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Summary of Contents for Bentone BG 800i M Biogas
- Page 1 178 034 82-5 P93783 2023-03-15 Providing sustainable energy solutions worldwide Installation- and maintenance instruction BG 800i M Biogas LMV37 MB-VGD 4.80 IP40 Translation of the original instructions.
- Page 2 1~230V 1,0A 50Hz IP 20 Motor supply MADE IN SWEDEN BY 1. Manualer på övriga språk 1. Manuals in other languages 1. Manualer på andre sprog 2. www.bentone.com\ 2. www.bentone.com\download 2. www.bentone.com\ nedladdning eller scanna or scan QR-code. download eller scan QR-koden.
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Page 3: Table Of Contents
Instructions .................. 84 Handing over of the installation ........113 Inspection and maintenance ............ 84 Troubleshooting ...............114 Preparation for assembly ............84 Gas supply ..................84 Service- and inspection protocol ........116 Electric connection ..............84 Handling and lifting instruction ..........85 Bentone... -
Page 4: General Information
Make sure that the burner is suitable for the application (see Technical • Data). All components must be installed without being bent, twisted or • subjected to mechanical or thermal forces that affect components. 172 515 01-2 2021-10-05 Bentone... -
Page 5: What To Do If You Smell Gas
Prevent open fl ames or sparking, e.g. do not turn lights on or off, do • not use any electrical appliances or mobile phones. • Evacuate the building. Notify the installer or gas supplier of the problem so that it can be • rectifi ed. Bentone... -
Page 6: Technical Data
A measure B measure C ø260 ø205 ø260 ø205 *730 *1022 **200 * The above dimensions are max. measurements. Depending on the components used, the measurements may vary. ** Min. recommended distance to floor. 172 545 03-1 2023-03-15 Bentone... -
Page 7: Capacity Range
HR, HU, IE, IS, IT, LT, LU, LV, MK, MT, NL, NO, PL, PT, RO, 40 mbar RS, SE, SI, SK, TR AT, CH, CY, DK, FI, LT, RO, SE, SK 40 mbar 2H3B/P GB, IE 40 mbar 2H3P NL, RO 40 mbar 2L3B/P 40 mbar 2E3B/P 40 mbar 2E(R)B 40 mbar Bentone... -
Page 8: Technical Specification
Installation must be done so it does not prevent air supply to the burner. Working field mbar G20, G25, G31 - 380-2400 kW Do not exceed working field. 1000 1200 1400 1600 1800 2000 2200 2400 Bentone... -
Page 9: Components
Change-over switch, Fixing flange Gas valve (MultiBloc) increase-decrease Gas pressure switch, min Transformer Air damper Burner Control Ball valve Air intake Contactor + Overload Damper motor Ignition electrodes protection Reset button Flame detector Cover, inspection glass Air pressure switch Bentone... -
Page 10: Skeleton Diagram 2-Stage Burner, Biogas
Pressure regulator Main fl ow restrictor stage 1 Pressure outlet (min load) Gas valve Hydraulic brake stage 1 to 2 Leakage control (VPS) Safety valve on-off Gas pressure switch Pe Pa Pressure before valve Pressure between valves 172 515 72-2 Bentone... -
Page 11: Adjusting The Gas Train
If this is screwed in, the gas fl ow to the burner is increased by lifting the valve. This valve is always open and this opening is what gives the min-load. Adjust the air damper for stage 1 for good combustion. Bentone... -
Page 12: Electric Equipment
The cables of the safety system must be separated so that the outgoing signal the burner. is not placed in the same cable as the incoming signal. Wiring diagram 220920 Brown 151015 Blue Green Yellow Gn/Ye Green/Yellow Black Grey White Orange Violet 172 625 35-1 2023-03-01 Bentone... - Page 13 Contact damper motor, air SQM 33 Contact damper motor, gas SQN 13 AZL display for LMV automatic control unit Contactor + Overload protection Transformer Fuse holder Branching point/ measureing point for ionisation LMV Automatic control unit Quick release switch for regulator Bentone...
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Page 14: Automatic Control Unit Lmv37
Example: Modulating gas burner The system components (display and operating unit, actuators) are connected directly to the LMV37.4... basic unit. All safety-related digital inputs and outputs of the system are monitored by a contact feedback network. 172 525 67 Bentone... -
Page 15: General Information
6.3 AT (DIN EN 60127 2 / 5) Mains supply: Input current depending on the operating state of the unit Under voltage Safety shutdown from operating position at mains voltage LMV37.400A2 Approx. AC 186 V Restart on rise in mains voltage LMV37.400A2 Approx. AC 195 V Bentone... - Page 16 X5-02 pin 2/3 RAST plug Function / Outputs pin number X3-05 pin 1 X4-02 pin 2/3 X6-03 pin 2/3 X8-02 pin 1/3 X7-01 pin 2/3 X7-02 pin 2/3 X3-05 pin 2 0° 0° 0° Legend to the sequence diagrams Bentone...
- Page 17 Postpurge time (t3) Evacuation of test space Atmospheric pressure test Filling of test space Gas pressure test Gas shortage waiting time Valve proving is performed depending on the parameter settings: Simultaneously with the prepurge time and/or the afterburn time. Bentone...
- Page 18 Only with fuel train Lo and 2 fuel valves Parameter 223: Repetition limit value gas pressure switch-min in connection with gas shortage program parameter 246 (phase 90) Max. drop-in/response time for air pressure switch Alternative to valve proving Alternative to pressure switch-max (Pmax) or POC Bentone...
- Page 19 0°/10% Position as supplied (0°) 90°/100% Actuator fully open (90°) Input/output signal 1 (ON) Input/output signal 0 (OFF) Input permissible signal 1 (ON) or 0 (OFF) Bentone...
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Page 20: Connection And Internal Diagram
Protection earth (PE) Supply for fuel meter Input fuel meter Shielding: For shielding the cables on the VSD, refer to: Siemens SED2 VSD Commissioning Manual (G5192), chapters 4 and 7, or • Danfoss Operation Manual VLT 6000 (MG60A703), chapter Installation • Bentone... - Page 21 Speed feedback signal Speed feedback signal Signal reference PWM speed output PWM speed output Signal reference DC 24 V external DC 24V external Controller input 4...20 mA Controller input 4...20 mA Power source Power source Analog Analog Controller Controller Bentone...
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Page 22: Operation
- For changing to a higher menu level (press button for 3…8 s) - For changing the operating mode (press button for >8 s) Enter in parameter setting mode • /reset • Reset in the event of fault • One menu level down Bentone... - Page 23 Figure 4: Meaning of display Fault status message Flame present Valve controlled Ignition controlled Fan motor controlled Oil preheater on Heat request from controllers Parameter setting mode Info mode Service mode h min s Actuator closing Actuator opening Unit of current display Bentone...
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Page 24: List Of Phase Displays
Postpurge time (t3) (abortion when load controller ON) Ph80 Valve proving test evacuation time Ph81 Valve proving test time atmospheric pressure, atmospheric test Valve proving filling test, filling Ph82 Ph83 Valve proving time gas pressure, pressure test Ph90 Gas shortage waiting time Bentone... -
Page 25: Automatic Control Unit Levels
Change to normal Change to normal display display >3 s <8 s Info level /reset >3 s <8 s /reset or automatic return after timeout of menu operation Service level (parameter 127) >8 s >1 s Parameter level Parameter level Bentone... - Page 26 Basic unit Air-fuel ratio control curves (primary setting) /reset Bild 388e/1109 /reset Air-fuel ratio control /reset The following sections explain the Actuator operating philosophy behind the parameter levels using a number of examples. /reset Error histery /reset Process data Bentone...
- Page 27 Standardized speed Number of faults Error history: 701-725.01.Code 701. chronological error list index value of index Indexlista: 01 = error code 02 = diagnostic code 03 = error class 04 = error phase 05 = startup counter 06 = output Bentone...
- Page 28 The next bar starts flashing. h min s Complete the rest of the password according to the principle described. Example: Password consisting of 4 characters. min s After entery of the last character the password must be confirmed by pressing /reset Bentone...
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Page 29: Setting The Automatic Control Unit
400 for initial commissioning and for setting air-fuel controll. Press /reset 201: appears fl ashing. h min s Press to go to the settings for air-fuel ratio control and parameter 201 for selecting the operating mode. Bentone... - Page 30 20 = gas modulating with pilot only when firing on gas (Gp1 mod fuel active) • 21 = gas modulating with pilot only when firing on gas (Gp2 mod fuel active) • 22 = oil modulating only when firing on oil (Lo mod fuel active) • Bentone...
- Page 31 Select your setting by pressing one of the buttons to save the setting for parameter 542: VSD Press This manual describes “0=VSD OFF” type burners. /reset Press: to return to parameter level. To the next parameter . Back to the previous parameter Bentone...
- Page 32 P0 of the fuel damper. Press simultaneously Set a suitable fuel-air mixture so that the burner starts. Example: 30.0 h min s to set ignition position P0 of the air actuator. Press simultaneously Bentone...
- Page 33 To the next curvepoint P9 appears flashing. Curvepoint for high-fire. Same procedure as with P0 h min s Note: is pressed first, the display jumps to 90! Back to the previous curvepoint When curvepoint 9 is set, press to start the burner. Bentone...
- Page 34 This method makes the setting work easier and faster to complete. A more “correct” setting is obtained straight away. The process may need to be redone if the wrong input power was set for P9 initially. For this reason, be extremely careful when entering the first setting of P9. Bentone...
- Page 35 Phase Fan ramp up (fan motor = ON, safety valve = ON) h min s Phase Traveling to prepurge position h min s Phase Prepurging h min s Phase Traveling to ignition position h min s Bentone...
- Page 36 Phase Traveling to ignition position h min s Phase Preignition h min s Phase for first safety time (ignition transformer ON) h min s Phase for first safety time (ignition transformer OFF), preignition time OFF h min s Phase Interval 1 min s Bentone...
- Page 37 Move along to curvepoint (high-fire point) P9; allow the burner to reach high-fire point P9. When P9 flashes, press If the burner goes into blocking mode when increasing to full load, restart the setting procedure and adjust the curvepoints in order to avoid the burner entering blocking mode. Bentone...
- Page 38 The setting curve is therefore adjusted to the highest input power that the installation can handle. The desired input power is then set by entering how much of the maximum power is required. Bentone...
- Page 39 When symbol or is no longer highlighted, you can press ESC a second time. h min s to exit parameter level. Press h min s The settings for air-fuel ratio control by the LMV37.4... are now completed. Bentone...
- Page 40 0 = QRB / QRC 1 = ION / QRA Factory settings marked with bold text. When replacing detector flame between ionisation and UV-cell (QRA), no change to the setting parameters is required; simply disconnect and connect ionisation and UV-cell (QRA) respectively.. Bentone...
- Page 41 When the Purging in the lockout position function is used, the fan may only be powered via a contactor and must not be connected directly to LMV37.4 (X3-05 pin 1)! Bentone...
- Page 42 23 hours and 45 min of uninterrupted operation, followed by an automatic restart. When forced intermittent operation is inactivated the burner will run continuously. Forced intermittent operation is a standard feature. 239 Gas: Forced intermittent operation 0 = inactivate 1 = activated Factory settings marked with bold text. Bentone...
- Page 43 After login is complete, continue with the setting work as shown below. h min s to select parameter 400 for initial commissioning and for setting air-fuel ratio control Press /reset Identifi cation of start for setting the curve parameters. h min s Bentone...
- Page 44 The value is adopted from P0. For fuel, keep depressed, for air , to adjust the value. Press h min s When symbol is no longer highlighted, the next curvepoint P2 can be selected with To the next curvepoint back to the previous curvepoint Bentone...
- Page 45 If required, readjust the gas pressure. For fuel, keep depressed, for air , to adjust the value. Press h min s When symbol is no longer highlighted, the curve is set and it is possible to go on with the rest of the setting. Bentone...
- Page 46 Adjust the setting downwards or upwards using the buttons h min s Press to save the setting. /reset to return to parameter level. Press Back to the previous Completing parameter parameterization of the curve Bentone...
- Page 47 ESC a second When symbol time. h min s h min s The warm settings for air-fuel ratio control by the LMV37.4... are now completed. Bentone...
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Page 48: Backup And Restore
After login is complete, continue with the setting work as shown below. for parameter level 000. Press Press /reset Display: Parameter 050, flashes, index 00, and value 0 do not. /reset Display: Parameter bAC_UP /reset Display: Value 0 Bentone... - Page 49 If an errror occurs during the backup process, a negativ value is displayed. For error diagnostics, the cause of the error can be determined from the diagnostic code of error message 137 (see Error code list) four times until the top menu is displayed. Press Bentone...
- Page 50 Display: Parameter 050, flashes, index 00, and value 0 do not. /reset Display: Parameter bAC_UP to select parameter rESstorE Press /reset Dispalay: Value 0 to select the restore process. Press /reset to shift the value in change mode 1 position to the left. Press Bentone...
- Page 51 Press /reset Dispalay: 1 appears After about 8 seconds (depending on the duration of the program), 0 appears on the display, indicating the end of the backup process. Display: 0 four times until the top menu is displayed. Press Bentone...
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Page 52: Fault Status Message, Display Of Errors And Info
SEr and then OPErAtE. For a list of parameters, see table 5.3.3. >5 s /reset h min s When the button is released, a change to info / service mode is made. >8 s /reset h min s Bentone... - Page 53 The unit initiates safety shutdown. The display shows current error code c: alternating with diagnostic code d:. h min s 1...3 s, to return to the normal display. Press /reset Example: Error code 12 / diagnostic code 0 h min s Bentone...
- Page 54 Press .01 = error code .02 = diagnostic code .03 = error class .04 = error phase .05 = startup counter h min s .06 = output Example: Parameter 701., index 05: for startup counter, diagnostic code ._._ /reset Bentone...
- Page 55 . Back to the previous index To the next index When this display appears, you have reached the end of the error history. Display – End – appears flashing. h min s Press twice. HISt 700: for error history h min s Bentone...
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Page 56: Dispaly Message Of Info
OFF UPr. h min s 5.7.3 Safety loop A unit whose safety loop and / or burner flange contact is open, and a controller ON signal is present, displays OFF S. h min s Bentone... -
Page 57: Resetting The Automatic Control Unit
Select another burner type than the one already selected by pressing one of the buttons Confirm this selection with The automatic control unit is now reset. /reset h min s Restart the setting process for the LMV automatic control unit as specified in 3.2.1. Bentone... -
Page 58: Manual Output
Manually OFF must not be used just to put a burner out of operation when doing mounting work, or when the burner is not ready for operation. The safety notes contained in chapter Safety notes must be observed! Bentone... -
Page 84: Installation
Connection must be done in accordance with the applicable • regulations. • Connection must conform to the wiring diagram. If any electrical connection other than that recommended by Enertech is used, there is a risk of property damage and personal injury. 172 535 09-2 Bentone... -
Page 85: Handling And Lifting Instruction
Handling and lifting instruction Lifting kits can be purchased as accessories. 172 515 37 Bentone... -
Page 86: Mounting
Connect the gas line, connect the supply cable, operating and safety circuits. Before obtaining access to electrical and fuel line components all supply circuits must be disconnected. 172 515 38-2 2023-03-09 Bentone... -
Page 87: Gas Nozzle
Gas nozzle Check that the ignition electrodes are correctly set before mounting on the boiler. Natural gas ≈ 1 15-20 Propane ≈ 1 Biogas (UV detector) Bentone... -
Page 88: Aerating
If leaks are found during measurement, locate the source using soapy water or leak detection spray. After sealing: check the leakage of the gas fixture again. Check for leaks in the gas line. Bentone... -
Page 89: Calculate Prepurge Time, Industrial Applications
The prepurge time must correspond to at least 5 complete air circulations in the fire box and adapted compartments. Calculate prepurge time using the following formula: V · 5 16.8 m · 5 150 s Q · 1.2 / 3600 1680 kW · 1.2 / 3600 172 535 97 2023-03-13 Bentone... -
Page 90: Calculation Of Gas Flow
Butan 32.25 116.09 Natural gas 29.25 Propan 24.44 88.00 Biogas 21.60 Lower calorific value H at normal conditions 15 °C and 1013 mbar, EN 676. For exact calorific value of the gas, contact the gas distributor. 172 515 53 Bentone... -
Page 91: Settings
Gas quality % CO Lambda 1.2 ≈10 Natural gas 3 - 5 11.9 ≈11.5 Propane 3 - 5 13.9 ≈11.5 Butane 3 - 5 14.1 Liquefied ≈11 3 - 5 13.8 petroleum gas Biogas 3 - 5 172 525 62-2 2023-03-10 Bentone... -
Page 92: Setting The Air Pressure Switch
Measure and note the lowest air pressure in the entire work area. Set the air pressure switch to about 10-15% lower than the lowest noted pressure. Test run the burner and check the function in the entire work area. Refi t protective cover. 172 535 11-2 Bentone... -
Page 93: Setting The Gas Pressure Switch, Min
When the gas pressure switch stops the burner, the measured value must approximately correspond to the setting on the gas pressure switch. Open ball valve. Remove manometer and close measuring socket. Refi t protective cover. Check gas tightness. 172 535 12-2 Bentone... -
Page 94: Setting The Gas Pressure Switch Max/ Overload Protection Switch
Set the gas pressure switch to a value 10-15% lower than the noted pressure. Test run the burner and check the function in the entire work area. Remove manometer and close measuring socket. Refi t protective cover. Check the gas tightness. 172 535 17-3 Bentone... -
Page 95: Damper Motors
60 sek Angular adjustment Usable range max. 90° Degree of protection IP40 0.7° Rated resolution encoder monitoring 0-position of actuator drive shaft Supply state 0 +2°/-2° Environmental conditions: Temperature range -10...+60 °C <95% r.h. Humidity 172 525 66-1 2021-05-20 Bentone... - Page 96 One-time bend when laying the cable: 2 x cable diameter • Always run the high-voltage ignition cables separate from the unit • and other cables while observing the greatest possible distance. The holding torque is reduced when the actuator is disconnected • from power. Bentone...
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Page 97: Damper Motor Sqm
50%, max. 3 min. continuously Perm. on time Angular adjustment Usable range max. 90° Degree of protection IP54 0.7° Rated resolution encoder monitoring 0-position of actuator drive shaft Supply state 0 ±0.6° Environmental conditions: Temperature range -20...+60 °C <95% r.h. Humidity Bentone... - Page 98 One-time bend when laying the cable: 2 x cable diameter • Always run the high-voltage ignition cables separate from the unit • and other cables while observing the greatest possible distance. The holding torque is reduced when the actuator is disconnected • from power. 172 525 66-1 2021-05-20 Bentone...
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Page 99: Gas Damper Dmk
Flanged versions: DMK 5065 and 5080 DMK 5065 and 5080 Environmental conditions: Temperature range -15...70 °C Humidity <95% r.h. Gas qualities No nonferrous materials. Suited for use with gases up to max. max. 0,1 vol. % H2S, dry 172 515 94 2018-08-10 Bentone... - Page 100 After working on a gas damper, check the gas tightness • Seal aluminum against aluminum parts with Synthesol Vlies or similar. • Seal aluminum to other materials with Synthesol Vlies, Loctite 5188 or • equivalent sealing material. Bentone...
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Page 101: Gas Valve, Multibloc Vgd40
Gas valve connection flange VGD40.65/SKP15/25 DN65 VGD40.80/SKP15/25 DN80 Environmental conditions: Temperature range -10...60 °C Humidity <95% r.h. Gas qualities No nonferrous materials. Suited for use with gases up to max. max 0,1 vol. % H2S, dry 172 515 90 2018-08-10 Bentone... -
Page 102: Overview
The burner can also be fi tted with an additional gas pressure switch to monitor that the nozzle pressure does not get too high. Bentone... -
Page 103: Installation Position
Pa, see image. Turning to right = higher regulator pressure Turning to left = lower regulator pressure Fit protective plug X. Possible output pressure range 15–120 mbar. Pressure is measured at the pressure outlet on SKP25. See section 10.2.2. Bentone... - Page 104 When replacing the impulse pipe, a steel pipe must be used with an inside diameter > 4 mm. The impulse pipe must be protected again breakage and damage. If damage should occur, the impulse pipe must be replaced before the burner is put into operation again. Bentone...
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Page 105: Service
Replacement upon fault detection Gas pressure switch 10 years 250,000 starts Safety blow-off system 10 years Damper motor 500,000 starts Contactor 10 years 500,000 starts The burner and its components must be recycled according to applicable regulations. 172 615 88-2 2022-09-08 Bentone... -
Page 106: Combustion Device
Switch on the main power and open the fuel supply. Start burner and check/adjust combustion. Check for leaks in the gas line. When servicing/replacing components that affect combustion, flue gas analysis and soot test must be carried out following installation. 172 615 17-2 2023-03-09 Bentone... -
Page 107: Air Damper
Fit the intake grille. Press the burner together and lock with nut (B). Switch on the main power and open the fuel supply. Start burner and check/adjust combustion. 172 525 50 2023-03-09 Bentone... -
Page 108: Fan
Refi t the parts. Switch on the main power and open the fuel supply. Start burner and check/adjust combustion. When servicing/replacing components that aff ect combustion, fl ue gas analysis and soot test must be carried out following installation. 172 625 33 Bentone... -
Page 109: Vibrations
• Check tightness of fasteners. Check fan wheel for damage and contamination (replace if necessary). • Check motor shaft and bearings. If they are worn, replace the motor. • Use screw to attach the vibration sensor. 172 625 05 2022-09-23 Bentone... -
Page 110: Flame Monitoring And Ionisation Current Check
Max. DC 16…40 µA, flame display approx. Possible detector current 100% Threshold values when flame is supervised by an ionization probe: Intensity of flame (parameter 954) ≥18% - Start prevention (extraneous light) Intensity of flame (parameter 954) >24% - Operation X10-05,2 172 615 57 2018-08-10 Bentone... -
Page 111: Flame Detector Qra
- Simultaneous operation of QRA... and ionization probe is not permitted! Threshold values when fl ame is supervised by QRA...: Start prevention (extraneous light) Intensity of fl ame (parameter 954) ≥18% • Operation Intensity of fl ame (parameter 954) >24% • 172 525 64-1 2021-04-26 Bentone... -
Page 112: Replacement Of Electrical Components
Switch on the main power and check the operation of the new component. Start burner and check/adjust combustion. When servicing/replacing components that affect combustion, flue gas analysis and soot test must be carried out following installation. 165 105 11-3 Bentone... -
Page 113: Handing Over Of The Installation
Instruct the persons in charge of the operation on the service and • maintenance of the installation and what to do should any troubles occur. Inspection and service must be carried out by authorized personnel. • Review and service should be performed by authorised personnel only. 172 615 04-2 Bentone... -
Page 114: Troubleshooting
Voltage lower than 185V. Contact an electrician. Ignition electrodes disrupting ionisation current. Adjust ignition electrodes. Re-polarise the transformer. Poor earth connection. Ensure adequate earth connection. Phase and neutral swapped around. Check wiring diagram and change accordingly. 172 615 06 2018-01-10 Bentone... - Page 115 Flame at incorrect angle due to combustion head out of Check the combustion head and readjust. position. Condensation build up in boiler and chimney: Raise the flue gas temperature by increasing gas volume Insulate Flue gas temperature too low or gas volume too low. the chimney. Bentone...
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Page 116: Service- And Inspection Protocol
16. Service- and inspection protocol Installation Boiler Efficiency kW: Name: Type: Address: Burner Efficiency kW: Type: Installed by: Date: Date gas/h Efficiency Governor Fluegas Ionisation Pressure temp current Fire Chimney room Measure- °C µ A ment Before After mbar mbar Small Flame Large Flame... - Page 117 EU Declaration of conformity Bentone Gas Burners Certifi cate No. Certifi cate No. Type: Type: BFG 1 CE-0123CT1269 BG 550 CE-0123CT1326 STG 120 CE-0123CT1270 BG 650 CE-0123CT1348 STG 146 CE-0123CT1281 BG 700 CE-0123CT1359 BG 300 CE-0123CT1292 BG 800 CE-0123CT1360 BG 400...
- Page 118 UK Declaration of conformity Bentone Gas Burners Type: BFG 1 BG 300 BG 550 BG 800 STG 120 BG 400 BG 650 BG 950 STG 146 BG 450 BG 700 This declaration of conformity is issued under the sole responsibility of the manufacturer.
- Page 120 Enertech AB. P.O Box 309, SE-341 26 Ljungby www.bentone.com...
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