Bentone BG 450 M Installation And Maintenance Manual
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Bentone BG 450 M Installation And Maintenance Manual

Bentone BG 450 M Installation And Maintenance Manual

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Installation and Maintenance Manual
BG 450 M
LME22.233C2
Jumo dTRON 316
MB-VEF 412
Translation of the original instructions.
Keep for future use.
Read carefully before use.
178 077 76-8 CR00783 2024-06-26

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  • Page 1 Installation and Maintenance Manual BG 450 M LME22.233C2 Jumo dTRON 316 MB-VEF 412 Translation of the original instructions. Keep for future use. Read carefully before use. 178 077 76-8 CR00783 2024-06-26...
  • 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

    What to do if you smell gas ............6 Leakage control ................37 6.4 Calculation of gas flow .............. 38 Technical data ...............7 Dimensions BG 450 M ..............7 Settings ................39 Gas categories, approved gases ..........8 Setting the combustion assembly ........... 39 2.4 Technical specification ..............

  • 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

    • Operation in installations according to EN 303 and EN 676. Fuels: • Natural gas H, E, L, LL. • LPG, Butane and Propane. Dimensions BG 450 M øB øC Flame tube Flame tube Flame tube Length of flame tube...

  • Page 8: Gas Categories, Approved Gases

    20 mbar 20 mbar 2EK3B/P Technical specification Measurements according to EN 15036-1:2006 BG 450 M Alt.1 The noise level of the burner can be Main supply 230V, 1~, 4.6A, 50Hz, IP20 reduced by equipping the burner with Max fuse rating, Operation silencer.

  • Page 9: Components

    BENTONE Components Flame tube Electrical connection Air pressure switch Brake plate Fan wheel Ball valve Nozzle Motor Air damper Nozzle assembly Reset button Gas pressure switch, min Fixing flange Damper motor Air intake Transformer Switch 0-I Gas valve (MultiBloc) Burner control...

  • Page 10: 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 11: 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 12: Function

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

  • Page 13: Control Program At Faults; Fault Mode Indicator Lme

    BENTONE Control program at faults; fault mode indicator LME ..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 □…………………...
  • Page 14 BENTONE 3.4.5 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 15: 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 16: Electrical Connection

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

  • Page 17: 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 18: 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 19 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 20 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 21: 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 22: 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 23 BENTONE Configuration level „ConF“ 4.8.2 Linearization 0 Linear 10 Thermocouple type U 1 Pt100 11 Thermocouple type L 2 Pt500 12 Thermocouple type K 3 Pt1000 13 Thermocouple type S 4 KTY11-6 14 Thermocouple type R 5 Thermocouple type C...
  • Page 24 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 25: 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 26: 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 27 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 28 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 29 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 30 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 31 BENTONE Controller parameters: Parameter set 1: Proportional band Pb1: 10.00 Pb2: 0.000 Derivative time 20 s Reset time Cycle time Cy1: 20.0 s Cy2: 20.0 s Contact spacing Differential Hys1: Hys2: 30 s Stroke time Working point Output limiting 100 %...
  • Page 32 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 33: 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 34: Handling And Lifting Instruction

    BENTONE Handling and lifting instruction The lifting aid are available as accessories.

  • Page 35: Mounting

    BENTONE Mounting Mount the burner to the boiler using 4 bolts (if new fixing holes need to be drilled, use the fixing flange as a template). Separate the fixing flange from the fan housing as follows: Remove cover of fan housing (A), disconnect ignition and ionizing cables and the control arm (B) from nozzle assembly.

  • Page 36: Gas Nozzle

    BENTONE Gas nozzle Check that the ignition electrodes are correctly set before mounting on the boiler. Natural gas Propane 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] 380 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 Setting the combustion assembly The burner is equipped with a lever that changes the position of the brake plate in the combustion head. This is used to set the correct pressure drop across the combustion assembly and thereby obtain good combustion without ripples.

  • 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! 8.6.1 Components Electrical connection Connection 1/8" P Test point connection 1/8" P...
  • Page 44 BENTONE 8.6.2 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 8.6.5 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 8.6.6 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. Remove cover (A), disconnect ignition and ionization cables and control arm (B) from nozzle assembly.

  • 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 cover (A), disconnect ignition and ionization cables and control arm (B) from nozzle assembly.

  • 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: 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 screw to attach the...

  • Page 52: 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 53 BENTONE 9.8.2 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 54: 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 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...

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