Enertech Bentone BFG1 Technical specifications

178 119 35-1 2015-09-23
Providing sustainable energy solutions worldwide
Installation- and maintenance instruction
BFG1

3Bentone BFG1
General
Table of contents
GENERAL
Important to remember! ______________________________________________4
Service _____________________________________________________________________5
What to do if you smell gas _________________________________________6
Safety instructions ______________________________________________________6
Delivery check____________________________________________________________7
1. TECHNICAL DATA _________________________________________________________8
1.1 Dimensions BFG1 ____________________________________________________8
1.1.1 Dimensions flanges________________________________________8
1.2 Capacity range BFG1 H1, BFG1 H2 and BFG1 H3 ______9
1.3 Model BFG1 H1_____________________________________________________10
1.3.1 Burner output/ Basic settings_______________________ 10
1.4 Model BFG1 H2_____________________________________________________11
1.4.1 Burner output/ Basic settings_______________________ 11
1.5 Model BFG1 H3_____________________________________________________12
1.5.1 Burner output/ Basic settings_______________________ 12
1.6 Description ____________________________________________________________14
1.6.1 Components_______________________________________________15
2. Skeleton diagrams ______________________________________________________ 16
2.1 Multi-bloc MBD-LE......B07 _____________________________________16
2.1.1 Electritrical connection MBD-LE......B07 ________16
2.1.2 Functional description of gas flow _________________18
2.1.3 Operating method of valve-regulator combina-
tion on valve V1 ________________________________________________ 18
2.1.4 Operating method of bypass valve V3 ___________18
2.1.5 Operating method of valve V2_______________________18
2.1.6 Closing function __________________________________________18
2.2 Delivery check _______________________________________________________ 19
2.3 Preparations for installation_____________________________________19
2.4 Gas supply ____________________________________________________________19
2.5 Electric connection_________________________________________________ 19
2.6 Setting brake plate and air flow________________________________ 19
2.7 Burner installation___________________________________________________ 20
2.7.1 Hole pattern________________________________________________ 20
2.7.2 Burner installation________________________________________20
2.7.3 Gas connections _________________________________________20
2.7.4 Electric connection ______________________________________20
2.8 Control measures___________________________________________________21
2.8.1 Gas quality _________________________________________________21
2.8.2 Bleeding_____________________________________________________21
2.8.3 Function test_______________________________________________ 21
2.8.4 Leakage testing___________________________________________ 21
3. BASIC SETTINGS ________________________________________________________ 22
3.1 Determination of gas quantity for the system_____________22
3.1.1 Example of how to calculate the gas quantity
(natural gas): _______________________________________________22
3.1.2 Nozzle assembly adjustment ________________________ 23
3.1.3 Air intake adjustment ___________________________________ 23
3.1.4 Air quantity setting procedure _______________________23
3.1.5 Inlet cone, air control ___________________________________24
3.1.6 Rotation of air intake____________________________________24
3.1.7 Air duct ______________________________________________________24
4. BURNER SERVICE ______________________________________________________ 25
4.1 Service__________________________________________________________________ 25
4.1.1 Combustion device service___________________________ 25
4.1.2 Fan motor replacement________________________________26
4.1.3 Air intake and inlet cone service ____________________ 27
4.1.4 Fan wheel check _________________________________________27
4.1.4.1 Inspection ______________________________________________27
4.1.5 Fan wheel service________________________________________28
4.1.6 Electrical package _______________________________________28
4.1.6.1 Complete electrical package replacement _____________29
4.1.6.2 Single electrical package component replacement ____30
5. Multi-Bloc, MB-DLE ...B07___________________________________________ 31
5.1 Overview _______________________________________________________________31
5.2 Mounting K01/1_____________________________________________________ 32
5.3 Adjustment of governor __________________________________________ 33
5.4 Adjustment of start gas flow valve V3 _______________________ 33
5.5 Flow adjustment main valve V2________________________________ 33
6. GENERAL INSTRUCTIONS __________________________________________ 34
6.1 Flame monitoring and ionisation current check __________ 34
6.1.1 Flame monitoring ionisation __________________________34
6.1.2 UV –detector (QRC)_____________________________________ 34
6.1.3 Flame monitoring UV-detector (QRC)_____________34
6.1.4 Setting of air pressure switch________________________ 35
6.1.5 Setting gas pressure switch min (option) ________ 35
6.1.6 Setting gas pressure switch max (option) _______35
6.1.7 Air pressure switch, gas pressure switch (option)
36
6.1.8 Handing over of the installation _____________________ 37
7. Electric equipment _____________________________________________________38
7.1 Gas burner control: LME21 _____________________________________38
7.2 Wiring diagram ______________________________________________________38
7.2.1 List of components______________________________________ 39
7.2.2 Function LME...___________________________________________ 39
7.3 Control program at faults; fault mode indicator LME .... _
40
7.3.1 Colour codes ______________________________________________40
7.3.1.1 Diagnosing alarm causes_______________________________40
7.3.1.2 Alarm code table _______________________________________41
7.3.1.3 Interface diagnostics ___________________________________41
8. FAULT LOCATION GUIDE ____________________________________________42
8.1 Gas Burner____________________________________________________________ 42
9. GENERAL INSTRUCTIONS FOR GASBURNERS __________47
General

4Bentone BFG1
General
Warning
!
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.

5Bentone BFG1
General
Warning
!
• Does this product need to be sorted as metal and plastic 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
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 servicing, shut off the fuel supply, switch off the installation’s
main switch and ensure accidental reconnection cannot take place.
• 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.

6Bentone BFG1
General
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. (Swedish building regulations BFS
2011:26).
• 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.
(Swedish building regulations BFS 2011:26).
• Separate boiler rooms and fuel stores immediately next to a separate
boiler room should be designed as individual fire compartments.
(Swedish building regulations BFS 2011:26).
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.

7Bentone BFG1
General
• 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.

8Bentone BFG1
General
135
286 195
186 35 195
B
A
ø89,7 17
130-150
10,3
ø90 5
125-150
10,3
145
109,5
10
23,5
1. TECHNICAL DATA
1.1 Dimensions BFG1
1.1.1 Dimensions flanges
Flange 1
BFG1 H1 and BFG1 H2
Flange 2
BFG1 H1 and BFG1 H2
Flange 3
BFG1 H3
* Depending on which components that are used, dimensions may vary

9Bentone BFG1
General
1.2 Capacity range BFG1 H1, BFG1 H2 and BFG1 H3
Capacity
kW
Gas quantity
at min. power
Nm3/h 1)
Gas quantity
at max. power
Nm3/h 1)
Max. inlet
pressure
mbar
Nominal inlet
pressure
mbar
15 - 60 BFG1 H1
G 20 1,5 6 60/360 2) 20
G 25 1,8 7,5 60/360 2) 25
G 30 0,44 1,7 60/360 2) 30
G 31 0,57 2,30 60/360 2) 30
15 - 65 BFG1 H2
G 20 1,5 6,5 60/360 2) 20
G 25 1,8 8,1 60/360 2) 25
G 30 0,44 1,9 60/360 2) 30
G 31 0,57 2,5 60/360 2) 30
25 - 100 BFG1 H3
G 20 2,5 10 60/360 2) 20
G 25 2,5 12,5 60/360 2) 25
G 30 0,7 2,9 60/360 2) 30
G 31 0,96 3,8 60/360 2) 30
Fitting 3) Motor Ignition transformer 4)
BFG1 H1 / H2 / H3
Natural gas, Propane
½” - 1”
110 W
230 V, 50/60 Hz
0,9 A
Prim. 230/240 V, 0,15 A
50-60 Hz
Sec. 26 kV Peak 40 mA
E.D. 50% in 3 min
1. Normal state at 15°C 1013,25 mbar (acc. to EN676).
2. Max inlet pressure can vary depending on choice of multiblock.
Indicated pressure applies to Dungs standard block type MBC...
3. The dimension should be adapted in accordance with capacity,
gas quality and inlet pressure.
4. Data apply to Fida model 26/40 50%.
1) A heat value in kWh/Nm3is used for the underlying calculation in normal
ambient conditions: 15°C 1013.25 mbar (as per SS-EN 676)
Calorific value:
G20 Natural gas 10,0 kWh/Nm3
G25 Natural gas 8,0 kWh/Nm3
G31 Propane 26 kWh/Nm3
G30 Butane 34 kWh/Nm3
Gas quantity and capacity vary according to grade of gas and connection
pressure.

10 Bentone BFG1
General
!Scale value valid at 0 mbar in furnace pressure.
ø89
9,5-10,5
2,5-3,0
7,0-8,0
0,0-2,0
-0 ,5
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
10 15 20 2 5 30 35 40 4 5 50 55 60 6 5
Pressure in the furnace mbar
Burner output kW
Scale
0
2
4
6
8
10
12
14
16
18
20
22
15 20 25 30 35 40 45 50 55 60
Burner output kW
Air setting
Nozzle assembly setting
1.3 Model BFG1 H1
1.3.1 Burner output/ Basic settings
15 - 60 kW
Blast tube length
mm
Blast tube
Dimension A mm
Flange
Dimension B ø
108 81 89
140 113 89
The above-mentioned measurements are maximum measurements. They
can vary, depending on which components are used.

11Bentone BFG1
General
!Scale value valid at 0 mbar in furnace pressure.
7,0-8,0
0,0-2,0
2,5-3,0
9,5-10,5
ø89
Pressure in the furnace mbar
Burner output kW
-0 ,5
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
10 1 5 2 0 25 30 3 5 4 0 45 5 0 5 5 60 65 7 0
0,0
2,0
4,0
6,0
8,0
10,0
12,0
14,0
16,0
18,0
20,0
22,0
15 20 2 5 3 0 3 5 40 4 5 5 0 5 5 60 6 5
Air setting
Nozzle assembly setting
Scale
Burner output kW
1.4 Model BFG1 H2
Blast tube length
mm
Blast tube
Dimension A mm
Flange
Dimension B ø
115 88 89
147 120 89
The above-mentioned measurements are maximum measurements. They
can vary, depending on which components are used.
1.4.1 Burner output/ Basic settings
15 - 65 kW

12 Bentone BFG1
General
!Scale value valid at 0 mbar in furnace pressure.
29,0-31,0
16,0-17,0
ø103
2,5-3,5
7,5-8,5
Pressure in the furnace mbar
Burner output kW
-0 ,5
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
20 3 0 4 0 50 6 0 7 0 80 9 0 10 0
Burner output kW
0,0
2,0
4,0
6,0
8,0
10,0
12,0
14,0
16,0
18,0
20,0
22,0
25 30 3 5 40 45 5 0 5 5 60 6 5 7 0 75 8 0 8 5 90 9 5 1 0 0
Air setting
Nozzle assembly setting
Scale
1.5 Model BFG1 H3
Blast tube length
mm
Blast tube
Dimension A mm
Flange
Dimension B ø
145 121,5 103
245 221,5 103
The above-mentioned measurements are maximum measurements. They
can vary, depending on which components are used.
1.5.1 Burner output/ Basic settings
25 - 100 kW

13Bentone BFG1
General

14 Bentone BFG1
General
4
3
5
1
6
2
10
16
9
15
14
13
7
8
22
11
12
1.6 Description

15Bentone BFG1
General
20
17
21
18
19
1.6.1 Components
1. 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. Ionisation electrode
21. Nozzle
22. Air flow indicator (indicates the air setting)

16 Bentone BFG1
General
3
pe
04
pa
5
pBr
61
2
5
pBr
4
pa
V1 V2
V3
0


6 6
1
0
5 3 4 4 5
2
0 Filter cover
1,3,4,6 G 1/8 screw plug
2 Test nipple (option)
5 M4 screwed sealing plug
2. Skeleton diagrams
2.1 Multi-bloc MBD-LE......B07
2.1.1 Electritrical connection MBD-LE......B07
P1
L1
P2
L2
Mp
N
MB-D(LE) B07
S22 / S52
P2
L2
P1
L1
MP
N
1
2
3

17Bentone BFG1
General
!When Bio gas is used, Bentone shall always be contacted.
MBD-LE......B07
V3
V1 V2
13
12
3
2
1
11
23
22
21
12
17
10
9
8
7
6
5
4
P
D
A
E
B
C
P
26
27
24
25
14
15
16
18
20
19
1. Pressure regulator
2. Microfilter
3. Valve V1
4. Connection flange
5. Closing spring V1
6. Housing
7. Armature V1
8. Regulating spring
9. Solenoid V1
10. Gas pressure switch (optional)
11. Electrical connection
12. Valve V2
13. Closing spring V2
14. Armature V2
15. Solenoid V2
16. Solenoid housing Setting:
17. - Gas pressure pa
18. - Main volume
19. - Fast stroke
20. Hydraulic brake
21. Bypass restrictor
22. Valve V3
23. Closing spring V3
24. Armature V3
25. Solenoid V3
26. Working diaphragm
27. Compensation diaphragm

18 Bentone BFG1
General
2.1.2 Functional description of gas
flow
1. When the valves V1 and V2 are closed, chamber
A is under inlet pressure.
2. A hole D in the filter housing connects min.
pressure switch with chamber A. If the inlet
pressure applied to the pressure switch exceeds
the incoming reference value, it switches through
to the automatic burner control.
3. After release by the automatic burner control,
valves V1 and V3 open.
The gas flows through chambers A, B and via
bypass valve V3 in C of the GasMultiBloc. The
ignition gas volume is adjusted by using the
bypass restrictor. The pressure regulator controls
the pressure upstream of valves V2 and V3.
4. When valve V2 is released, the gas flows directly
into chamber C, the bypass valve V3 remains
open.
2.1.3 Operating method of valve-
regulator combination on valve V1
A regulator, compensating for residual pressure is
integrated in valve V1 (pressure regulating part).
Armature 7 is not connected to the valve plate unit 3.
When it opens, armature 7 pretensions compression
spring (V1) 5 and releases the valve plate unit.
When the valve closes, the armature acts directly on the
valve plate unit.
The output pressure upstream of valve V2 is defined by
pretensioning the regulating spring 8 (tension spring)
via setting screw 17. The output pressure acts via
opening E on the working diaphragm 26 of the regulator.
In regulated state, setting spring inlet pressure and
pressure of working diaphragm are in force equilibrium.
The compensating diaphragm ensures the fast closing
function of valve V1 and a high regulating quality.
2.1.4 Operating method of bypass
valve V3
The bypass valve V3 opens at the same time as valve
V1. Ignition gas flow is set by using bypass restrictor 21.
2.1.5 Operating method of valve V2
Armature 14 of valve V2 is connected to valve plate
unit 12. When it opens, armature 14 pretensions
compression spring 13. The maximum valve opening can
be set by limiting the armature stroke by means of the
main volume restrictor 18.
Min. opening (residual stroke) of valve (0.5 to 1.0 mm)
The main volume restrictor is set by rotating the adjusting
plate or the hydraulic brake. The fast and/or slow
opening characteristic is influenced by setting fast stroke
19 at the hydraulic brake under the cover.
2.1.6 Closing function
When the supply voltage to the main valve solenoid coils
is interrupted, valves V1, V3 and V2 are closed within < 1
s by the compression springs.

19Bentone BFG1
General
2.2 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.
2.3 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.
2.4 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.
2.5 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)
2.6 Setting brake plate and air flow
Before the placing into service, the burner should be initially set according to
diagram.
(Refer to Basic settings). Note that it is only a question of 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.

20 Bentone BFG1
General
E
F
X1
X2
2.7 Burner installation
2.7.1 Hole pattern
Check that the hole pattern on the boiler matches that of the flange.
(Refer to Technical data.)
2.7.2 Burner installation
1. Install the flange with gasket on the boiler.
2. Insulate between the blast tube and the boiler door to minimize heat
radiation.
3. Check the ignition electrode and ionisation electrode.
(Refer to Technical data).
4. Install the burner on the boiler and lock into the flange (E).
5. Install the gas line on the burner. Check that the O-ring has not been
damaged during installation, fasten with the screws (F).
6. Where support for the multiblock is included, this should be installed.
2.7.3 Gas connections
1. Check the gas pipe dimensions. (According to local regulations).
2. Connect the gas pipe to the gas flange of the multiblock.
3. A manual gas valve should be installed in the vicinity of the burner.
4. No mechanical stresses/forces should exist in the gas connection.
5. Check the sealing of the gas connections, including the multiblock and
flanges.
NOTE!
If the gas connection is via a hose, the support for the multiblock that is
supplied with the burner should be mounted (F). Install the support so that
the underneath of the multiblock rests on it.
2.7.4 Electric connection
If the boiler does not have a pre-wired connector, connect in the included
connector, X2 according to the wiring diagram.
1. Turn off the main switch.
2. Connect the Eurostecker X2 acc. to Alt. 1 - 3 (Refer to Electric equipment).
3. Install the Eurostecker X2 on the burner.
4. Turn on the main switch.