Bentone BG400M Technical specifications

Installation- and maintenance instruction
BG400M
172 115 58 07-01

178 024 74

172 205 40 08-01
DESCRIPTION
Components
Switch 0-I
Switch I-II
Cover, inspection glass
Reset button
Air pressure switch
Damper motor
Inner assembly adjustment
(not for town gas)
Flame cone
1.
2.
3.
4.
5.
6.
7.
8.
Multibloc
Connecting pipe
Air damper
Air intake
Gas pressure switch
Ball valve
Electrical panel
Fan wheel
9.
10.
11.
12.
13.
14.
15.
16.
Electrical connection
Motor
Ignition electrode
Transformer
Ionization electrode
Inner assembly
Nozzle
Brake plate
17.
18.
19.
20.
21.
22.
23.
24.

Capacity chart according
to EN 676
Output range
TECHNICAL DATA
The above dimensions are max. measurements. Depending on the compo-
nents used, the measurements may vary.
172 215 14 07-01
1) Caloricvalue:
Natural gas 10 kWh/Nm3
LPG 26 kWh/Nm3
2) Dimension and capacity depen-
ding on gas quality and available
pressure
Length of burner
tube
Flange
Measure A
Standard 172 155
Long design 272 255
Town gas 172 155
Type Capacity
kW
Gas volume at a min.
output Nm3/h 1)
Gas volume at a max
output Nm3/h 1)
Max. inlet
pressure mbar
Rated inlet
pressure mbar
Natural gas/LPG Natural gas LPG Natural gas LPG Natural gas LPG
400 60-318 6 2,3 31,8 12,2 100 20 20
(5,0 kg/h) (24,8 kg/h)
2) Town gas 2) Town gas 2) Town gas 2) Town gas
Connection 2) Motor Ignition transformer
Natural gas/LPG
1"
2) Town gas
1-phase, 0,25 kW
2800 r/m, 230V
Primary 230 V, 1 A
Secondary 8 000 V
100 410
250
505
ø140
A
ø108
195
506
Type designation BG 400
Dimensions

TECHNICAL DATA
172 215 30 07-01
ø175-240
M10
Dimensions of ange
ø140

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. When
modulaing operation is required
this valve is equipped with controls
for variable opening.
Incorporated in the MultiBloc
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.
172 415 05 07-01
When Bio gas is used, Bentone shall always be contacted.
!

Removal of fan house unit from
burner.
Loosen the screws. Swing out the fan
house. Remove the ionisation and
ignition cables from the electrodes.
Removetheboltontheange.
Remove the combustion unit from the
burner. Fit the enclosed ange and
gaskettotheboiler.Ifnewxingholes
mustbedrilled,usethexingange
as a pattern.
Removal of valve unit from burner
Remove the plug-in contact from the
multi-bloc. Loosen the union nut.
absolutely straight.
MOUNTING ON THE BOILER
Installation example
Connect the gas to the burner by
means of 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 42 07-01

172 425 51 07-01
ELECTRIC EQUIPMENT
Gas burner control: LMG22.../LME22...
Wiring diagram
*
* If there is no Plug-in contact (X4,X16) on the boiler, connect to the contact enclosed.
1N ~50-60 Hz 230V
1(5)

172 425 51 07-01
ELECTRIC EQUIPMENT
List of components
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.
Air damper motor opens.
The air damper motor opens the damper to max. position. A control is made that
theairpressureswitchindicatessufcientfanpressure.
Air damper motor closes.
The air damper motor closes to min. load position. Then the ignition spark is
formed.
Main and safety valves open
Thegasisignited.Theionizationelectrodeindicatesaame.
The safety time expires.
Theignitionsparkgoesout.Thesafetytimeexpires.Ifthereisnoameoriffor
somereasontheamedisappearsafterthistimelimit,theburnercontrollocks
out.
Operating position.
The burner is in operating position and can now change over to the capacity
controlled by the regulator.
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.
1.
2.
3.
4.
5.
6.
7.
•
Mains connection in fuse in accordance with local regulations.
A1 Gas burner control
A2 Power control
B1 Ionization electrode
F1 Operating fuse
H1 Operating lamp
H3 Alarm signal 230 V
M1 Burner motor
M2 Damper motor, L&S SQN75.624A21B
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 switch
S11 Change-over switch, Aut.-Man.
S12 Change-over switch, Increase-Reduce
S15 Control thermostat, 3-pole (only for 2-stage sliding)
T1 Ignition transformer
X1 Connection terminal board
X2 Earth terminal
X3 Plug-in contact, burner
X4 Plug-in contact, boiler
X15 Plug-in contact, power controller, burner
X16 Plug-in contact, capacity regulator, boiler
S9 Gas pressure switch
Y1 Gas solenoid valve 1
Y3 Safety solenoid valve
Function Gas burner control: LMG22.../LME22...
2(5)

172 425 51 07-01
Control diagnosis under fault conditions and lockout indication LMG ....
Diagnosis of cause of fault
AL
FS
Red LED on
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:
Error code table
Blink code Possible cause
2 x
••
• Noestablishmentofameattheendof«TSA»
- Faulty or soiled detector electrode
- Faulty 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
6 x
••••••
Free
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
18x
••••••••••
••••••••
• Air pressure monitor opens during pre-purging or operation
- «LP»incorrectly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
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 button
for 0.5...3 seconds
ELECTRIC EQUIPMENT
Connecting signal amplier
3(5)
A1 = LMG
GP
R/W
Q1 = AGQ2...
QRA
12 2 11 1
br bl rt Sw
rtSw
Blink code
LEDon(waitingtime≥10s)
Fault
Press lockout reset button
for > 3 s Off Blink code
Approx.
3 s

172 425 51 07-01
ELECTRIC EQUIPMENT
Control program when disruption; disruption display LME ....
Colour codes
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.
AL
FS
lights red
Light period (waiting time ≥10s) Flash code Pause Flash code
Approx. 3 s
Press the
reset button > 3s
Diagnostics alarm trigger
The red alarm signal lamp lights continuously after the alarm is disconnect-
ed.Diagnosticsforalarmtriggerscanbereadasspeciedbythefollowing
sequence:
……Continuous
○ Off
▲ Red
● Yellow
□ Green
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.
4(5)

172 425 51 07-01
ELECTRIC EQUIPMENT
Alarm control table LME ....
Connecting signal amplier
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 8x
••••••••
Free
Flashing 9x
•••••••••
Free
Flashing 10 x
••••••••••
Connection fault or internal fault, outgoing contacts
or other fault.
Flashing 14 x
••••••••••
••••
CPI contact not closed.
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.
A1 = LME
Q1=AGQ 3...
br bl rt sw
sw
GP
R/W
bl
QRA
LN
12 211 1
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.
5(5)

MEASURES AND CHECKS BEFORE START-UP,
General rules
Care should be taken by the installer
to ensure that no electrical cables or
fuel/gaspipesaretrappedordamaged
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 (30-35sec.). 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.
172 205 34 07-01
Leakage control
Gas train
Note on 2-stage and modulating burn-
ers 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.
Whenusing LPG(Propane) theburner
should be connected for post-purge.
Move connection to terminal 6 to ter-
minal 7 in the base of LFL1.
2-STAGE- OR MODULATING BURNERS
MultiBloc

MEASURES AND CHECKS BEFORE START-UP
172 205 78 07-01
INNER ASSEMBLY
Town gas
INNER ASSEMBLY
Natural gas, LPG
INNER ASSEMBLY
Biogas (UV-detector)
Natural gas
LGP
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.

DUNGS COMBI BLOC WITH RATIO ADJUSTMENT MB-VEF BO1, 412 - 425
Electrical connection gas pressure switch mini
Electrical connection gas valve
Pressure switch mini
Flange connection inlet
Test point connection 1/8" before V1
Filter(onMulti-Bloc425externallter)
Data plate
Connection 1/8" PL
Adjustment screw V for ratio PBr:PL(max. load)
Test point connection 1/8" before V1(before governor)
Connection M4 for measurement of burner presssure after V2
Adjustment screw for zero point adjustment N (min. load)
Test point connection 1/8" PF
Test point connection 1/8" PBr(after V2burner)
Flange connection, outlet
Test point connection 1/8" Pa before V2(after governor)
Indication of V1and V2in operation (not standard)
ImpulseangePBr (gas pressure)
Impulse line PL(air pressure)
Impulseline(reroom)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
172 205 70 07-01
22
8. MULTI-BLOC
1. Electrical connection gas pressure switch mini
2. Electrical connection gas valve
3. Pressure switch mini
4. Flange connection inlet
5. Test point connection 1/8” before V
1
6. Filter (on Multi-Bloc 425 external filter)
7. Data plate
8. Connection 1/8” P
L
9. Adjustment screw V for ratio P
Br
: P
L
(max. load)
10. Test point connection 1/8” before V
1
(before governor)
11. Connection M4 for measurement of burner pressure after V
2
12. Adjustment screw for zero point adjustment N (min. load)
13. Test point connection 1/8” P
F
14. Test point connection 1/8” (after V
2
burner)
15. Flange connection, outlet
16. Test point connection 1/8” P
a
before V
2
(after governor)
17. Indication of V
1
and V
2
in operation (not standard)
18. Impulse flange P
Br
(gas pressure)
19. Impulse line P
L
(air pressure)
20. Impulse line (fire room)
It is possible to connect a leakage control VPS 504 and a gas pressure
switch maxi.
8.1 View
8.1.1 MB-VEF 412 - 425 B01
201379
19
8
6
5
4
3117 2 16 10 11 18
14
15
12
View
It is possible to connect a leakage control VPS 504 and a gas pressure
switch maxi.

Adjustment possibilities
Adjustment range
Effective burner pressure
∆
Effective fan pressure
∆
Adjustment range
MB-VEF
Adjustment range
Impulse lines shall be mounted in such a way that
 nocondensatecanowbackintothemultibloc.This
is especially important when PFis concerned.
Impulse lines shall be mounted in such a way that
they are protected against rupture and damage.
Impulse lines shall be as short as possible
-
-
-
Impulse lines should preferably be made of steel.
Inside diameter >ø 4 mm (steel tube ø 6/4)
For PLother material can be used.
Impulse lines PLand PBR are ready from factory
-
-
-
Mounting instruction - impulse lines PL, PFand PBr
Max inlet pressure 360 mbar
Valves V1+V2class A group 2 in accordance with EN
161
Governor class A group 2 in accordance with EN88
Ratio V PBr:PL 0,75:1-3:1
Filter according to DIN 3386
Ambient temperature -15°C- +70°C
Protection standard type IP54 (according to IEC 529,
DIN 40050)
-
-
-
-
-
-
-
Gas family 1 +2 +3
Outlet pressure 0,5 - 100 mbar
Zero point adjustment N ±2 mbar
Pressure switch DIN3398 TI
Fan pressure PL0,4-100 mbar
Fire room pressure PF -2 -+5mbar
Burner pressure PBr 0,5 - 100 mbar
-
-
-
-
-
-
-
TECHNICAL DATA WITH RATIO ADJUSTMENT
172 215 16 07-01
PBr = PBr - PF
PL= PL-PF
!
!
PL, max. = 100 mbar
PBr max. = 100 mbar
V=3:1
V=1:1
V=0,75:1
V
V=3:1
V=1:1
V=0,75:1
+ N
- N
∆pBr, min =0,5 mbar
∆pL, min =0,4 mbar
∆ PBr
∆PL
∆PL
∆ PBr
{
{
N=-2
N=+2

172 305 68 07-01
Adjustment of gas ow
Before the burner starts vent
the lines to make sure that there
is gas available at the multibloc
Use an allen key size 2,5 mm
for adjusting N and V.
Connect a pressure gauge for
measuring PBr,(advisabletond
out if the valves are open)
Set the switch in position MAN.
Set the gas pressure switch
min. and air pressure switch on
min. adjustment. Set the gas
pressure switch max, if any, on
max. adjustment.
–
–
–
–
–
If necessary repeat the controls
of the adjustment made on min.
(N) and max. load(V).
Thedesiredgasowonmin.
and max. has now been ad-
justed by changing the orange
and the red cams. Check the
gasowonthegasmeteravai-
lable on the installation.
Note! Do not forget to set the air
and gas pressure switches after
the adjustment, see special
instructions.
Releasing button
By pressing the button and snap-
ping it down, the motor will be
released and the damper can easily
be turned. This function facilitates
an exchange of damper motor.
–
–
–
Start the burner, observe the
pressuregauge,ifnoameis
established and the pressure
gaugeneedledoesnoticker,
increaseN.Whentheameis
establishedadjustthegasow
by means of the screw N. Use a
uegasinstrument.
Change over to max. load,
press the switch “increase”
AdjustthegasowwithVand
check at the same time the
combustion values.
Go back to min. load and check
the combustion value. Adjust if
necessary.
–
–
–
–
Damper motor, air volume
Adjust the orange cam for min. load
(about 5-10 on scale)
Adjust the red cam for max. load
(90° )
The blue cam is factory set for
closed position during standstill
The black cam has no function at
modulating operation
ADJUSTMENT OF GAS FLOW
Max. load (red)
Min. load (orange)
Closed damper (blue)
Gas valve (black)
Releasing button N.B.
The upper position is
the standard position

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
inaccordancewithboilermanu-facturers
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 installers of gas burners should
therefore be acquainted with all regu-
lations 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 accom-
panying 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.
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, com-
bustion 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 adjust-
ment device changing the position of
thebrakeplateintheburnerhead.This
is used to adjust the correct 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.
172 305 28 07-01
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 com-
bustion 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 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).
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 29 07-01
GENERAL INSTRUCTIONS
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ow.
It is therefore always necessary to
makeaneadjustmentoftheairby
means of the air adjustment device
of the burner.
Control of burner head
To check the burner head, brake plate
andelectrodesproceedasfollows:
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 the inner assembly can be
pulled out.
Adjustment of inner assembly
Control of burner head