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178 111 35-1 2014-11–12

Installation- and maintenance instruction

BFG1STG146

Biogas

3

GeneralGeneral

Table of contents

GENERALImportant to remember! ______________________________________________4Service _____________________________________________________________________5What to do if you smell gas _________________________________________5Safety instructions ______________________________________________________6Delivery check ____________________________________________________________6

1. Dimensions BFG1 Biogas __________________________________________71.1 Description BFG1 _____________________________________________________8

1.1.1 Components BFG1 _______________________________________9

2. Dimensions STG Biogas __________________________________________102.1 Description STG _____________________________________________________11

2.1.1 Components _______________________________________________12

3. MULTIBLOC ____________________________________________________________133.1 DMV-DLE... ___________________________________________________________13

3.1.1 Disassembly of the the Multiblock _________________143.2 Gas pressure regulator Type FRS _____________________________17

4. ELECTRIC EQUIPMENT LME... ________________________________204.1 Wiring diagram ______________________________________________________20

4.1.1 List of components ______________________________________214.1.2 Function LME... ___________________________________________21

4.2 Control program at faults; fault mode indicator LME .... _22

4.2.1 Colour codes ______________________________________________224.2.1.1 Diagnosing alarm causes_______________________________224.2.1.2 Limiting of starting repetitions __________________________224.2.1.3 Alarm code table _______________________________________234.2.1.4 Interface diagnostics ___________________________________23

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General

Varning!

Important to remember!This installation and maintenance manual is intended for the user and qualified professionals. It should be taken into account by all those who work with the burner and associated system components. Work with the boiler may only be carried out by individuals who have completed certified training.

• This manual is to be regarded as part of the burner and must always be kept near the installation site. Enertech AB reserves the right to make changes and correct any printing errors.

• All products are packed to prevent any damage occurring when they are handled. Handle the products with care. Two or more people are needed to move large packages. All products must be stored upright on a level, dry surface.

• The weight is on the label cardboard box.

• The burner may be installed by authorised personnel only.

• Check that the burner is compatible with the boiler’s output range.

• The burner must be installed so that it complies with local regulations on fire safety, electrical safety and boiler and fuel distribution.

• Make sure when installing the equipment that enough room is left to service the burner.

• Permitted temperature during operation +3 to +30°C

• Temperature during transport/storage -10 to +60°C

• Max. relative air humidity 80%, no condensate

• The installer must ensure that the room has sufficient fresh air ventilation as per local norms.

• The room must comply with local regulations applicable to its intended use.

• If any electrical connection is used other than that recommended by Enertech, there may be a danger of damage to property and personal injury.

• The electrical installation must be carried out in accordance with applicable heavy current regulations and in a professional manner, avoiding the risk of gas leaks, fire or personal injury.

• Care should be taken by the installer to ensure that no electrical cables or gas pipelines are crushed or damaged during installation or servicing.

• If the boiler has a door that opens, this should be locked with a door switch.

• Does this product need to be sorted as metal, plastic and electrical when being recycled? Used material must be handled appropriately and in an environmentally friendly manner. Observe local regulations.

• When in operation the burner’s noise level can exceed 85 dBA. Wear ear defenders when in the same room.

• It is not permitted to use the burner outside the intended area of use.

• The burner may not be commissioned with safety or protective devices that are not fit for purpose. Nor are custom design modifications or the installation of accessories not tested together with the

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General

Varning!

burner permitted. Commissioning is to be carried out by qualified professionals only.

• Prior to commissioning, the following points should be checked:

- all fitting and installation work has been completed and approved

- the electrical installation has been carried out properly, the correct fuses added to circuits and measures to safeguard enclosures on electrical devices and all wiring have been checked

- flue gas ducts and combustion air ducts are not blocked

- all actuators and control and safety devices are in working order and set correctly

Service • Service should be performed after approx. 3,000 working hours, but

no less than once a year.

• Only authorised personnel should perform the service.

• Before obtaining access to terminals, all supply circuits must be disconnected.

• Be careful: certain parts exposed after separation of the burner can be hotter than 60°C.

• Care should be taken by the installer to ensure that no electrical cables or gas pipelines are crushed or damaged during installation or servicing.

• Only spare parts recommended by Enertech should be used.

What to do if you smell gas• Prevent open flames or sparking, e.g. do not turn lights on or off, do

not use any electrical appliances, do not use mobile phones. Open windows and doors. Close the gas ball valve. Warn residents; do not use doorbells. Vacate the building. Notify the company/installer or gas supplier once the building has been vacated.

• Turn off the equipment and take the boiler out of operation. Open windows and doors. Notify the company/installer.

• Check that the burner is approved for the intended grade of gas and connection pressure.

• No safety systems on the burner may be disconnected.

• General advice on how to eliminate a fire

• One or more boilers for solid or liquid fuel whose total rated output exceeds 60 kW should be installed in a separate boiler room. An airlock should be the only way a separate boiler room is connected to evacuation routes from residential buildings in activity class 3, and offices in activity class 1 that do not constitute an integrated part of an industrial activity or similar activity. Ensure that local rules and regulations are observed.

• The term “separate boiler room” refers to boiler rooms which are specially designed to provide protection against the starting and spreading of fire and the production and spreading of combustion gas. Ensure that local rules and regulations are observed.

• Separate boiler rooms and fuel stores immediately next to a separate boiler room should be designed as individual fire compartments. Ensure that local rules and regulations are observed.

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General

Safety instructions• Read the manual before installation or commissioning.

• The burner may be installed by authorised personnel only.

• Check that the burner is compatible with the boiler’s output range.

• The power data on the type sign refers to the burner’s min. and max. power.

• Check that the burner’s dimensions and capacity range are suitable for the boiler in question.

• The electrical installation must be carried out in accordance with applicable heavy current regulations and in a professional manner, avoiding the risk of gas leaks, fire or personal injury.

• If any electrical connection is used other than that recommended by Enertech, there may be a danger of damage to property and personal injury.

• Care should be taken by the installer to ensure that no electrical cables or gas pipelines are crushed or damaged during installation or servicing.

• The burner must be installed so that it complies with local regulations on electrical safety and boiler and fuel distribution.

• Check that the burner is approved for the intended grade of gas and connection pressure.

• No safety systems on the burner may be disconnected.

• The installer must ensure that the boiler room has sufficient fresh air ventilation as per local norms.

• Gas leak checks should be carried out on installation and servicing to avoid a gas leak and the associated hazards and risks.

• Before servicing, shut off the fuel supply and turn off the power to the burner.

• The surface temperature of the burner’s components may exceed 60°C.

• Be careful when servicing: there may be a risk of pinching.

• Ensure that the burner is protected against direct spraying of water, since it is not designed to withstand this.

• Only spare parts recommended by Enertech should be used.

• This burner cannot be used for biogas without first contacting Enertech.

• If the boiler has a door that opens, this should be locked with a door switch.

Delivery check• Make sure everything is delivered and the goods have not been

damaged during transit.

• If something is wrong with the delivery, report it to the supplier.

• Transport damage must be reported to the shipping company.

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General

195

186

35

245

350

1. Dimensions BFG1 Biogas

The above-mentioned measurements are maximum measurements. They can vary, depending on which components are used.

135

286

B

A

-0,5

0,0

0,5

1,0

1,5

2,0

2,5

3,0

10 15 20 25 30 35 40 45 50 55

Connection pressure 25 mbar

60% H4

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General

1.1 Description BFG1

7

8

10

11

12

13

14

15

16

22

1

2

3

4

56

24

23

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General

1.1.1 Components BFG11. Blast tube

2. Gas pressure switch

3. Connection multiblock

4. Ignition transformer

5. Motor

6. Capacitor

7. Multiblock

8. Air pressure switch

9.

10. Air intake

11. Air regulation

12. Electric connection

13. Gas burner control

14. Reset button

15. Nozzle assembly adjustment

16. Screw for division of burner in front and rear part

17. Nozzle assembly

18. Brake plate

19. Ignition electrode

20.

21. Nozzle

22. Air flow indicator (indicates the air setting)

23. Pressure regulator

24. Filter

18

19

1721

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General

2. Dimensions STG Biogas

290

139

11

1314

15

244

192

450

103

61

249

-1,0

0,0

1,0

2,0

3,0

4,0

40 60 80 100 120

Connection pressure 45 mbar

60% H4

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General

7

8

10

9

1

23

5

6

12

4

2.1 Description STG

2324

16

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General

17

18

19

21

2.1.1 Components1. Blast tube

2. Gas pressure switch

3. Connection multiblock

4. Ignition transformer

5. Motor

6. Capacitor

7. Multiblock

8. Air pressure switch

9. Test point for the air pressure switch on the low-pressure side

10. Air intake

11. Air regulation

12. Electric connection

13. Gas burner control

14. Reset button

15. Nozzle assembly adjustment

16. Screw for division of burner in front and rear part

17. Nozzle assembly

18. Brake plate

19. Ignition electrode

20.

21. Nozzle

22.

23. Pressure regulator

24. Filter

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General

3. MULTIBLOC3.1 DMV-DLE...Double solenoid valve Type DMV-D.../11 Type DMV-DLE.../11

Nominal widths Rp 1/2 - Rp 2 Electrical connection IEC 730-1 (VDE 0631 T1)

Volt U n ~(AC) 230 V

Valve 2 x Class A

Ambient temperature -15 °C … +60 °C

IP 54

Family 1 + 2 + 3

Max. operating pressure 500 mbar

DMV 505-520/11 Pressure taps 1, 2, 3, 4 Sealing plug

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General

! After completion of the jobs on the gas components, perform leakage control and function control.

1. Loosen screws A and B do not remove. Figs 1 and 2

2. Remove screws C and D. Figs 1 and 2

1. 2.

3.1.1 Disassembly of the the Multiblock

Screw plugs 1,2,3 may also be replaced by a measuring socket G 1/8 DIN ISO 228.Concealed connecting bore for system accessories.

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General

4.3.

5.

6.

Vmin. / mini.> 0.1 x Vmax. / maxi.° °

2.

1.3.

3. Remove double solenoid valve between the threaded flanges. Figs 3 and

4. After mounting, perform leakage and functional tests.

5. Lead seal Lead seal eye 2 in 1.5 mm dia. sealing valve. Lead seal eye 3 in 1.5mm cap stand headed screw. After setting the requested pressure setpoint:

1. Close protective valve 1.

2. Route wire through 2 and 3, Fig. 2.

3. Press lead around wire ends, keep wire loop short.

6. DMV - D 507/11 - 525/11 DMV-DLE 507/11 - 525/11 Main flow setting only possible at V1! Set main volume on open valve. Set valve V1 during operation.Check setting values continuously. Smallest setting volume flow:

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General

7.

8.

9.

7. DMV-DLE Rapid stroke adjustment V start Factory setting DMV-DLE: Rapid stroke not adjusted

1. Unscrew the adjustment cap E from the hydraulic brake.

2. Turn the adjustment cap and use as a tool.

3. Turn a-clockwise = increase rapid stroke (+).

8. Replacing hydraulic brake unit or adjustment plate1. Switch off firing system.

2. Remove locking varnish from countersunk screw A.

3. Unscrew countersunkscrew A.

4. Unscrew socket headscrew B.

5. Raise adjustment plate C or hy-draulic brake D.

6. Remove sealing plug E

7. Exchange adjustment plate C or hydraulic brake D

8. Screw in countersunk and socket head screw. Only tighten socket head screw so that hydraulic brake can just be turned.

9. Coat countersunk screw A with locking varnish.

10. Leakage test: Pressure tap at sealing plug 2: DMV 507-520/11 Pressure tap at sealing plug 3: DMV 525/11 p max. = 500 mbar.

11. Perform functional test.

12. Switch on firing system.

9. Replacing the solenoid Versions with adjusting plate DMV-D 5.../11or hydraulic brake DMV-DLE 5../11

1. Remove hydraulic brake or adjusting plate as described on page 6: ”Replacing the hydraulic brake or adjusting disk”, steps 1 - 5.

2. Replace solenoid Important: Make sure that the solenoid no. and voltage are correct!

3. Remount hydraulic brake or adjusting plate as described on page 6. ”Replacing the hydraulic brake or adjusting plate”, steps 7 -11.

! After completion of the jobs on the gas components, perform leakage control and function control.

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General

! Never close vent nozzle!

1.2.

Vent nozzle

Vent plug

Max. operating pressure 500 mbar

Pressure regulator Class A

Ambient temperature -15 °C … +70 °C

Inlet pressure range 5 - 500 mbar

Family 1 + 2 + 3

Outlet pressure range 2,5 - 200 mbar

Dimensions [ mm]

e

c

f

h

DN

af

e

d

bb

h

dD

Nc

a

3.2 Gas pressure regulator Type FRSNominal diametersRp 3/8 - Rp 2 1/2DN 40 - DN 150

2. Pressure taps1. Vent plug

2. Connection for external pulse G 1/4 screw plug ISO 228, on both sides, optional.

3. G 1/4 screw plug ISO 228, in inlet pressure range, on both sides

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General

Type OrderWeightNumbe

p max.[mbar]

Rp / DN Dimensions

(mm) kg

a b c d e f g h

FRS 507 070 391 500 Rp 3/4 100 130 28 165 G1/4 G1/4 G1/8 245 1,00

FRS 510 070 409 500 Rp 1 110 145 33 190 G1/4 G1/4 G1/8 310 1,20

FRS 515 058 446 500 Rp 1 1/2 150 195 40 250 G1/2 G1/4 G1/4 365 2,50

FRS 520 058 628 500 Rp 2 170 250 47 310 G1/2 G1/4 G1/4 450 3,50

FRS 525 083 303 500 Rp 2 1/2 230 285 60 365 G1/2 G1/4 G1/4 550 6,00

FRS 5065 058 792 500 DN 65 290 285 95 405 G1/2 G1/4 G1/4 590 7,50

FRS 5080 079 681 500 DN 80 310 285 95 405 G1/2 G1/4 G1/4 590 10,00

! Do not use unit as lever.

DN 40 50 65 80 100 125 150

Rp 3/8 1/2 3/4 11 1/2 2 2 1/2 -- -- -- --

M max. 70 105 225 340 610 1100 1600 2400 5000 6000 7600

(Nm) ≤ 10s

T max 35 50 85 125 200 250 325 400 -- -- --

(Nm) ≤ 10s

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General

Adjustment of outlet pressure (setpoint adjustment)Factory setting: Standard spring p2 10-30 mbar1.

1. Unscrew protective cap A.

2. Adjustment (+) Setting spindle B ”Turn counter-clockwise” = Increasing outlet pressure (setpoint)

3. 4.

1.

BA

2.

B

B

E

C/D

B

A

2.

Adjustment (-) Setting spindle B”Turn clockwise” = Reducing outlet pressure (setpoint)1. Check setpoint

2. Screw on protective cap A.

3. Attach lead seal (Page 5).

Replace setting spring 3-4

1. Remove protective cap. A. Release spring by turning adjustment spindle B counter clockwise. Turn spindle to stop.

2. Unscrew complete adjustment device B and remove spring C.

3. Insert new spring D.

4. Assemble complete adjustment device and adjust desired off-set.

5. Screw on protective cap A. Stick adhesive label E onto typplate.

6. Attach lead seal.

or

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General

4. ELECTRIC EQUIPMENT LME...4.1 Wiring diagram

Alt. 1

Enl. DIN 4791

Alt. 2 Alt. 3

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General

4.1.1 List of components

A1 Gas burner control S7 Main switch

A3 Valve, leak tester, Dungs VPS504 (optional)

S8 Air pressure switch

B1 Ionisation electrode S9 Gas pressure switch

U2 UV-detectorQRC (LME23...) S30 External reset

F1 Fuse T1 Ignition Transformer

H1 Lamp, operation Y1 Solenoid valve

M1 Burner motor X3 Plug-in contact, burner

P1 Timer total operating time X4 Plug-in contact, boiler

S3 Control thermostat X17 Plug-in contact, burner external reset (optional)

S4 Temperature limiter X18 Plug-in contact, boiler external reset (optional)

4.1.2 Function LME...

1. Operating switch ON-Thermostat ON-Gas pressure switch ONA check that the air pressure switch does not indicate fan pressure is carried out

2. Burner motor startsA check that the air pressure switch indicates sufficient fan pressure is carried out

3. The ignition spark is created

4. The gas solenoid valve is openThe gas is ignited. The ionisation electrode now indicates a flame

5. The safety time expiresThe ignition spark ceases. The safety period ceases. If the spark is missing or it disappears after this time limit, the gas burner control is blocked

6. Operating position

7. StopThe operation of the burner can now be stopped with the control switch or thermostat

If the gas burner control is blockedRed light in the gas burner control is lit. The burner is restarted by pushing the reset button

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General

Light period (waiting period ≥ 10 s)

Blinking code Pause Blinking code

Press the reset button > 3 s

4.2 Control program at faults; fault mode indicator LME ....

4.2.1 Colour codes

Table colour codes for multi-coloured signal light (LED)

Status Colour codes Colours

Waiting period «tw», other waiting periods

○………………… Off

Ignition phase, ignition controlled •○ •○ •○ •○ •○ • Blinking yellow

Normal operation □………………… Green

Operation, poor flame signal □○□○□○□○□○ Blinking green

Illegal flame signal during start-up □▲□▲□▲□▲□▲ Green-Red

Undervoltage ●▲●▲●▲●▲●▲ Yellow-Red

Fault, alarm ▲………………… Red

Blinking code for fault codes ▲○ ▲○ ▲○ ▲○ Blinking red

Interface diagnostics ▲▲▲▲▲▲▲▲ Red flicking

4.2.1.1 Diagnosing alarm causes

After alarm disconnection, the red alarm signal light is lit continuously.The diagnosing of the alarm cause can be read according to the following sequence:

…… Continuous

○ Off

▲ Red

● Yellow

□ Green

4.2.1.2 Limiting of starting repetitions

LME 11... has a function with start repetition if the flame is not created at start or disappears during operation.. LME 11... allows max. three repetitions during continuous starting cycle.

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General

4.2.1.3 Alarm code table

Red blinking code onsignal lamp (LED)

Possible causes

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” defective- No air pressure switch signal after “t10”- “LP” is welded in open position

Blinking 4 x....

Illegal flame signal during start-up

Blinking 5 x.....

Time out “LP”- “LP” is welded in open position

Blinking 6 x......

Free

Blinking 7 x.......

Too many flame disappearances during operation- poor burner setting- defective or fouled fuel valves- defective or fouled flame monitoring

Blinking 8 x........

Free

Blinking 9 x.........

Free

Blinking 10 x..........

Connection fault or internal fault, outgoing contacts or other faults

Blinking 14 x..............

CPI contact not closed

During the diagnosing of the alarm cause, the control outputs are voltage-free.

• The burner is disconnected

• Exception, alarm signal «AL» at board 10

• Reconnection of the burner happens after resetting only.

• Press the reset button 0.5...3 s

4.2.1.4 Interface diagnostics

To change to interface mode, press and hold the reset button longer than 3 s. To go back to the normal position, press and hold the reset button longer than 3 s. If the gas burner control is in the alarm position, it is reset by pressing the reset button 0.5...3 s.

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Enertech AB. P.O Box 309, SE-341 26 Ljungby.

www.bentone.se, www.bentone.com