Enertech Bentone BFG1 Series Installation And Maintenance Instruction
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Summary of Contents for Enertech Bentone BFG1 Series
- Page 1 178 088 35-4 2018-03-13 Providing sustainable energy solutions worldwide Installation- and maintenance instruction BFG1 2-stage...
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Page 3: Table Of Contents
General Table of contents GENERAL 4. Burner Service ____________________________________________________________ 4.1 Service __________________________________________________________________ 1. General Information _______________________________________________________ 4.1.1 Combustion device service ___________________________ Safety instructions ______________________________________________________ 4.1.2 Fan motor replacement ________________________________ Actions to take if you smell gas ____________________________________ 4.1.3 Air intake and inlet cone service ____________________ Burner servicing schedule ___________________________________________... -
Page 4: General Information
• work with the burner may only be carried out by certifi ed installers/ personnel Enertech AB is not liable for any typographical errors and reserves the right to make design changes without prior notice. Safety instructions • The burner may only be used for its intended purpose in accordance with the product’s technical data. -
Page 5: Actions To Take If You Smell Gas
• The electrical installation must be professionally carried out in accordance with applicable high voltage regulations, as per Enertech’s recommendations. • Before servicing, shut off the fuel supply and turn off the power to the burner. • Seal inspections must be performed during installation and servicing to prevent gas leakage. -
Page 6: Burner Servicing Schedule
Burner servicing schedule Servicing must be carried out once a year or after 3000 hours of operation Burner 1 year 3000 hrs Inspection of electrical installation 1 year 3000 hrs Leakage check 1 year 3000 hrs Filter 1 year replacement at ∆p>10 mbar 3000 hrs replacement at ∆p>10 mbar Electrodes... -
Page 7: Technical Data
2. Technical data 2.1 Burners are intended for use at: • Hot water boilers in intermittent operation 2.2 Dimensions • Gas connection ¾-1¼” The above-mentioned measurements are maximum measurements. They can vary, depending on which components are used. 1.0.1 Dimensions flanges Flange 3 109,5 23,5... -
Page 8: Capacity Range Bfg1 H3
2.3 Capacity range BFG1 H3 Capacity Gas quantity Gas quantity at min. power at max. power BFG1 H3 25 - 100 kW G 20 2,65 10,58 G 25 3,10 12,41 G 30 0,75 3,10 G 31 1,02 4,09 MB-Bloc Max. connection Min connection pressure mbar pressure mbar... -
Page 9: Gas Categories, Approved Gases
2.3.1 Gas categories, approved gases Only dry gas is permitted for use Gerätekategorien Versorgungsdrücke Bestimmungsländer Bermerkungen appliance categories supply pressures countries of destination remarks II2H3B/P 20:30/360 mbar AT,CH,CZ,DK,EE,FI,GR,HU IS,IT,LT,NO,SE,SK,SI,TR II2E3B/P 20:30/360 mbar LU,PL II2H3P 20:30/360 mbar ES,GB,IE,PT II2ELL3B/P 20:25:30/360 mbar II2Er3P 25:30/360 mbar II2L3B/P... -
Page 10: Model Bfg1-2 H3
2.4 Model BFG1-2 H3 29,0-31,0 2,5-3,5 7,5-8,5 Blast tube length Blast tube Flange Dimension A mm Dimension B ø 121,5 221,5 The above-mentioned measurements are maximum measurements. They can vary, depending on which components are used. Do not exceed working 2.4.1 Burner output/ Basic settings field 22,0... -
Page 11: Description
2.5 Description 26 25 Bentone BFG1... -
Page 12: Components
2.5.1 Components Multiblock Adjustment gas valve, first stage Adjustment gas valve, second stage Protective cover start gas adjustment Adjustment regulator pressure Electrical contact, Multiblock Electrical contact, gas pressure switch S9 Gas pressure switch Connection multiblock Ignition transformer Gas burner control Electrical contact, X3 (see wiring diagram) Motor Capacitor... -
Page 13: Installation
3. Installation 3.1 Skeleton diagrams Incorporated in the multiblock Ball valve Filter Pressure regulator Outlet for gas pressure measuring Gas pressure switch, min. Gas pressure switch, max. Main valve Safety valve Leakage control Air pressure switch Gas burner control Pos. 5b: Components not required acc. to EN 676. Required above 1200 kW acc. -
Page 14: Delivery Check
fit directly to the burner. If not, use the connectors included. (Refer to connection under Electric equipment) If an electric connection other than the one recommended by Enertech is used, a risk of damage and injury can arise. 3.6 Setting brake plate and air flow Before the placing into service, the burner should be initially set according to diagram. -
Page 15: Burner Installation
3.7 Burner installation 3.7.1 Hole pattern Check that the hole pattern on the boiler matches that of the flange. (Refer to Technical data.) 3.7.2 Burner installation Install the flange with gasket on the boiler. Insulate between the blast tube and the boiler door to minimize heat radiation. -
Page 16: Control Measures
3.8 Control measures 3.8.1 Gas quality Check that the combustion head is intended for the gas quality to be used (refer to Technical data). 3.8.2 Bleeding Bleeding of the gas pipe can be achieved by removing the screw on the test nipple for the inlet pressure. -
Page 17: Recommended Excess Air When Using Default Setting
3.9 Recommended excess air when using default setting Grade of gas Excess air flue gases Max. % CO % CO Lambda 1.2 Natural gas 3–5 ≈10 11.9 Propane 3–5 ≈11.5 13.9 Butane 3–5 ≈11,5 14,1 Liquefied petroleum 3–5 ≈11 13,8 gas (LPG) 3.10 Determining the gas quantity for the system... -
Page 18: Example Of How To Calculate The Gas Quantity (Natural Gas G20)
3.10.1 Example of how to calculate the gas quantity (natural gas G20): Desired quantity of gas Boiler output [kW] Gas heat value [kWh/Nm ] or [MJ/Nm ] or [kcal/ Nm3] η Boiler efficiency Calculation example: 50 kW Example A: 34020 MJ/Nm Example B: 9.5 kWh/Nm Example C: 8126 kcal/Nm η... -
Page 19: Calculating The Quantity Of Gas Supplied
Calculation example: T = 15°C B = 945 mbar P = 15 mbar 945+15 ≈ 0.90 Nm 273+15 1013.25 This means that the quantity of gas read from the gas meter should actually be read off as 1.11 . the calculated flow in a normal state. 0.90 ≈... -
Page 20: Nozzle Assembly Adjustment
3.11.1 Nozzle assembly adjustment The burner is equipped with a control which changes the position of the brake plate in the blast tube. This is used to set the correct pressure differential across the combustion device and thereby get a good combustion without pulsations. The setting to be used depends on the set effect and the overpressure in the boiler. -
Page 21: Inlet Cone, Air Control
3.11.4 Inlet cone, air control The air flow is also affected by the position of the intake cone. This rarely needs adjustment, however, and should be maintained in the standard position ”STD” for good operation and starts. (A cast-in arrow on the fan housing indicates the position of the inlet cone. -
Page 22: Burner Service
4. Burner Service 4.1 Service Service should be performed after approx. 3000 working hours, but no less than once a year. Only authorized personnel should perform the service. Warning Before any kind of service is performed, switch off the current with the line breaker and turn off the gas supply. -
Page 23: Fan Motor Replacement
4.1.2 Fan motor replacement Switch off the main current, disconnect the 7-pole Euro plug from the burner and turn off the gas. Loosen the screw assembling the front piece of the burner and the fan housing, but not more than that the fan housing can be removed from the front piece. -
Page 24: Air Intake And Inlet Cone Service
4.1.3 Air intake and inlet cone service Switch off the main current, disconnect the 7-pole Euro plug from the burner and turn off the gas. Loosen the screw assembling the front piece of the burner and the fan housing, but not more than that the fan housing can be removed from the front piece. -
Page 25: Fan Wheel Check
4.1.4 Fan wheel check 4.1.4.1 Inspection Switch off the main current, disconnect the 7-pole Euro plug from the burner and turn off the gas. Loosen the screw assembling the front piece of the burner and the fan housing, but not more than that the fan housing can be removed from the front piece. -
Page 26: Electrical Package
4.1.6 Electrical package Check that the screw holding the electrical bracket is tightened so that good earth connection between the package and the burner body is obtained. Use only electric components recommended by Enertech. Warning 4.1.6.1 Complete electrical package replacement Switch off the main current, disconnect the 7-pole Euro plug from the burner and turn off the gas. -
Page 27: Single Electrical Package Component Replacement
4.1.6.2 Single electrical package component replacement Switch off the main current, disconnect the 7-pole Euro plug from the burner and turn off the gas. Loosen the screw assembling the front piece of the burner and the fan housing, but not more than that the fan housing can be removed from the front piece. -
Page 28: Multiblock Mb-Zrdle 405-412
4.2 Multiblock MB-ZRDLE 405-412 All gasline components shall be assembled and mounted without bending, torque and outher me- chanical or thermal stress. Gas pressure switch Max. inlet pressure: 360 mbar. Adjustable governor pressure: Inlet pressure 405 - 412 S50 = 4 - 50 mbar Governor with pressure adjustment 415 - 420 S20 = 4 - 20 mbar Hydraulic device, adjustment of stage 2... - Page 29 Flow adjustment 2-stage design Adjustment of start gas flow For stage 1, loosen the lock screw a. Turn the hydraulic Remove the protective cover c. device e: Turn the adjustment knob d (use the protective cover as to the right = the gas flow is reduced a tool) to the desired start gas flow.
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Page 30: Pressure Taps
4.2.1 Pressure taps 1,2,3,4,5 1/8 screwed sealing plug 4.2.2 Electrical connection S 20/S 50 172 515 11 2018-01-03 Bentone... -
Page 31: General Instructions
5. General instructions 5.1 Flame monitoring and ionisation current check The burner is monitored according to the ionisation principle. The ionisation current should be checked at initial starting and at each service visit. The reason for low ionisation current can be leakage current, poor connection to earth, fouling or incorrectly placed ionisation electrode in the combustion head. -
Page 32: Setting Of Air Pressure Switch
5.1.4 Setting of air pressure switch The air pressure switch should block the burner if the air quantity is insufficient. The air monitoring device should be set so that, if there is missing air supply at the burner’s max. or min. capacity, it reacts before the monitored pressure is less that 80% of the pressure on the controlled stage and before the CO-level in the flue gases exceeds 1 per cent by volume. -
Page 33: Setting Gas Pressure Switch Min
5.1.5 Setting gas pressure switch min The min. switch should react to a gas pressure that is too low and prevent start of the burner. Too low a gas pressure during operation should stop the burner. The burner can start again when the nominal gas pressure has been corrected. Remove the protective cover. -
Page 34: Handing Over Of The Installation
5.1.7 Handing over of the installation • Perform repeated start tries to check that the settings work. • Close the ball valve during operation to check that the gas pressure switch breaks at set value. • Remove the hoses for the air pressure switch to check that the burner goes into blocking. -
Page 35: Electric Equipment Lme
6. Electric equipment LME... 6.1 Wiring diagram Bentone BFG1... -
Page 36: List Of Components
6.1.1 List of components Huvudbrytare Gas burner control Lufttryckvakt Valve, leak tester, Dungs VPS504 (optional) Gas pressure switch Ionization electrode External reset (optional) UV-detector QRC (LME23...) Ignition transformer Operating fuse Gas solenoid valve 1 Lamp, low capacity Gas solenoid valve 2 Burner motor Plug-in contact, burner Damper Motor STM6SF-L... -
Page 37: Control Program At Faults; Fault Mode Indicator Lme
6.2 Control program at faults; fault mode indicator LME ..6.2.1 Colour codes Table colour codes for multi-coloured signal light (LED) Status Colour codes Colours ○………………… Waiting period «tw», other waiting periods •○ •○ •○ •○ •○ • Ignition phase, ignition controlled Blinking yellow □…………………... -
Page 38: Alarm Code Table
6.2.1.3 Alarm code table Red blinking code Possible causes signal lamp (LED) Blinking 2 x No flame creation at End of “TSA” - defective or fouled flame monitoring - defective or fouled fuel valves - poor burner setting - defective firing device Blinking 3 x “LP”... -
Page 39: Troubleshooting
7. Troubleshooting Gas Burner Conditions favourable to disruption-free operation of the system can only be guaranteed through the interaction between three factors – electricity, gas flow and combustion air. A change in any of these factors may cause disruptions. It has been shown that a large proportion of disruptions can be attributed to relatively small things. - Page 40 Cause of fault Action Burner control faulty Replace Air pressure gauge incorrectly set or faulty Check the settings and reset, or replace No acknowledgement signal due to incorrect adjustment or Check the settings and realign. misalignment of the control motor cams. Burner trips after safety time limit despite flame propagation No ionisation current or UV cell incorrectly positioned Adjust ionisation electrode and UV cell...
- Page 41 Cause of fault Action Flue gas temperature too high Boiler overloaded Decrease the gas volume, sweep the chimney if necessary content too low Choke the air supply. Check the boiler for any leakages. Choke the draught if too high CO content too high Surplus air when using natural gas and liquefied petroleum Choke the air supply (propane, butane)
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Page 42: Declaration Of Conformity
11. EU Declaration of conformity 8. DECLARATION OF CONFORMITY Bentone Gasburners 172 905 04 2018-02-15... -
Page 43: General Instructions For Gasburners
9. General instructions for gasburners 9.2.1 Installation Follow standards and instructions applicable to the Check that the burner is adapted to the gas quality in installation of gas burners question Ensure that the electric installation is made in accordance Check that the input pressure of the gas is correct with existing regulations Check that the dampers of the boiler are open Check that the fresh air intake of the boiler room is... - Page 44 Service- and inspection card Installation Boiler Name: Type: Efficiency kW: Address: Burner Type: Efficiency kW: Installed by: Date: Date gas/h Governor Fluegas Ionisation Pressure Efficiency temp current Fire Chimney room Measu- rement Before After °C µ A mbar mbar Small Flame Large Flame...
- Page 48 Enertech AB. P.O Box 309, SE-341 26 Ljungby. www.bentone.se, www.bentone.com...
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