Bentone BG 400 User manual

Providing sustainable energy solutions worldwide
Installation- and maintenance instruction
BG 400
LME21.550C2
MB-DLE412
Translation of the original instructions.
CR00264 178 043 73-2 2021-06-11

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
Table of contents
1. General Information __________________________________ 4
Safety instructions_____________________________________ 4
Actions to take if you smell gas __________________________ 5
Burner servicing schedule ______________________________ 6
Component replacement intervals________________________ 6
Delivery check ________________________________________ 6
2. Technical Data _______________________________________ 7
Burners are intended for use at: _________________________ 7
2.1 Dimensions BG 400 _______________________________ 7
2.3 Gas categories, approved gases ____________________ 8
2.2 Capacity range ___________________________________ 8
2.4 Working field _____________________________________ 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
5. Setting the burner ___________________________________ 16
5.1 Air adjustment ___________________________________ 16
5.2 Adjustment of brake plate _________________________ 16
5.3 Control of burner head ____________________________ 16
5.4 Setting the air pressure switch _____________________ 18
5.5 Setting the min. gas pressure switch ________________ 19
5.6 Skeleton diagram CPi_____________________________ 20
6. Multi-Bloc __________________________________________ 21
MB-DLE 407 B07 S22 GW150A5_______________________ 21
6.1 Overview _______________________________________ 21
6.2 Mounting closed position indicator (CPi) _____________ 22
6.3 Adjustment of governor ___________________________ 23
6.4 Adjustment of start gas flow valve V3________________ 23
6.5 Flow adjustment main valve V2_____________________ 23
6.6 Skeleton diagrams _______________________________ 24
6.7 Recommended excess air when using default setting __ 26
6.8 Determining the gas quantity for the system __________ 26
6.9 Calculating the quantity of gas supplied _____________ 28
7. Service_____________________________________________ 29
7.1 Servicing the combustion assembly _________________ 29
7.2 Servicing air dampers_____________________________ 30
7.3 Flame monitoring and ionisation current check________ 31
8. Handing over of the installation _______________________ 33
9. Fault location, functional troubles_____________________ 33
10. Electric equipment ________________________________ 34
Safety system _______________________________________ 34
10.1 Wiring diagram LME... ____________________________ 35
10.2 Function LME... __________________________________ 36
10.3 Control program when disruption; __________________ 37
Disruption display, Gas burner control: LME.... ___________ 37
11. Troubleshooting __________________________________ 39
Gas Burner__________________________________________ 39
12. General instructions for gasburners_________________ 42
Service- and inspection card ___________________________ 43

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

5Bentone
• 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.

6Bentone
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.

7Bentone
172 525 21-2 2021-04-29
2. Technical Data
* Depending on which components that are used, dimensions may vary
*I
ØC
A D
H
F
E
Ø B
*G
J
K
L
* The above dimensions are max. measurements. Depending on the
components used, the measurements may vary.
**Min recommended distance to floor.
Burners are intended for use at:
• Hotwater in intermittent operation.
2.1 Dimensions BG 400
• Gas connections 1”
Type Length of
burner tube
Flange
measure A
BG 400
Standard 1 172 155
Standard 2 272 255
Standard 3 372 355
B C D E F G H I
BG 400 Ø 140 Ø108 100 410 250 *410 192 *506 **200
J K L
BG 400 M10 Ø 175-240 Ø 140

8Bentone
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
G20 61-320 6.4 33,7 360
G25 61-320 7.4 39,0 360
G30 61-340 1,9 10,5 360
G31 61-340 2,5 13,8 360
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
2.2 Capacity range

9Bentone
Burner correspond to IP20
2.5 Electric Specification EN 60335-2-102
BG 400
250W 230V 1,7A 50Hz
C10A
230V 2,2A 50Hz
85 dBA ± 0,5 dBA
Type
Motor supply
The recommended main fuse
motor
Main supply
Sound
!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.
Max operating current, see data plate.
-1
0
1
2
3
4
5
50 100 150 200 250 300 350
mbar
kW
G20, G25 61-320 kW
G30, G31 61-340 kW
160302-229-2
2.4 Working field

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

11Bentone
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

14 Bentone
172 515 07 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.
!If the burner is
directly connected,
ensure that all
components on
the burner are
without power.

15Bentone
172 515 07 2018-01-02
4.8 Gas nozzle
Natural gas
Propane
Biogas (UV detector)
2,5
8,0

16 Bentone
172 515 09
5. Setting the burner
5.1 Air adjustment
Loosen the stop screw and turn the knob along the scale to the desired
position and tighten the screw. Check the air adjustment by making a flue
gas analysis.
5.2 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.
5.3 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
Air adjustment
Adjustment of inner assembly

17Bentone
172 515 09
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.
User manual
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

18 Bentone
172 515 09
!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
5.4 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.
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

19Bentone
172 515 09
5.5 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

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172 525 15 2020-10-08
5.6 Skeleton diagram CPi
1. Ball valve
2. Filter
3. Governor
4. Pressure gauge with shut-off cock
5a. Gas pressure switch, mini
5b. Gas pressure switch, maxi
6a. Main valve
6b. Safety valve
7. 1) Valve proving system
9. Air pressure switch
10. Electrical connection
11. Solenoid V3
Pos. 5b, 7: Components not required according to EN 676.
1) Required over 1200 kW according to EN 676.
1 2 3
5a 5b
411
6b 6a
7
10
9