Enertech Bentone BG400 Technical specifications

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178 024 73-3 2016-12-06
Installation- and maintenance instruction
BG400

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
16. Motor
17. Ignition electrode
18. Transformer
19. Ionization electrode
20. Inner assembly
21. Nozzle
22. Brake plate
8. Air dampe
9. Air intake
10. Gas pressure switch
11. Ball valve
12. Control box
13. Electrical connection
14. Reset button
15. Fan wheel
172 205 39 08-01
DESCRIPTION

Capacity chart according
to EN 676
Output range
TECHNICAL DATA
The above dimensions are max. measurements. Depending on the compo-
nents used, the measurements may vary.
172 215 13 12-01
1) Calorifi c value:
Natural gas 10 kWh/Nm3
LPG 26 kWh/Nm3
2) Dimension and capacity depen-
ding on gas quality and available
pressure
Type Capacity
kW
Gas volume at a min.
output Nm3/h 1)
Gas volume at a max
output Nm3/h 1)
Max. inlet
pressure mbar
Rated inlet
pressure mbar
Natural gas/LPG Natural gas LPG Natural gas LPG Natural gas LPG
400 60-318 6 2,3 31,8 12,2 100 20 20
(5,0 kg/h) (24,8 kg/h)
2) Town gas 2) Town gas 2) Town gas 2) Town gas
Type designation BG 400
Dimensions
Length of burner tube Measure A
Standard 172 155
272 255
372 355
Gas fi ttings2) Motor Ignition transformer
Natural gas, LPG 1-phase, 0,25 kW, Primary 230 V, 1, A
1" 2 800 r/m, 230 V Secondary 8 000 V
2) Town gas
506
ø108
A 100
192
250
410
ø140
410

TECHNICAL DATA
172 215 30 07-01
ø175-240
M10
Dimensions of fl ange
ø140

SKELETON DIAGRAMS, 1-STAGE BURNER
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
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.
When Bio gas is used, Bentone shall always be contacted.
!
172 415 04 08-01
Incorporated in the MultiBloc
3
6b
5b
10
6a
9
7
12
5a
4

Removal of fan house unit from
burner.
Loosen the screws. Swing out the fan
house. Remove the ionisation and
ignition cables from the electrodes.
Remove the bolt on the fl ange.
Remove the combustion unit from the
burner. Fit the enclosed fl ange and
gasket to the boiler. If new fi xing holes
must be drilled, use the fi xing fl ange
as a pattern.
Removal of valve unit from burner
Remove the plug-in contact from the
multi-bloc. Loosen the union nut.
MOUNTING ON THE BOILER
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.
172 205 36 08-01

172 425 16 16-01
ELECTRIC EQUIPMENT
Component list
A1 Gas burner control
A2 Twin thermostat
B1 Ionization electrode
F1 Fuse
H1 Alarm, 230 V
If there is no plug-in contact (X2) on the
boiler, connect to the contact enclosed.
In case the twin thermostat is in series
on incoming phase L1,
a loop between the terminals T1 and
T2 is necessary.
Mains connection in accordance with local regulations.
M1 Burner motor
S3 Main switch
S8 Air pressure switch
S9 Gas pressure switch
T1 Ignition transformer
X1 Plug-in contact, burner
X2 Plug-in contact, boiler
Y1 Gas solenoid valve
Gas burner control: LME11/LME21
Wiring diagram
1(3)

172 425 16 16-01
2(3)
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
Gas burner control: LME....
Colour codes
Diagnostics alarm trigger
The red alarm signal lamp lights continuously after the alarm is disconnected.
Diagnostics for alarm triggers can be read as specifi ed by the following sequence:
Limit on start attempts
LME 11 … limits the number of start attempts if the fl ame does not ignite on start-up
or goes out during operation. LME 11 … permits a maximum of three start attempts if
the start cycle is uninterrupted.
Continuous
Off
Red
Yellow
Green
Colour code table for multi-coloured signal lamps (Light diodes)
Status Colour codes Colours
Waiting time «tw», other waiting times ○………………… Off
Ignition phase, ignition checked •○ •○ •○ •○ •○ • Flashing yellow
Normal operation □………………… Green
Operation, poor fl ame signal □○□○□○□○□○ Flashing green
Prohibited fl ame signal during start up □▲□▲□▲□▲□▲ Green-Red
Undervoltage ●▲●▲●▲●▲●▲ Yellow-Red
Disruption, alarm ▲………………… Red
Flashing code for fault codes ▲○ ▲○ ▲○ ▲○ Flashing red
Interface diagnostics ▲▲▲▲▲▲▲▲ Red fl ickering
Light period (waiting time ≥ 10 s)
AL
FS
Flash code Pause Flash code
Approx. 3 s
lights red Press the reset
button > 3 s

172 425 16 16-01
3(3)
ELECTRIC EQUIPMENT
Control diagnosis under fault conditions and lockout indication
Gas burner control: LME...
During alarm trigger diagnostics, control outputs are to be disconnected from all
power.
– The burner is disconnected
– Exception, the «AL» alarm signal at connection block 10
– The burner is only to be reconnected after it is reset
– Press the reset button 0.5...3 s
Interface diagnostics
To switch to interface mode, hold the reset button depressed for more than 3 s. To
return to normal mode, hold the reset button depressed for more than 3 s. If the fi ring
unit is in the alarm mode, it is reset by pressing the reset button 0.5...3 s.
Connecting signal amplifi er
Alarm control table
Red fl ashing code
on signal lamp
(LED)
Possible causes
Flashing 2 x
••
• No fl ame at End of «TSA»
– Defective or obscured fl ame monitor
– Defective or obscured fuel valves
– Poor burner installation
– Defective ignition unit
Flashing 3 x
•••
«LP» defective
– No air monitor signal after «t10»
– «LP» is welded in the open position
Flashing 4 x
••••
Prohibited fl ame signal during start up
Flashing 5 x
•••••
Time out «LP»
– «LP» is welded in the closed position
Flashing 6 x
••••••
Free
Flashing 7 x
•••••••
Too many loss of fl ame during operation
– Poor burner installation
– Defective or obscured fuel valves
– Defective or obscured fl ame monitor
Flashing 8 x
••••••••
Free
Flashing 9 x
•••••••••
Free
Flashing 10 x
••••••••••
Connections fault or internal fault,
outgoing contacts or other fault
Flashing 14 x
••••••••••
••••
CPI contact not closed
A1 = LME
GP
R/W
L N
br bl rt sw
sw rtQ1 = AGQ 3...
QRA
11112 2

MEASURES AND CHECKS BEFORE START-UP, 1-STAGE BURNER
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/mainte-
nance.
Inner assembly
Ensure that the ignition and ionisation
electrodes are correctly adjusted. The
sketch shows the correct measure-
ments.
Gas quality
Ensure that the burner head is meant
for the gas quality to be used (see fi g.)
Venting
The gas line is vented by loosening the
screw on the test nipple for the inlet
pressure. Connect a plastic hose and
conduct the gas into the open. After
having vented the gas line tighten
the screw again.
172 205 33 08-01
Leakage control
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 fi g.
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 fl ame 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 fi nished.
NOTE! Applies only to gas burner
control LFL1.
When using LPG (Propane) the burner
should be connected for post-purge.
Move connection to terminal 6 to ter-
minal 7 in the base of LFL1.

MEASURES AND CHECKS BEFORE START-UP
172 205 78 07-01
INNER ASSEMBLY
Town gas
INNER ASSEMBLY
Natural gas, LPG
INNER ASSEMBLY
Biogas (UV-detector)
Natural gas
LGP
2,5
8
be taken into account as follows:
Net calorifi c value
Calorifi c value of the gas A. 37 144 kJ/Nm
ηExpected effi ciency 90%
≈
η
≈
Specifi cations on natural gas, town

172 205 16 07-01
If the barometer height, pressure and temperature of the gas deviate very much from the normal values this must
be taken into account as follows:
f = 273+t . 1013,25
273 B+Pu
t = Temperature of the gas at the gas meter (15°C)
B = Barometer height (945 mbar)
Pu= Pressure of the gas at the gas meter (15,0 mbar)
f = 273+15 . 1013,25
273 945+15
f = 11,1
The gas volume read on the gas meter actually reads 1,11 .12,9 = 14,4 m3/h.
Net calorifi c value
Gas quality kWh/Nm3kJ/Nm3kcal/Nm3
Natural gas 10,3 37 144 8 865
Propane 26,0 93 647 22 350
Butane 34,3 123 571 29 492
Town gas 4,9 17 653 4 213
Bio gas 7,0 25 219 6 019
V = Gas volume Nm3/h
Q = Boiler output 120 kW
Hu=Calorifi c value of the gas A. 37 144 kJ/Nm3, B. 10.3 kWh/Nm3
η=Expected effi ciency 90%
Ex. A v= Q .3 600 =120 .3 600 ≈12,9 Nm3/h
Hu
· η37 144 .0,90
Ex. B v= 120 ≈12,9 Nm3/h
10,3 · 0,90
Example how to calculate the gas volume (natural gas)
DETERMINATION OF GAS VOLUME FOR THE INSTALLATION
Specifi cations on natural gas, town
gas and bio gas vary. For more exact
information please contact the gas
distributor.

ADJUSTMENT OF MULTI-BLOC, MB-DLE 405-407
Flow adjustment
Loosen the fixing screw a. Turn the
hydraulic device b:
to the right = the gas flow is reduced
to the left = the gas flow is increased
Do not forget to tighten the fixing screw
again.
The flow adjustment can also be made by
means of the governor. Adjust the outlet
pressure to a value giving the desired
gas flow on the fully open valve. At small
capacities (gas flows) it is also necessary
to adjust as above.
Adjustment of governor
Adjust outlet pressure from governor by
means of a screw . Min. and max. outlet
pressures corresponds to appr. 60 turns
of the spring. It is not possible to change
pressure springs in order to change the
outlet pressure.
Turn to the right = the outlet pressure is
increased
Turn to the left = the outlet pressure is
reduced
Adjustment of start gas flow
Remove the protective cover c.
Turn the adjustment knob d (use the
protective cover as a tool) to the desired
start gas flow.
Turn to the right = the start gas flow is
reduced
Turn to the left = the start gas flow is
increased
Max. inlet pressure: 360 mbar. Adjustable
governor pressure:
405 - 412 S50 = 4 - 50 mbar
415 - 420 S20 = 4 - 20 mbar
415 - 420 S50 = 20 - 50 mbar
Solenoid valve: Slow opening valves with
adjustable start load and max. flow.
172 505 38 16-02
16
2 3 4
5
6
7
8
9
10
11
12
13
14
15
1
1. Electrical connection for valves (DIN
EN 175 301-803 connector)
2. Operation display V1, V2 (optional)
3. Lead seal eye, Gouvernor
adjustment
4. Setting cap
5. Hydraulic brake / setting plate
6. Solenoid
7. Test point connection G 1/8
possible
8. Test point connection G 1/8
downstream of valve 1, possible on
both sides
9. Output flange
10. Gas flow direction
11. Test point connection G 1/8
upstream of V1, possible on both
sides
12. Vent nozzle, regulator
13. Filter (below flange)
14. Input flange
15. Pressure switch
16. Electrical connection for pressure
switch (DIN EN 175 301-803
connector
Adjustment of start gas flow
d
c
a
b
Adjustment of governor
checking of fl ue gas temperatures,
After the burner has been fi tted to
of a fl ue gas analysis device. Adjust
the burner to appr. 20% excess air
the fl ue gas temperature. Calculate
the effi ciency. Check also the actual
by qualifi ed personnel. Replacement
to fi re another gas quality it must be
fi red the combustion head must be
% % %

GENERAL INSTRUCTIONS
Adjustment of burner
The burner is from the factory pre-set
to an average value that must then be
adjusted to the boiler in question.
All burner adjustments must be made
inaccordance withboilermanu-facturers
instructions. These must include the
checking of fl ue gas temperatures,
average water temperature and CO2
or O2concentration.
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 regu-
lations 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 operating instructions accom-
panying the burner should be left
in a prominent position in the boiler
room.
Instructions
The user should be thoroughly
instructed in the function of the gas
burner and the whole installation.
The supplier must instruct the user.
Inspection and maintenance
Daily inspection is advisable.
Start up
After the burner has been fi tted 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, com-
bustion 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 adjust-
ment 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.
172 305 28 07-01
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 com-
bustion quality is checked by means
of a fl ue gas analysis device. Adjust
the burner to appr. 20% excess air
in accordance with the table. Check
the fl ue gas temperature. Calculate
the effi ciency. 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 qualifi ed personnel. Replacement
parts should be of the same make and
approved by the same authorities as
the original. If the burner is converted
to fi re another gas quality it must be
re-commissioned. If town gas is to be
fi red 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 3,5 11,9
LPG 11,5 3,5 13,9

172 305 31 08-01
GENERAL INSTRUCTIONS, 1-STAGE BURNER
Adjustment of inner assembly
Control of burner head
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 fl ue
gas analysis.
Adjustment of brake plate
- Loosen the screw on the adjust-
ment 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 fl ow. It is
therefore always necessary to make a
fi ne adjustment of the air by means of
the adjustment device of the burner.
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.
Air adjustment
of the fl ame electrode in the burner
fl ame electrode and the gas burner
Connect the µA-meter, see fi gure. Min.
Adjustment range:
fi gure) until the gas pressure switch
appr. ± 15 %. Open the ball valve.
scale ±15%.
in such a way that if there is insuffi cient
sure is less than 80% of the pressure
exceeds 1% by volume.
Adjustment range ca:

172 305 25 16-01
Flame monitoring and measure-
ment of ionisation current
The burner is monitored according
to the ionisation principle. Check the
ionisation current on start-up and on
each service call.
The reason for a low ionisation current
may be leaking currents, bad connec-
tion to earth, dirt or a faulty position
of the fl ame electrode in the burner
head. Sometimes also a faulty gas/air
mixture may cause too weak a ionisation
current.
The ionisation current is measured
by means of a microampere meter
(µA) connected in series with the
fl ame electrode and the gas burner
control.
Connect the µA-meter, see fi gure. Min.
required ionisation current according
to table. In practice this current must
be considerably higher, preferably
more than 10 µA. All the gas burners
are equipped with a ionisation cable
that can be slit which facilitates the
connection of the µA-device.
Gas pressure switches:
Adjustment range:
2,5-50 mbar GW 50
5-150 mbar GW 150
Adjustment of min. gas pressure
switch
The min. pressure switch should react
if the gas pressure is too low and
prevent the burner from starting. Too
low a gas pressure during operation
should stop the burner. The burner
may start again when the rated gas
pressure has been reached.
Remove the protective cover. Connect
a pressure gauge for measuring the
rated pressure. Decide on pressure
at which the gas switch should switch
off. Set this pressure by means of the
valve. Carefully turn the knob (see
fi gure) until the gas pressure switch
switches off. The value shown on the
scale should then approximately cor-
respond with the value shown on the
pressure gauge. Tolerance on scale
appr. ± 15 %. Open the ball valve.
GENERAL INSTRUCTION
Adjustemnt of max. gas pressure
switch
The burner is equipped with a max.
gas pressure switch only on request.
It should stop the burner if the gas
pressure exceeds the set value. The
burner can then only be re-started
manually (gas burner control or
overpressure switch).
Remove the protective cover. Connect
a pressure gauge for measuring the
rated gas pressure. Decide on pres-
sure at which the gas pressure switch
should switch off.Turn the adjustment
knob to this value. Tolerance on the
scale ±15%.
Adjustment of air pressure switch
The air presure switch should stop the
burner if the air volume is reduced.
The air proving device shall be adjusted
in such a way that if there is insuffi cient
air supply at the highest or lowest
burner operating stage, the device
operates before the supervised pres-
sure is less than 80% of the pressure
at the controlled stage and the CO
content of the combustion products
exceeds 1% by volume.
Air pressure switch:
Adjustment range ca:
1-10 mbar LGW 10
2,5-50 mbar LGW 50
Flame monitoring
Gas pressure switch, air pressure
switch
Gas control Connection to terminal
in gas control
Min. ionisation
current required
LME 15 µ A
LFL 24 10 µ A

FINAL TEST OF THE INSTALLATION
172 305 17 07-01
–Make repeated start attempts to
ensure that the adjustments
function.
–Close the ball valve during
operation to check that the gas
switch switches off at the set
value.
–Remove the hose for the air
pressure switch to check that
the burner locks out.
–Check that all protective covers
and measurement nipples are
mounted and fastened.
–Fill out necessary test reports.
–Instruct the persons in charge
of the operation on the service
and maintenance of the installa-
tion and what to do should any
troubles occur.
–Inspection and service must
only be carried out by author-
ized people.
Fault location, functional troubles
Trouble free operation is dependent
on three factors: electricity, gas and air
supply. Should there be any changes
in the ratio between these three factors
there is a risk of break downs. It has
been proved that most break downs
are caused by simple faults. Before
callingtheserviceengineer,the following
should therefore be checked:
–Is the gas cock open?
–Are all fuses in order and the
current switched on?
–Are the thermostats correctly
set?
–Are pressostats, overheating
protection etc. in operating posi-
tion and not locked-out?
–Is the gas pressure suffi cient?
–Is the gas burner control in start
position?
–Has the gas control or the motor
protector locked out? - Reset.
–Is the circulation pump in opera-
tion?
–Is there a supply of fresh air to
the installation?
If integral components are of a
different make from what is stated
in this manual, see the enclosed
loose-leaf.

170 091 16 15-01
1. Fault location guide
Gas burner
The basis for a trouble free operation can only be ensured by the correct
combined effect of the three factors:
electricity, gas flow and combustion air. Should any of these factors change,
troubles may arise.
t has been proved that many troubles have rather simple causes. Before
calling the serviceman, the following checks should be made:
o facilitate fault location we have drawn up a scheme showing the most
frequent faults in a gas burner installation and the remedies.
1. Are the gas cocks of the installation open?
2. Are the fuses in order and the current switched on?
3. Are the controls (room thermostat, boiler thermostat etc.) correctly
adjusted?
4. Is the gas pressure to the burner sufficient?
5. Is the gas relay of the burner ready for start and not locked out?
6. Is the air supply to the burner sufficient?
Cause Remedy
The burner does not start
No gas Check that all gas cocks are open.
No voltage Check fuses, thermostats and electrical
connections.
The burner motor fails to start The thermal protection has locked out.
Motor defective.
The gas relay is defective Replace
Burner motor is running but no
ignition after the pre-purge time has elapsed
No voltage on the terminals Check the contact. Replace faulty relay
The ignition electrodes in contact with each other or with earth Adjust
The porcelain of the electrodes is broken Replace the electrodes
The cable shoes have bad contact Improve the contact
The ignition cables are damaged Replace
The ignition transformer is damaged, no voltage on the secondary
side
Replace the transformer
The ignition cable and the ionisation cable have been transposed. Change
No flame establishment despite a trouble free start
The gas solenoid valve defective Replace
The gas solenoid valve does not open despite its obtaining voltage Replace coil or the whole valve if necessary.
No voltage to the solenoid valve Check the contact
1(3)

170 091 16 15-01
Cause Remedy
No electrical connection through the air pressure switch Test the adjustment and the function of the
air pres-sure switch.
The starting load is not correctly adjusted Reduce or increase the gas supply, reduce
the quanti ty of air.
Gas relay defective Replace
Air pressure switch incorrectly adjusted or defective Check the adjustment and readjust.
No reponse as the cams of the servomotor are not correctly
adjusted or out of position.
The burner locks out after the safety time has el-apsed in
spite of flame establishment
No ionisation current or the UV-cell in wrong position Adjust the ionisation electrode and the UV-
cell, examine cables and connections.
The supervision part of the gas relay is defective Replace the relay
Voltage lower than 185 V Contact the electricity authorities.
The ignition electrodes are disturbing the ionisation current Adjust the ignition electrodes, repole the
ignition transformer if necessary.
Bad earthing Arrange for proper earthing.
Phase and neutral transposed See wiring diagram and change.
The burner locks out during pre-purge
Air pressure switch defective or incorrectly adjusted Reduce or increase the gas supply. Reduce
the quantity of air.
The starting load is not correctly adjusted Reduce or increase the gas supply. Reduce
the quantity of air.
The gas pressure is too low Increase the pressure. Contact the gas
supply company if necessary.
Pulsations at start
The ignition electrodes are wrongly adjusted Readjust
The gas pressure is too high Check and adjust by means of a pressure
gauge and a pressure adjustment valve.
The flue gas side is blocked Check the chimney flue.
Pulsations during operation
The burner is not correctly adjusted Readjust
The burner is dirty Clean the burner.
Defective chimney Check and change the dimensions if
necessary.
2(3)