BENSON LD7 1LP Parts List And Service Manual

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BENSON LD7 1LP Parts List And Service Manual | Manualzz

PORTABLE HEATER PARTS LIST AND SERVICE MANUAL

BENSON HEATING LTD

INTRODUCTION

The C.S.H heater is designed and manufactured within the quality guidelines of ISO 9001

Care should be taken to ensure that the information used from this manual is applicable to the model of heater.

This manual provides the necessary information for the safe operation, cleaning, and servicing of the C.S.H.

Heater.

Whilst every care is taken to ensure that the information in this manual is correct Benson Heating accept no liability for misuse or from any loss, damage, or injury caused by errors in, or omissions from the information supplied.

HEALTH AND SAFETY AT WORK ACT 1974

Under section 6 of the Health & Safety at work act 1974 the manufacturer has taken reasonable and practical steps to ensure that the Benson range of appliances are safe and without risk when properly used.

These Heaters should therefore only be used in the manner and purpose for which they were intended and in accordance with the recommendations detailed herewith.

The Heaters have been designed, manufactured, assembled, and inspected with safety in mind, there are certain basic precautions which the user should be aware of and the user is therefore strongly advised to read the operating instructions before operating the Heater

SAFETY INFORMATION FOR HEATER

OPERATION

This equipment should only be used by a competent person who has read and understood the following instructions

Do not use this equipment if you are ill feeling tired or under the influence of alcohol or drugs.

WARNING

Keep animals and children away from heater NEVER leave them alone when heater is in use

Never use the heater if highly flammable vapours are present, or in a dUSty environment.

Never stack or lean objects on or against the heater whilst in operation

Never restrict the air supply to the heater

Ensure the operating area is well ventilated restricted combustion can cause carbon monoxide - concentrated carbon monoxide kills

Never Operate the heater near vehicle exhaust fumes

Never fill the heater whilst it is hot or running

Always wear protective ciothing when filling heater

(Gloves Goggles etc)

Never smoke or allow naked light into the area when refueling

Always mop up any spillage immediately

Never breathe any unbumt gas oil vapours

Contained within the text of this manual the words

CAUTION and WARNING are used to highlight certain points.

Always ensure heater is standing on a firm level noncombustible surface

Never move the heater whilst it is in operation

CAUTION Is used when failure to adhere to the instruction could result In premature failure or damage to the heater.

WARNING is used when failure to heed or implement the instruction can lead to component damage or risk of personal injury.

WARNING Before carrying out any work on the heater ensure that electrical supply is isolated 110 Volt heaters piug into a standard 110 volt generator ensure flex and plugs are undamaged. Uncoil extension leads fully

Never run leads through water or over sharp objects

Never carry or pUll heater by the electrical cable

WARNING use of electrical equipment in damp or wet conditions can be dangerous

Ensure that the sections on Heater Controls and

Heater Operation are read and understood before operation of this equipment.

For further information contact and advice contact

Spares

I

Service Depts. at Knighton Powys

TELEPHONE 01547 528534 FAX 01547 520399

I

PAGE No2

~ECHNICAL

SPECIFICATION

CONFINED SPACE HEATER.

(DIESEL)

Heat Output

Air Delivery (cold)

11

Kw

(37,500Btu)

@ 7mtrs

0.202m

3

@ 14mtrs 0.185 m

/s

Temperature Rise through Unit @7mtrs 40°C

@ 14mtrs 30°C

Nozzle size

Pump Pressure (Diesel)

Max Fuel Throughput

Sound Level (D.b.a.)

Electricity Supply

Motorsize

Start current

Run current

Weight

FuelType

Tank Capacity

Danfoss 0.30 Usg x 60° H

90 Psi

1.3ltrs/hr

70 D.b.a.

11

OVolt

150Hz

2550 Rpm

220 Watts

4.5 Amp

2.0 Amp

48 Kgs

Diesel

16

Us

PAGE No 3

I

PARTS LIST

16

15

1 1A

14

2

13

4

3

11

10

8

9

12

25

26

5

6

7 17

17A

18 19

20

21

22

23

24

27

29

28

42

41

30

39

40

38

31

32

31A

33

34

37

44

45

30

43

43A

35

36

PAGE No 2

PARTS LIST

Item No

28

29

30

31

24

25

26

27

17

18

19

19A

20

21

22

23

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

40

41

42

43

43A

44

45

36

37

38

39

32

33

34

35

Parts Description No Off Part No

Top cover outer casing

Flue Pipe assembly

Burner cover

Pressure switch

Photocell

Allen screws - hexagon head

Burner assembly including base

Electrode assembly

1

1

21-30-011

21-30-057

1

1

E8010810000100

1

1

1

E8010610000000

2

E8040017320000

E8020003000001

Blast tube

Blast tube mounting collar

Burner Gasket

Nozzle

1

1

1

1

E8000400100400

E8000100500101

21-30-061

Heat exchanger

Heat shield assembly

Thermostat

Thermostat - reset type

1

1

1

1

21-30-001

28-16-049

28-16-050

Inlet valve solenoid assembly 1

E80010403110300

Quick release valve 1

E8030120220200

Filter bowl complete with filter cartridge

Filter cartridge

Elbow

Fuel pump

Quick release valve

Ignition unit

Fan cover assembly

Control Box

Fan and motor

Capacitor

Outer cover base panel

Outlet spigot assembly

3 core cable 110 Volt Yellow

Thermostat

Thermostat mounting plate

Neon - Yellow

Neon - Green

Neon - Red

Switch ON/OFF

Base cover - outer power inlet

Base mounting frame

Burner casing Lower panel

Base blanking panel

Front cover - Lower inner

110 Volt 3 pin connection plug - transformer

110 Volt 3 pin connection plug - heater

110 Volt 3 pin socket - heater

Terry clip - Air ducting

Air ducting - Flexible

1

1

1

1

1

1

1

1

1

1

1

1

E9030310110100

3

E8030010420100

1

1

E8030110430100

1

E8010203210000

21-30-012

E8010511003500

28-09-070

21-30-010

21-30-022

1 28-02-184

1 28-16-047

21-30-030

28-50-022

28-50-021

28-50-020

1

1

1

1

28-40-127

21-30-032

21-30-023

21-30-024

21-30-031 1

1

1

1

28-06-044

28-06-039

1 28-06-035

1 28-01-079

1 28-01-077

PAGE No 3

PARTS LIST

PAGE No 4

3

4

4A

5

6

7

8

1

2

PARTS LIST

Item No

7

8

5

6

3

4

1

2

Parts Description

Fuel pipes

Fuel Elbows

Fuel tank

Heater mounts

Frame

Spindle

Locking dome - wheel

Wheel

No Off Part No

2

2

1

1

1

2

2

2

28-08-009

29-00-258

21-30-071

21-30-070

21-30-045

21-30-067

A30-01-030

A30-01-002

PAGE No 5

I

INSTALLATION AND CONTROLS

1 MOBILE HEATERS FUEL SUPPLY

HEATER CONTROLS

All Mobile Heaters are set to operate on a two-pipe system.

In order to promote trouble free operation it is necessary that the oil does not fall below the cold filter plugging point with class D fuel this is -4°C

Summer grade and -12°C Winter grade

All pipe work and fittings must be sealed so as to prevent the ingress of air.

1.

THREE POSITION SWITCH ( HEAT

I

OFFI VENT)

110 Volt supply indicated by a green Neon light on panel

(Heat position) Operates the bumer control circuit to the control box

(Off position) Breaks the bumer control circuit to the control box

(Vent position) operates the fan only for ventilation purposes

ELECTRICAL SUPPLY

110 Volt

electrical supply connection is made to the heater via the generator

THERMOSTAT CONNECTION

2.

THERMOSTAT CONTROL KNOB

Enables the temperature in the air ducting to be regulated to the desired temperature. The orange neon light on the panel (bumer run light) will be on until the desired temperature is reached and the burner switches off.

A temperature control thermostat located within the heater air discharge spigot can be adjusted to the required temperature via the dial located on the heater control panel.

FLUE INSTALLATION

C.S.H. Mobile Heaters are dispatched with the requisite stack spigot and flue pipe.

3.

CONTROL BOX

Situated on the control panel, monitors the combustion process of the heater to ensure that all components are operating correctly, it will shut down the heater if a fault occurs, a red light showing in the center of the Satronic

Control Box will flash periodically as the box monitors the burner operation

If this light is permanently on it indicates that there is a fault with the operation of the bumer and it has gone to lockout the red button should be pressed (LOCKOUT

RESET)

See fault-finding chart in bumer manual.

It is recommended that O.5mm stainless steel flue be fitted

In general each indirect heater should have its own flue, which should terminate approximately 500mm above the heater.

When siting the heater and flue the proximity of other buildings and obstacles should be considered.

FLEXIBLE DUCTING

IMPORTANT The flexible ducting supplied with the heater should be fitted with the direction of flow which is indicated by an arrow on the duct pointing away from the heater

It should be secured to the outlet spigot with the pull strap provided.

4.

OVERHEAT THERMOSTAT

Located on the heat shield is a safety overheat thermostat, this thermostat will operate if the combustion chamber becomes to hot in the event of a fan failure or restricted air flow.

The thermostat when it operates will immediately shut down the bumer and a red ** neon light will be illuminated on the control panel.

The thermostat can be reset by pushing the plastic reset button located on the top cover, the red** neon will go out when reset.

IT MUST BE MANUALLY RESET AND THE CAUSE OF

THE OVERHEAT SHOULD BE INVESTIGATED

The

above

red

**

neon is dual purpose see also operating instructions.

I

PAGENoB

~PERATING

INSTRUCTIONS

COMMISSIONING PROCEDURE

The heater should be positioned on firm ground ensuring that the air intake is clear of vehicle exhaust fumes and other hazardous conditions:

Connect the 110 Volt supply cable from the generator to the heater.

The green neon will be illuminated.

1 Ensure heater has fuel supply.

2 Ensure thermostat is at desired ternperature

3 Connect electrical supply

4 Switch to heat position

5 Ensure lockout button on control box is reset, burner sequence should start immediately

6 Run heater for approx.15 minutes

7 Switch heater to OFF check operation of overrun thermostat

8 Restart heater to check correct operation of thermostat

Ensure fuel supply is clean.

Connect the ducting to the duct spigot on the heater using pull strap provided ensuring the correct direction of flow

Fit the flue pipe to the top of the heater

MAINTENANCE INSTRUCTIONS

The heater is now ready for use

To VENT only, put three position switch to vent position, the fan only will operate

WARNING

Before carrying out any maintenance work on the heater ensure that electrical supply is isolated and fuel supply disconnected.

To HEAT, put three position switch in heat position

FUEL SYSTEM

The main fan will run and the red** neon on the controi panel will illuminate indicating that the pre heater fitted to the burner is operating and pre heating the fuel prior to the burner start .

FILTERS

All heaters are supplied with a filter located in the fuel line the paper filter cartridge cannot be cleaned and must be totally replaced during servicing or when contaminated,

NOTE the red** neon will indicate pre heat at initial start up only, if the neon is illuminated at any other time the heater is at overheat.

FUEL PUMP PRESSURE ADJUSTMENT

After approximately 150 seconds the red" neon will go out and the bumer will fire, the orange neon on the control panel will illuminate.

The heater will now operate controlled by the thermostat.

To STOP put three position switch to off position.

The burner ON orange neon will go off, and the main fan will continue to run for a further 5 minutes to sufficiently cool the combustion chamber the fan will then switch off .

Only then rnay the electrical supply be safely disconnected.

WARNING

Failure to cool the heater sufficiently will cause damage to the combustion chamber and lead to nuisance overheat lockout problems.

Ensure electrical supply is off and disconnected.

Remove rear lower base cover on heater

Remove vent plug located on the end of the brass extension pipe on the pump body (in the center when viewed from rear of heater)

Fit pressure gauge to brass extension

Re connect electrical supply

Switch Burner ON observe reading on gauge

Set pressure to (90 psi) diesel only

If adjustment is required situated above the fuel inlet connection (left side when viewed from rear) is a screw and locknut undo the locknut insert PhiJlips screw driver into the screw head adjuster, turn clockwise to increase anticlockwise to decrease the pressure.

When the pressure is correctly set tighten locknut disconnect the electrical supply, remove gauge and replace bleed screw and ensure it is tightly located

Replace rear cover

PAGE Nog

I

[ MAINTENANCE

PHOTOCELL

BURNER MAINTENANCE

Burner Maintenance should only be carried out by competent personnel and will require the complete rernoval of the Burner from the combustion chamber

Ensure that the photocell is clean (wipe clean with a soft cloth)

CONTROL BOX

BURNER ASSEMBLY

see pages 15 & 16 for further detail

Disconnect the electrical supply to the heater

Disconnect fuel supply

Carefully roll heater on to its side and remove the 4 x M5

Screws from the base return unit to upright position

Remove top cover of heater 6 X M5 Screws

Remove bottom rear panel 4 x M5 Screws

Remove fan assernbly Screws 4 X M5 (lower two can be accessed by inserting screw driver through the holes in the base of the heater) and lift fan assembly out

Disconnect the wires from the block at the rear of the burner head

Remove the thermostat capillary from the securing clips in nose cone and lower into the heater base through the hole provided.

Remove the blanking panel 4 X M5 Screws

Rernove the two screws securing the burner to the combustion chamber flange

The burner, blast tube, and control base can now be cornpletely removed through the rear of the heater.

Maintenance of the Burner is detailed in the Installation and Service Manual supplied separately.

The control box cannot be repaired if the box is faulty it should be replaced with a new box

WARNING

The control box should not be reset more than twice

before the fault is located and corrected, or any

surplus oil emitted into the chamber has been mopped out through the burner entrance.

HEAT EXCHANGER REMOVAL

Remove complete burner assernbly

If required the combustion chamber can be removed by bending up the chamber retaining clips and sliding the chamber towards the rear of the heater

Chamber can now be cleaned by tapping the outside of the chamber with a hide hammer or piece of wood. Care should be taken not to damage the burner flange.

Rernove any loose soot, carbon through the draught tube aperture or the flue stack spigot

Re assemble in reverse order of above instruction.

Clean soot or carbon deposits from diffuser, end ring, or electrode tips

Clean and inspect electrodes for cracks replace if necessary

Reset electrodes to dimensions shown in Burner manual do not over tighten securing screw

A new Nozzle should be fitted every 12months or if existing nozzle is damaged or worn.

Reassemble taking care that all parts are clean and dry.

Ensure fuel pipe is kept free from dirt whilst burner head is dismantled

I

PAGE No 10

I

FAULT FINDING

Fault

Heater Fails to start when heat is switched ON

Thermostat calling for heat

Red light showing on satronic control box

Heater runs for short period does hot light control box goes to lockout

Cause

Remedy

(a) No Electricity Supply

(b) Switch fan to manual

(c) Faulty Thermostat

(d) Overheat thermostat tripped

(a) No fuel

(b) Air lock in fuel supply

(c) Photocell not detecting flame

(d) Faulty electrodes

(e)

Faulty control box

(afPhotocell notaetecting flame

(b) No fuel

(c) Ignition failure

(d) Fuel pump failure

(e)

Faulty solenoid valve

Check Supply

Fan runs supply correct

Check thennostat

Reset red button on trip,

Investigate cause

Check fuel

Bleed Fuel system

Check & clean Photocell

Check electrode for cracks, check ignition leads

~heck

photocell bheck fuel supply bheck ignition leads bheck electrodes are clean & gap

~et correctly

~heck

solenoid valve bheck electrical connection to valve

Red neon light on fan not working

(a) Heater gone to overheat

Reset overheat thermostat

Heater attempts to light up but

Burner Control box goes to lockout

(a) Photocell not detecting light

~heck photocell operation

(b) Faulty photocell connection /:heck wiring connection in control box

(c) Faulty control box

(d) Air pressure switch not bperating solenoid bhange control box bheck switch

Heater runs but emits black smoke rom stack box

Heater runs but fan overrun does hot work when switched off****** n order to check this fault the lleater should be run to ensure the k;ombustion chamber is hot enough

(a) Air control incorrectly set

(b) Nozzle loose or incorrect

(c) Incorrect fuel pressure

(d) Exhaust stack restricted

(e)

Excess carbon in the

~raught

tube

(a) Loose wire on the overrun device

(b) Overrun device faulty

Reset air control

Check nozzle

Check fuel pressure

Clear stack

Clean carbon from draught tUbe

Check wiring

Replace overrun device

Heater runs but flame is intermitten

(a) Air in the fuel supply

(b) Heater running out of fuel

(c) Filter blocked

(d) Dirty nozzle

Check fuel pipe for cracks, check pipe unions are tight

Check fuel supply

Clean filter

Check nozzle

PAGENo11

SERVICE MANUAL

1 TO REPLACE THE FAN UNIT AND/OR

CAPACITOR AND/OR TEMPERATURE

CONTROL THERMOSTATS

NOTE:

FOR ALL SERVICE PROCEDURES EXCEPT

PRESSURE TESTING THE HEATER MUST BE

REMOVED FROM THE TRANSPORT CRADLE.

REMOVE THE 4 PHILIPS HEAD SCREWS

HOLDING THE HEATER TO THE CRADLE.

1:1 BEFORE REMOVING THE HEATER FROM THE

TRANSPORT CRADLE REMOVE THE LOWER

REAR COVERS (FIG. 2), BY REMOVING THE 4

ALLEN SCREWS ON THE OUTER COVER TO

GAIN ACCESS TO THE FUEL SUPPLY AND

RETURN PIPES, AND UNCLIP THE PIPES (FIG.

3), AND CAREFULLY FEED THEM THROUGH

THE CASING.

FIG. 1

FIG. 2

4 PHILIPS HEAD

SCREWS

UNCLIP THE FUEL PIPES AND FEED

THEM THROUGH THE CASING

FIG. 3

PAGE No 6

SERVICE MANUAL

1:2 REMOVE THE FLUE COVER (FIG. 4) BY

LIFTING OVER THE FLUE

1:3 REMOVE THE TOP COVER (FIG. 4), BY

REMOVING THE 4 ALLEN SCREWS

1:4 TO REMOVE/REPLACE THE CAPACITOR,

REMOVE ITS LOCATION NUT, AND WIRING

FROM THE TERMINAL BLOCK.

REPLACE WITH A NEW UNIT AND CONNECT

ALL WIRING, AND REPLACE ALL COVERS.

FIG. 4

UNSCREW THE

RETAINING NUT

AND WIRING FROM

THE TERMINAL

BLOCK

1:5 TO REMOVE/REPLACE THE THERMOSTATS,

REMOVE THE LOCATION SCREWS, AND

SPADE CONNECTORS, AND REMOVE THE

THERMOSTATS (FIG. 6).

REPLACE WITH A NEW UNITS AND CONNECT

ALL WIRING, AND REPLACE ALL COVERS.

FIG. 5

UNSCREW THE

RETAINING

SCREWS AND

REMOVE THE

SPADE TERMINALS

FIG. 6

PAGE No 7

SERVICE MANUAL

1:6 TIP THE HEATER ON ITS SIDE TO EXPOSE

THE 2 LOWER FAN RETAINING SCREWS, AND

REMOVE THE TWO SCREWS (FIG. 7)

1:7 PLACE THE HEATER IN ITS NORMAL

POSITION AND REMOVE THE REMAINING 2

ALLEN SCREW (FIG. 8)

FIG. 7

1:8 UNPLUG THE MULTI WAY CONNECTOR AND

THE 4 THERMOSTAT LEADS (2 ORANGE 2

YELLOW)

1:9 UNPLUG THE PHOTOCELL (FIG. 9)

FIG. 8

FIG. 9

1:10 CAREFULLY REMOVE THE FAN AND COVER

(FIG. 10) ASSEMBLY FROM THE CASING, AND

THEN REMOVE THE FAN FROM THE REAR

SLOTTED COVER BY REMOVING THE 4

ALLEN SCREWS.

1:11 REPLACE WITH A NEW UNIT.

1:12 RE ASSEMBLE BY REVERSING THE STRIP

DOWN PROCEDURE

(NOTE WHEN REPLACING THE PHOTOCELL

UNIT- IT ONLY FITS ONE WAY, DO NOT USE

EXCESSIVE FORCE WHEN REPLACING - IT

COULD BE DAMAGED)

FIG. 10

PAGE No 8

SERVICE MANUAL

2 TO REPLACE THE INJECTOR

FOLLOW THE PROCEDURE FOR REMOVING THE

FAN (1:1 TO 1:9)

2:1 ROTATE THE HEATER ON TO ITS SIDE AND

REMOVE THE 4 ALLEN SCREW HOLDING THE

BURNER TRAY ASSEMBLY INTO POSITION

(FIG. 11).

2:2 REMOVE THE 2 LONG ALLEN SCREWS

HOLDING THE BURNER ON TO THE HEAT

EXCHANGER (FIG. 12).

FIG. 11

REMOVE 4 SCREWS

FROM CASING

UNDERSIDE

2:3 REMOVE THE ‘P’ CLIP FROM THE GUARD,

AND REMOVE THE CAPILARY TUBE.

FROM THE CASING (FIG. 13), AND

CAREFULLY SLIDE THE COMPLETE BURNER

TRAY ASSEMBLY OUT OF THE BOTTOM

TRAY.

WHEN THE TRAY IS REMOVED THIS GIVES

ACCESS TO ALL OTHER SERVICEABLE ITEMS

(FIG. 13)

FIG. 12

REMOVE THE

‘P’ CLIP

FIG. 13

PAGE No 9

SERVICE MANUAL

2:3 REMOVE THE 3 SCREWS HOLDING THE

BLAST TUBE IN POSITION. (FIG. 14)

NOTE: THE BURNER TRAY PRESSING IS

SHOWN CUT AWAY FOR CLARITY

2:4 REMOVE THE INJECTOR, USING A 16MM

LOCK SPANNER AND A 14MM SPANNER.

CARE MUST BE TAKEN NOT TO DAMAGE THE

IGNITION ELECTRODES WHEN

REMOVINGAND REPLACING THE INJECTOR.

REPLACEMENT IS THE REVERSAL OF

REMOVAL

BLAST RING

& 3

RETAINING

SCREWS

INJECTOR

3 TO REPLACE THE IGNITION ELECTRODES

FOLLOW STEPS FOR REMOVING THE FAN AND

INJECTOR

3:1 REMOVE THE BURNER COVER, BY

UNSCREWING THE 4 ALLEN SCREWS (FIG.

14)

3:2 REMOVE THE COVER RING (A), BY

UNSCREWING THE SINGLE BUTTON HEAD

ALLEN SCREW (FIG. 15), TO GAIN ACCESS TO

THE INJECTOR.

3:3 UNCLIP THE IGNITION LEADS AND REMOVE

THE ALLEN SCREW, AND REMOVE AND

REPLACE THE ELECTRODE ASSEMBLY.

FIG. 14

ELECTRODE ASSY.

& ALLEN SCREW

COVER RING

& ALLEN

SCREW

14MM

LOCK

SPANNER

FLATS

IGNIGNITION

LEADS

BLAST

RING

BURNER

COVER

4 TO REPLACE THE IGNITION UNIT

FOLLOW STEPS FOR REMOVING THE

INJECTOR

4:1 UNPLUG THE IGNITION LEADS (FIG. 16)

4:2 REMOVE THE 2 ALLEN SCREWS AND

REPLACE WITH A NEW UNIT

FIG. 15

FIG. 16

PAGE No 10

IGNITION

LEADS

ALLEN

SCREWS

SERVICE MANUAL

5 TO REPLACE THE CONTROL BOX

FOLLOW STEPS FOR REMOVING THE

INJECTOR

5:1 TAKE OFF THE 2 ALLEN SCREWS HOLDING

THE CONTROL BOX ASSY TO THE BASE (FIG.

17)

5:2 REMOVE THE SINGLE SCREW RETAINING

THE CONTROL BOX TO THE BASE

MOULDING

5:3 REPLACE CONTROL BOX AND RE-ASSEMBLE

ALL COMPONENTS

2 ALLEN

SCREWS

RETAINING

CONTROL

BOX ASSY TO

BASE

FIG. 17

6 TO REPLACE THE THERMOSTAT, NEONS AND

ON/OFF SWITCH

FOLLOW STEPS FOR REMOVING CONTROL

BOX

6:1 TO REMOVE THE THERMOSTAT, REMOVE

THE CONTROL KNOB, AND UNSCREW THE 2

RETAINING SCREWS. REPLACE WITH A NEW

UNIT, AND REFIT ALL ITEMS (FIG. 18).

6:2 TO REMOVE AND REPLACE A NEON.

UNSCREW YTHE LEADS AT THE CONNECTOR

BLOCK (THEY ARE FLYING LEADS), NOTING

THEIR TERMINAL NUMBERS.

UNSCREW THE RETAINING NUT, WITHDRAW

THE NEON, AND REPLACE.

6:3 TO REPLACE THE ON/OFF SWITCH.

UNPLUG ALL WIRES FROM THE SWITCH,

NOTING THEIR TERMINAL NUMBERS, UNCLIP

THE SWITCH, AND FIT A REPLACEMENT.

REFIT ALL WIRES, AND OTHER COMPONENTS.

7 TO REPLACE THE POWER INPUT SOCKET

FOLLOW STEPS FOR REMOVING CONTROL

BOX

7:1 TO REMOVE THE POWER INPUT SOCKET,

NSCREW THE 3 POWER RING TERMINALS/

WIRES FROM THE SOCKET, AND THEN

UNSCREW THE 4 NUTS HOLDING THE

SOCKET IN PLACE (FIG. 19).

REPLACE WITH A NEW ITEM, REFIT

REVERSING THE REMOVAL PROCEDURE.

FIG. 18

FIG. 19

SINGLE SCREW

RETAINING

CONTROL BOX

TO BASE

MOULDING

PAGE No 11

SERVICE MANUAL

8 TO REPLACE THE PRESSURE SWITCH

FOLLOW STEPS FOR REMOVING THE

INJECTOR, BUT DO NOT REMOVE THE

INJECTOR.

8:1 TO REMOVE THE PRESSURE SWITCH,

REMOVE THE NEGATIVE AND POSITIVE

PRESSURE TUBES FROM THE SWITCH -

NOTING THAT THE POSITIVE TUBE GOES TO

THE REAR INLET ON THE SWITCH (FIG. 20).

8:2 UNSCREW THE SINGLE SCREW AND

REMOVE THE SWITCH SO THAT THE COVER

CAN BE REMOVED.

8:3 REMOVE THE COVER, AND REMOVE THE

POWER LEADS - NOTING THAT BROWN

GOES TO COMMON AND BLUE TO

‘NORMALLY OPEN’ (NO ON SWITCH).

3:4 REPLACE ALL COMPONENTS - REVERSING

THE STRIP DOWN PROCEDURE.

9 TO REPLACE THE SOLENOID

FOLLOW STEPS FOR REMOVING THE

INJECTOR, BUT DO NOT REMOVE THE

INJECTOR.

9:1 UNPLUG THE 3 WAY SOCKET FROM THE

SOLENOID (FIG. 21).

9:2 REMOVE THE FUEL INLET CONNECTOR UNIT

9:3 REMOVE THE SOLENOID RETAINING CIRCLIP

9:4 SLIDE THE SOLENOID OFF THE FUEL INLET

9:5 REPLACE THE DEFECTIVE UNIT AND REFIT

ALL COMPONENTS, REVERSING THE STRIP

DOWN PROCEDURE

FIG. 20

BROWN

TO

COMMON

NEGATIVE

TUBE

REAR

INLET

FRONT

INLET

POSITIVE

TUBE GOES TO

REAR INLET

BLUE

TO N.O.

NEGATIVETUBE

GOES TO

FRONT INLET

FIG. 21

PAGE No 12

SERVICE MANUAL

10 TO REPLACE THE SOLENOID VALVE

FOLLOW STEPS FOR REMOVING THE

INJECTOR, BUT DO NOT REMOVE THE

INJECTOR.

10:1 UNPLUG THE 3 WAY SOCKET FROM THE

SOLENOID (FIG. 22, 23)

10:2 REMOVE THE FUEL INLET CONNECTOR UNIT

10:3 REMOVE THE SOLENOID RETAINING CIRCLIP

10:4 SLIDE THE SOLENOID OFF THE FUEL INLET

10:5 UNFASTEN THE BURNER NOZZLE FUEL INLET

FROM THE SOLENOID VALVE USING A 10MM

AF OPEN ENDED SPANNER

10:6 REMOVE THE SOLENOID VALVE USING A

12MM AF OPEN ENDED SPANNER

10:5 REPLACE THE DEFECTIVE UNIT AND REFIT

ALL COMPONENTS, REVERSING THE STRIP

DOWN PROCEDURE

NOTE ON THE UNDERSIDE OF THE VALVE

THERE IS AN ARROW - THE VALVE MUST BE

FITTED WITH THIS POINTING TO THE

NOZZLE INJECTOR FUEL PIPE

FIG. 22

3 WAY

SOCKET

CIRCLIP

SOLENOID

FIG. 23

VALVE

PAGE No 13

SERVICE MANUAL

11 TO REPLACE THE FUEL PUMP

NOTE THIS IS A NON SERVICEABLE ITEM

AND MUST BE REPLACED AS A UNIT

FOLLOW STEPS FOR REMOVING THE

SOLENOID AND VALVE

11:1 TO REMOVE THE FUEL PUMP, UNSCREW THE

2 ALLEN SCREWS FASTENING THE PUMP TO

ITS MOUNTING BRACKET (FIG. 24).

2 ALLEN SCREWS

12

TO REPLACE THE FUEL FILTER.

NOTE:

THE HEATER CAN REMAIN IN ITS TRANSPORT

CRADLE FOR THIS OPERATION.

12:1 REMOVE BOTH REAR INNER AND OUTER

BOTTOM PANELS (FIG. 25).

12:2 UNSCREW THE FILTER BOWL, REMOVE THE

FILTER, CLEAN THE BOWL IF DIRTY AND FIT A

NEW FILTER.

12:3 REFIT THE BOWL/FILTER ASSEMBLY, ENSURE

IT IS ADEQUATELY TIGHTENED TO AVOID

LEAKS, AND REPLACE BOTH BOTTOM

PANELS.

FIG. 24

MOUNTING

BRACKET

FUEL PUMP

PRESSURE

TESTING ‘T’

FIG. 25

PAGE No 14

SERVICE MANUAL

13 TO TEST FUEL PUMP PRESSURE

NOTE: FOR THIS OPERATION THE HEATER MUST

BE ON ITS CRADLE WITH THE FUEL LINES

CONNECTED.

13:1 REMOVE BOTH REAR INNER AND OUTER

BOTTOM PANELS.

13:2 UNSCREW AND REMOVE THE PRESSURE

TESTING POINT BLANKING PLUG (FIG. 26)

13:3 CONNECT THE FUEL FEED PIPES

13:4 SCREW IN THE PRESSURE TESTING GAUGE

13:5 TO ADJUST THE PRESSURE UNLOCK THE

LOCK NUT (A) AND ADJUST THE SCREW (B) IN

OR OUT TO ACHIEVE THE REQUIRED

PRESSURE. THE CORRECT PRESSURE 90

PSI.

13:6 WHEN THE PRESSURE IS CORRECTLY SET

RE -FIT ALL COMPONENTS

ADJUSTING

SCREW (B)

FIG. 26

LOCK NUT

(A)

PRESSURE

GAUGE

BLANKING

PLUG

PAGE No 15

BENSON HEATING LTD

LUDLOW ROAD

KNIGHTON

POWYS

LD7 1LP

TELEPHONE 01547 528534

FACIMILE 01547 520399 email [email protected]

web www.bensonheating.com

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