Bentone bg 300 User manual

BG 300
172 601 83 98-01

178 002 71

172 205 31 97-01
DESCRIPTION
COMPONENTS
1. Cover,inspection glass
2. Air pressure switch
3. Air adjustment
4. Inner assembly adjustment
(not town gas)
5. Flame cone
6. Connecting pipe
13. Motor
14 Ionizationelectrode
15. Transformer
16. Inner assembly
17. Nozzle
18. Brake plate
7. Air damper
8. Air intake
9. Ignitionelectrode
10. Controlbox
11. Resetbutton
12. Fanwheel

CAPACITYCHARTACCORDINGTO
EN 676
Gas fittings2) Motor Ignitiontransformer
Natural gas, LPG Town gas 1-phase, 0,18 kW, Primary 230 V, 1, A
1" 1½" 2 800 r/m, 230 V Secondary 8 000 V
TECHNICAL DATA
Type designation BG 300
1) Calorific value:
Natural gas 10 kWh/Nm3
LPG 26 kWh/Nm3
2) Dimensionandcapacitydepen-
ding on gas quality and availa-
ble pressure
Type Capacity Gas volume at a min. Gas volume at a max Max. Inlet Rated inlet pressures
kW ouput Nm3/h 1) output Nm3/h 1) pressure mbar mbar
Natural gas/LPG Natural gas LPG Natural gas LPG Natural gas LPG
300 60-190 6 2,3 19 7,3 100 20 20
(4,6 kg/h) (14,8 kg/h)
2) Town gas 2) Town gas 2) Town gas 2) Town gas
172215 11 00-02
Length of burner tube Measure A Measure B
Standard 145 125 ø120
Long design 245 225 ø120
Town gas 172 155 ø140
The above dimensions are max. measurements. Depending on the compo-
nents used, the measurements may vary.
OUTPUT RANGE
DIMENSIONS
170
B
A
460
ø108
372
100
220
380

TECHNICAL DATA
172 215 29 95-01
DIMENSIONS OF FLANGE
ø175-240
M10
ø120

SKELETON DIAGRAMS, 1-STAGE BURNER
1. Ball valve
2. Filter
3. Governor
4. Pressuregaugewithshut-offcock
5a. Gas pressure switch, mini
5b. Gas pressure switch, maxi
123
4
5a 5b 6b 6a
7
10 9
Incorporated in the MultiBloc
6a. Main valve
6b. Safetyvalve
1) 7. Valveprovingsystem
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.
172415 04 03-01
When Bio gas is used, Bentone shall always be contacted.

MOUNTING ON THE BOILER
REMOVAL OF FAN HOUSE UNIT
FROM BURNER.
Loosen the screws. Swing out the fan
house.Removetheionisationandigni-
tioncablesfrom the electrodes.Rem-
ovethe bolton the flange.
Removethecombustionunitfromthe
burner. Fit the enclosed flange and
gaskettotheboiler.Ifnewfixingholes
mustbedrilled,usethefixingflangeas
apattern.
REMOVAL OF VALVE UNIT FROM
BURNER
Remove the plug-in contact from the
multi-bloc.Loosen the unionnut.
172 205 36 93-01
INSTALLATIONEXAMPLE
Connect the gas to the burner by
meansoftheballvalve.Ensurethatthe
unionnut,ballvalveandtubingmake
it easy to remove the burner for in-
spection and service.

ELECTRIC EQUIPMENT
GAS BURNER CONTROL: LGB21/LMG21
WIRING DIAGRAM
COMPONENT LIST
A1 Gas burner control
A2 Twin thermostat
B1 Ionizationelectrode
F1 Fuse
H1 Alarm, 220 V
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
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.
172 425 16 99-02Mains connection in accordance with local regulations.

172425 57 01-01
Operating concept
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:
Diagnosisofcauseoffault
AL
FS
LED on (waiting time 10 s)
Fault
Press lockout reset button
for > 3 s Blink code Off Blink code
Approx.
3 s
ELECTRICEQUIPMENT
CONTROL DIAGNOSIS UNDER FAULT CONDITIONS AND LOCKOUT INDICATION
GAS BURNER CONTROL: LMG ...
AL
• Burner control has initiated lockout • Reset
> RedfaultLEDon Press lockout reset button for 0.5 ...3 s
• Diagnosisofcauseoffault
- Wait >10 s
- Press lockout reset buttonj for >3 s
- Read blink code of red fault LED
>«Errorcodetable»
Error code table
Blink code Possiblecause
2x • No establishment offlame at theend of «TSA»
•• - Faulty or soiled detector electrode
- Faultyorsoiledfuelvalves
- Pooradjustmentof burner
3x • 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
burnerstartup
•••• -«LP» faulty
- «LP» incorrectly adjusted
5x • Extraneouslightduringpre-purging
••••• - Orinternal devicefault
7 x • Loss of flame during operation
••••••• - Pooradjustmentof burner
- Faultyorsoiledfuelvalves
- Short-circuitbetweendetector electrode andground
8...17 x • Free
••••••••
..................
••••••••••
•••••••
18x • Air pressure monitor opens during pre-purging or operation
•••••••••• - «LP» incorrectly adjusted
•••••••• - Four times loss of flame during operation (LMG25)
19x • Faultyoutputcontact
•••••••••• - Wiring error
••••••••• - Externalpowersupplyonoutputterminal
20x • Internaldevicefault
••••••••••
••••••••••
Duringthetimethecauseof
the fault is diagnosed, the
control outputs are deacti-
vated.
- Theburner remains shut
down
- Exception:faultstatussig-
nal «AL» at terminal 10
The burner is switched on
onlyafter areset is made.
- Presslockoutresetbutton
for 0.5...3 seconds
RedLEDon

MEASURES AND CHECKS BEFORE START-UP, 1-STAGE BURNER
INNER ASSEMBLY
Ensure that the ignition and ionisa-
tion electrodes are correctly adjus-
ted. The sketch shows the correct
measurements.
GAS QUALITY
Ensurethattheburnerheadismeant
for the gas quality to be used (see
fig.).
VENTING
The gas line is vented by loosening
the screw on the test nipple for the
inletpressure.Connectaplastichose
and conduct the gas into the open.
After having vented the gas line tigh-
ten the screw again.
LEAKAGE CONTROL
Whenmakingaleakagecontrolofthe
gassupplysystemthesolenoidvalve
shouldbe closed. Connecta pressu-
regaugetothetestnipplePa,seefig.
Thetestpressureinthesystemshould
be 1,5x max. inlet pressure or min.
150 mbar. If any leakage, locate the
source bymeansofsoapywaterora
leak location spray. After tightening
repeat the test.
ELECTRIC FUNCTION TEST:
Ensurethatphaseandneutralarenot
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 swit-
ched on and the thermostats have
beenadjustedthepre-purgingperiod
begins(30-35sec.).Attheendofthis
period the pre-ignition period starts
(0,5-2,5 sec. dependent on the de-
signofthegascontrol).Thegasvalve
is energized and opens and flame is
established. At the end of the safety
time (2-3 sec.) the gas control locks
out.Thesolenoidvalveandthemotor
will be "dead". Remove the link from
thegaspressureswitchafterthetest
is finished.
NOTE! APPLIES ONLY TO GAS
BURNER CONTROL LFL1.
When using LPG (Propane) the bur-
ner should be connected for post-
purge.Moveconnectiontoterminal6
to terminal 7 in the base of LFL1.
172 205 33 97-02
LEAKAGE CONTROL

MEASURES AND CHECKS BEFORE START-UP
INNER ASSEMBLY
Town gas
INNER ASSEMBLY
Natural gas, LPG
172 205 78 98-01
INNER ASSEMBLY
Biogas (UV-detector)
Natural gas
LGP
2,5
8

172 205 16 98-01
DETERMINATION OF GAS VOLUME FOR THE INSTALLATION
V = GasvolumeNm3/h
Q = Boiler output 120 kW
Hu= Calorific value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm3
= Expected efficiency 90%
Ex. A V = Q 3 600 = 120 3 600 12,9Nm3/h
Hu37 144 0,90
Ex. B V = 120 12,9Nm3/h
10,3 0,90
Ifthebarometerheight,pressureandtemperatureofthegasdeviateverymuch
fromthe normalvalues thismust 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 1.11
Thegas volumeread onthe gasmeter actuallyreads 1,11.12,9 = 14,4 m3/h.
Net calorific value
Gasquality kWh/Nm3kJ/Nm3kcal/Nm3
Naturalgas 10.3 37 144 8 865
Propane 26.0 93 647 22 350
Butane 34.3 123571 29 492
Towngas 4.9 17 653 4 213
Bio gas 7.0 25 219 6 019
Specifications on natural gas, town
gasandbiogasvary.Formoreexact
information please contact the gas
distributor.
EXAMPLE HOW TO CALCULATE THE GAS VOLUME (NATURAL GAS)
.
.
. .
.
.

ADJUSTMENT OF MULTI-BLOC, MB-DLE 405-420
Max. inlet pressure: 360 mbar.
Adjustablegovernorpressure:
405 - 412 S50 = 4 - 50 mbar
415 - 420 S20 = 4 - 20 mbar
415 - 420 S50 = 20 - 50 mbar
Solenoidvalve: Slow openingvalves
with adjustable start load and max.
flow.
1. Protectivecoverstartload ad-
justment
2. Hydralicdamping
3. Fixingscrew
4. Testnipple(inletpressure)
5. Testnipple (pressureafter go-
vernor)
6. Test nipple (pressure in inner
assembly)
7. Governor
8. Filter
9. Gaspressure switch
10. Solenoidvalve
FLOWADJUSTMENT
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
Donotforgettotightenthefixingscrew
again.
Theflowadjustmentcanalsobemade
bymeansofthegovernor. Adjust the
outlet pressure to a value giving the
desired gas flow on the fully open
valve.Atsmallcapacities(gasflows)it
is also necessary to adjust as abore.
ADJUSTMENT OF GOVERNOR
Adjustoutletpressurefromgovernor
by means of a screw . Min. and max.
outletpressurescorrespondstoappr.
60turnsofthespring.Itisnotpossible
tochangepressurespringsinorderto
changetheoutletpressure.
Turntotheright=theoutletpressure
is increased
Turntotheleft=theoutletpressureis
reduced
ADJUSTMENT OF START GAS
FLOW
Removetheprotective coverc.
Turn the adjustment knob d (use the
protectivecoverasatool)tothedesi-
red start gas flow.
Turntotheright=thestartgasflowis
reduced
Turn to the left = the start gas flow is
increased ADJUSTMENT OF START GAS
FLOW
ADJUSTMENT OF GOVERNOR
FLOWADJUSTMENT
172 505 02 97-02

GENERAL INSTRUCTIONS
ADJUSTMENT OF BURNER
Theburnerisfromthefactorypre-set
toanaveragevaluethatmustthenbe
adjusted to the boiler in question.
Allburneradjustmentsmustbemadein
accordancewithboilermanu-facturers
instructions.These must include the
checking of flue gas temperatures,
averagewatertemperatureandCO2or
O2concentration.
GENERALINSTRUCTIONS
Theinstallationofthegasburnermust
be carried out in accordance with
currentregulationsandstandards.The
installersofgasburnersshouldthere-
forebeacquaintedwithallregulations
and ensurethattheinstallationcomp-
lieswiththerequirements.Theinstal-
lation,mountingandadjustmentshould
be made with the greatest care and
only the correct gas should be used.
OPERATINGINSTRUCTIONS
Theoperatinginstructionsaccompanying
the burner should be left in a prominent
positionintheboilerroom.
INSTRUCTIONS
The user should be thoroughly in-
structed in the function of the gas
burnerandthewholeinstallation.The
supplier must instruct the user.
INSPECTIONANDMAINTENANCE
Daily inspection is advisable.
START UP
Aftertheburnerhasbeenfittedtothe
boilerandtheelectricconnection,the
leakage control, the venting and the
electric function test have been car-
ried out, the burner will be ready for
start-up.
Howerer, study the sections dealing
with adjustments of multi-bloc, com-
bustion air and combustion head.
Opentheballvalveandswitchonthe
main switch. If the burner starts the
actual adjustment can be made.
ADJUSTMENT OF BURNER HEAD
The burner is equipped with an ad-
justmentdevicechangingtheposition
of the brake plate in the burner head.
Thisisusedtoadjustthecorrectpres-
suredropoverthecombustiondevice
inordertoobtainagoodpulsationfree
combustion.
Which position to use depends on
input and overpressure in the boiler. 17230528 97-01
A general rule is that the lower capa-
citythe smallerthe opening between
brakeplateand combustion device.
COMMISSIONINGOFINSTALLA-
TION
Controlofthecombustion.Thecom-
bustion quality is checked by means
of a flue gas analysis device. Adjust
theburnertoappr.20%excess air in
accordancewiththetable.Checkthe
flue gas temperature. Calculate the
efficiency.Checkalsothe actual gas
volume on the gas meter so that the
correct input is achieved.
SERVICE
Serviceshouldonly becarriedoutby
qualified personnel. Replacement
parts should be of the same make
and approved by the same authoriti-
es as the original. If the burner is
convertedtofireanothergasqualityit
must be re-commissioned. If town
gasistobefiredthecombustionhead
must be converted and the gas train
adjusted to suit (e.g.a larger gas ar-
mature or a different spring in the
governor may be required).
Gasquality CO2%0
2% max.CO2%
lambda1,2
Naturalgas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

GENERAL INSTRUCTIONS, 1-STAGE BURNER
AIR ADJUSTMENT
Loosen the stop screw and turn the
knob along the scale to the desired
positionandtightenthescrew.Check
the air adjustment by making a flue
gas analysis.
ADJUSTMENT OF BRAKE PLATE
- Loosen the screw on the adjust-
ment device.
- To reduce the opening: turn the
knob to the left.
- To increase the opening: turn the
knob to the right.
The adjustment of the position of the
brake plate affects the air flow. It is
therefore always necessary to make
a fine adjustment of the air by means
of the adjustment device of the bur-
ner.
CONTROL OF BURNER HEAD
Tochecktheburnerhead, brake pla-
teandelectrodesproceedasfollows:
Loosen the nuts a. Swing out the
burner. Remove the screw b and the
knob for adjustment of burner head.
Loosen the screw c so much so that
theinnerassemblycanbepulledout.
172 305 31 94-01
AIR ADJUSTMENT
ADJUSTMENT OF INNER ASSEMBLY
CONTROL OF BURNER HEAD

172 305 25 00-01
FLAMEMONITORINGANDMEASU-
REMENTOFIONISATIONCURRENT
The burner is monitored according to
the ionisation principle. Check the io-
nisation current on start-up and on
each service call.
Thereasonforalowionisationcurrent
maybeleakingcurrents,badconnec-
tiontoearth,dirtorafaultypositionof
theflameelectrodeintheburnerhead.
Sometimesalsoafaultygas/airmixtu-
re may cause too weak a ionisation
current.
Theionisationcurrentismeasuredby
means of a microampere meter (µA)
connected in series with the flame
electrode and the gas burner control.
Connect the µA-meter, see figure.
Min. required ionisation current ac-
cording to table. In practice this cur-
rentmustbeconsiderablyhigher,pre-
ferably more than 10 µA. All the gas
burnersareequippedwithaionisation
cable that can be slit which facilitates
the connection of the µA-device.
GAS PRESSURE SWITCHES:
Adjustmentrange:
2,5-50 mbar GW 50
5-150 mbar GW 150
ADJUSTMENTOFMIN.GASPRES-
SURE SWITCH
Themin.pressureswitchshouldreact
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.
Removetheprotectivecover.Connect
a pressure gauge for measuring the
ratedpressure.Decideonpressureat
whichthegasswitchshouldswitchoff.
Set this pressure by means of the
valve. Carefully turn the knob (see
figure) 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
ADJUSTEMNTOFMAX.GASPRES-
SURE SWITCH
Theburnerisequippedwithamax.gas
pressure switch only on request. It
shouldstoptheburnerifthegaspres-
sureexceedsthesetvalue.Theburner
can then only be re-started manually
(gas burner control or overpressure
switch).
Removetheprotectivecover.Connect
a pressure gauge for measuring the
rated gas pressure. Decide on pres-
sureatwhichthegaspressureswitch
shouldswitchoff.Turntheadjustment
knob to this value. Tolerance on the
scale ±15%.
ADJUSTMENT OF AIR PRESSURE
SWITCH
Theairpresureswitchshouldstopthe
burner if the air volume is reduced.
Theairprovingdeviceshallbeadjus-
ted in such a way that if there is
insufficientairsupplyatthehighestor
lowest burner operating stage, the
deviceoperatesbeforethesupervised
pressureislessthan80%ofthepres-
sureatthecontrolledstageandtheCO
content of the combustion products
exceeds1%byvolume.
AIR PRESSURE SWITCH:
Adjustmentrangeca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50
FLAMEMONITORING
GAS PRESSURE SWITCH, AIR
PRESSURESWITCH
Gascontrol Connectiontoterminal Min. ionisation
in gas control current required
LMG 1 2 µ A
LGB 1 10 µ A
LFL 24 10 µ A
MMI810 2 5 µ A
TMG740-3 1 5 µ A

HANDING OVER OF THE INSTALLATION
172 305 17 93-01
- Makerepeatedstartattemptsto
ensurethatthe adjustmentsfunc-
tion.
- Closetheball valve during opera-
tion to check that the gas switch
switches off at the set value.
- Removethehosefortheairpressu-
re switch to check that the burner
locks out.
- Checkthat all protectivecovers
andmeasurementnipplesare
mountedandfastened.
- Fill out necessary test reports.
- Instructthepersonsinchargeofthe
operationontheservice andmain-
tenanceoftheinstallationandwhat
to do should any troubles occur.
-Inspection and service must only
be carried out by authorized
people.
FAULT LOCATION, FUNCTIONAL
TROUBLES
Troublefreeoperationisdependenton
three factors: electricity, gas and air
supply. Should there be any changes
intheratiobetweenthesethreefactors
there is a risk of break downs. It has
beenprovedthatmostbreakdownsare
causedbysimplefaults.Beforecalling
the service engineer, the following
should therefore be checked:
- Is the gas cock open?
- Are all fuses in order and the cur-
rentswitchedon?
- Arethethermostatscorrectlyset?
- Arepressostats,overheatingpro-
tection etc. in operating position
andnotlocked-out?
- Is the gas pressure sufficient?
- 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 diffe-
rent make from what is stated in this
manual,seetheenclosedloose-leaf.

170 091 16 97-01
Gas burner
FAULTLOCATIONGUIDE
Thebasisfortroublefreeoperationcanonlybeensured
by the correct combined effect of the three factors:
electricity, gas flow and combustion air. Should any of
these factors change troubles may arise.
Ithasbeenprovedthatmanytroubleshaverathersimple
causes. Before calling the serviceman the following
checks should be made:
1. Are the gas cocks of the installation open?
2. Are the fuses in order and the current switched on?
3. Arethecontrols(roomthermostat,boilerthermostat
etc.) correctly adjusted?
4. Is the gas pressure to the burner sufficient?
5. Is the gas relay of the burner ready for start and not
lockedout?
6. Is the air supply to the burner sufficient?
To facilitate fault location we have drawn up a scheme
showing the most frequent faults in a gas burner instal-
lationandthe remedies.
CAUSE
The burner does not start
Nogas
Novoltage
The burner motor fails to start
The gas relay is defective
Burnermotorisrunningbutnoignitionafterthepre-
purge time has elapsed
Novoltageontheterminals
Theignitionelectrodesincontactwitheachotherorwith
earth
The porcelain of the electrodes is broken
Check that all gas cocks are open.
Check fuses, thermostats and electrical connections.
Thethermalprotection has lockedout.Motor defective.
Replace
Check the contact. Replace faulty relay
Adjust
Replacetheelectrodes
REMEDY
1(4)

REMEDY
Improvethecontact
Replace
Replacethetransformer
Change
Replace
Replace coil or the whole valve if necessary.
Check the contact
Testtheadjustmentand thefunctionoftheairpressure
switch.
Reduceorincreasethegassupply, reducethequantity
of air.
Replace
Checktheadjustmentandreadjust.
AdjusttheionisationelectrodeandtheUV-cell,examine
cables and connections.
Replacetherelay
CAUSE
Thecable shoeshave bad contact
Theignition cablesare damaged
The ignition transformer is damaged, no voltage on the
secondary side
The ignition cable and the ionisation cable have been
transposed.
Noflameestablishmentinspiteofatroublefreestart
Thegassolenoidvalvedefective
The gas solenoid valve does not open in spite of its
obtainingvoltage
Novoltagetothesolenoidvalve
Noelectricalconnectionthrough theairpressureswitch
The starting load is not correctly adjusted
Gasrelaydefective
Air pressure switch incorrectly adjusted or defective
No reponse as the cams of the servomotor are not
correctly adjusted or out of position.
Theburnerlocksoutafterthesafetytimehaselapsed
inspiteofflameestablishment
No ionisation current or the UV-cell in wrong position
The supervision part of the gas relay is defective
2(4)

CAUSE
Voltagelowerthan 185 V
The ignition electrodes are disturbing the ionisation
current
Badearthing
Phaseandneutraltransposed
The burner locks out during pre-purge
Air pressure switch defective or incorrectly adjusted.
The starting load is not correctly adjusted
The gas pressure is too low
Pulsations at start
Theignitionelectrodesarewronglyadjusted
The gas pressure is too high
The flue gas side is blocked
Pulsationsduringoperation
The burner is not correctly adjusted
The burner is dirty
Defective chimney
The burner is operating correctly but locking out
now and then
The ionisation current is too low
The UV-cell is in a wrong position
Voltage drop at certain times
Air pressure switch defective or incorrectly adjusted
Spark-over in ignition electrodes
REMEDY
Contact the electricity authorities.
Adjusttheignitionelectrodes,repoletheignitiontransfor-
mer if necessary.
Arrange for proper earthing.
See wiring diagram and change.
Reduceorincreasethegassupply.Reducethequantity
of air.
Increasethepressure.Contactthegassupplycompany
if necessary.
Readjust.
Check and adjust by means of a pressure gauge and a
pressureadjustmentvalve.
Check the chimney flue.
Readjust
Clean the burner.
Check and change the dimensions if necessary.
Check. Must be at least 4 µ A according to the relay
manufacturer but should be 8-20 µ A.
Adjust.
Mustnotdropmorethan15%oftheratedcurrent.Contact
the electricity authorities if necessary.
Replacetheelectrodes
3(4)