Bentone BG 800 M Technical specifications

Providing sustainable energy solutions worldwide
178 071 81-3 2018-03-08
Installation- and maintenance instruction
BG 800 M

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General
Table of contents
1. General Information _____________________________________________ 4
2. Technical data BG800 ___________________________________________ 7
2.1 Burners are intended for use at: ________________________________ 7
2.2 Dimensions _________________________________________________ 7
2.3 Description_________________________________________________ 10
3. General instruktions ____________________________________________ 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 Skeleton diagrams __________________________________________ 13
4.6 Handling and lifting instruction ________________________________ 14
4.7 Mounting on the boiler _______________________________________ 15
4.8 Inspection of gas nozzle before commissioning __________________ 16
4.9 Leakage control ____________________________________________ 17
4.10 Gas nozzle_________________________________________________ 18
4.11 Setting Air damper __________________________________________ 19
4.12 Damper motor, air volume ____________________________________ 19
4.13 Adjustment of gas flow_______________________________________ 19
5. Setting the burner ______________________________________________ 20
5.1 Setting the air pressure switch ________________________________ 20
5.2 Setting the min. gas pressure switch ___________________________ 21
5.3 MB-VEF BO1, 415 - 425 _____________________________________ 22
5.4 Recommended excess air when using default setting _____________ 25
5.5 Determining the gas quantity for the system _____________________ 25
5.6 Calculating the quantity of gas supplied ________________________ 27
6. Service________________________________________________________ 28
6.1 Servicing the combustion assembly ____________________________ 28
6.2 Servicing air dampers________________________________________ 29
6.3 Replacement of damper motor, air _____________________________ 30
6.4 Vibration___________________________________________________ 31
6.5 Flame monitoring and ionisation current check___________________ 32
6.6 UV detector ________________________________________________ 32
7. Handing over of the installation __________________________________ 33
8. Fault location, functional troubles________________________________ 33
9. Electric equipment _____________________________________________ 34
9.1 Safety system ______________________________________________ 34
9.2 Wiring diagram LFL1.... ______________________________________ 35
9.3 List of components__________________________________________ 36
9.4 Leakage control Dungs VPS 504 ______________________________ 38
10. Troubleshooting _____________________________________________ 40
11. EU Declaration of conformity _________________________________ 43
13. General instructions for gasburners____________________________ 44

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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.
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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 10000 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 3000 hrs
Inspection of electrical installation 1 year 3000 hrs
Leakage check 1 year 3000 hrs
Filter 1 year replacement at ∆p>10 mbar 3000 hrs replacement at ∆p>10
mbar
Electrodes Replacement/Cleaning 1 year Replacement/Cleaning 3000 hrs
Brake disc Replacement/Cleaning 1 year Replacement/Cleaning 3000 hrs
Motor 1 year 3000 hrs
Fan wheel 1 Year
Replacement when cleaning
needed/ imbalance
3000 h
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 3000 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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E
H
I
C
B
E
F
G
D
A
Type Length of
burner tube
Flange
measure A
Burner tube
measure B
Burner tube
measure C
BG 800 Standard 1 396 361 260 205
Standard 2 696 661
D E F G H I
BG 800 820 410 510 *730 *1022 472
* The above dimensions are max. measurements. Depending on the
components used, the measurements may vary.
Min. recommended distance to
floor. 200mm
2. Technical data BG800
2.1 Burners are intended for use at:
• Water heating generators
2.2 Dimensions
• Connection 1½-3"
Dimensions stated in mm
2.2.1 Heat generator connection dimensions
***Dimensions when installing blast tubes from the
inside of the heat generator
K
L
M
K L M
BG 800 M14 (Ø 280) Ø320-380 ***(Ø 210) Ø 270

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2.2.2 Capacity range
2.2.3 Appliance categories
Only dry gas is permitted for use
BG 800
G20 380-2400 40 252
360G25 380-2400 46 293
G31 380-2400 15.5 98
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
Capacity kW Gas quantity
at min. power
Nm3/h 1)
Gas quantity
at max. power
Nm3/h 1)
Max. connection
pressure mbar
Nominal connection
pressure mbar
see data plate
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.
Gerätekategorien
Appliance categories
Versorgungsdrücke
Supply pressures
Bestimmungsländer
Countries of destination
II2R/3R 40-360mBar ”CZ, DE, EE, ES, FR, GR, IT,
LT, LU, LV, IT, NO, PT, SI,
All countries”
II2H3B/P 40-360mBar ”AT, CH, CY, DK, FI, LT, RO,
SE, SK”
II2H3P 40-360mBar GB, IE,
II2L3B/P 40-360mBar NL, RO
II2E3B/P 40-360mBar PL, RO
I2E(R)B 40-360mBar BE
I2H 40-360mBar HU, LT, LV
I3B/P 40-360mBar BE, HU, LT

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Type BG 800
Motor 230/400V 20,0/11,5A
The recommended main fuse
motor D20A
Control power 1~230V 2,5A 50Hz IP20
Sound 96 dBA ± 0,5 dBA
!Do not exceed working
field
Burner correspond to IP20
2.2.4 Electric Specification
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.
BG 800
G20, G25, G30 380-2400 kW
-4
0
4
8
12
16
20
24
28
32
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
kW
mbar
kW

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2.3 Description
Components
1. Flame cone
2. Flange
3. Guide bar
4. Fan wheel
5. Fan house
6. Shrouded disc
7. Ignition electrode
8. Nozzle
9. Ionisation electrode
10. Motor
11. Connection gas fittings
12. Ignition transformer
13. Air damper
14. Air damper motor
15. Air pressure switch
16. Fuse holder
17. Change-over switch increase-
decrease
18. Change-over switch manually-
automatically
19. Indicating lamp
20. Switch 0-1
21. Time meter (option)
22. Contactor with thermal
overload protection
23. Control box
24. Gas train
25. MultiBloc

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3. General instruktions
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
See service schedule.
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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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.
(Refer to connection under Electric equipment)
!If an electric connection other than the one recommended by Enertech is used, a risk of damage and
injury can arise.

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4.5 Skeleton diagrams
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, 2 -stage. When modulaing operation is required this
valve is equipped with controls for variable opening.
6b. Safety valve
1)7. Valve proving system
9. Air pressure switch
10. Gas burner control
Pos. 5b, 7: Components not required according to EN 676.
1) Required over 1200 kW according to EN 676.hhh

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!Option
The lifting aids we use here are
available as accessory, Figure 1
4.6 Handling and lifting instruction
bild 1
1
2
3
1
2
1
3

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4.7 Mounting on the boiler
Mount the burner to the boiler using 4 bolts. See technical data for the hole
pattern.
To make the fitting process easier, it is possible to separate the burner body
from the gas flange with the combustion head and valve assembly in place.
Proceed as follows:
1. Ensure that no power is going to the burner. Break the main current
and disconnect the Euro plugs from the burner. NB: If the burner is
directly connected, ensure that all components on the burner are
without power.
2. Remove the cover plate from the fan housing.
3. Disconnect the electrical cables to the valve assembly and gas damper
motor.
4. Undo the screws (B) on both sides.
5. Undo the end stops (C) on the guides.
6. Disconnect the ignition cable and ionisation cable from the gas nozzle.
7. Pull out the burner body from the guides and put it in a suitable place.
After separating the burner body and the gas flange, it is easier to mount
the gas flange with the burner head and valve assembly to the boiler (loosen
the valve assembly if required). Once the gas flange is fitted to the boiler, it
is easy to lift the burner body up onto the guides. Assemble the burner in
reverse order to its disassembly.
Service position
!Check the gas tightness.
!For maintenance of the brake plate, nozzles, electrodes etc, when using a long
design of the burner tube, you have to remove the nozzle assembly from the
connecting pipe and move the assembly backwards in the fan housing (from the
boiler).

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Service position
4.8 Inspection of gas nozzle before
commissioning
The gas nozzle can easily be inspected by using the guides on the burner.
Proceed as follows:
1. Ensure that no power is going to the burner. Switch off the main power
supply and disconnect the Euro plugs from the burner.
2. Remove the cover plate from the fan housing.
3. Disconnect the ignition cable and ionisation cable for the gas nozzle.
4. Ensure there is enough slack in the electrical cables to the valve
assembly and gas damper motor to pull out the burner body in the rear
position on the guides. If there is not enough slack the cables can be
disconnected.
5. Undo the screw (B) on both sides.
6. Pull out the burner on the guides.
7. Undo the screw(s) (A) on the gas flange.
8. Take out the gas nozzle.
9. See section Gas nozzle
Re-assemble the burner in reverse order to that described above. When re-
assembling, make sure that the O-ring located between the gas nozzle and
the gas flange is in the correct position when the nozzle is re-fitted.
!If the burner is directly connected, ensure that all components on
the burner are without power.

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4.9 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.

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Natural gas Propan
Biogas (UV-detektor)
4.10 Gas nozzle

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4.9 Setting Air damper
4.10 Damper motor, air volume
Adjust the orange cam for min. load (about 5-10 on scale)
Adjust the red cam for max. load (90° )
The blue cam is factory set for closed position during standstill
The black cam has no function at modulating operation
4.11 Adjustment of gas flow
-Before the burner starts vent the lines to make sure that there is gas
available at the multibloc
-Use an allen key size 2,5 mm for adjusting N and V.
-Connect a pressure gauge for measuring PBr, (advisable to find out if
the valves are open)
-Set the switch in position MAN.
-Set the gas pressure switch min. and air pressure switch on min.
adjustment. Set the gas pressure switch max, if any, on max. adjust-
ment.
-Start the burner, observe the pressure gauge, if no flame is esta-
blished and the pressure gauge needle does not flicker, increase N.
When the flame is established adjust the gas flow by means of the
screw N. Use a flue gas instrument.
-Change over to max. load, press the switch “increase”
-Adjust the gas flow with V and check at the same time the combusti-
on values.
-Go back to min. load and check the combustion value. Adjust if
necessary.
-If necessary repeat the controls of the adjustment made on min. (N)
and max. load(V).
-Increased power on minimum and maximum have now been adjusted
by changing the orange cam and red cam. Check the gas flow on the
gas meter available on the installation.
-Note! Do not forget to set the air and gas pressure switches after the
adjustment, see special instructions.
-Releasing button
By pressing the button and snapping it down, the motor will be released and
the damper can easily be turned. This function facilitates an exchange of
damper motor.
Releasing button
N.B! The upper position is
the standard positiont
High capacity (red)
Low capacity (orange)
Closed damper (blue)
Solenoid valve
High capacity (black)
Releasing button

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!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. Setting the burner
5.1 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