Bentone BG 400-2 Technical specifications

Providing sustainable energy solutions worldwide
CR00301 178 001 74-5 2021-06-09
Installation- and maintenance instruction
BG 400-2
LME22.232C2E
MB-ZRDLE 407-412
Translation of the original instructions.

2Bentone
example Beispielexempel
352011030141
Designation
Type
Model
Serial no.
Motor supply
Main supply
MADE IN SWEDEN BY
LIGHT OIL 35-90kW 1,25-6,0 cSt 7-14bar
BF 1 KS 76-24
BF 1
BF 1 KS 76-24
1234567
1~230V 1,0A 50Hz IP 20
Man.Year 2019
Cap. Min-Max
3
?
1
-sv
1. Manualer på övriga språk
2. www.bentone.com\
nedladdning
eller scanna QR-koden.
3. Skriv in brännarens
artikelnummer som finns på din
typskylt (se bild) och välj ditt
språk.
Detaljerad ecodesign information
kan laddas ner på:
www.bentone.com/ecodesign.
-en
1. Manuals in other languages
2. www.bentone.com\download
or scan QR-code.
3. Enter the burner`s article
number on your data plate (see
picture) and select language.
Detailed ecodesign information
can be downloaded at:
www.bentone.com/ecodesign.
-da
1. Manualer på andre sprog
2. www.bentone.com\download
eller scan QR-koden.
3. Indtast brænderens
artikelnummer, der findes på
typeskiltet (se billede), og vælg
dit sprog.
Detaljerede oplysninger om
ecodesign kan downloades på:
www.bentone.com/ecodesign.
-fr
1. Manuels dans d’autres
langues
2. www.bentone.com\download
ou scannez le code QR.
3. Saisir le numéro d’article
du brûleur sur votre plaque
signalétique (consultez
l’illustration) et sélectionnez la
langue.
Des informations détaillées
sur l’écodesign peuvent être
téléchargées à l’adresse:
www.bentone.com/ecodesign.
-de
1. Gebrauchsanweisungen in
anderen Sprachen
2. www.bentone.com\download
oder scannen Sie den QR-Code.
3. Geben Sie die Artikelnummer
des Brenners auf Ihrem
Typenschild ein, (siehe Bild) und
wählen Sie die Sprache aus.
Detaillierte Informationen zum
Ecodesign können unter
www.bentone.com/ecodesign
heruntergeladen werden.
2

3Bentone
General
Table of contents
1. General Information__________________________________ 4
2. Technical data _______________________________________ 7
2.1 Dimensions _____________________________________ 7
2.2 Capacity range __________________________________ 8
2.3 Gas categories, approved gases____________________ 8
2.4 Working field BG 400-2, BG 400 M _________________ 9
2.5 Electric Specification EN 60335-2-102 ______________ 9
2.6 Description ____________________________________ 10
3. General instructions ________________________________ 11
3.1 General instructions _____________________________ 11
3.2 Installation and maintenance instructions____________ 11
3.3 Instructions_____________________________________ 11
3.4 Inspection and maintenance ______________________ 11
3.5 Start up________________________________________ 11
3.6 Commissioning of installation _____________________ 11
4. Installation _________________________________________ 12
4.1 Delivery check __________________________________ 12
4.2 Preparations for installation _______________________ 12
4.3 Gas supply _____________________________________ 12
4.4 Electric connection ______________________________ 12
4.5 Setting brake plate and air flow ____________________ 12
4.6 Mounting on the boiler ___________________________ 13
4.7 Inspection of gas nozzle before commissioning ______ 14
4.8 Gas nozzle _____________________________________ 15
4.9 Setting Damper motor 2-stage ____________________ 16
5. Setting the burner __________________________________ 17
5.1 Adjustment of brake plate ________________________ 17
5.2 Control of burner head ___________________________ 17
5.3 Setting the air pressure switch_____________________ 19
5.4 Setting the min. gas pressure switch _______________ 20
5.5 Skeleton diagrams ______________________________ 21
5.6 Multiblock MB-ZRDLE 405-420 ___________________ 22
5.7 Recommended excess air when using default setting _ 25
5.8 Determining the gas quantity for the system _________ 25
5.9 Calculating the quantity of gas supplied_____________ 27
6. Service ____________________________________________ 28
6.1 Servicing the combustion assembly ________________ 28
6.2 Replacement of damper motor, air _________________ 29
6.3 Flame monitoring and ionisation current check_______ 30
7. Handing over of the installation ______________________ 32
8. Fault location, functional troubles ____________________ 32
9. Electric equipment__________________________________ 33
9.1 Safety system __________________________________ 33
9.2 Wiring diagram LME _____________________________ 34
9.3 Function LME... _________________________________ 35
9.4 Control program at faults; fault mode indicator LME .... 36
10. Troubleshooting __________________________________ 38
11. General instructions for gasburners_________________ 41

4Bentone
1. General Information
This Installation and Maintenance manual:
• is to be regarded as part of the burner and must always be kept near
the installation site.
• is intended for use by authorised personnel.
• must be read prior to installation.
• must be observed by all who work with the burner and associated
system components.
• work with the burner may only be carried out by certified 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.
• The burner may only be installed and operated by authorised
personnel.
• The product is packaged to prevent damage from occurring during
handling. Handle the product with care. Lifting equipment must be
used to lift larger packages.
• The products must be transported/stored on a level surface in a dry
environment, max. 80% relative humidity, no condensation.
Temperature -20 to +60 °C.
• Check that the burner is compatible with the boiler’s output range.
• All components must be installed without being bent, twisted or
subjected to mechanical or thermal forces which can affect the
components.
• The burner must be installed so that it complies with local regulations
for fire safety, electrical safety, and fuel distribution.
• The gas outlet from the pressure regulator shall be configured in
accordance with applicable regulations and lead to a safe area.
• Make sure when installing the equipment that there is enough space to
service the burner.
• Permitted temperature during operation -10 to +60 °C. Max 80%
relative humidity, no condensation.
• The installer must ensure that the room has adequate air supply.
• The room must comply with local regulations pertaining to its intended
use.
• The installation site must be free of chemicals.
• Burner pipes, fan wheels and air dampers may contain sharp edges.
• The surface temperature of the burner’s components can exceed
60°C.
• Caution: The burner has moving parts, and there is risk of crushing
injuries.
172 515 01 2018-01-02

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• 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.
• Care should be taken by the installer to ensure that no electrical cables
or fuel lines are crushed or otherwise damaged during installation or
servicing.
• If the boiler is equipped with an access hatch, this must be equipped
with a hatch opening switch connected to the burner's safety system.
• When in operation, the burner’s noise level can exceed 85 dBA.
Use hearing protection.
• The burner must not be put into operation without proper safety and
protection devices.
• A Class BE fire extinguisher is recommended.
• It is forbidden to alter thedesign or use accessories which have not
been approved by Enertech in writing.
• Prior to operation, the following points must be checked:
-fitting and installation work has been completed and approved
-electrical installation has been correctly performed
-flue gas ducts and combustion air ducts are not blocked
-all actuators and control and safety devices are in working order and
correctly set
Actions to take if you smell gas
Turn off the equipment and the boiler. Open windows and doors. 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. Evacuate
the building. Notify the installer or gas supplier once the building has been
evacuated.

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Control system 10 years 250 000 starts
Valve control system 10 years 250 000 starts
Pressure switch 10 years 250 000 starts
Ignition system with flame guard 10 years 250 000 starts
UV flame sensor 10 000 hrs N/A
Gas pressure regulators 15 years N/A
Gas valve without seal testing 10 years 250 000 starts
Gas valve with seal testing Replacement upon fault detection N/A
Gas pressure switch 10 years 250 000 starts
Safety blow-off system 10 years N/A
Damper motor N/A 500 000 starts
Contactor 10 years 500 000 starts
Burner 1 year 3 000 hrs
Inspection of electrical installation 1 year 3 000 hrs
Leakage check 1 year 3 000 hrs
Filter 1 year replacement at Δp>10 mbar 3 000 hrs replacement at
Δp>10 mbar
Electrodes Replacement/Cleaning 1 year Replacement/Cleaning 3 000 hrs
Brake disc Replacement/Cleaning 1 year Replacement/Cleaning 3 000 hrs
Motor 1 year 3 000 hrs
Fan wheel 1 Year
Replacement when cleaning
needed/imbalance
3 000 hrs
Replacement when cleaning
needed/imbalance
The burner and its components must be recycled according to applicable regulations.
Burner servicing schedule
Servicing must be carried out once a year or after 3 000 hours of operation.
Component replacement intervals
Delivery check
• Make sure everything is delivered and the goods have not been
damaged during transit.
• If something is wrong with a delivery, report it to the supplier.
• Transport damage must be reported to the shipping company.

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172 515 61-2 2021-04-16
Type Length of burner
tube
Flange
measure A
Burner tube
measure B
Burner tube
measure C
BG 400 Standard 1 172 155 ø140 ø110
Standard 2 272 255 ø140 ø110
D E F G H I J
BG 400 410 250 100 *410 *506 192 **200
2. Technical data
Burners are intended for use at:
• Hot water boilers in intermittent operation.
2.1 Dimensions
• Gas connection ¾-2".
K
L
M
H
øC
A F
I
E
D
øB
G
**J
2.1.1 Heat generator connection dimensions
* The above dimensions are max. measurements. Depending on the
components used, the measurements may vary.
** Min. recommended distance to floor.
***Dimensions when installing blast tubes from the inside of the boiler.
K L M
BG 400 M10 ø 175-240 ø145(***115)

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2.2 Capacity range
2.3 Gas categories, approved gases
Only dry gas is permitted for use.
Capacity kW Gas quantity
at min. power
Nm3/h 1)
Gas quantity
at max. power
Nm3/h 1)
Max.
connection
pressure
mbar
Min connection
pressure mbar
see data plate
1) Lower heat value Hu at normal state 15°C and 1013.25 mbar EN676
Grade of gas
Natural gas
Natural gas
Butane
Propane
Gas quantity and capacity vary according to grade of gas and connection
pressure.
BG 400-2, BG 400 M
G20 61-325 6.4 34,2 360
G25 61-310 7.4 37,8 360
G30 61-350 1,9 10,5 360
G31 61-340 2,5 14,2 360
kWh/Nm3MJ/Nm3kcal/Nm3
G20 9.5 34.02 8126
G25 8.2 29.25 6986
G30 32.5 116.09 27728
G31 24.6 88.00 21019

9Bentone
Burner correspond to IP20
2.5 Electric Specification EN 60335-2-102
!Do not exceed
working field.
Measurements according to EN 3746: 2010
Alt.1 The sound level of the burner can be reduced by equipping the burner
with silencer. Installation must be done so it does not prevent air supply
to the burner.
Alt.2 The burner’s noise level can be reduced by connecting the burner’s air
intake to the air duct that opens into an appropriate location. Installation
must be done so it does not prevent air supply to the burner.
2.4 Working field BG 400-2, BG 400 M
Type BG 400
Motor 250W, 230V, 1.7A, 50Hz
The recommended main fuse motor C10A
Control power 230V, 2.2A, 50Hz
Sound 85 dBA ± 0.5 dBA
-1
0
1
2
3
4
5
6
7
8
50 100 150 200 250 300 350
mbar
kW
G20 61-325 kW
G25 61-310 kW
160302-579-2
-1
0
1
2
3
4
5
6
7
8
50 100 150 200 250 300 350
mbar
kW
G30 61-350 kW
G31 61-340 kW
160303-249-2

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2.6 Description
Components
1. Switch 0-I
2. Switch I-II
3. Cover, inspection glass
4. Reset button
5. Air pressure switch
6. Damper motor
7. Inner assembly adjustment
(not for town gas)
8. Flame cone
9. Multibloc
10. Connecting pipe
11. Air damper
12. Air intake
13. Gas pressure switch
14. Ball valve
15. Electrical panel
16. Fan wheel
17. Electrical connection
18. Motor
19. Ignition electrode
20. Transformer
21. Ionization electrode
22. Inner assembly
23. Nozzle
24. Brake plate

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172 515 03-2
3. General instructions
3.1 General instructions
The installation of the gas burner must be carried out in accordance with
current regulations and standards. The installers of gas burners should
therefore be acquainted with all regulations and ensure that the installation
complies with the requirements. The installation, mounting and adjustment
should be made with the greatest care and only the correct gas should be
used.
3.2 Installation and maintenance
instructions
The maintenance instructions supplied with the burner must be kept at an
easily accessible location in the boiler room.
3.3 Instructions
The user should be thoroughly in-structed in the function of the gas burner
and the whole installation. The supplier must instruct the user.
3.4 Inspection and maintenance
The unit must be serviced and maintained at the interval specified in the
service schedule. If the burner is in a dirty environment, service should be
done at more frequent intervals than specified.
3.5 Start up
After the burner has been fitted to the boiler and the electric connection, the
leakage control, the venting and the electric function test have been carried
out, the burner will be ready for start-up.
Howerer, study the sections dealing with adjustments of multi-bloc,
combustion air and combustion head. Open the ball valve and switch on the
main switch. If the burner starts the actual adjustment can be made.
3.6 Commissioning of installation
Control of the combustion. The combustion quality is checked by means
of a flue gas analysis device. Adjust the burner to appr. 20% excess air in
accordance with the table. Check the flue gas temperature. Calculate the
efficiency. Check also the actual gas volume on the gas meter so that the
correct input is achieved.

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172 515 03-2
4. Installation
4.1 Delivery check
Check that all has been delivered and that the goods have not been
damaged during transport. If that is not the case, please notify the delivery
company. Transport damages should be reported to the forwarding agency.
4.2 Preparations for installation
Check that the measurements and capacity range of the burner are
compatible with the boiler. The power ratings on the type plate refer to the
min. and max. power of the burner.
4.3 Gas supply
For good operating safety, it is important that the gas supply system is
installed correctly.
Consider the following:
1. Check that the burner is approved for the gas quality of the installation.
If not, please contact the supplier.
2. Check that the gas components of the burner are approved for
indicated gas pressure.
3. The gas supply system should be installed in accordance with current
standards.
4. Pipe lines should be run so that service on boiler and burner is
facilitated.
5. Pipe lines should be run so that eventual contaminants cannot come
into contact with the gas components.
6. Gas discharge system must be installed prior to local regulations.
4.4 Electric connection
Before starting the electric installation, the main switch must be turned off.
If the boiler has a 7-pole and a 4-pole Eurostecker connector, these usually
fit directly to the burner. If not, use the connectors included, (see connection
under Electric equipment).
4.5 Setting brake plate and air flow
Before the placing into service, the burner should be initially set according to
diagram, (see Basic settings). Note that it is only a basic setting which should
be adjusted once the burner has been started.
!If an electric connection other than the one recommended by Enertech is used, a
risk of damage and injury can arise.

13Bentone
4.6 Mounting on the boiler
Remove the combustion unit from the burner. Fit the enclosed flange and
gasket to the boiler. If new fixing holes must be drilled, use the fixing flange
as a pattern.
Removal of valve unit from burner
Remove the plug-in contact from the multi-bloc. Loosen the union nut.
Removal of fan house unit from burner.
Remove the screws (A). Swing out the fan housing. Remove the ionisation
and ignition wires from the electrodes. Remove the bolt (B) on the spectacle
flange. Lift away the fan housing.
Installation example
Connect the gas to the burner by means of the ball valve. Ensure that
the union nut, ball valve and tubing make it easy to remove the burner for
inspection and service.
B
A
!Check the gas tightness.
172 515 06 2018-01-02

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172 515 08 2018-01-02
4.7 Inspection of gas nozzle before
commissioning
General rules
Care should be taken by the installer to ensure that no electrical cables
or fuel/gas pipes are trapped or damaged during installation or service/
maintenance.
Gas nozzle
Check that the ignition and ionisation electrodes are correctly set. In
the figure (see the gas nozzle chapter), the dimensions are specified for
adjustment of the ignition and ionisation electrodes.
Gas quality
Ensure that the burner head is meant for the gas quality to be used (see
capter gas nozzle).
De-aerating
De-aerating of the gas line is conducted, for example, by unscrewing
the screw on the measuring nipple for the connection pressure. Connect
a plastic hose and release the gas in a safe place. Once de-aerating is
completed, be sure to refit the screw on the measuring nipple.
Leakage control
When making a leakage control of the gas supply system the solenoid valve
should be closed. Connect a pressure gauge to the test nipple Pa, see fig.
The test pressure in the system should be 1,5x max. inlet pressure or min.
150 mbar. If any leakage, locate the source by means of soapy water or a
leak location spray. After tightening repeat the test.
Electric function test:
Ensure that phase and neutral are not reversed. The gas shut-off cock
should be closed.To prevent the gas pressure switch from locking out it
should be linked temporarily.
After the main switch has been switched on and the thermostats have been
adjusted the pre-purging period begins (30-35sec.). At the end of this period
the pre-ignition period starts (0,5-2,5 sec. dependent on the design of the
gas control). The gas valve is energized and opens and flame is established.
At the end of the safety time (2-3 sec.) the gas control locks out. The
solenoid valve and the motor will be "dead". Remove the link from the gas
pressure switch after the test is finished.
Note on 2-stage and modulating burners that during the pre-purging period
the damper opens to the set value for air on stage 2 and just before the
end of the pre-purging period it goes down to the air setting for stage 1. On
some burners under 350kW the pre-purging mainly takes place with the air
damper set for stage 1.
!If the burner is
directly connected,
ensure that all
components on
the burner are
without power.

15Bentone
172 515 08 2018-01-02
4.8 Gas nozzle
Natural gas
Propan
Biogas (UV detector)
2,5
8,0

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172 511 14-2 2021-05-03
4.9 Setting Damper motor 2-stage
Release button
High load (red)
Low load (orange)
Closed air damper (blue)
Solenoid valve High load (black)
Air adjustment
The damper motor rotates the air damper between
three preset positions: completely closed, low load and
high load. These positions are controlled in the motor
by colored cam discs, the black cam disc controls the
switching on/off of the solenoid valve. Adjust the amount
of air by changing the position of the cam discs.
Blue cam disc is the limit position for closed air dampers
and does not normally need to be changed.
Low load
• Set control switch for load position to position II
(high load).
• Turn orange cam disc to 0° to reduce airflow and
to 90° to increase airflow.
• Return the control switch to position I (low load)
and check the combustion values.
High load
• Set control switch for load position to position I
(low load).
• Turn red cam disc to 0° to reduce airflow and to
90° to increase airflow.
• Place black cam disc in a position between red
and orange cam discs and adjust to obtain a good
load change.
• Return the control switch to position II (high load)
and check the combustion values.
Release
By pressing the button, the motor is disengaged and the
air damper can be turned. The function is used when
servicing air dampers.

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172 515 10 2018-01-02
5. Setting the burner
5.1 Adjustment of brake plate
-Loosen the screw on the adjustment device.
-To reduce the opening: turn the knob to the left.
-To increase the opening: turn the knob to the right.
The adjustment of the position of the brake plate affects the air flow. It is
therefore always necessary to make a fine adjustment of the air by means of
the adjustment device of the burner.
5.2 Control of burner head
To check the burner head, brake plate and electrodes
proceed as follows:
Loosen the nuts a. Swing out the burner. Remove the
screw b and the knob for adjustment of burner head.
Loosen the screw c so much so that the inner assembly
can be pulled out.
Control of burner head
Adjustment of inner assembly

18 Bentone
General instructions
The installation of the gas burner must be carried
out in accordance with current regulations and
standards. The installers of gas burners should
therefore be acquainted with all regulations and ensure
that the installation complies with the requirements. The
installation, mounting and adjustment should be made
with the greatest care and only the correct gas should be
used.
Operating instructions
The installation and maintenance instructions supplied
with the burner must be kept at an easily accessible
location in the boiler room.
Instructions
The user should be thoroughly in-structed in the function
of the gas burner and the whole installation. The supplier
must instruct the user.
Inspection and maintenance
Inspection as needed, preferably daily. Maintenance per
service schedule.
Start up
After the burner has been fitted to the boiler and the
electric connection, the leakage control, the venting
and the electric function test have been carried out, the
burner will be ready for start-up.
Howerer, study the sections dealing with adjustments of
multi-bloc, combustion air and combustion head.
Open the ball valve and switch on the main switch. If the
burner starts the actual adjustment can be made.
Adjustment of burner head
The burner is equipped with an adjustment device
changing the position of the brake plate in the burner
head. This is used to adjust the correct pressure drop
over the combustion device in order to obtain a good
pulsation free combustion.
Which position to use depends on input and
overpressure in the boiler.
A general rule is that the lower capacity the smaller the
opening between brake plate and combustion device.
Commissioning of installation
Control of the combustion. The combustion quality is
checked by means of a flue gas analysis device. Adjust
the burner to appr. 20% excess air in accordance with
the table. Check the flue gas temperature. Calculate the
efficiency. Check also the actual gas volume on the gas
meter so that the correct input is achieved
Service
Service should only be carried out by qualified personnel.
Replacement parts should be of the same make and
approved by the same authorities as the original. If the
burner is converted to fire another gas quality it must
be re-commissioned. If town gas is to be fired the
combustion head must be converted and the gas train
adjusted to suit (e.g.a larger gas armature or a different
spring in the governor may be required).
Gas quality CO2%
lambda 1,2
02% max. CO2%
Natural gas 10,0 4±1 11,9
LPG 11,5 4±1 13,9

19Bentone
!Be careful when adjusting the air pressure switch; it contains a
live component.
Inställningsområde ca:
LGW 10 1-10 mbar
LGW 50 2,5-50 mbar
5.3 Setting the air pressure switch
The air pressure switch should block the burner if the air quantity supplied
for combustion is insufficient. The air pressure switch must be set so that,
if there is a defective air supply at the burner’s max. or min. capacity, it
reacts before the monitored pressure falls so much that it results in poor
combustion.
Setting for air pressure switch
1. Remove the protective cover, screw (Y).
2. Start the burner.
3. Carefully turn the scale on the air pressure switch clockwise until the air
pressure switch stops the burner. Is the tolerance on the scale for
the min. air pressure switch approx. ±15%?
4. Try to find the pressure at which the burner stops for both the
minimum and maximum input power by turning the scale. Make a note
of the values and then set the air pressure switch on the basis of the
highest pressure noted at which the burner stopped.
5. The air pressure switch should be set to a pressure approx. 10–15%
lower than the highest noted pressure at which the burner stopped.
6. After setting the air pressure switch, perform repeated starts and run
through the burner’s set output range several times. This is to ensure
the reliable function of the burner. If breakdowns or interruptions occur,
the air pressure switch is probably set to a too narrow position.
7. Fit the protective cover, screw (Y).
Y
Y

20 Bentone
5.4 Setting the min. gas pressure
switch
The min. gas pressure switch should react to a burner connection pressure
that is too low and in such cases prevent the burner from starting. If the
connection pressure to the burner is too low during operation, the min. gas
pressure switch should stop the burner. The burner can start again once
the connection pressure has risen above the pressure set for the min. gas
pressure switch.
Setting for min. gas pressure switch
1. Remove the protective cover, screw (Y).
2. Open the pressure outlet (X) and connect a manometer to measure the
connection pressure.
3. Start the burner.
4. Measure and make a note of the connection pressure to the burner
during normal operation at the highest input power.
5. Based on the desired connection pressure set, determine the
connection pressure at which the gas pressure switch should stop the
burner. Set the connection pressure at which the burner is stopped at
a level where the burner is stopped before poor combustion occurs.
6. Set the min. gas pressure switch to this value by turning the scale.
7. Check the setting by carefully closing the ball valve while measuring the
connection pressure.
8. When the min. gas pressure switch stops the burner, the value
measured should then approximately correspond to the setting on the
min. gas pressure switch. The tolerance on the scale for the min. gas
pressure switch is approx. ±15%.
9. Open the ball valve.
10. Remove the pressure gauge and close the pressure outlet (X).
11. Fit the protective cover, screw (Y).
!Check the gas tightness.
X
Y