Bentone BG 400-2 Installation And Maintenance Manual
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Bentone BG 400-2 Installation And Maintenance Manual

Bentone BG 400-2 Installation And Maintenance Manual

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Installation and Maintenance Manual
BG 400 M
LME22.233C2
Jumo dTRON 316
MB-VEF 412
Translation of the original instructions.
Keep for future use.
Read carefully before use.
178 076 74-8 CR00783 2024-06-17

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Summary of Contents for Bentone BG 400-2

  • Page 1 Installation and Maintenance Manual BG 400 M LME22.233C2 Jumo dTRON 316 MB-VEF 412 Translation of the original instructions. Keep for future use. Read carefully before use. 178 076 74-8 CR00783 2024-06-17...
  • 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\nedladdning eller 2. www.bentone.com\download 2. www.bentone.com\download eller scanna QR-koden. or scan QR-code. scan QR-koden.

  • Page 3: Table Of Contents

    BENTONE Table of contents General Information ............5 Mounting ................35 Delivery inspection................ 5 Gas nozzle..................36 Safety ....................5 De-aerating ................... 37 What to do if you smell gas ............6 Leakage control ................37 6.4 Calculation of gas flow .............. 38 Technical data ...............7 Dimensions BG 400 M ..............

  • Page 5: General Information

    BENTONE General Information The burner may only be used for its intended purpose in accordance with the product’s technical data. We reserve the right to make design changes and cannot be held liable for any misprints or typographical errors. Modifying the design or using accessories or components that have not been approved by CTC in writing is strictly prohibited.

  • Page 6: What To Do If You Smell Gas

    BENTONE • Care must be taken by the installer to ensure that no electrical cables or fuel lines are pinched or otherwise damaged during installation or service. Sharp edges can occur on, for example: flame tube, fan wheel and air •...

  • Page 7: Technical Data

    BENTONE Technical data The burner is intended for: • Operation in installations according to EN 303 and EN 676. Fuels: • Natural gas H, E, L, LL. • LPG, Butane and Propane. Dimensions BG 400 M øC øB Flame tube...

  • Page 8: Gas Categories, Approved Gases

    Gas quantity Gas quantity at min. power at max. power connection connection pressure mbar pressure mbar BG 400-2 / BG 400 M G20  61 - 325 See data plate. 34.4 G25  61 - 310 38.1 G30  61 - 340 10.5 G31  61 - 350 14.3...

  • Page 9: Technical Specification

    BENTONE Technical specification BG 400 M Main supply 230V, 1~, 3.0A, 50Hz, IP20 Max fuse rating 6.3A -class 2 G20 / 3 G25, G30, G31 Noise level 85dBA Measurements according to EN 15036-1:2006 Alt.1 The noise level of the burner can be reduced by equipping the burner with silencer.

  • Page 10: Components

    BENTONE Components Switch 0-I Gas valve (MultiBloc) Motor Connection, gas fittings Changeover switch, Ignition electrode Man-Auto Air damper Transformer Cover, inspection glass Air intake Ionization electrode Reset button Gas pressure switch, Min. Nozzle Air pressure switch Burner control Brake plate...

  • Page 11: Skeleton Diagrams

    BENTONE Skeleton diagrams Ball valve Filter Pressure regulator Pressure gauge with shut-off cock Gas pressure switch, min Gas pressure switch, max Main valve, 2 -stage. In modulaing operation, this valve is equipped with controls for variable opening. Safety valve Leakage control...

  • Page 12: Electric Equipment

    BENTONE Electric equipment Safety system The safety system (safety switch for hatches, doors, water level, pressure, temperature and other safety devices) must be installed in the safety circuit in accordance with current regulations for the system. The cables of the safety system must be separated so that the outgoing signal is not placed in the same cable as the incoming signal.

  • Page 13: Function Lme

    BENTONE 3.2.1 Components Burner control time Ignition transformer Power control R316 Operating switch Connection terminal board A6(2) PT 100-sensor, Thermocouple, Control thermostat Earth terminal current/voltage Temperature limiter Plug-in contact, burner Ionization electrode Saftey switch for hinged door Plug-in contact, boiler...

  • Page 14: Control Program At Faults

    BENTONE Control program at faults 3.4.1 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 □………………… Normal operation Green □○□○□○□○□○ Operation, poor flame signal Blinking green □▲□▲□▲□▲□▲...
  • Page 15 BENTONE 3.4.4 Alarm code table Red blinking code on 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.

  • Page 16: Controller Jumo Dtron 316

    BENTONE Controller JUMO dTRON 316 Preface These brief operating instructions only cover those actions that are essential for starting up the controller. The complete configuration options can be found in the comprehensive Operating Manual or can be downloaded from: http://www.jumo.net.

  • Page 17: Electrical Connection

    BENTONE Electrical connection 4.4.1 Connection diagram L1(L+) N(L-)

  • Page 18: Displays And Keys

    BENTONE Displays and keys EXIT 7-segment display (factory setting: process value) four-digit, red, decimal place is configurable (automatic adjustment on display overflow) Active setpoint (factory setting: SP1) SP1, SP2, SP3, SP4 (SP=setpoint); green; 7-segment display (factory setting: setpoint) four-digit, green, decimal place is configurable; also used for operator...

  • Page 19: Operation

    BENTONE Operation 4.6.1 Levels The diagram below shows the three instrument levels. The diagram below shows the three instrument levels. Time-Out If no key is pressed for 30 sec, the instrument returns to normal display. 4.6.2 Level inhibit The access to the individual levels can be inhibited by entering a code number.
  • Page 20 BENTONE 4.6.3 Entering times When entering times (e.g. time of timer), the time unit is shown in addition. Select Alter parameter parameter I I I I I I I I I I I I I The highest time unit of the display is shown for the unit.
  • Page 21 BENTONE 4.6.5 Operation of the program controller The program controller will only function if - the program controller function has been configured ( Fnct = 1 ...4) - the program setpoints (SPP1 ... SPP8) and segment times (tP 1 ... tP 8) have been entered...

  • Page 22: Parameter Level „Para

    BENTONE 4.6.6 Operator level „OPr“ Process data ProC Symbol Meaning Setpoint 1 (editable) SP 1 Setpoint 2 (editable) SP 2 Setpoint 3 (editable) SP 3 Setpoint 4 (editable) SP 4 Ramp setpoint (only if configured) Measurement of analog input 1...

  • Page 23: Configuration Level „Conf

    BENTONE Configuration level „ConF“ Depending on the equipment level of the instrument, individual parameters or groups of parameters are switched out of display. Analog selector With some parameters, you can choose from a series of analog signals. The list below gives you an overview of the selection options.
  • Page 24 BENTONE Configuration level „ConF“ 4.8.2 Linearization 10 Thermocouple type U 0 Linear 11 Thermocouple type L 1 Pt100 12 Thermocouple type K 2 Pt500 13 Thermocouple type S 3 Pt1000 14 Thermocouple type R 4 KTY11-6 5 Thermocouple type C...
  • Page 25 BENTONE 4.8.5 Outputs „OutP“ Numbering of the outputs Standard: relay 1=output 1; relay 2=output 2; binary output 1=output 3; binary output 2=output 4 Slot Plug-in board with Plug-in board with Plug-in board with 1 analog output 1 binary output 2 binary outputs...

  • Page 26: Autotuning

    BENTONE Autotuning The autotuning facility can be used to automatically adapt the controller parameters to the process. The autotuning function determines the controller parameters for a PID controller or, if dt=0 is set, for a PI controller in a closed control loop.

  • Page 27: 4.11 Factory Settings Controller Jumo

    BENTONE 4.11 Factory settings Controller JUMO Controller with modulating operation and temperature sensor PT-100 (120 527 01) 4.11.1 Function Temperature Setpoint 1 (SP 1) the desired temperature is changed with the up or down arrow buttons, adjustable from 0-100 in the delivery version.
  • Page 28 BENTONE 4.11.2 Parameters ( 120 527 01) Hardware: Device type: 703041 JUMO dTRON 316 Parameter list: 12135101 Slots: Expansion slot 1: Changeover relay output Expansion slot 2: Not fitted Analog inputs (InP): Analog input 1 (InP1): Sensor type (SEnS): Resistance thermometer (3-wire)
  • Page 29 BENTONE Generator (Pro): Globals: Function (Fnct): Fixed-setpoint controller Basic status: Control contacts: SK 1: SK 2: SK 3: SK 4: Limit comparators (LC): 1. Limit comparator (LC1): Function (Fnct): lk 5 Limit value (AL): 5.000 Differential (HySt): 4.000 Hysteresis function:...
  • Page 30 BENTONE Logic functions (binF): Binary inputs: Binary input 1: Function (bin1): none Additional functions: none Binary input 2: Function (bin2): none Additional functions: none Limit comparators: 1.Limit comparator : Function (LC1): none Additional functions: none 2.Limit comparator : Function (LC2):...
  • Page 31 BENTONE other: Tolerance band signal: Function (TolS): none Additional functions: none Program end signal: Function (PrES): none Additional functions: none Text display: Static text: ALRT Display (diSP)/ Operation: Globals Function (upper display) (diSU): Process value Function (lower display) (diSL): Current setpoint...
  • Page 32 BENTONE Controller parameters: Parameter set 1: Proportional band Pb1: Pb2: 10.00 0.000 Derivative time Reset time 20 s Cycle time Cy1: Cy2: 20.0 s 20.0 s Contact spacing Differential Hys1: Hys2: Stroke time 30 s Working point Output limiting 100 %...
  • Page 33 BENTONE Undocumented parameters: Bit parameter: Parameters 1: Parameters 25: Parameters 2: Parameters 26: Parameters 3: Parameters 27: Parameters 4: Parameters 28: Parameters 5: Parameters 29: Parameters 6: Parameters 30: Parameters 7: Parameters 31: Parameters 8: Parameters 32: Parameters 9: Parameters 33:...

  • Page 34: Installation

    BENTONE Installation General instructions Installation must be carried out in accordance with current regulations and instructions. The supplier/installer of the facility is obliged to familiarize himself with all regulations so that the installation meets the requirements of the local authorities.

  • Page 35: Mounting

    BENTONE Mounting The burner is mounted on the boiler according to the hole pattern on the fixing flange. Remove the gas valve from the burner. Remove fan housing by loosening nut (A), swing out fan housing. Disconnect ionisation and ignition cables from the electrodes.

  • Page 36: Gas Nozzle

    BENTONE Gas nozzle Check that the ignition and ionization electrodes are correctly set before mounting on the boiler. Propan Natural gas Biogas (UV detector)

  • Page 37: Aerating

    BENTONE De-aerating De-aerating the gas line by closing the tap to the gas connection and unscrewing the screw on the measuring nipple for the connection pressure. Connect a plastic hose, open the tap and drain the gas in a safe place. When the de-aerating is completed, be sure to refit the screw on the measuring nipple.

  • Page 38: Calculation Of Gas Flow

    BENTONE Calculation of gas flow Formula symbol Description Example values Standard gas volume [Nm3/h] Gas volume at normal condition 15 °C 1013 mbar Boiler output [kW] 230 kW Lower calorific value of gas [kWh/m 9.45 kWh/m Natural gas under normal conditions 15 °C 1013 mbar, EN 676 η...

  • Page 39: Settings

    BENTONE Settings Brake plate adjustment The position of the brake plate must be adjusted to achieve the most favorable pressure drop across the brake plate. oosen the screw on the adjustment device. • To reduce the opening: turn the knob to the left.

  • Page 40: Setting The Air Pressure Switch

    BENTONE Setting the air pressure switch The air pressure switch must block the burner if the amount of air for combustion becomes too low. The air pressure switch must be set so that in the event of a lack of air supply at the burner’s max. or min. capacity reacts before the monitored pressure drops so much that poor combustion occurs.

  • Page 41: Setting The Gas Pressure Switch, Min

    BENTONE Setting the gas pressure switch, min. The gas pressure switch must react to too low a connection pressure to the burner, prevent the burner from starting and stop the burner during operation. The burner may start again when the connection pressure has risen above the set pressure on the gas pressure switch.

  • Page 42: Setting Damper Motor, Modulating Operation

    BENTONE Setting Damper motor, Modulating operation Air adjustment The damper motor rotates the air damper between • Return to low load ”-”, check combustion value three preset positions: completely closed, low load and and adjust if necessary. high load. These positions are controlled in the motor by •...

  • Page 43: Gas Valve, Multibloc Mb-Vef 407-412

    BENTONE Gas valve, MultiBloc MB-VEF 407-412 All gasline components shall be assembled and mounted without bending, torque and outher mechanical or thermal stress. Check the filter at least once a year! 8.7.1 Components Electrical connection Connection 1/8" P Test point connection 1/8" P...
  • Page 44 BENTONE 8.7.2 Technical data – Max inlet pressure 360 mbar 529, DIN 40050) – Valves V1+V2 class A group 2 in accordance with – Gas family 1 +2 +3 EN 161 – Outlet pressure 0,5 - 100 mbar – Governor class A group 2 in accordance with –...
  • Page 45 BENTONE 8.7.5 Pressure taps min. 5 x DN p , extern PN1, DN 4 1,3,4,5 G 1/8 screwed sealing plug 2 Measuring nozzle 6,7,8 G 1/8 female thread for P pulse lines 8.7.6 Electrical connection S 10/S 30...

  • Page 46: Service

    BENTONE Service Service and maintenance work may only be performed by qualified personnel. Perform operational check of all safety systems and components at each service. Only CTC original parts should be used when replacing components. Use caution when operating the burner, surfaces may be hot.

  • Page 47: Combustion Device

    BENTONE Combustion device Disconnect the main power and shut off the fuel supply. Before obtaining access to electrical and fuel line components all supply circuits must be disconnected. Loosen screws (A) and swing the burner out. Disconnect the ignition and ionisation cables.

  • Page 48: Air Damper

    BENTONE Air damper Disconnect the main power and shut off the fuel supply. Before obtaining access to electrical and fuel line components all supply circuits must be disconnected. Remove the cover on the damper motor. Detach the solenoid valve cables from the fuel valve.

  • Page 49: Replacement, Damper Motor Air

    BENTONE Replacement, Damper motor air Disconnect the main power and shut off the fuel supply. Before obtaining access to electrical and fuel line components all supply circuits must be disconnected. Note the connection position of cables to the damper motor.

  • Page 50: Fan

    BENTONE Disconnect the main power and shut off the fuel supply. Before obtaining access to electrical and fuel line components all supply circuits must be disconnected. Detach the electrical panel (Y). Loosen the motor electrical connection and screws (X) enough to turn and lift out the motor.

  • Page 51: Replacement Of Electrical Components

    BENTONE Replacement of electrical components Disconnect the main power and switch off the fuel supply. Before obtaining access to terminals, all supply circuits must be disconnected. Note the connection of the existing component and disassemble. Fit new component with same connection or with specified alternative connection.

  • Page 52: Vibrations

    BENTONE Vibrations Maximum permitted vibration level is 5.0 mm/s. • 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 the screw on the cover to attach the vibration sensor.

  • Page 53: Control Of Flame Monitoring And Ionization Current

    BENTONE Control of flame monitoring and ionization current The burner is monitored in the standard version according to the ionization principle. The ionization current must be checked at each service occasion. The ionization current is measured with a microampermeter (µA) which is connected in series with the flame electrode and the gas burner control.
  • Page 54 BENTONE 9.9.2 UV –detector (QRC) The UV sensor should not be exposed to temperatures higher than 60 °C. The current passing through the UV sensor when it is lighted must be at least 70 µA. The current can be measured using a rotary coil instrument. A check is necessary only if a malfunction is suspected.

  • Page 55: 10. Handing Over Of The Installation

    BENTONE 10. Handing over of the installation • Make repeated start attempts to ensure that the adjustments function. • Close the ball valve during operation to check that the gas switch switches off at the set value. • Remove the hose for the air pressure switch to check that the burner locks out.

  • Page 56: 11. Troubleshooting

    BENTONE 11. Troubleshooting Conditions favourable to trouble-free operation of the system can only be guaranteed through the interaction between three factors: electricity, gas flow and combustion air. If any of these factors change, it may cause a malfunction. Before requesting servicing, check the following points: Are the system’s gas taps open?
  • Page 57 BENTONE Cause of fault Action Burner trips during pre-aeration: Air sensor faulty or incorrectly set. Increase/decrease air setting. Reduce air volume. Ignition load incorrectly set. Increase/decrease gas supply Reduce airflow. Gas pressure too low. Increase pressure. If necessary, contact gas supplier.

  • Page 58: 12. Service- And Inspection Protocol

    12. Service- and inspection protocol Installation: Boiler: Name: Type: Efficiency kW: Address: Burner Type: Efficiency kW: Installed by: Date: Date Efficiency gas/h Governor Fluegas Ionisation Pressure temp current Fire room Chimney Measure- ment Before After °C µ A mbar mbar Small Flame Large Flame...
  • Page 59 EU Declaration of conformity Bentone Gas Burners Certificate No. Certificate 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 CE-0123CT1304...
  • Page 60 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 64 CTC AB Box 309 SE-341 26 Ljungby info@bentone.se +46 372 88 000 www.bentone.se...

This manual is also suitable for:

Bg 400 m

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