Bentone BG 450 User manual

Providing sustainable energy solutions worldwide
178 003 75-2 2016-02-01
Installation- and maintenance instruction
BG 450

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 quali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
regulations 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 tter is to ensure that the boiler room is supplied with fresh air
ventilation that is suf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
Safety directions – The electrical installation shall be made according to valid regulations
for heavy current and in a professional way, so that the risk of leaking
gas, 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.
Acceptance inspection – 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.
– Any transport damage should be reported to the forwarding company.
Preparations for installation – 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.
172 155 15 08-01
Warning
!

172 205 92 08-01
DESCRIPTION
Components
1. Flame cone
2. Inner assembly
3. Fixing ange
4. Electric panel
5. Fan wheel
6. Fan house
7. Shrouded disc
8. Ignition electrode
9. Ionisation electrode
10. Motor
18. Switch l-ll
(For modulating burner:
Change-over switch manually-
automatically)
19. Indicating lamp Stage 1
20. Switch 0-1
21. Contactor
22. Control box
23. Ignition transformer
24. MultiBloc
11. Connection gas ttings
12. Air intake
13. Air damper
14. Air pressure switch
15. Conical shield plate
16. Fuse
17. Indicating lamp Stage 2
(For modulating burner: Change-
over switch increase-decrease)

640
262
A 538
252
ø160
ø130
500
328
252
Armatur 2) Motor Ignition transformer
Natural gas LPG 1-fas, 450W, 2 800 r/m, Primary 230 V, 1 A
1
1/2"230/240 V Secondary 8 000 V
2) Town gas
CAPACITY CHART ACCORDING TO
EN 676
Type Capacity Gas volume at a min.Gas volume at a max Max. inlet Rated inlet pressure
kW output Nm3/h 1) output Nm3/h 1) pressure mbar mbar
Natural gas/LPG Natural gas LPG Natural gas LPG Natural gas LPG
450 120-550 12 4,6 55 21 360 40 30-50
2) Town gas 2) Town gas 2) Town gas 2) Town gas
Out range
TECHNICAL DATA
Type designation BG 450
Dimensions
1) Caloric value:
Natural gas 10 kWh/Nm3
LPG 26 kWh/Nm3m3
2) Dimension and capacity depen-
ding on gas quality and available
inlet pressure
Length of burner Flange
tube Measure A
Standard 256 226
356 326
456 426
The above dimensions are max. measurements. Depending on the components
used, the measurements may vary.
172 215 50 12-01

TECHNICAL DATA
DIMENSIONS OF FLANGE
172 215 19 08-01

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
6a. Main valve.
7
123
5a 5b
4
6b 6a
10
Incorporated in the MultiBloc
9
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 accor -
ding to EN 676.
172 415 08 10-01
When Bio gas is used, Bentone shall always be contacted.

MOUNTING OF THE BURNER
172 205 20 08-01
Fit the burner to the boiler by means
of 4 bolts M12. For ange and bolt
dimensions see technical data.
If for some reason you want to sepa-
rate the burner from the gas ange
with burner head and valve package
you can do so.
Do like this:
- Remove the cover of the fan hou-
sing.
- 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 ass-
embly.
- Pull out the burner on the pull rods
and put it in a suitable place.
When the burner head and the gas
ange have been 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 hous-
ing.
- 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
ange.
- Withdraw the gas assembly.
Ensure that the O-ring between the
gas assembly and the gas ange will
be in the correct position when the
gas assembly is 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.
SERVICE POSITION
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).

172 425 99 14-01
ELECTRIC EQUIPMENT
Gas burner control: LGB21/LMG21/LME11/LME21
Wiring diagram
1(5)
1N ~ 50/60 Hz 230 V
List of components
A1 Gas burner control
B1 Ionization electrode
F1 Fuse
H1 Lamp, low capacity
H3 Alarm signal 220 V
K1 Motor contactor
M1 Burner motor
P1 Time meter, total operating time
S1 Operating switch
S3 Control thermostat
S4 Temperature limiter
S5 Micro switch for hinged door
S7 Main switch
S8 Air pressure swith
S9 Gas pressure switch
T1 Ignition transformer
X1 Connection terminal board
X2 Earth terminal
X3 Plug-in contact, burner
X4 Plug-in contact, boiler
Y1 Gas solenoid valve
Mains connection in accordance with
local regulations.
If there is no Plug-in
contact (X4,X6) on
the boiler, connect
to the contact
enclosed. Max loading K1
Connection A1,A2 / 95, 96 / 97, 98
Max 0,2A/15W

172 425 99 14-01
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 99 14-01
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 99 14-01
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 99 14-01
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

MEASURES AND CHECKS BEFORE START-UP, 1-STAGE BURNER
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.
172 205 33 08-01
Leakage control
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 (30-35sec.). At the end of this
period the pre-ignition period starts
(0,5-2,5 sec. dependent on the design
of the gas control). The gas valve is
energized and opens and 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 nished.
NOTE! Applies only to gas burner
control LFL1.
When using LPG (Propane) the burner
should be connected for post-purge.
Move connection to terminal 6 to ter-
minal 7 in the base of LFL1.

MEASURES AND CHECKS BEFORE START-UP
Inner assembly
Town gas
Inner assembly
Natural gas, LPG
Inner assembly
Biogas ((UV-detector)
LPG Natural gas
172 205 18 12-01
45°

DETERMINATION OF GAS VOLUME FOR THE INSTALLATION
Specications on natural gas, town gas and biogas vary. For more exact
information please contact the gas distributor.
Example how to calculate the gas volume (natural gas)
172 205 16-1 12-01
Net caloric value
Gas quality kWh/Nm3 kJ/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
Biogas 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
If the barometer height, pressure and temperature of the gas deviate consi-
derably 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.

172 501 28 16-02
INSTÄLLNING AV MULTIBLOCK, MB-DLE 405-420
Mängdinställning
Lossa låsskruven a. Vrid hydraulikdonet b:
åt höger = mindre gasmängd
åt vänster = större gasmängd
Glöm inte att åter skruva fast låsskruven.
Mängdinställning kan även ske med hjälp
av tryckregulatorn. Det utgående trycket
anpassas till ett värde som ger önskad
gasmängd vid fullt öppen ventil. Vid små
kapaciteter (gasmängder) är det även
nödvändigt att ställa in enligt tidigare.
Inställning av tryckregulator
Utgående tryck från regulatorn inställes
med hjälp av en skruvmejsel. Min. och
max. utgående tryck motsvarar ca 60 varv
på fjädern. Det är inte möjligt att skifta
tryckfjädrar för ändring av utgångstryck.
Vridning åt höger = högre utgångstryck
Vridning åt vänster = lägre utgångstryck
Inställning av startgasmängd
Tag av skyddshuven c.
Vrid inställningsskruven d (använd
skyddshuven som verktyg) till önskad
startgasmängd.
Vridning åt höger = minskad
startgasmängd
Vridning åt vänster = ökad
startgasmängd
Max. anslutningstryck: 360 mbar.
Inställbart regulatortryck:
405 - 412 S50 = 4 - 50 mbar
415 - 420 S20 = 4 - 20 mbar
415 - 420 S50 = 20 - 50 mbar
Magnetventil: Långsamt öppnande ventiler
med inställbar startlast och max. mängd.
1. Elanslutning tryckvakt (stickpropp
DIN EN 175 301-803)
2. Driftindikator V1, V2 (tillbehör)
3. Tryckregulator
4. Justeringskåpa,
5. Hydraulikdon / justeringstallrik
6. Magnetventil
7. Mätanslutning G 1/8 möjlig
8. Mätanslutning G 1/8 efter ventil 1,
möjligt på båda sidor
9. Utgångsfläns
10. Gasflödesriktning
11. Mätanslutning G 1/8 före V1 möjligt
på båda sidor.
12. Andningsdysa, regulator
13. Filter (bakom flänsen)
14. Ingångsfläns
15. Tryckvakt
16. Elektrisk anslutning ventil (kontakt
DIN EN 175 301-803)
Startgasmängd
d
c
a
b
Tryckregulator
16
2 3 4
5
6
7
8
9
10
11
12
13
14
15
1

GENERAL INSTRUCTIONS
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 burner adjustments must be made
in accordance with boiler manu-facturers instructions.These must include
the checking of ue gas temperatures, average water temperature and
CO2or O2concentration.
General instructions The installation of the gas burner must be carried out in accordance with
current regulations and standards. The installers of gas burners should
therefore be acquainted with all regulations and ensure that the instal-
lation 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 accompanying the burner should be left in a
prominent position in the boiler room.
Instructions The user should be thoroughly in-structed in the function of the gas burner
and the whole installation. The supplier must instruct the user.
Inspection and maintenance Daily inspection is advisable.
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.
Howerer, study the sections dealing with adjustments of multi-bloc,
combustion air and combustion head. Open the ball valve and switch on
the main switch. If the burner starts the actual adjustment can be made.
Adjustment of burner head The burner is equipped with an adjustment device changing the po si tion
of the brake plate in the burner head. This is used to adjust the cor rect
pressure drop over the combustion device in order to obtain a good
pulsation free combustion.
Which position to use depends on input and overpressure in the boiler. A
general rule is that the lower capacity the smaller the opening between
brake plate and combustion device.
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.
Service
Service should only be carried out by qualied personnel. Replacement
parts should be of the same make and approved by the same authori-
ties 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).
172 305 28-1 12-01
Gas quality CO2% 02% max. CO2%
lambda 1,2
Natural gas 10,0 3,5 11,9
LPG 11,5 3,5 13,9

172 305 25-1 12-01
Flame monitoring and measurement 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
connection 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 accor-
ding to table. In practice this current must be considerably higher, prefe-
rably 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.
GENERAL INSTRUCTION
Flame monitoring
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

UV-detector
This should not be exposed to temperatures exceeding 60°C. The current
passing through the UV-detector, when it is being illuminated, should be
at least 70 µ A for LFL1.. This current can be measured by means of a
moving coil instrument. Checks should only be made if a fault is suspected.
The capacitor, which sould be placed between the terminals on the moving
coil instrument, must be of 100 µ F 10-25 V.
GENERAL INSTRUCTION
Flame monitoring
Control box LFL1
UV-detector