately in the case of any fault. If the fault
condition occurs at a time between start and pre-ignition, which is not indicated by
symbols, the cause is usually a switch-off by the air pressure switch LP or a too early,
i.e. faulty, ame signal.
• After supply voltage failure: Start-up repetition with unabridged programme.
• If premature ame signal at start of pre-purge time: Immediate lock-out.
• If contacts of air pressure switch LP have welded during tw: No start.
• If no air pressure signal: Lock-out when t10 has elapsed.
• If air pressure failure after elapse of t10: Immediate lock-out.
• If burner does not ignite: Lock-out when safety time t2 has elapsed.
• If ame is lost during operation: Immediate lock-out.
• For ignition spark proving with QRE: If no ignition spark signal, the valves remain
closed and there is lock-out when t2 has elapsed.
Resetting the burner controls
The controls can be reset immediately after any fault condition. The programme re-
verts to its start position and programmes the controls for restarting the burners.
Connecting signal amplier
2(5)
A1 = LGB
GP
R/W
L N
br bl rt sw
sw rtQ1 = AGQ 1...
QRA
11112 2

172 425 16 08-01
3(5)
During the time the cause
of the fault is diagnosed,
the control outputs are
deactivated.
– The burner remains shut
down
– Exception: fault status
signal «AL» at terminal 10
The burner is switched on
only after a reset is made.
– Press lockout reset but-
ton for 0.5...3 seconds
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
Gas burner control: LMG ...
Diagnosis of cause of fault
After lockout, the red fault LED is steady on. For reading the cause of fault, refer to
the blink code given in the following table:
Connecting signal amplier
Error code table
Blink code Possible cause
2 x
••
• No establishment of ame at the end of «TSA»
– Fault or soiled detector electrode
– Fault or soiled fuel valves
– Poor adjustment of burner
3 x
•••
• Air pressure monitor does not close
– «LP» faulty
– «LP» incorrectly adjusted
– Fan motor does not run
4 x
••••
• Air pressure monitor does not open or extraneous light on
burner startup
– «LP» faulty
– «LP» incorrectly adjusted
5 x
•••••
• Extraneous light during pre-purging
– Or internal device fault
7 x
•••••••
• Loss of ame during operation
– Poor adjustment of burner
– Faulty or soiled fuel valves
– Short-circuit between detector electrode and ground
8...17 x
••••••••
.................
••••••••••
•••••••
• Free
18 x
••••••••••
••••••••
• Air pressure monitor opens during pre-purging or operation
– «LP» correctly adjusted
– Four times loss of ame during operation (LMG25)
19 x
••••••••••
•••••••••
• Faulty output contact
– Wiring error
– External power supply on output terminal
20 x
••••••••••
••••••••••
• Internal device fault
A1 = LMG
GP
R/W
L N
br bl rt sw
sw rtQ1 = AGQ 2...
QRA
11112 2
AL
FS
Red LED on LED on (waiting time≥10 s)
Fault
Press lockout reset button
for > 3 s Blink code Off Blink code
Approx.
3 s

172 425 16 08-01
4(5)
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
Gas burner control: LME....
Colour codes
Diagnostics alarm trigger
The red alarm signal lamp lights continuously after the alarm is disconnected.
Diagnostics for alarm triggers can be read as specied by the following sequence:
Limit on start attempts
LME 11 … limits the number of start attempts if the 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.
Continuous
Off
Red
Yellow
Green
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 ame signal □○□○□○□○□○ Flashing green
Prohibited ame signal during start up □▲□▲□▲□▲□▲ Green-Red
Undervoltage ●▲●▲●▲●▲●▲ Yellow-Red
Disruption, alarm ▲………………… Red
Flashing code for fault codes ▲○ ▲○ ▲○ ▲○ Flashing red
Interface diagnostics ▲▲▲▲▲▲▲▲ Red ickering
Light period (waiting time ≥ 10 s)
AL
FS
Flash code Pause Flash code
Approx. 3 s
lights red Press the reset
button > 3 s

172 425 16 08-01
5(5)
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
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
Interface diagnostics
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 ring
unit is in the alarm mode, it is reset by pressing the reset button 0.5...3 s.
Connecting signal amplier
Alarm control table
Red ashing code
on signal lamp
(LED)
Possible causes
Flashing 2 x
••
• No ame at End of «TSA»
– Defective or obscured 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 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 ame during operation
– Poor burner installation
– Defective or obscured fuel valves
– Defective or obscured ame monitor
Flashing 8 x
••••••••
Free
Flashing 9 x
•••••••••
Free
Flashing 10 x
••••••••••
Connections 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

MEASURES AND CHECKS BEFORE START-UP
172 205 82 07-01
Leakage control
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/mainte-
nance.
Inner assembly
Ensure that the ignition and ionisation
electrodes are correctly adjusted. The
sketch shows the correct measure-
ments.
Gas quality
Ensure that the burner head is meant
for the gas quality to be used (see
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. After
having vented the gas line tighten the
screw again.
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 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.
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 (30-50 sec.). At the end of this
period the pre-ignition period starts
(0,5-3 sec. dependent on the design
of the gas control). The gas valve is
energized and opens.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 nished.
Inner assembly
Town gas
Inner assembly
Natural, LPG

MEASURES AND CHECKS BEFORE START-UP
172 205 77 07-01
Inner assembly
Town gas not CE approved
Inner assembly
Natural gas, LPG
Inner assembly
Biogas (UV-detector)
Natural gasLPG
2,5
8
2,5
8

172 205 16 07-01
If the barometer height, pressure and temperature of the gas deviate very much from the normal values this must
be taken into account as follows:
f = 273+t . 1013,25
273 B+Pu
t = Temperature of the gas at the gas meter (15°C)
B = Barometer height (945 mbar)
Pu= Pressure of the gas at the gas meter (15,0 mbar)
f = 273+15 . 1013,25
273 945+15
f = 11,1
The gas volume read on the gas meter actually reads 1,11 .12,9 = 14,4 m3/h.
Net caloric value
Gas quality kWh/Nm3kJ/Nm3kcal/Nm3
Natural gas 10,3 37 144 8 865
Propane 26,0 93 647 22 350
Butane 34,3 123 571 29 492
Town gas 4,9 17 653 4 213
Bio gas 7,0 25 219 6 019
V = Gas volume Nm3/h
Q = Boiler output 120 kW
Hu=Caloric value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm3
η=Expected efciency 90%
Ex. A v= Q .3 600 =120 .3 600 ≈12,9 Nm3/h
Hu
· η37 144 .0,90
Ex. B v= 120 ≈12,9 Nm3/h
10,3 · 0,90
Example how to calculate the gas volume (natural gas)
DETERMINATION OF GAS VOLUME FOR THE INSTALLATION
Specications on natural gas, town
gas and bio gas vary. For more exact
information please contact the gas
distributor.

ADJUSTMENT OF MULTI-BLOC, MB-DLE 405-407
Flow adjustment
Loosen the fixing screw a. Turn the
hydraulic device b:
to the right = the gas flow is reduced
to the left = the gas flow is increased
Do not forget to tighten the fixing screw
again.
The flow adjustment can also be made
by means of the governor. Adjust the
outlet pressure to a value giving the
desired gas flow on the fully open valve.
At small capacities (gas flows) it is also
necessary to adjust 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 cover c.
Turn the adjustment knob d (use the
protective cover as a tool) to the desired
start gas flow.
Turn to the right = the start gas flow is
reduced
Turn to the left = the start gas flow is
increased
Max. inlet pressure: 360 mbar. Adjustable
governor pressure:
405 - 412 S50 = 4 - 50 mbar
415 - 420 S20 = 4 - 20 mbar
415 - 420 S50 = 20 - 50 mbar
Solenoid valve: Slow opening valves with
adjustable start load and max. flow.
172 505 38 16-02
16
2 3 4
5
6
7
8
9
10
11
12
13
14
15
1
1. Electrical connection for valves (DIN
EN 175 301-803 connector)
2. Operation display V1, V2 (optional)
3. Lead seal eye, Gouvernor
adjustment
4. Setting cap
5. Hydraulic brake / setting plate
6. Solenoid
7. Test point connection G 1/8
possible
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 pressure
switch (DIN EN 175 301-803
connector
Adjustment of start gas flow
d
c
a
b
Adjustment of governor

Adjustment of burner
The burner is from the factory pre-set
to an average value that must then
be adjusted to the boiler in question.
All burneradjustments must bemade in
accordance with boiler manufacturers
instructions. These must include the
checking of ue gas temperatures,
average water temperature and CO2
or O2concentration
General instructions
The installation of the gas burner must
be carried out in accordance with
current regulations and standards. The
installersofgasburnersshouldtherfore
be acquainted with all regulations and
ensure that the installation complies
with the requirements. The installation,
mounting and adjustment should be
made with the greatest care and only
the correct gas should be used.
Operating instructions
The operating instructions accompa-
nying the burner should be left in
a prominent position in the boiler
room.
Instructions
The user should be thoroughly
instructed in the function of the gas
burner and the whole installation. The
supplier must instruct the user.
Inspection and maintenance
Daily inspection is advisable.
Service
Service should only be carried out
by qualied personell. Replacement
parts should be of the same make and
approved by the same authorities as
the original. If the burner is converted
to re another gas quality it must be
re-commissioned. If town gas is to be
red the combustion head must be
converted and the gas train adjusted
to suit, (e.g.a larger gas armature or
a different spring in the governor may
be required).
Start up
After the burner has been tted to
the boiler and the electric connection,
the leakage control, the venting and
the electric function test have been
carried out, the burner will be ready
for start-up.
Hower, study the sections dealing
with adjustments of multi-bloc,
combustion air and combustion
head.
172 305 52 07-01
GENERAL INSTRUCTIONS
Open the ball valve and switch on the
main switch. If the burner starts the
actual adjustment can be made.
Air adjustment
On all burners the air adjustment can
be made with or without the cover
tted. Final ne adjustment must be
made with the cover on.
Adjustment of burner head
The burners are equipped with an
adjustment device changing the
position of the brake plate in the burner
head. This is used to adjust the corect
pressure drop over the combustion
device and thereby obtain a good
pulsation free combustion.
Which position to use depends on
input and overpressure in the boiler.
Ageneral rule is that the lower capacity
the smaller the opening between brake
plate and combustion device.
Adjustment of brake plate
–Turn by means of an allen key the
screw in the desired direction.
STG120/1, STG120/2, STG146/1
–To reduce the opening: turn the
screw to the left.
–To increase the opening: turn the
screw to the right.
STG146/2
–To reduce the opening: turn the
screw to the right.
–To increase the opening: turn the
screw to the left.
The adjustment of the position of the
brake plate affects the air ow. It is
therefore always necessary to make a
ne adjustment of the air by means of
the adjustment device of the burner.
Control of burner head
To check the burner head, brake plate
and electrodes proceed as follows:
Remove the cover. Loosen the union
nut between inner assembly and multi-
bloc. Loosen the burner from the
ange and withdraw the burner from
the boiler. If it is necessary to remove
the burner tube, loosen the two allen
screws, turn and withdraw the burner
tube.
Commissioning of installation
Control of the combustion. The
combustion quality is checked by
means of a ue gas analysis device.
Adjust the burner to appr. 20% excess
air in accordance with the table. Check
the ue gas temperature. Calculate
the efciency. Check also the actual
gas volume on the gas meter so that
the correct input is achieved.
Gas quality CO2%
lambda 1,2
02%max CO2%
Natural gas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

172 305 50 07-01
GENERAL INSTRUCTIONS
Control of burner head
Air adjustment
Adjustment of inner assembly

172 305 25 11-01
Flame monitoring and measure-
ment of ionisation current
The burner is monitored according
to the ionisation principle. Check the
ionisation current on start-up and on
each service call.
The reason for a low ionisation current
may be leaking currents, bad connec-
tion to earth, dirt or a faulty position
of the ame electrode in the burner
head. Sometimes also a faulty gas/air
mixture may cause too weak a ionisation
current.
The ionisation current is measured
by means of a microampere meter
(µA) connected in series with the
ame electrode and the gas burner
control.
Connect the µA-meter, see gure. Min.
required ionisation current according
to table. In practice this current must
be considerably higher, preferably
more than 10 µA. All the gas burners
are equipped with a ionisation cable
that can be slit which facilitates the
connection of the µA-device.
Gas pressure switches:
Adjustment range:
2,5-50 mbar GW 50
5-150 mbar GW 150
Adjustment of min. gas pressure
switch
The min. pressure switch should react
if the gas pressure is too low and
prevent the burner from starting. Too
low a gas pressure during operation
should stop the burner. The burner
may start again when the rated gas
pressure has been reached.
Remove the protective cover. Connect
a pressure gauge for measuring the
rated pressure. Decide on pressure
at which the gas switch should switch
off. Set this pressure by means of the
valve. Carefully turn the knob (see
gure) until the gas pressure switch
switches off. The value shown on the
scale should then approximately cor-
respond with the value shown on the
pressure gauge. Tolerance on scale
appr. ± 15 %. Open the ball valve.
GENERAL INSTRUCTION
Adjustemnt of max. gas pressure
switch
The burner is equipped with a max.
gas pressure switch only on request.
It should stop the burner if the gas
pressure exceeds the set value. The
burner can then only be re-started
manually (gas burner control or
overpressure switch).
Remove the protective cover. Connect
a pressure gauge for measuring the
rated gas pressure. Decide on pres-
sure at which the gas pressure switch
should switch off.Turn the adjustment
knob to this value. Tolerance on the
scale ±15%.
Adjustment of air pressure switch
The air presure switch should stop the
burner if the air volume is reduced.
The air proving device shall be adjusted
in such a way that if there is insufcient
air supply at the highest or lowest
burner operating stage, the device
operates before the supervised pres-
sure is less than 80% of the pressure
at the controlled stage and the CO
content of the combustion products
exceeds 1% by volume.
Air pressure switch:
Adjustment range ca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50
Flame monitoring
Gas pressure switch, air pressure
switch
Gas control Connection to terminal
in gas control
Min. ionisation
current required
LME 15 µ A
LGB 110 µ A
LFL 24 10 µ A
MMI 810 25 µ A
TMG 740-3 15 µ A

FINAL TEST OF THE INSTALLATION
172 305 17 07-01
–Make repeated start attempts to
ensure that the adjustments
function.
–Close the ball valve during
operation to check that the gas
switch switches off at the set
value.
–Remove the hose for the air
pressure switch to check that
the burner locks out.
–Check that all protective covers
and measurement nipples are
mounted and fastened.
–Fill out necessary test reports.
–Instruct the persons in charge
of the operation on the service
and maintenance of the installa-
tion and what to do should any
troubles occur.
–Inspection and service must
only be carried out by author-
ized people.
Fault location, functional troubles
Trouble free operation is dependent
on three factors: electricity, gas and air
supply. Should there be any changes
in the ratio between these three factors
there is a risk of break downs. It has
been proved that most break downs
are caused by simple faults. Before
calling the service engineer, the following
should therefore be checked:
–Is the gas cock open?
–Are all fuses in order and the
current switched on?
–Are the thermostats correctly
set?
–Are pressostats, overheating
protection etc. in operating posi-
tion and not locked-out?
–Is the gas pressure sufcient?
–Is the gas burner control in start
position?
–Has the gas control or the motor
protector locked out? - Reset.
–Is the circulation pump in opera-
tion?
–Is there a supply of fresh air to
the installation?
If integral components are of a
different make from what is stated
in this manual, see the enclosed
loose-leaf.