BENSON
MH150
( OIL FIRED MARQUEE HEATER )
INSTALLATION COMMISSIONING
SERVICING
USER INSTRUCTIONS
MH150 DIMENSIONS
2
Section
Contents
Page No
1.0
Compliance Notices
4
1.1
Certificates of Conformity
5
1.2
General product Information
5
1.3
General Requirements
5
1.4
Delivery & Pre-installation Checks
6
1.5
Warranty
6
2.0
Location & Positioning
7
2.1
Fuel supply-general
7
2.2
Fuel
7
2.3
Electrical Supply
7
2.4
Air Supply
8
2.5
Air Distribution
8
2.6
Flue System
9
3.0
Installation
10
3.1
Flue Installation
10
3.2
Heater Siting
10
3.3
Electrical installation & Connection
10
3.4
Air Distribution
10
3.5
Heater Control Installation
11
4.0
Commissioning
11
4.1
Pre test
11
4.2
Ignition
12
4.3
Air Delivery System
13
4.4
Hand Over
14
5.0
Servicing
14
5.1
Planned Servicing
14
5.2
Servicing Procedure
15
6.0
Fault diagnosis by flow chart
18
7.0
Wiring Diagrams
21
8.0
Technical data
22
9.0
Reference Documents
23
3
It is the responsibility of the installer, owner,
user, or hirer, of such products supplied by
Benson Heating to ensure that they are
familiar with the appropriate information/
manuals, supplied by the manufacturer, and
that they are suitably aware of the purpose of
the manuals and the safety instructions. In
addition, operators must be suitably trained in
the use of the appliance so as to ensure its
continued safe and efficient use.
1.0 Compliance notices
The Benson MH 150 oil fired Heater detailed
herewith is manufactured by Benson Heating
within a strictly controlled quality environment
within the parameters of ISO 9001.
The Benson MH 150 has been tested and
assessed for compliance with the following
European Directives.
Benson Heating has a commitment to
continuous improvement, and therefore
reserves the right to amend or change the
specification of the MH 150 Heater subject to
compliance with the appropriate European,
national, and local regulations.
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC &
93/68/EEC)
Electromagnetic Compatibility Directive
(89/336/EEC & 91/31/EEC)
Contained within the text of the manual, the
words 'Caution' and 'Warning' are used to
highlight certain points.
Product Liability Directive (65/374/EEC)
The manufacturer has taken reasonable and
practical steps to ensure that Benson MH 150
Heaters 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, inspected, and
tested, with safety and quality in mind, there
are certain basic precautions which the
installer and user should be aware of, and they
are strongly advised to read the appropriate
sections of the information pack accompanying
the heater, prior to installation or use.
Caution is used when failure to follow or
implement the instruction(s) can lead to
premature failure or damage to the heater or
its component parts.
Warning is used when failure to heed or
implement the instruction(s) can lead to not
only component damage, but also to a
hazardous situation being created where there
is a risk of personal injury.
The Benson MH 150 Oil fired heaters conform
to the following harmonized standards;
BS EN 292 - Part 1 : 1991
Safety of Machinery - Basic Concepts, General
Principles for Design Basic terminology,
methodology
Benson Heating supports all new products
being supplied to their customers with a
comprehensive information pack; this clearly
defines mandatory instructions for the safe
installation, use, and maintenance, of the
appliance(s).
BS EN 292 - Part 2 : 1991
Safety of Machinery - Basic Concepts, General
Where proprietary items are incorporated into Principles for Design Technical Principles and
Benson Heating products, detailed information Specifications
and instructions are also provided as part of
BS EN 60204 - Part 1 : 1993
the information pack.
Safety of Machinery - Electrical Equipment for
Machines Specification for General
Requirements
4
BS EN 60335 - Part 1 : 1988
Safety of Household and Similar Electrical
Appliances General Requirements
1.3 General requirements
Caution
Ensure that the fuel supply is in accordance
with the manufacturer's recommendations and
is as stated on the appliance data plate.
BS EN 55014 - 1993
Limits and methods of measurement of radio
disturbance characteristics of electrical motoroperated and thermal appliances for
household and similar purposes, electrical
tools and similar electric apparatus
Installation, commissioning, and servicing must
only be carried out by appropriately qualified
and competent persons.
BS EN 50165 - 1997
Electrical Equipment of non-electric heating
appliances for household and similar
purposes, safety requirements
Warning
Unauthorised modifications to the appliance, or
departure from the manufacturers guidance on
intended use, or, installation contrary to the
manufacturers recommendations may
constitute a hazard.
1.1 Certificates of conformity
Note
To ignore the warning and caution notices, and
to ignore the advice from the manufacturer on
installation, commissioning, servicing, or use,
will jeopardise any applicable warranty,
moreover, such a situation could also
compromise the safe and efficient running of
the appliance itself, and thereby constitute a
hazard.
Certificates are available from the Quality
Control Department at Benson Heating.
1.2 General product information
The Benson MH 150 model has an output
range of 150 kW.
The MH 150 units can suit either ducted
applications, or be used as free blowing units,
but each heater must be connected to its own
individual open flue.
The installation of the appliance must meet all
the relevant European, National, and Local
criteria.
Each heater is fitted with a forced draught
burner which has been test fired and pre-set
prior to dispatch. The safety functions of the
burner are by way of a fully sequential control
box fitted to the burner.
Caution
The heater must not be installed where high
wind velocities may affect burner operation.
Suitable protection should be provided for the
appliance when it is located in a position where
it may be susceptible to external mechanical
damage from; for example, fork lift trucks,
Note
Neither asbestos nor soft soldered joints are
used in the construction or manufacture of the
Benson Heating range of Heaters.
The materials selected for use can withstand
the mechanical, chemical, and thermal
stresses which they will be subject to during
foreseen normal use when installed in
accordance with the manufacturers
recommendations.
5
1.4 Delivery and pre-installation checks accordance with the manufacturers technical
The heater is supplied wrapped in heavy duty
protective polythene. On receipt of the heater,
the following checks
should be carried out;
a) The model is as per order
specifications
b) That it is undamaged
f) The main electrical supply input to the heater
has been interrupted during the heating mode
e) Internal wiring on the heater has been
tampered with or unauthorised service/repairs
undertaken
c) That it is suitable for the fuel supply
g) The heater has been subject to and affected
by the ingress of water in any form
d) That it is suitable for the electrical supply
h) The heater is not operated at the rating(s)
laid down in the manufacturers technical
specifications
If any of these points are not satisfied then
contact should be made with the Sales Office
at Benson Heating as soon as possible by
telephoning 01547 528 534 In the case of
claims for damage, this must
be reported in writing within 24 hours of
delivery, in order to comply with insurance
criteria
i) The heater has not been operated or used
within the normal scope of its intended
application
j) The manufacturer's recommended minimum
service requirements have not been complied
with
1.5 Warranty
The heater is supplied with a 2 year warranty
made up as follows; first year covering parts
and labour, and second year covering parts
only. In addition to this there is also a 10 year
time related warranty on the combustion
chamber/heat exchanger. The warranty
commences from the date of dispatch from the
manufacturer, and is subject to the terms
detailed within the Benson Heating 'conditions
of business'.
Note (ii)
All warranty claims must contain the following
information to enable processing to take place;
(1) Heater model
(2) Heater serial number
(3) Order reference/date of order, together
with full installation details (name and address)
(4) Details or symptoms of fault
Faulty parts must be returned to the Spares
Department, the address of which is provided
on the rear cover of this manual. Any such
parts will undergo inspection to verify the
a) The warranty registration/commissioning
claim. Replacement parts supplied prior to this
card has not been completed and returned to
may be charged, and a credit supplied upon
Benson Heating
subsequent validation of the warranty claim.
Consumable items are specifically not included
b) The installation is not in accordance with the
within the scope of the warranty.
general requirements of this manual
Note (iii)
Notification is required immediately a fault is
c) The flue arrangement and air supply for the
suspected.
heater are not in accordance with the
The manufacturer will not accept responsibility
manufacturers recommendations, codes of
for any additional damage that has been
practice, or similar standards
caused, expense incurred, or consequential
loss resulting from any failure of the heater(s).
d) Air flow through the heater is not in
Note (i)
The warranty may be invalidated if –
6
2.0 Location/positioning
2.1 Fuel supply - general
Warning
All of the basic criteria must be satisfied prior to
commencing installation and commissioning,
additionally, the heater must be positioned and
installed so as to comply with all the relevant
standards and guide lines (see section 9.0), as
well as meeting national and local fire
regulations and insurance criteria, especially if it
is proposed that the heater is to be installed
within a special risk area (e.g. proximity to
where petrol engined vehicles are stored or
parked, where cellulose spraying takes place,
where woodworking machinery is operated,
etc,).
Indirect fired heaters must not be located in
hazardous areas, however, it is permissible for
the heater to supply air to such areas.
The Benson MH 150 of oil fired heater are all
manufactured and pre-set for use with 35
second gas oil from the internal tank.
The heater must not be installed within an
environment where there is a high
concentration of chlorides,
fluorides, salts, or other aggressive or volatile
chemicals/compounds.
2.2 Fuel
In order to promote trouble free operating it is
necessary that the oil within the storage tank
and oil line does not fall below the cold filter
plugging point (cfpp), in this country and with
class D fuel (also referred to as gas oil). The
critical temperature is -4oC for this summer
grade.
The cfpp critical temperature for the winter
grade is -12oC.
If summer grade fuel is stored for winter use in
areas prone to severe frosts and low
temperatures it will be necessary to insulate or
even heat the supply tank and pipe work.
Warning
The pump pressure must not exceed a
maximum of 0.4 bar, this is because beyond
this point gas is liberated from the oil.
The location must also allow for adequate
clearance for the air supply, return air
circulation, oil supply, electrical supply, whilst
also providing good and safe working access.
Note
The oil feed to each heater must be fitted with a
fire check valve and isolating valve.
The fire check valve must be operated by way
Any combustible material adjacent to the heater of a fusible link positioned so that it is above the
or flue system must be so placed or shielded so burner.
that its surface temperature does not exceed
65o C.
Warning
Prolonged exposure and contact with Gas Oil
can result in the natural oils being removed
TRANSPORTATION and LIFTING
from the skin, sensitisation can result in
dermatitis.
Ensure that Forklift or Mechanical
Lifting Devices are suitable for purpose. Always ensure that the appropriate personal
protective equipment is used.
The heater should be kept in a
HORIZONTAL position at all times when
being transported by fork lift truck or other
mechanical devices .
2.3 Electrical supply
Wiring external to the cabinet heater must be
installed in accordance with any local, national,
and European regulations, as well as meeting
the appropriate requirements of IEE
regulations.
7
Caution
The means of connection to the main electrical Additionally, an automatic control interlocked
to the burner must be fitted to ensure burner
supply must allow for complete electrical
isolation of the heater, furthermore, in the case shutdown in the event of airflow failure or
restriction.
of a unit wired for a three phase supply, the
supply should only be used to serve the heater
itself and no other plant or equipment.
2.5 Air distribution system
Warning
Ensure that the electric and oil supplies are
turned off before any electrical work is carried
out on the heater.
Ensure that wiring cannot make contact with
any surfaces liable to be subject to high
temperatures or where the insulation of the
wiring could be impaired as a result of such
contact.
All materials used within the construction of the
delivery and return air ducts must not
represent a fire hazard and should be made
from thermally inert materials.
The selection of materials must take account
of the environment into which the heater and
its air delivery system is expected to work, it
must also take account of the stresses and
loadings placed upon it during its normal
working life.
All Benson heaters must be earthed.
Where interjoist spaces are used to route
ducting these must be lined with fire resistant
Caution
insulation material.
The main electrical supply must not be
In installations where forced recirculation is a
switched off or disconnected as a method for
feature, a full and unobstructed return air path
stopping the heater, the exception to this is in to the heater(s) must be provided, with return
an emergency, or during servicing, when the
air grilles connected by ducting directly to the
heat exchanger has been allowed to cool
return air inlet on the heater.
sufficiently to prevent any damage from
The limit for recirculation should not be greater
occurring.
than 85% re-circulated air to 15% fresh air.
Claims for damage will not be considered if
If the inlet air is ducted to the outside, then the
they have resulted from incorrect wiring or the lowest edge of the inlet air duct must be at
incorrect use of the heater.
least 500mm above the outside floor or ground
level, it must also be fitted with an access point
(s) to allow for cleaning and servicing to occur.
2.4 Air supply
The openings in the structure through which
Provision must be made for the existence of an the ductwork passes must be of fire resistant
air supply for both combustion and ventilation. material and constructed to prevent the
likelihood of any fire from spreading.
It is a requirement that the area where the air
In ducted applications the ductwork must be
heater is located must have a permanent air
designed so as to give a static pressure within
vent of negligible resistance direct to the
the limits stated in section 8 of this manual.
outside air.
Such air vents must be positioned so as not to It should be noted that if the static pressure is
become blocked or flooded, nor should they be too high, nuisance shut-down will occur when
the heater goes out on the overheat limit
placed so as to introduce undesirable matter
thermostat, if the static pressure is too low,
(e.g. flammable, volatile, or aggressive
chemicals/compounds or potentially hazardous then damage can be caused to the fan motor.
or harmful substances) either direct from the
Warm air outlets on ducted applications must
outside, or through their proximity to an
be such that they cannot be closed or become
adjacent extraction system.
blocked, which again would lead to an
8
recommended, as they tend to inhibit the
formation of condensates.
Where condensation is unavoidable traps
should be included to encourage the
condensates to flow freely to a point from
which they may be released, preferably into a
gully.
The condensate pipe from the flue to the
disposal point must be made from corrosion
resistant pipe of not less than 25mm internal
diameter.
increase in static pressure and nuisance shutdown.
The outlets must not be sited so that warm air
can be discharged onto combustible materials,
if necessary, guard rails should be used to
ensure that effected areas are kept clear.
Return air intakes must not be located so that
potentially harmful or hazardous contaminated
air can be drawn into the system.
2.6 Flue system
If the flue passes through a wall, ceiling, or
roof made from combustible material then it
has to be sleeved so as to provide a minimum
of a 25mm void between the exterior of the flue
and the internal wall of the sleeve.
The maximum permitted temperature of any
adjacent combustible material is 65oC.
Warning
Each heater must have its own separate flue,
with a flue diameter of not less than is detailed
in section 8 within this manual.
The minimum vertical length of flue must
not be less than 1m.
The maximum vertical length of flue must
not be more than 20 m.
The position of the flue and its terminal should
be such that it does not impair the combustion
process.
It should terminate in an exposed position so
as to allow the escape and dissipation of flue
gases without risk of their re-entering the
property through windows, ventilation ports,
etc.
Care should be taken to ensure that the flue
The flue should extend to at least 1m above
terminal is not situated in a high-pressure area, the height of any object within 3,5m of the
the proximity of buildings and other obstacles terminal.
which will influence this must be taken into
Flue terminals should be fitted on all flues with
account.
a diameter of 200mm or less.
The terminal must be of the approved type,
Provision must be made for the disconnection and have outlet grilles on all sides giving a
of the flue for inspection and service
total free area of at least double that of the
requirements, and it is strongly advised that
flue.
where bends are fitted inspection covers are
included.
Note
It should be noted that claims made under
The materials from which the flue is
warranty and attributed to the ingress of water
constructed must be non-combustible,
may not be considered especially if an
resistant to internal and external corrosion, and approved method of sealing has not been
be capable of withstanding the stresses and
used, or if the design of the flue has not made
loadings associated with normal use.
provision for possible condensation problems.
The flue should rise vertically, and the number
of bends should be kept to a minimum.
It is strongly advised that BS 5854; 1980, and
BS 5440; parts 1 and 2, are used as
consultative documents when considering flue
requirements.
When designing the flue system the prevention
of the formation and entrapment of
condensation must be a key consideration.
Twin wall or insulated systems are
9
Separate user information is provided for the
time control unit and the burner, and forms part
of the product information pack which
accompanies every heater when dispatched.
Warning
Always isolate from mains electrical supply
before commencing work on the heater.
3.0 Installation
3.1 Flue Installation
An integral flue spigot is fitted to all Cabinet
Heaters thereby allowing the flue to connect
directly to the heater.
The design of the flue must ensure that it can
be disconnected to allow for cleaning and
servicing, furthermore, all of the flue section
joint sockets must face upwards, and the seal
between the sections achieved through
mechanical joints or through the use of
approved caulking string and grout. It is
strongly advised that BS 5854 and BS 5440
parts 1 and 2 are referred to.
Always ensure that the appropriate personal
protective equipment is used.
3.4 Air Distribution Installation
Warning
Always ensure that the appropriate
personal protective equipment is used.
3.2 Heater Siting
The heater must be installed on a level surface
capable of supporting the weight of the heater
and any ancillary equipment.
3.3 Electrical Installation/connection
Benson MH 150 heaters are
415V 50 Hz 3PH NEUTRAL & EARTH
It is recommended that reference is made to
the wiring diagrams contained within section 7
of this manual prior to installation or
connection to the supply.
The electrical supply must be as specified and
suitable for the heater, and must be run within
conduit to a point adjacent to the heater, and
be terminated to provide an isolation point that
will prevent remote or inadvertent activation.
Cables, conduit, and fittings that are used to
make the connection between the isolator and
the heater must conform to the appropriate IEE
regulations. All heaters are supplied fused and
pre-wired, all must be earthed.
Final connections for any additional external
controls must be completed on site, and must
be carried out according to IEE regulations.
The materials selected must be of low heat
capacity, and it is preferable that all warm air
ductwork is thermally insulated.
Where ducting may be subject to deterioration
from exposure to moisture or high humidity
material selection and insulation are prime
considerations.
Joints and seams must be airtight and
fastened securely and designed to remain so,
even when operating at high temperatures.
Adequate support must be designed into the
layout of the ductwork to ensure that the
integrity of the seams and joints is maintained.
The support must be independent and
separate from the heater and the ducting, to
allow for free movement during expansion and
contraction.
Where ducting passes through walls or
partitions sufficient clearance must be left,
irrespective of any fire stop requirement, to
allow for expansion and contraction.
Failure to adhere to these latter two points can
result in the generation and transmission of
excess noise.
Where ducting is installed in concrete flooring
a permanent membrane must be used to
isolate the ducting from the corrosive effect of
the alkaline salts within the concrete.
Care should be taken to ensure that soft
insulation material does not become
compressed and thereby lose its effectiveness.
10
3.5 Heater Control Installation
4.1 Commissioning - Pretest
Warning
Isolate heater from mains before undertaking
any electrical work.
(a) On/off switch
(b) Ventilation/heat switch (summer/winter
switch)
(c) Manual/automatic switch
(d) Thermostat
(e) Phase change over switch
Check to ensure electrical safety, and inspect
and check the oil system, testing for leaks.
(a) Ensure that the electrical supply is turned
off.
(b) Ensure that the oil supply is turned off.
(c) Check that all panels and fasteners are
secure and in place.
4.0 Commissioning
(d) Check that the heater is installed so that it
is square and that the support is adequate.
Note
It is a requirement that only suitably qualified
and competent personnel are allowed to
undertake the
commissioning of the heater.
It is also strongly recommended that prior to
commissioning the engineer familiarises
himself with; the information contained within
the information pack that accompanies the
heater, the heater itself, and with the specific
requirements of the installation/application.
The following checks should be carried out
after the familiarisation process.
(e) Ensure that warm air delivery outlets are
open and that ducting is adequately supported.
(f) Ensure that if filter assemblies are fitted
that they are secure and correctly located.
(g) Check that air inlets are clear and that
return air paths are adequate.
(h) Ensure that the flue is secure, adequately
supported, and that the various joints are
properly sealed.
Warning
All Heaters undergo a rigorous test programme
prior to being dispatched, whilst such a
programme does involve pre-commissioning
and setting up the heater to operate efficiently
and well within its designed operational limits,
this does not mean that on site commissioning
is less important than might otherwise be the
case. The idiosyncrasies of each installation
can only ever be allowed for, through the use
of thorough on site commissioning carried out
by trained and experienced personnel
equipped with the correct tools and apparatus.
Note
It is strongly recommended that equipment
used for the sampling and analysis of flue
gases is accurate to within +/- 0.1% and
maintained so that it is regularly calibrated.
(i) Check that condensate trap and drain
facilities are adequate (if fitted).
(j) Check that there is provision for flue gas
sampling and that this sample point can be
plugged and sealed after commissioning.
(k) Check that fan and limit stat settings have
not been disturbed and are as follows
Fan on
- 40oC
Overheat limit - 100oC
Fan off
- 30oC
Also check that the white button (automatic) is
pulled outward and that the red button (reset)
is pushed inwards to the reset position.
(l) Ensure that the burner is securely attached
to the heater.
11
(m) Test for electrical earth continuity between
the heater, oil pipe work, and mains supply.
(n) Turn on main electrical supply, select the
following switch settings
-------- E I T H E R -------3 >15s Ignition failure caused by oil
starvation resulting in burner lock-out/shutdown...
(g) Set heater on/off switch to off position
On/Off
Heat/Ventilation
Manual/Automatic
- On
- Ventilation
- Manual
(h) Attach oil manifold (bleed screw and
pressure gauge)
(i)
The fan will start enabling fan direction etc to
be verified. Reset on/off switch to off position.
Open oil supply valves and bleed air
from pipe work and adjust burner oil
pressure as per detailed in burner
manual
Repeat steps 4.1 q, and 4.2 c,e,f.
(o) Turn mains electrical supply to off, replace (j)
--------- O R -----------and secure lower louvred panel covering fan
and motor assembly.
4 >15s Burner ignition.flame detection...
(p) Set thermostat to 'demand' position.
5 <20s Burner ignition cycle complete
4.2 Commissioning - Ignition
(c) Select the following switch settings on the
heater
On/Off
- off
Heat/Ventilation - heat
Manual/Automatic - automatic
Note
It is strongly recommended that the separate
manual concerning the operational details of
the burner supplied with the heater as part of
the information package is studied prior to
commissioning.
Time intervals within the ignition sequence will
vary slightly from one model to another.
Warning
If burner ignition is not satisfactorily
accomplished, commissioning must not
proceed until the reason or fault has been
identified and rectified, if necessary by
reference to the separate burner information or
to section 6 of this manual.
(d) Turn on main electrical supply.
(k) Repeat steps 4.2 c,a,
Warning
Do not proceed with commissioning unless all
the criteria detailed within sections 4.0 and 4.1
have been satisfied.
(a) Ensure that the electrical supply is turned
off.
(b) Ensure that the oil supply is turned off.
(e) Select 'on' position for heater on/off switch. (l) Repeat steps 4.2 d,e,f, allowing the heater
to reach thermal equilibrium.
(f) Check for the following burner sequence
Interval
Operand
1
<5s
Combustion air damper actuated,
burner fan motor initiates purge
cycle...
2
<15s Solenoid valve opens ignition
transformer provides spark for
burner ignition...
(m) Adjust thermostat to its highest setting,
and allow the heater to continue to fire.
(n) Gradually reduce the temperature setting
on the thermostat until the burner shuts down,
(@ < ambient and then gradually increase the
temperature setting on the thermostat until
heat is called for, (@ > ambient) and the
burner automatically re-fires.
12
the following action is recommended.
* Re-check all readings and calculations.
(o) Check fan and limit stat by depressing and
holding in the fan motor overload re-set button, * Adjust burner as per manufacturers
located on the heater electrical panel. The time instructions.
* Consult Benson Heating Technical
between the fan stopping and burner shut
Department.
down should be noted, once the burner has
shut down the overload on the motor should be
(q) Complete commissioning card and provide
released.
operating instructions for the user, high-light
the fact that the manufacturer recommends
If the time interval between fan stop and
that in the interests of safety and efficiency the
burner shut down is greater than 90 seconds
heater is serviced on a regular basis only by
further checks should be made.
qualified and competent persons.
These are as follows
(i) Check settings on fan and limit stat are
correct, ie, fan on 40oC, fan off 30oC, limit
100oC.
(ii) Check that the position of the unit is
correct, ie, equi-distant between heat
exchanger body and heat shield panel.
(iii) Check integrity of unit, ensuring that
neither the bi-metallic strip nor its casing is
damaged.
(p) Undertake flue gas analysis using
approved and calibrated analysing equipment
recording data on the commissioning card, ie,
CO, CO2, net and gross flue temperatures.
Record burner oil pump pressure, ambient
temperature, barometric pressure, and smoke
reading (0 - 1 Baccarach scale).
The completed commissioning card must be
returned to the Service Department
immediately after the satisfactory completion of
commissioning, failure to do so can invalidate
any subsequent warranty claim.
(s) Set all controls to the requirements of the
user.
4.3 Commissioning - air delivery system
Caution
On ducted applications it is necessary that the
system is balanced in order to optimise the
efficiency of the heater and the air distribution
and delivery system
Failure to balance the system can result in fan
motor overloading and premature component
failure, it can also result in an inefficient
heating/ventilation system.
Note (i)
The burner air and oil pressure settings should
(a) Check that the amount of fan produced air
be only very finely adjusted to achieve a CO2
volume is in accordance with the heater
reading of 12.5%
specification, if the volume is too great the fan
(+/- 0.5%).
can be overloaded.
Ensure that the running current is as per that
Note (ii)
stated on the heater data plate.
The gross efficiency must be approximately
Alternatively, the static pressure should be
80%.
measured at the start of the ductwork to
confirm that it is within the permissible
Note (iii)
tolerance.
All Heaters are test fired and precommissioned as part of the manufacturing
(b) If the current drawn is greater than the
process, if however, during on site
commissioning the data are found to be not in stated running current, in most probability this
accordance with the manufacturers data, then will be caused by insufficient static pressure
13
within the ductwork, in which case system
resistance should be increased through the
introduction of a damper placed as close to the
start of the ductwork as possible, thereby
resulting in a reduction in drawn current.
The damper should be adjusted until the
current is in accordance with that stated on the
data plate.
(c) If the current drawn is too low the duct
outlet grilles will require opening to reduce
static pressure and increase air volume, if this
is not the case overheat cut outs can be
caused.
4.4 Commissioning - hand over
(a) Upon full and satisfactory completion of
commissioning, a record of commissioning
information (contact, date, etc) should be left
with the heater, a copy of which must also be
forwarded to Benson Heating Service
Department.
Warning
Servicing must be carried out on a regular
basis, the maximum interval between services
being 1 year. It is a requirement that only
suitably qualified and competent persons are
allowed to undertake servicing.
Before any maintenance or servicing work
is carried out the heater must be shut down
and allowed to cool, and have the oil and
electric supplies to it turned off at the
supply valve and isolator respectively.
Caution
Certain component parts are factory sealed
and are designed so as to be tamper proof.
Usually such items do not require servicing,
and therefore should not be tampered with.
Failure to comply with this can invalidate any
warranty, and can also lead to premature
failure.
The following parts fall within this category:
thermostat, , fan and motor.
(b) The commissioning engineer must ensure
that the user is familiar with the safe and
efficient use of the heater, detailing the
function of all controls, and main components.
Additionally, the fan and limit stat has been
factory set, and must not be re-set without
formal consent from the manufacturer.
(c) The user should be made aware of the
following in particular
Reference should be made to the separate
information covering the operational details of
the burner and timer.
(i) Lighting, shutdown, and operational
information.
(ii) Safety features, data plate, and labelling.
Only approved spare / replacement parts
can be fitted, failure to comply with this can
compromise the safe and efficient running
of the heater, and can also invalidate any
warranty claim
(iii) The requirement for regular inspection especially if the heater is within a more
5.1 Planned Servicing
demanding environment - and the need for
regular servicing carried out by competent and
In order to maintain the efficient operation of
qualified persons.
the heater it is recommended that the following
planned servicing and preventative
(Caution
After approximately 100 hours of running, the maintenance program is adopted by the user.
tension of the fan belts must be checked to
ensure that they are correct and that they have
not stretched. See section 5.2 for further
Quarterly Inspection
instructions.
(a) Visual inspection of the burner
5.0 Servicing
(b) Clean and check spark
14
electrode
(c) Clean and check photocell
(d) Check overheat safety is
operational
Bi-Annual Inspection
(a) As per quarterly inspection,
plus...
(b) Combustion check
(c) Smoke test
Annual Inspection
(a) As per half year inspection,
plus...
(b) Heat exchanger and cleaning
(c) Electrical connections
(d) Main fan motor
(e) Main fan assembly
(f) Pulleys
(g) Fan belts
(h) Oil supply including filter
(i) Burner
(j) Air delivery system
(k) Flue
(l) Report
compressed air and through the use of a soft
bristle brush and cloth.
Solvent wipes may be used to remove heavy
soiling from the motor casing.
5.2 Servicing Procedure - Major
Component Parts
Main Fan
Traces of surplus lubricants spreading from the
bearings should also be cleaned away.
Where motors are fitted with grease nipples
bearings should be lubricated with the correct
grade of lubricant. Motors which do not have
grease nipples feature sealed bearings which
are lubricated during manufacture for their life.
The electrical connections should be checked
as follows.
The cover to the terminal box should be
removed by undoing the screws which secure
it.
Check connections for signs of corrosion,
tightness, and ensure that there are no stray
strands which could form a short circuit.
Clean, tighten, and replace as necessary.
Replace cover and secure.
Remove dust and other foreign matter by
blowing off with compressed air or through the
use of a soft bristle brush.
Flue
Check that the bearings do not show signs of
A visual inspection should be carried out to
excessive wear.
ensure that the flue remains adequately
supported, both internally as well as externally, It should be noted that these bearings do not
require lubricating.
and that the various joints are effectively
If the bearings require replacing the following
sealed.
procedure should be followed.
Inspection covers, where fitted, should be
removed and the flue checked to see whether
(a) Remove belt(s).
cleaning is required
If inspection covers are not fitted the flue gas (b) Loosen set screw on eccentric collar and
tap collar in the opposite direction to fan
exit duct and flue spigot will provide not only
an indication of the cleanliness of the flue, but rotation.
(c) Remove collar and bearing.
will also enable access for cleaning.
(d) Check shaft for alignment and straightness.
The presence of the flue terminal should be
(e) Locate the bearing in its seat and place on
checked.
the shaft with the cam facing outwards.
If a condensate trap and drain facility is fitted
(f) Fit the eccentric collar and engage the
this should be checked to ensure that it
cams.
continues to function correctly, and the
(g) Tighten initially by rotating, and then by
drainage of condensates is not impaired.
tapping in the direction of the fan rotation.
(h) Replace fasteners and secure.
Main Fan Motor
Remove access panel. Dust and other foreign (i) Turn by hand to ensure free fan rotation.
matter should be cleaned by blowing over with
15
(e) Tighten adjustment bolt to hold motor.
(f) Tighten fan securing bolts ensuring that the
Check pulleys for alignment using a straight
edge, if necessary reposition either or both of fan is square and the pulleys aligned.
(g) Check belt tension, making final
the pulleys and the fan motor.
adjustments as necessary.
Check for excessive wear within the root and
sides of the grooves, and check for any other (h) Tighten and clamp fasteners to hold fan
signs of wear or damage, if necessary replace motor in position.
the pulley as follows.
Heat Exchanger
(a) Release tension on belts and remove.
(b) Release the taper locks by slackening the The heat exchanger requires a visual
securing screws by several complete turns.
inspection at least once per year, this should
(c) Fully remove one screw from the taper lock, be accompanied by cleaning. It is
and having oiled it, insert into the threaded
recommended that a flue brush and vacuum
jacking point.
cleaner be used to facilitate this.
(d) Tighten screw until the taperlock is free.
Access to the heat exchanger is gained
(e) Remove taperlock and pulley.
through the removal of the front panel and heat
(f) Fit taperlock in new pulley, and provisionally shield.
position on the shaft.
(g) Remove the screw from the jacking point,
Servicing and cleaning should be performed as
and tighten both screws in their clamping
follows.
points until the pulley can just be moved on the
shaft by hand.
(a) Remove brass nuts and cover from heat
(h) Align pulleys using a straight edge, and by exchanger end assembly to expose heat
gradual alternate tightening of the screws
exchanger tubes.
clamp in position.
(i) Refit belts and check for the correct amount (b) Remove any accumulated deposits from
of tension.
the tubes by pushing through the full length
with a flue brush.
Pulleys
Fan Belts
Check belts for signs of wear.
Frayed or split belts must be replaced using
belts with a common batch code.
Belt tension must be checked, and if on multibelt units it is found that one belt contains
more slack than its accompanying belts, then
all the belts on the unit must be replaced,
again using a common batch code.
Replacement and tensioning is carried out as
follows.
Note
The maximum displacement at the mid point of
the top edge of the belt must not be greater
than 16mm per metre of span, when a force of
3kg is applied in a plane perpendicular to the
belt.
(a) Loosen fan motor securing bolts on
chassis.
(b) Loosen fan motor slide adjustment bolt.
(c) Slide fan towards fan to slacken belts.
(d) Replace belts, pull fan motor away from fan
until belts are tight.
(c) The flue brush should be withdrawn so as
to pull any deposits back into the bottom of the
flue box where they can then be removed by
using a vacuum cleaner.
(d) Particular attention should be paid to the
upper internal surfaces of the tubes, where
through convection heavier deposition is likely
to occur.
(e) Any deposits which may have accumulated
within the combustion chamber can be
removed with a vacuum cleaner once the
burner is removed.
Note
It is most important that a build up of deposits
is not allowed to occur as this can have an
adverse effect upon the efficiency of the heater
and reduce the life of the heat exchanger.
(f) The heat exchanger and combustion
16
chamber should be visually inspected for signs
of splits, cracks, and distortion.
(g) All gaskets should be checked to ensure
that they continue to provide a gas tight seal, if
there is an element of doubt then they should
be replaced.
Note
Any waste oil or sludge must be disposed
of correctly. Never dispose of it by
dumping or tipping it down drains or into
water courses where ground water can
become polluted and environmental
damage caused.
If the condition of the heat exchanger gives
cause for concern the Service Department
at Benson Heating should be advised
pending a more detailed examination.
Electrical Supply
Burner
All connections must be checked to ensure
that they are secure, and free from corrosion.
Terminals and connections should also be
checked to ensure that no stray strands are
bridging terminals.
Electrical continuity should also be checked.
Service requirements for the burner fitted to
the heater are covered in the separate manual
prepared by the burner manual.
Oil Supply
The oil supply pipe work, tank, and fittings
should all be inspected to ensure that they are
free from corrosion, and to ensure that where
brackets have been fitted these remain secure
and offer adequate support.
The oil filter should be replaced with a new
one, and the system should be checked for
leaks.
If the oil level is such to allow removal of any
sludge or other contaminants from the tank this
too should be undertaken, particularly if there
have been problems of poor firing associated
with contaminants reaching the burner.
17
6.0 Fault Finding
No Power
Check Isolator
Check Fuses
Burner Lockout
Burner
fails to
Run
Fan / Limit
Thermostat
Room
Thermostat
No
Demand
Check
Controls
Timer
Heat / Ventilate
Switch
On / Off Switch
Fuel Feed
Incorrect
Burner
starts
Ignition
sequence
but fails to
light and
Lockout
Occurs
Check that the
Oil Pressure is
correct
Check that Head
of Gravity is
Sufficient
Check that the
suction Lift is not
too great (two
pipe system)
Check Burner
Air Setting
Bleed System
Fuel / Air
Problem
Air in System
Restricted Fuel
Feed
No Spark
Check
Electrode
18
Check that the
Bypass Plug is
Present
Possible Fuel
Contamination
Check Valves,
Fuel Feed, Filter
Nozzle for
Blockages or
Restrictions
Check Control
Adjust Air
Damper
Air / Fuel Mix
Ratio Incorrect
Burner gives a
sparky flame
Too Much Air
Check for Air in
Fuel Line
Check Fuel
Pressure
Check Nozzle
Fuel Feed
Restricted
Check Filter
Check Fuel
Lines
Check Valves
Check Oil
Pressure
Insufficient
Combustion Air
Check Air Damper
Check Nozzles
Check if Correctly
fitted
Burner
gives a
smokey
flame
Poor
Combustion
Check if Correct
size
Check if Damaged
or Worn
Inadequate Flue
Draught
19
Check Flue
Foreign M atter in
Fan
Check Burner
Fan M otor
Burner
giving
excessive
noise
W orn / Dry
Bearing
Suction Lift to
Great
Insecure Burner
Fan
Check Burner
Oil Pum p
W ater in Fuel
Line
Fuel Feed
Restriction
Check for High
Resistance
W arm Air
Short Circuit
Adjust W arm Air
Discharge and
Cool Air Inlet
Accordingly
Check Outlet
Grilles are not
shut or
Check Filter is
Clear
Fan and
Lim it
regularly
go to
lockout
Check Pulleys
are Secure
Check for no
Loose
Contacts
Check Belts
and Tension
Insufficient Air
Flow over the
Heat Exchanger
Limit Control
Incorrectly Set
Check Fan and
Motor
Assembly
Reset to 100C
Fan and / or
Motor not at
Correct Speed
Check Fan and
M otor are
Secure
Check that Fan
is not Blocked
or Restricted
Check that
Impellor is not
Slipping
20
7.0 Wiring Diagram 20-48-286RS
21
8.0 MH 150 TECHNICAL DATA
Heat Input (Nett)
kW
170.9
Heat output
kW
149.4
Nett efficiency
%
87.4
Fuel consumption
L/hr
17.2
Oil pressure
Psi
170
Burner type / control
Riello
R40 G20S On/Off
Nozzle specification
Danfoss
3.5 x 60 s
Fuel specification
35 Sec Gas oil
Fuel Capacity
Litres
520
Burner Air Setting
No
5
Burner Head Setting
No
3
CO
ppm
0
%
12.5
O2
%
4.5
Duct diameter
mm
4 X 300
Maximum duct length
m
50
Electrical supply
V/Hz/Ph
415/50/3
Running Current
Amps / ph
7.6
Start Current
Amps / ph
22
Power Consumption
W
3300
Max Running Hours
Hrs
30
IP Rating
IP
44
Air volume
3
M /s
3.0
Static pressure
pa
450
Discharge velocity
M/s
11.5
CO
2
Temperature rise
0
40.6
Overheat thermostat setting
0
100
Fan Overrun setting
0
C
30
Noise level
Dba @ 3 m
76
Flue diameter
mm
200
C
C
0
Flue temp
C
280
Weight
kg
1086
Height
mm
2438
Width
mm
870
Length
mm
2700
3
Heated Area
M
22
3700
9.0 Reference Information
Doc/Ref
BS 5410
Part 1 ; 1977 and Part 2 ; 1978
BS EN 292
Title/Subject
Code of Practice for oil firing
Parts 1 and 2; 1992
Safety of Machinery
BS EN 60204 Part 1; 1993
Safety of Machinery - Electrical
BS EN 60335 Part 1; 1988
Safety of Electrical Appliances
BS EN 55014 1993
Electromagnetic Compatibility
BS EN 50165 1997
Safety of Electrical Equipment
BS 5854
1980
Code of Practice - Flues/Flue Structures
BS 799
Part 5 ; 1987
BS 715
1993
Metal Flue Pipes and Fittings
BS 5440
Part 1 ; 1990
Specification/Installation of Flues
BS 5440
Part 2 ; 1989
Ventilation Requirements Gas Appliances
BS 779
Part 2 ; 1991
Oil burning equipment - burners
ISO 228/1
Oil Burning Equipment - oil tanks
See also BS 2779 and BS 5380) Pipe Threads Seals and Couplings
23
BENSON HEATING LTD
LUDLOW ROAD
KNIGHTON
POWYS
LD7 1LP
Telephone +44 (0) 1547 528534
Facsimile +44 (0) 1547 520399
email information@bensonheating.co.uk
Web www.bensonheating.com
24
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