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Assembly and maintenance instructions

BG100

1 172 117 42 05-01


178 005 21
DESCRIPTION

COMPONENTS
1. Multi-block
2. Ionization electrode
3. Diffuser tube
4. Flame holder disc
5. Jet
6. Ignition electrode
7. Nozzle carrier line
8. Electrical connection
9. Transformer
10. Air pressure switch
11. Control box
12. Reset button
13. Engine
14. Adjustment, nozzle line
15.Rotor
16. Air Intake Box
17. Air adjustment

GENERAL INSTRUCTIONS VANNEGAZ: FLAME CONTROL:


The installation of the burner must be Multi-block Dungs MBDLE... Ionization
carried out by qualified personnel, in or corresponding type
accordance with the rules of the art. CONTROL BOX:
GAS PRESSURE SWITCH: (MIN) Landis & Gyr or similar. The designation
The operating instructions supplied Integrated in the multi-block depends on the standards in force
with the burner should remain with Adjustable from 2.5-50 mbar
the burner.
PRESSURE SWITCH:
- Users must be kept informed of the Adjustable from l to 1 - 10 mbar
operating methods of the burner as
well as of any ĺ heating installation.

- Inspection: Daily inspection is


recommended

- Maintenance: Maintenance should


only be carried out by qualified
personnel. Replaced parts must be
replaced by parts with identical
technical characteristics. If the
nature of the gas changes, the
burner must be redefined, especially
if it is town gas.

172 207 15 93-05


TECHNICAL CHARACTERISTICS
Designation BG 100
DIMENSIONS

129 *)
AT

94
ø89

155
148
202 7 296

Flange A Flange B
Length, Diffuser Tube Coast A Coast A

Standard 147 126 131


long model 224 203 208
The above ribs are maximum ribs. According to the components used the
ribs may vary.
* ) 200 for city gas

TECHNICAL DATA

Kind Power Minimum flow Maximum flow Inlet pressure


kW in meters3/h1) in meters3/h1) mbar
Natural gas, LPG Natural gas LPG town gas Natural gas LPG town gas Natural gas LPG town gas
100 7-41.5 0.7 0.27 1.59 4.5 1.7 10.2 20 30 8
City gas
7-32.4

1) Calorific value retained:


Connection2) Engine Transformer Natural gas 10 kWh/m3
ignition LPG 26 kWh/m3
Mains gas 4.4 kWh/m3
Natural gas, LPG Town gas 220/240V,2800r/m, Electronic
½" 1" 50Hz, 70-90W, 0.65A 230/11000V, Ampl. 2 ) Dimension depends on gas type
and inlet pressure.

FUNCTIONAL DIAGRAM-
MENTELONEN 676
NB For capacities between 7-12kW
a special model of the combustion
head is required. In such cases
please contact Bentone.

172 217 06 00-02


TECHNICAL CHARACTERISTICS
FLANGE DIMENSIONS

ø89.5 17

Flange A
10.5

130-150

ø89.5 12
Flange B
12

130-150
172 217 21 96-02
FLOWSHEET

Incorporated in the MultiBloc

1. Stop valve 6b. Safety valve Pos. 5b, 7: Components which are not
2. Filter 1)7. Leak test required according to EN 676.
3. Pressure regulator 9. Air pressure switch
4. Manometer with shut-off valve 10. Security box Necessary above 1200 kW
1)

5a. Minimum gas pressure switch according to EN 676.


5b. Maximum gas pressure switch
6a. main valve

When biogas is used, always contact Bentone.

172 417 07 03-01


MOUNTING ON THE BOILER

Fix the flange and its seal on the The multi-block is ex works mounted INSTALLATION EXAMPLE
boiler. Use the flange as a "Master" horizontally with the gas inlet on the Connect the gas to the shut-off
if new holes need to be drilled. Use right side. The multi-block can valve using the union to facilitate
M8-M10 fixing screws. however be oriented in any other maintenance operations. Check
direction. A gas inlet from the rear is that the positioning of the shut-off
also possible. If there is no space, valve and the gas inlet is made in
the multi-block can also be such a way that the burner can be
Insert the burner into the flange
connected outside the boiler. Make easily removed in the event of
and secure it as shown below. Make
sure, however, that the distance inspection and maintenance.
sure the burner is vertical.
between the multi-block and the gas
line is not too great. If the distance is
large the burner does not have time
to ignite.

172 207 16 93-05


ELECTRICAL EQUIPMENT
SAFETYBOX: LGB21/LMG21 WIRING
DIAGRAM

If the boiler is not equipped with a


"European" plug (X2) use the one
supplied with the burner. If the
double thermostat is in series on the
input phase, a connection between
terminals T1 and T2 is necessary.

LISTOFCOMPONENTS
A1 Gas control relay M1 burner motor T1 Ignition transformer "Euro"
A2 Double thermostat S3 Main switch X1 socket on the burner side
B1 Ionization electrode S8 Air pressure switch X2 "Euro" socket on the boiler
F1 Fuse S9 Gas pressure switch Y1 side Magnetic valve
H1 Alarm, 220V

Mains supply and installation circuit breaker according to local instructions.


172 407 36 99-02
ELECTRICAL EQUIPMENT
CONTROL DIAGNOSIS IN THE EVENT OF FAULTS AND FAULT POSITION INDICATION. SAFETY
BOX: LMG ...

Order concept • Device in fault • Unlock


> fault signal lamp (red) on Press the unlock button for 0.5 ...3 s

• Failure cause diagnosis


- wait >10s
- press the unlock button for >3 s

AL - read the flashing code on the red


signal lamp
> “Trouble Code Table”

Fault cause diagnosis After lockout, the fault signal lamp (red) stays on continuously. The reading of the
fault cause diagnosis results from the following sequence:

red, on to push on
Lighting phase (delay 10s) > 3 s Blink code Pause Blink code

FS AL Disturbance approx. 3 sec

Fault Code Table


Blink code Possible cause
Blink 2x • no flame formation at the end of “TSA”
•• - faulty or clogged electrode-probe
- faulty or clogged fuel valves
- incorrect burner adjustment
Blink 3x • the air pressure switch does not close
••• - "LP" defective
- "LP" incorrectly set
- the fan motor does not work
Blink 4x • the air pressure switch does not open or stray light when the
•••• burner starts
- "LP" defective
- "LP" incorrectly set
Blink 5x • stray light during pre-ventilation
••••• - or internal device fault
Blink 7x • flame interruption during operation
••••••• - incorrect burner adjustment
- faulty or clogged fuel valves
During fault cause - short circuit between the electrode-probe and ground
diagnosis, the control Flashing 8...17 x • free
outputs are de-energized. ••••••••

..................

- the burner remains ••••••••••

disconnected •••••••

- exception, fault signal Blink 18x • the air pressure switch opens during pre-ventilation or in service
"AL" on terminal 10 •••••••••• - "LP" incorrectly set
•••••••• - flame interruption for 4thtimes in service (LMG25)
The burner is only Blink 19x • output contact fault
restarted after unlocking. •••••••••• - wiring fault
••••••••• - foreign power supply on the output terminals
- press the unlock button Blink 20x • internal device fault
for 0.5 to 3 s. ••••••••••

••••••••••

172 407 52 01-01


CHECKS BEFORE COMMISSIONING, BURNER AT 1 STAGE
GAZLINE LEAKING CONTROL
Check that the position of the ignition
and ionisation electrodes conforms to
the diagram opposite.

GAS QUALITY
Check at the same time that the
burner head is designed for the
quality of gas used. (See figure).

PURGE
The gas line is purged by unscrewing
the upstream pressure tap screw.
Connect it to a plastic pipe leading to
the open air. Tighten the screw after
bleeding.

LEAKING CONTROL
The leak test must be carried out with
the shut-off valve closed. Connect the
control manometer to the Pa pressure
tap, as shown in the figure. The test
must be carried out at 1.5 times the
upstream pressure and at a minimum
of 150 Mbar. In the event of a leak
locate it using soapy water or a
suitable product. After repair, repeat
the check.

FUNCTION CONTROL
ELECTRICAL
Make sure the phase and neutral
are not reversed and that the motor
is running in the correct direction (if
three-phase). To prevent the gas
pressure switch from tripping, it
must be temporarily switched off.
After opening the thermostat and
the main switch, the pre-ventilation
starts (30-35 seconds). At the end of
this period pre-ignition starts (0.5-3
seconds depending on the model)
then the valve opens. At the end of
the safety period (2-3 seconds) the
control box locks and the burner
stops. Don't forget to reset the gas
pressure switch.

NOTE: ONLY CONCERNS THE


SAFETY BOX LFL1... If supplied with
LPG, the burner must operate in
post-ignition; modify the connection
on the base of the LFL1... Change
the connection from terminal 6 to
terminal 7.

172 207 29 97-02


CHECKS BEFORE COMMISSIONING

GAS LINE
Natural gas, LPG

GAS LINE
City gas

GAS LINE
Biogas (UV probe)

172 207 05 97-01


DETERMINATION OF GAS VOLUME REQUIRED
The calorific values of gases vary
Lower calorific value kWh/
according to the regions, contact the
distributors to know the precise Qualitygas m3 kJ/m3 kcal/m3
calorific value.
Natural gas 10.3 37,144 8,865
Propane 26.0 93,647 22,350
Butane 34.3 123,571 29,492
City gas 4.9 17,653 4,213
Biogas 7.0 25,219 6,019

EXAMPLE OF CALCULATION (NATURAL GAS)

V = Quantity in m3/h

Q = Boiler power 120 kW

Ha = Calorific value of gas A. 37,144 kJ/m3, B. 10.3 kWh/m3

= Boiler efficiency 90%

Example A
V=
Q.3,600 =
120.3,600 12.9m3/h
Ha. 37,144.0.90

Example B
V=
120 12.9m3/h
10.3.0.90
If the barometric pressure or gas temperature deviates from normal
standards, the following corrections should be made.

f = 273+t .
1013.25
273 B+P a

.
you= Gas temperature at meter (15°C)

B = Barometric pressure (945 mbar)

P a = Gas pressure at meter (15.0 mbar)

f = 273 + 15 .
1013.25
273 945 + 15

f 1.11

The volume of gas then becomes 1.11.12.9 = 14.4m3/h.

172 207 13 93-01


SETTING THE MB-DLE 403/MB-DLE 053 MULTI-BLOCKS
Maximum pressure at MB-DLE 403
inlet: 200 mbar (360 mbar for
France)
Output pressure adjustable from: 4
to 50 mbar.
MB-DLE 053: 60mbar
Output pressure adjustable from: 4
to 20 mbar.
Magnetic valve: progressive
opening, flow adjustment.

1. Protective cover
2. Hydraulic brake
3. Locking screw
4. Upstream pressure tap
5. Downstream pressure tap
6. Pressure tap in the line
7. Pressure adjustment
8. Filter
9. Gas pressure switch
10. Solenoid valve

FLOW ADJUSTMENT
Unscrew the screw a - Tournel the
hydraulic device b:
- on the right: to reduce the flow
- on the left: to increase the flow Don't
forget to retighten the screw after
adjustment.
The flow rate can also be adjusted
by acting on the pressure regulator:
fully open the valve, then adjust the
pressure to a value corresponding
to the desired flow rate. At small
flow rates it is also necessary to
make the adjustment mentioned FLOW ADJUSTMENT
above.

ADJUSTINGPROGRESSIVENESS
Remove the protective cover c.
Proceed with adjustment by
pressing button d (using the bonnet
to operate it).
- right: flow reduction at start-
up
- on the left: increased flow at
start-up

PRESSURE ADJUSTMENT
Adjust the pressure using a
screwdriver. 60 revolutions are
required from minimum to maximum
pressure. It is not possible to change
the spring of the device to modify the
outlet pressure.
Turn right: pressure increase ADJUSTING THE
PROGRESSIVENESS
PRESSURE ADJUSTMENT
Turn left: pressure decrease

172 507 01 00-01


GENERAL INSTRUCTIONS
GETTING STARTED COMBUSTION CONTROL The
When the burner has been mounted quality of combustion is checked by
on the boiler, the electrical means of a smoke analyzer. Adjust
connection, the tightness control, the the burner with approximately 20%
purge and the control of the electrical excess air according to the table
functions have been carried out, the opposite. Check the flue gas
burner is ready to start. However, temperature. Calculate the yield.
read the sections dealing with the Also check the gas volume on the
adjustment of the multi-block, the gas meter to ensure the flow rate is
combustion air and the combustion achieved.
head. Open the stop valve, and open
the main switch. If the burner starts
the adjustment can begin.

AIR ADJUSTMENT Qualitygas CO%


2
0%
2
max CO2%
Fine tuning should be done with the Lambda 1.2
hood mounted so that the air
volume is not changed after tuning. natural gas 10.0 3.5 11.9
LPG 11.5 3.5 13.9

BURNER HEAD ADJUSTMENT

The burners are equipped with an


adjustment device modifying the
position of the flame holder in the
combustion head. It is used to adjust
the pressure at the combustion head
and optimize combustion.

The setting depends on the back


pressure of the boiler.

As a general rule, the lower the


power, the smaller the opening must
be between the flame holder and the
inside of the diffuser tube.

ADJUSTING THE FRAM-ME HOOK

- Unscrew the adjusting device


screw
- To reduce the opening: turn left

- To increase the opening: turn


right
The modification of the position of the
disc affecting the flow of air, it is
therefore always necessary to adjust
the adjustment of the air flap.

BURNER HEAD CONTROL To check


the burner head, the flame holder
disc and the electrodes proceed as
follows:

Remove the hood. Loosen the union


between the gas line and the multi-
block. Loosen the burner from the
flange and pull it out of the boiler. If it
is necessary to remove the diffuser
tube, loosen the two allen screws and
pull the diffuser tube by turning it.
172 307 15 93-05
GENERAL INSTRUCTIONS

FIXING THE BURNER ON THE


BOILER

AIR ADJUSTMENT ADJUSTING THE TORCH-ME

BURNER HEAD CONTROL

172 307 22 93-05


GENERAL INSTRUCTIONS
IONI-SATION FLAME AND MAXIMUM GAS PRESSURE SWITCH PRESSURE SWITCH ADJUSTMENT
CURRENT CONTROL CHECK ADJUSTMENT The air pressure switch is triggered in
The burner is only equipped with a the event of a drop in air pressure.
The control of the burner is carried out maximum gas pressure switch on
according to the principle of ionization. request. This must stop the burner The air control device must be adjusted
The value of the ionization current must if the gas pressure exceeds the in such a way that in the event of an
be checked on commissioning and each value set on the scale. A start is only insufficient air supply at the maximum
time the after-sales service intervenes. possible after a manual reset (the and minimum flow rate of the burner, it
control box or the overpressure reacts before the controlled pressure
A value that is too low may be the switch). rises to less than 80% of the pressure on
result of a leak, poor grounding, Remove the protective cover. the controlled rate and before the CO
fouling or a faulty position of the Connect a manometer to measure content in the fumes exceeds 1% by
ionization electrode. Sometimes an the nominal pressure. Determine volume.
incorrect gas/air mixture can cause the pressure. Turn the adjustment
the reading to be too low. To knob to this value. Scale tolerance is PRESSURE SWITCH:
measure the ionization current, ±15%. Adjustablefrom:
connect a micro-ammeter ( µ A); put 1-10 mbar LGW10
in series with the ionization circuit 2.5-50 mbar LGW50
and the control box.

Connect the micro-ammeter


according to the figure. The
minimum value of the ionization
current which is necessary is given Control box Connection to the Minimum value
in the table. In practice this current terminal in the box
should be much higher, above 10
µA if possible. All gas burners are LMG 1 2µA
equipped with a divisible ionization LGB 1 10µA
cable which facilitates the LFL 24 10µA
connection of the micro-ammeter. MMI 810 2 5µA
TMG740-3 1 5µA
GAS PRESSURE SWITCHES:
Air pressure switch:
2.5-50mbar GW 50
5-150mbar GW 150
FLAME CONTROL

ADJUSTING THE MINI GAS PRESSURE


SWITCH
The minimum pressure switch must
react to too low gas pressure and
prevent burner start-up. Too low
gas pressure, in operation, must
stop the burner. A restart of the
burner will take place as soon as the
nominal gas pressure has been
reached. Remove the protective GAS PRESSURE SWITCH,
cover. Connect a manometer to AIR PRESSURE SWITCH
measure the pressure. Determine
the pressure switch cut-out
pressure. You will obtain this
pressure by closing the shut-off
valve. Slowly turn the adjusting
knob until it clicks. The value
indicated on the scale should then
correspond approximately to the
value on the manometer. (The scale
tolerance is ± 15%.) Reopen the
shutoff valve.

172 307 21 00-01


HANDOVER OF THE INSTALLATION,

- Carry out repeated starting FAULT DIAGNOSTICS


attempts to check the settings. Operation depends on three supplies:
electricity, gas and air. A change in
- Close the shut-off valve during the ratio between these three
service to check that the gas elements leads to the risk of
pressure switch trips at the set breakdowns. It is proven that most
value. breakdowns are due to simple causes.
Before notifying a specialized service,
it is a good idea to check the following
- Remove the hose from the air pressure points:
switch to check that the burner goes
- is the gas shut-off valve open?
into safety.

- Check that all protective covers and


- are the fuses good? Is the current
measurement connections are
coming?
mounted and fixed with screws.

- are the thermostats correctly


- Complete the necessary test
open?
protocols.

- are the pressure switches, the


- Instruct users on the service and
overheating thermostats not
maintenance operations to be
tripped?.
carried out as well as the
measures to be taken in the event
of a problem. - is the gas pressure sufficient?

- Inspection and service operations


can only be carried out by - is the relay or the thermal
authorized persons. protection of the burner tripped?
Press the reset button?

- is the control relay in the "start"


position?

- is the circulation pump working?

- Is the air inlet in the boiler room


not blocked?

172 307 14 93-01


TROUBLESHOOTING MANUAL
gas burner
Proper burner operation for a given power can only 5. the positioning of the burner relay: in working
be guaranteed if the correct ratio of the three factors order and not locked.
participating in its adjustment is maintained, namely: 6. Proper opening of the burner air supply damper -
Also check whether the fresh air inlet to the room
- electricity is not obstructed.
- the gas
- combustion air In order to facilitate fault finding, we have drawn up a
If one of these values changes, a fault may occur. master plan relating to the most common faults likely
to occur on a gas burner installation, as well as the
remedies to be applied.
The faults occurring on the gas burners are very often
of quite simple origin, therefore, before calling the
Technician-Installer, it is recommended to check:

1. Opening the gas taps


2. the good condition of the fuses and the
setting "On" of the power switch.
3. Control thermostat setting temperatures

4. the gas pressure at the burner (see if it is


sufficient)

FAILURE MANIFESTATION REMEDY

The burner does not start

no gas Check that all gas taps are open

No voltage at the relay current terminals Check line voltage, fuses, thermostats and electrical
connection.

Burner motor does not start Relay locked in safety position: reset it. Faulty motor:
replace it.

The gas relay is faulty Replace it

Motor runs but no spark after pre-ventilation time


expires

No voltage across transformer terminals Check the contacts: Replace the faulty relay if
necessary.

The electrodes touch each other or are in contact with the Set them
ground

The porcelain of the electrodes is broken Replace electrodes

Poor contact of cable connections Check the tightness of the terminals and improve the contacts

1(4)
170 091 15 97-01
FAILURE MANIFESTATION REMEDY

HV cables are damaged replace them

No voltage on the secondary of the transformer: Replace transformer


device damaged

The HT cables and the ionization cable are swapped Put them back in place

No flame despite a perfect start

The magnetic valve is defective replace it

Despite a normal power supply the magnetic valve Replace the coil of the magnetic valve and possibly
does not open the complete valve

No voltage at the solenoid valve terminals Control contacts

Electric circuit cut to the right of the air pressure Check the wiring, adjustment and operation of the
switch lack of air pressure switch

The starting load is not set correctly Reduce or increase gas supply. If necessary, reduce
the amount of air.

Defective relay Replace it

Lack of air pressure switch incorrectly set or defective Check it and if necessary resume the adjustment

No response because the servo motor cams are not


properly adjusted or out of position.

The burner locks out after the expiry of the safety


time despite the formation of a flame

No ionization current (or UV cell in incorrect position) Readjust Í ionization electrode (or UV cell). Check HV
cables and electrical connections.

The active block of the relay is faulty Replace relay

2(4)
170 091 15 97-01
FAILURE MANIFESTATION REMEDY

Current voltage less than 185 V Contact the Electricity Company for the purpose of
readjusting the voltage

The electrodes interfere with the ionizing current Resume electrode adjustment. Invert the
transformer power supply wires if necessary.

Bad grounding Establish proper grounding

Inversion of phase and neutral lines See the wiring diagram and rectify ĺ inversion

The burner locks out during the prevetilation


period

Lack of air pressure switch faulty or incorrectly set

The starting load is not set correctly Reduce or increase gas supply. If necessary reduce
the amount of air.

The gas pressure is too low Increase the pressure. Contact the gas company if
necessary.

Startup pulses

Improper adjustment of the electrodes Set them again

The gas pressure is too high Check and adjust using a manometer and a
pressure adjustment valve

Poor combustion gas release Check the flue and its free outlet to the atmosphere

Pulsation while walking

Incorrect burner setting Resume its setting

dirty burner clean it

Defective chimney Check it and modify its dimensions if necessary.

The burner works well but sometimes locks up

The ionization current is too low Check its value: must be at least 4 µ A, depending on
the brand of relay, but 8-20 µ A is recommended.

The UV cell in the wrong position Adjust it

Voltage drop from time to time The voltage must not touch more than 15% of the
nominal voltage: Contact the Electricity Company if
necessary.
3(4)
170 091 15 97-01
FAILURE MANIFESTATION REMEDY

Lack of air pressure switch faulty or incorrectly set

Ground electrodes Replace the electrodes and readjust them

The ambient temperature of the relay is too high Thermal insulation of the relay provided for 60° C
maximum: not to be exceeded in service

The ignition spark is too weak Check transformer

Bad combustion

Bad draw conditions Control the chimney

Temperature too high at the gas outlet The boiler is overloaded: Reduce the gas flow

The CO content is
2
too low Reduce to air damper opening. Check the tightness of
the fireplace and the flues of the boiler. Reduce the
draft if it is too high.

The CO content is too high

Excess air, when using natural gas, propane and reduce the air
butane

Air deficit Open air. Control the free outlet of fumes to the
atmosphere

Gas nozzle holes are clogged clean them

Air intake too low Check it and increase it if necessary

The flame is oblique due to incorrect positioning of Check the burner head and readjust it
the burner head

Formation of condensation in the boiler and


chimney

The gas temperature is too low: gas quantity too low Raise the temperature of the fumes by increasing the
quantity of gas. Insulate the chimney.

4(4)
170 091 15 97-01
DECLARATION OF CONFORMITY

We
(Name of supplier)

.B E NOT T..ONOT E
. . .. . .. . . . . .. . ..........................................

(address)

PO Box 309, S-341 26 Ljungby, Sweden


...........................................................

declare under our sole responsibility that the product


(name, type or model, batch, sample or serial number, possibly sources and number of copies)

.B
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to which this declaration relates is in conformity with the standard(s) or other normative document(s) (title
and/or no. and date of publication of the standard(s) or other normative document(s)

.P r..E..NOT 6..7..6..,..D
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4.
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in accordance with the provisions of Directive


(if applicable)

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(place and date)

BENTONE
Sven-Olov Lövgren

..........................................................................................................................

(name and signature of authorized signatory)

172 907 01 03-02

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