BENSON AH150, AH200, AH100, AH500, AH600 Installation, Commissioning And User Instructions

PAKAWAY

OIL

FIRED CABINET
HEATER RANGE

INSTALLATION,

COMMISSIONING,

SERVICING

AND

USER

INSTRUCTIONS

((

C

...

Jrl

Lfi

cnh!

Number"

FM 14923

-CONTENTS­SECTION A

1.0

1.1

1.2

1.3

1.4

1.5

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

4.0

4.1

4.2

4.3

4.4

5.0

5.1

5.2

5.3

6.0

7.0

8.0

9.0

9.1

31-28-054

Compliance

Notices

Certificates

of

Conformity

General

Product

Information

General

Requirements

Delivery

& Pre-installation

Checks
Warranty
Location & Positioning
Fuel

Supply -General
Fuel
Fuel

Storage

Tank

Single

Pipe

System -Gravity

Feed

Two

Pipe

System

Pressurised

Ring

Main

System

Pipework

and

Fittings

Electrical

Supply

Air

Supply

Minimum

Space

Requirements

Air

Distribution

System

Flue

System
Ins

talla

tion

Packaging

& Siting

Flooring
Minimum

Clearances
Assembly
Flue Installation

Oil Installation &

Connection

Electrical Installation &

Connection

Air

Distribution

Installation

Warm

Air

Registers

Heater

Control

Installation
Commissioning
Pre-Test
Ignition
Air

Distribution

System

Hand

Over

Servicing

.

Planned

Servicing

Servicing

Procedure

- Major

Component

Parts

Servicing -

Recommissioning

Fault

Diagnosis

by

Flow

Charts

Wiring

Diagrams

by

Model

and

Burner

Type

Technical

Data

Reference

Documents -Standards,

Codes

of

Practice

Parts

Listing

Page No.

3
4

4

5

5

7

8
8

9
9

9

12
12
12
12

13

14
14

15

19
19
19
19
19
20
20
20

21
21
21

22

23
25

27
27
27
28

29

31

32

35
38

41
42

03.96/ PM / CE (1)

SECTIONB

Warranty

Registration

Burner Information

Manual

Timer

Information

Manual

SECTION C

10.0 Introduction

10.1

Commissioning/hand

over

10.2 Servicing

10.3 Start

up

procedure

10.4 Stop

procedure

10.5

Shutdown

procedure

10.6 Ventilation

only

10.7 Lockout situations

10.8 Contact Information

ILLUSTRATIONS

Fig 1 Exploded

view

Fig 2 - 8 Fuel

systems

and

storage

Fig 9

-19

Flue

systems

Fig

20

Heater

control

panel

Fig

21

Time clock controls

Fig

22

Fan

and

limit

thermostat

Fig

23 -25

Fan

and

motor

configurations

Fig

26 -31

Fault diagnosis flow charts

Section A - Page No.

6

10-11

16-18

22
22

23
24

32-34

2

1.0 Compliance notices

The

Pakaway

range

of oil fired

Cabinet

Heaters

detailed

herewith

is

manufactured

by

Benson

Environmental

Limited

within

a strictly controlled

quality

environment

within

the

parameters

of

ISO

900l.

The

Pakaway

AH

range

has

been

independently

tested

and

assessed,

and

has

been

found

to

meet

The Essential

Requirements

of

the

following

European

Directives.

Machinery

Directive

(89/392/EEC)

Low Voltage Directive

(73/23/EEC & 93/68/EEC)

Electromagnetic Compatibility Directive

(89/336/EEC & 91/31

/EEC)

Product

Liability Directive

(65/374/EEC)

The

manufacturer

has

taken

reasonable

and

practical

steps

to

ensure

that

Pakaway

Cabinet

Heaters

are safe

and

without

risk

when

properly

used. These heaters

should

therefore

only

be

used

in

the

manner

and

for

the

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.

Benson

Environmental

Limited

supports

an

new

products

being

supplied

to

their

customers

with a comprehensive

information

pack; this

dearly

defines

mandatory

instructions for

the

safe

installation, use,

and

maintenance,

of the appliance(s).

Where

proprietary

items

are

incorporated

into

Benson

Environmental

Ltd

products,

detailed

information

and

instructions are also

provided

as

part

of

the

information

pack.

It

is

the

responsibility of

the

installer, owner, user,

or

hirer, of

such

products

supplied

by

Benson

Environmental

Ltd, 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.

Benson

Environmental

Ltd

has a commitment

to

continuous

improvement,

and

therefore

reserves

the

right

to

amend

or

change

the

specification of

the

Pakaway

AH

Cabinet

Heater

range

subject to

compliance

with

the

appropriate

European,national

and

local regulations.

Contained

within

the

text

of

the

manua

l,

the

words

'Caution'

and

'Warning'

are

used

to

highhght

certain points.

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

Pakaway

AH

range

of

gas

fired

cabinet

heaters

conform

to

the

following

harmonised

standards;
BS

EN 292

-

Part

1 : 1991

Safety of

Machinery

- Basic Concepts, General Principles for Design

Basic

terminology, methodology

3

BS

EN 292 -

Part

2:

1991

Safety of Machinery - Basic Concepts, General Princi pIes for Design

Technical

Principles

and

Specifications

BS

EN 60204 - Part 1 : 1993

Safety of Machinery - Electrical

Equipment

for Machines

Specification

for

General

Requirements

BS

EN 60335 -

Part

1 : 1988

Safety

of

Household

and

Similar Electrical Appliances

General

Requirements

BS

EN 55014 - 1993

Limits

and

methods

of

measurement

of

radio

disturbance

characteristics

of

electrical

motor-operated

and

thermal

appliances

for

household

and

similar

purposes, electric tools

and

similar electric

apparatus

prEN

50165 - 1995

Electrical

Equipment

of non-electric heating appliances for

household

and

similar

purposes,

safety requirements

1.1 Certificates

of

conformity

Certificates

are

available

from

the

Quality

Control

Department

at

Benson

Environmental

Limited.

1.2 General product information

The

Pakaway

AH

models

have

an

output

range

from approximately 30kW to 293kW,

and

are

available

in

a configuration

that

will allow for floor

mounting

only.

The

Pakaway

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.

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.

Note

Neither

asbestos

nor

soft

soldered

joints are

used

in the

construction

or

manufacture

of

the

Pakaway

range

of Cabinet 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.

4

1.3 General requirements

Caution

Ensure

that

the

fuel s

upply

is in accordance

with

th e

manufacturer's

recommendations

and

is as

stated

on

the

appliance

data

plate.

Installation,

commissioning,

and

servicing

must

only

be

carried

out

by

appropriately

qualified

and

competent

persons.

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

.

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.

The

installation

of

the

appliance

must

meet

all

the

relevant

European,

national,

and

local

criteria. (See sections 3

and

9).

Prior

to installation

the

following

points

should

be

considered;

a)

The

position

of

the

heater

for the

optimum

efficient

distribution

and

circulation

of

warm

air

b)

The

position

of

the

heater

relative to the

route

of

the flue

c)

The

position

of

the

heater

relative to

the

supply

of

fuel

d)

The

position

of

the

heater

relative to the electrical services,

and

if

appropriate,

any

additional

controls.

e)

The

position of

the

heater

relative to the

supply

of

fresh

air

f)

The

position of

the

heater

relative to service

and

maintenance

requirements

Caution

The

heater

must

not

be

installed

within

an

area

where

the

conditions

are

unsuitable,

e.g.

where

the

atmosphere

is

highly

corrosive,

has a high

degree

of

salinity,

or

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,

overhead

cranes etc.

1.4

Delivery

and pre-installation checks

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

b)

That

it is

undamaged

c)

That

it is

suitable

for

the

fuel

supply

d)

That

it is

suitable

for

the

electrical

supply

5

Fig 1 -

Exploded

View

6

If

any

of these

points

are

not

satisfied

then

contact

should

be

made

with

the

Sales Office

at

Benson

Environmental

Ltd as

soon

as possible

by

telephoning

01547-528534. 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.

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

Environmental

Ltd '

conditions

of

business'.

Note (i)

The

warranty

may

be

invalidated

if -

a)

The

warranty

registration / commissioning

card

has

not

been

completed

and

returned

to

Benson

Environmental

Ltd

b) The installation is

not

in accordance

with

the

general

requirements

of this

manual

c)

The

flue

arrangement

and

air

supply

for

the

heater

are

not

in

accordance

with

the

manufacturers

recommendations,

codes of practice,

or

similar

standards

d) Air flow

through

the

heater

is

not

in

accordance

with

the

manufacturers

technical specifications

e) Internal wiring

on

the heater

has

been tampered

with

or

unauthorised

service/repairs

undertaken

f)

The

main

electrical

supply

input

to the

heater

has

been

interrupted

during

the

heating

mode

g) The

heater

has

been

subject to

and

affected

by

the

ingress of

water

in

any

form

h) The heater is

not

operated

at the rating(s) laid

down

in the manufacturers technical specifications

i)

The

heater

has

not

been

operated

or

used

\vithin

the

normal

scope of its

intended

application

j)

The

manufacturer's

recommended

minimum

service requirements

have

not been complied

with

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 (5) instaHers

name

and

address.

Faulty

parts

must

be

returned

to

the

Knighton

Spares

Department,

the

address

of

which

is

provided

on

the

back

cover

of

this

manual

and

section

10.8 .

Any

such

parts

will

undergo

inspection

to verify the

claim. Replacement

parts

supplied

prior

to this

may

be

charged,

and

a

credit

supplied

upon

subsequent

validation

of

the

warranty

claim. Consumable

items

are

specifically

not

included

within

the

scope of the warranty.

Note

(iii)

Notification

is

required

immediately

a fault is

suspected.

The

manufacturer

will

not

accept

responsibility for

any

additional

damage

that

has

been

caused,

expense

incurred,

or

consequential

loss resulting from

any

failure of

the

heater(s).

7

2.0 Location/positioning

Warning

All of

the

basic criteria

must

be satisfied

prior

to

commencing

installation

and

commissioning,

additionally, the

Cabinet

Heater

must

be

positioned

and

installed

so

as

to

comply

with

all

the

relevant

standards

and

guidelines

(see section 9.0), as well

as

meeting

national

and

local fire

regulations

and

insurance

criteria, especially if it is

proposed

that

that

heater

is to be installed

within

a special risk area (e.g.

where

petrol

engined

vehicles are

stored

or

parked,

wher

e 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 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. Nor

should

the

heater

be positioned

where

the

burner

could

be adversely affected

by

high

winds

or

draughts

.

The location

chosen

for the

heater

must

allow

for the fitting of

an

effective flue system. The

location

must

also allow for

adequate

clearance for the air supply,

return

air circulation, oil supp]y,

electrical supply, whilst also

providing

good

and

safe

working

access.

The heater

must

be installed

on

a flat

and

level surface

made

from non-combustible material,

which

is sufficiently

robust

to

withstand

the

weight

of the he

ater

and

any

ancillary

equipment.

Any

combustible material adjacent to the heater

or

flue

system

must

be so placed

or

shielded

so

that

its surface

temperature

does

not

exceed 65°C.

In areas

where

it is

proposed

that

more

than

one

heater is to be installed, a general

scheme

of

circulation

should

be

drawn

up

and

maintained,

thereby offering the best heat distribution.

All

Pakaway

Cabinet Heaters are fitted

with

a pressure relief facility, this is

incorporated

into

the design of the flue gas exit duct. Care

should

therefore be taken in siting service connections

and

controls well

away

from the pressure relief vent.

Warning

Under

no circumstances

must

the pressure relief be restricted, blocked,

or

have

the free exit of

exhaust

gas

impaired

or

re-directed .

2.1

Fuel supply - general

The

Pakaway

AH

range

of oil fired cabinet heaters are all

manufactured

and

pre-set for

use

with

35 second gas oil delivered to the

burner

via a suitable

piped

system

from the oil storage tank.

The constraints of the application will, to a large extent,

determine

whether

it is preferable to

use a single

pipe

gravity

feed

system, or

whether

the

two

pipe

pumped

system

is

more

appropriate.

Where

more

than

one

appliance

is to

share a common

supply

it will be necessary to

use

a pressurised

ring

main

system. All

pipework

must

be constructed

and

installed

so

that

it

does

not

permit

the ingress of air.

The

contruction,

size,

and

position

of

the

oil

storage

tank

must

take

account

of

the

current

regulations, as well as

suiting

the requirements of the installation.

Note

Please refer to figures 2 - 8 for

additional

information.

Caution

On

pumped

systems

always

check

that

the

pump

is correctly

set

up

prior

to

running, and

always

ensure

that

valves

are

open

allowing a free flow of oil

through

the

system

.

8

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 0

fuel (also referred to as

gas

om,

the

critical

temperature

is -4°C for

the

summer

grade.

The

cfpp

critical

temperature

for

the

winter

grade

is -12°

e.

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

pipework.

Note

The

fuel

supplier

should

be

contacted

prior

to installation

so

that

any

requirements

concerning

delivery,

transport,

storage

and

use

can

be

addressed

before

work

commences

.

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.

2.3 Storage tank

Any

externally

painted

steel

storage

tank

to

BS

799

part

5 1987 is

required,

and

must

include

the

following;

- a fuel level

gauge

(not

made

from glass)

- a

vent

pipe

with a diameter

greater

than

that

of

the

filler

and

featuring a weather

proof

termina

tion

- a

sludge

valve

-

an

outlet

valve

situated

at

the

opposite

end

of the

tank

to the

sludge

valve

- a filler

pipe

connection

situated

at

the

opposite

end

to the

outlet

valve

The size of

the

storage

tank

must

take

account

of the

estimated

consumption

and

any

quantity

price

breaks

offered

by

the oil supplier.

It

is preferable to install the

tank

outside,

however, if this

is

not

practicable

and

the

tank

has

to

be

installed

indoors

advice

must

be

sought

about

its siting,

especially so far as fire

regulations

are

concerned.

If

a

separate

fire resistant

chamber

cannot

be

provided

for

indoor

installations, a

catchment

pit

with

a capacity ten

percent

greater

than

that

of

the

storage

tank

must

be

provided

. Storage

tanks

can

if

necessary

be

sited

on

a roof,

but

this is

subject

to

special

regulations

as

well

as

local

authority

approval

and

compliance

with

fire

regulations,

reference to

BS

5410

part

2 1978 is

strongly

suggested.

It

is

advisable

to

leave

the

tank

unpainted

on

the

inside,

but

to

paint

the

outside

with

a

proprietary

grade

of

anti-corrosive

paint. A galvanised

or

open

topped

tank

is

strictly

not

allowed.

If

a

medium

density

polyethylene

oil

tank

is to

be

used

then

it

must

be

OFTEC certified to OFS

T-100. Local, national,

European

and

fire

regulations

must

also be

complied

with.

2.4

Single

pipe

system

(gravity feed)

For

installation

where

the

oil

tank

is

200mm

or

more

above

the

level

of

the

fuel

pump

the

principle

of

gravity

feed

may

be used.

The

draw

off

point

for

the

supply

to the

burner

must

not

be

positioned

any

lower

than

100mm

above

the

bottom

of

the

tank.

Where a return

valve

is fitted

this

must

be

tamper

proof

to

prevent

inadvertent

operation.

9

Drain

Valve

Fuel

Tank

lilled

to facilitate drainage

Vent

Pipe

Isolating

Air

Nozzles

Fusible

a--+--c::l"'---t

Link

Fire

Burner

Filler

Valve

Valve

Fig

2.

Typical

arrangement

of

oil storage

tank

and

single

pipe

system

1.

Gate valve

2.

In-line tilter

3. Pump

4.

Reliet valve

5.

Pressure gauge

6. Pressure reducing valve

7.

Return to tank

7

I

.- ----I

Note:

1. Pump duty and pipe sizing depend upon

application.

If

no

doubt contact our

Technical Department.

2. Pressure reducing

vatve

6 must be set to

give a maximum outlet pressure

of

4 p

.s.

i.

2

Fig

3.

Pressurised

oil feed

system

Warning: Before starting the burner make sure that the return pipeline

Is

not clogged; any

obstruction would cause the pump seals to break.

0

A '

..

I[

t -

.,'.

Y

n

::~:

y"ifD"

Nole: All burners are despatched suitable

for

gravity feed installations.

Fig

4.

Burner

oil

pump

details

for

heater

models

100 to 600 -

Oil

Lines

H=D

iff

erence

of

level; L=Length of the suction line; I.D.=Intemal diameter of the oil pi

pes.

~

L melres

H

-

--

m

1.0. 1.0.

--

---

-

Bmm

10mm

- I

.=--==

-=:.

1

----

0.5

10

20

-

--

I

-

1

20

40

--

-

-=-'

1.5

40

80

2

60

100

E

'"

J:

>i

'"

E

I

0

I

0

I i

~"I:.

10

Fig 5.

,-----r

~

f----IH

f--

-.-

: -

---=

--'

---

r

LmetrH

H

1.0 .

m

1.0.

Smm

10mm

0

35

100

0.5

30

100

1

25

100

1.5 20

90

2

15

70

3

8

30

3.5

6

20

The

pump suction should not exceed a

maximum of 4

matre.

(13ft). Beyond Ihls

limit gas

is

released from the oil.

OH

line.

musl

be

complelely alrtighL

The

return

line

Ihould

terminate

within

the

oil tank at the same level

IS

the

sucllon

line; in this case a non-return valve

Is

not

requi red.
Should, however, the return /ine

terminate

ovef

the fuel

~evel,

a non-return valve

is

essential.

This solution, however, is less safe

than

the

previous one, due to the possibility

of

leakage

of

the

valve.

Priming the

pump

: start the

burner

and

await

priming.

Should

lock-out

occur

prior

to

the

ar

rival

01

the fuel, wait at least 20

seconds

before repeating the operation.

Burner

oil

pump

details

for

heater

models

100 to 600 -

Oil

Lines

1l=Differ

ence

of level;

L=Lcn

gth

of the

suction

line; I.D .=

lnternal

diameter

of

the oil

pip

es.

Fig

6.

~

L

I

1~1

H

I.D.8mm

t.D.10mm

0.315"

0.394"

p

m

It

m

II

m

ft

lL

II·[CJ

:J

0.5

l'

6" 5

16

10 33

1

3'

0"

10 33

20

66

~

1.5

4' 6" 15

49 30

99

2

6'

0" 20

66

40

130

The

dimension

P should

not

exceed 4m (13'),

v

to avoid damage to the pump seal

s.

Burner

oil

pump

details

for

heater

mode

ls 800 &

tooo

-

Gravity

Feed

from

the

bottom

of

the

oil-storage

tank

l-1

=Diffe re n

ce

in height; L=To

tall

eng

th

of

su ction line,

including

the

vertical le

ngth

wit

hin

the

tank

Fig

7.

The

dtmen

sio

n P

shoutd

nol

exceed

4m (13'),

to

avoid damage

to

the

pump

seals.

L

H

I.D

. Smm

t.D.

l0mm

0.315"

0.394"

m II m

It

m

It

0

0

32 105

70

230

0.5

l ' 6"

28

92

62

200

1

3'

0"

24

79

55

180

1.5

4' 6"

20

65

48

157

2

6' 0"

16

52

40

130

3

9' 0" 7

23

25

83

3.5

10' 6"

-

-

10 33

Burner

oil

pump

details

for

heater

models

800 & 1000 -

Gravity

Feed

over

the

top

of

the

oil-storage

tank

H=Differen.ce in

height;

L= Total len

gth

of suction

line, i

ncludi

ng

the

vertical

length

within

the

t,lnk

Fig

8.

The p

ump

suction

must

not

exceed 4m

(13');

beyond

Ihis value

the

pump

becomes

noisy.

The

return valve

must

terminate at the same

level

as

the

foot

valve, otherwise the pump may

become

air-locked.

H =Difference

In

heigh!; L =T otat length of

suction line,

including

the vertical length

within

the

tank.

Burner

oil

pump

details

for

heater

models

800 & 1000 -

Suction

Feed

II :;Difference

in height; L

;::;:

Totallength

of

suction

line,

includin

g

tlw

vertical

length

within

the

tank

11

Caution

If

the

valve is closed

when

the

pump

is

running

the oil pressure can be increased sufficiently so

as to cause

damage

to the seals within the

pump.

The return oil should preferably be discharged through an elbow onto a tank plate situated within

the tank, this

should

be positioned so as not to introduce air

or

air bubbles into the

draw

off pipe.

2.5 Two pipe system

This is used

where

the oil storage tank is lower than the

pump.

Access for the fuel feed to the

burner

should

be via a suitable

tapping

made

in the top of the tank,

and

the fuel feed pipe

should

extend to

not

less than

lOOmm

above the bottom of the tank. A none return valve

with

a metal to

metal seat

should

be fitted, especially if the return

pipework

is terminated at a level above the

draw

off tube.

The

none

return valve

must

be removable for service

and

maintenance purposes,

and

the

return

pipe

from the

pump

must

therefore

be

extended

down

into the tank to the

same

level as the

suction pipe. The presence of a

tamper

proof isolating valve fitted within the return

pipe

is only

required if there is a risk that oil will

siphon

out

of the tank if the return pipe is disconnected at the

pump

during

maintenance

or

servicing

and

if the none return valve has been omitted.

2.6 Pressurised ring main system

This

system

is

used

to

supply a number

of

units from a

common

storage tank. A booster

pump

is

used

to

provide

the

pressure

storage tank. A booster

pump

is

used

to

provide

the pressure to

push

the oil

around

the ring main

and

back to the tank. Pressure reducing valves

should

be fitted

on

the delivery

pipe

to each heater to ensure that

the

pressure at the

burner

pump

is less

than

6 psi.

Caution

The internal by-pass

plug

must

be

removed

from the

pump

when

used

in a pressurised ring

main application.

2.7 Pipework and fittings

Caution

Galvanised

pipework

and

fittings

must

not

be

used.

All joints

must

be

sealed

properly,

if

necessary

using

PTFE

tape

or

other

approved

sealing media. The

pipework

must

be

effectively

sealed so as to

prevent

the ingress

of

air.

It

is advisable to check all

pipework

prior

to installation to

ensure

that there is no loose debris or

scale present. Black iron pipes can be

hammered

to assist in the removal

of

these contaminants.

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

of a fusible link positioned so

that

it is above the burner.

2.8 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

lEE regulations .

The

means

of

connection

to

the

main

electrical

supply

must

allow

for

complete

electrical

isolation

of

the heater(s), furthermore, in the case of heaters wired for a three

phase

supply, the

12

supply

should

only

be

used

to

serve

the heater(s) .

The

position of

the

isolation

switch

must

be

such

that

it is adjacent to the heater(s)

and

easily accessible

at

all times,

additionally

the

isolator itself

must

have

a contact

separation

of

not

less

than

3mm

(as

per

BS

5991 clause 20.2).

The

main

isolator

fuse ratings are

detailed

on

the

appliance

data

plate.

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

Pakaway

cabinet heaters

must

be

earthed.

Caution

The

main

electrical

supply

must

not

be

switched

off

or

disconnected

as a

method

for

stopping

the

heater,

the

exception to this is in

an

emergency,

or

during

servicing,

when

the

heat

exchanger

has

been

allowed

to cool sufficiently to

prevent

any

damage

from occurring.

Claims

for

damage

will

not

be

considered

if

they

have

resulted

from incorrect

wiring

or

the

incorrect

use

of

the

heater.

2.9

Air

supply

Provision

must

be

made

for

the

existence

of

an

air

supply

for both

combustion

and

ventilation.

It

is a

requirement

that

the

area

where

the air

heater

is located

must

have a

permanent

air

vent

of

negligible resistance direct to the

outside

air. Such air vents

must

be

positioned so as

not

to

become

blocked

or

flooded,

nor

should

they

be placed so as to introduce

undesirable

matter

(e.g. flammable,

volatile,

or

aggressive

chemicals/

compounds

or

potentially

hazardous

or

harmful

substances)

either direct from the outside,

or

through

their proximity to

an

adjacent extraction system.

The criteria necessary for establishing the

minimum

size of

natural

vents

is detailed below;

Position

of

vent

Low level

(inlet)

High

level

(outlet)

Area

of

vent

direct

to

outside

540cm

2

+ 4.5cm

2

per

kW of

rated

input

per

heater

270cm

2

+ 2.25cm2

per

kW of

rated

input

per

heater

Where

mechanical ventilation is

used

it is a

requirement

that

the

inlet is

of

the

mechanical type,

and

the

outlet

is

either

mechanical

or

natural.

Caution

Systems of ventilation

that

employ

mechanical extraction

and

natural

inlet

must

not

be

used.

Furthermore,

where

the air

supply

is

by

way

of a mechanical

means

the inlet

must

be

positioned

at

low

level

and

be

capable

of

providing a minimum

throughput

as

detailed

in

section

8 of this

manual.

The

natural

extraction

air

vents

must

have a minimum

area as

per

above,

and

it is

strongly

recommended

that

natural

extraction

vents

are

situated

at

high level. Additionally,

an

automatic

control interlocked to the

burner

must

be

fitted to

ensure

burner

shutdown

in

the

event

of

air

flow

failure

or

restriction.

If

the

heater

is to

be

installed

within

its

own

separate

building

or

plant

room, the

above

details

do

still apply, as

does

the

requirement

for

minimum

space.

13

2.10

Minimum

space requirements

The

minimum

space

requirements

for single

and

multiple

heater

applications

are

detailed

in

section 3.3

later

within

this

manual.

2.11 Air distribution

system

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.

Where

interjoist spaces are

used

to route

ducting

these

must

be lined with fire resistant

insulation material.

In installations

where

forced recirculation is a feature, a full

and

unobstructed

return

air

path

to

the

heater(s)

must

be

provided,

with

return

air

grilles connected

by

ducting

directly to the

return

air

inlet

on

the heater. The limit for recirculation

should

not

be greater

than 85% recirculated

air

to 15%

fresh air.

Where

the

heater

is installed within a

compartment

or

plant

room the

return

air

and

discharge air

arrangement

must

be

such

that

the

air

circulation fan does

not

interfere with the operation of the

flue.

The

return

air intake

and

warm

air

outlet

should

therefore be fully

ducted

to

and

from the

heater

respectively, within the

compartment

or

plant

room.

If

the inlet air is

ducted

to the outside,

then

the lowest

edge

of the inlet air

duct

must

be

at

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. The

openings

in the

structure

of the

plant

room,

through

which

the

duct

work

passes

must

be

of fire

resistant material

and

constructed to

prevent

the likelihood of

any

fire from

spreading

.

In

ducted

applications the

ductwork

must

be

designed

so as to give a static pressure within the

limits

stated

in section 8 of this manual.

It

should

be

noted

that

if

the static

pressure

is too

high

,

nuisance

shut-down

will occur

when

the

heater

goes

out

on

the

overheat

limit thermostat, if the

static

pressure

is too low, then

damage

can

be

caused to the fan

motor

.

Warm

air

outlets

on

ducted

applications

must

be

such

that

they

cannot

be

closed

or

become

blocked,

which

again

would

lead

to

an

increase in static

pressure

and

nuisance

shut-down.

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.

14

2.12 Flue

system

Warning

It

is essential

that

the

products

of

combustion

are flued to the

outside

of the building. 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 3m. 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

,,,,hen considering

flue requirements.

Care

should

be taken to

ensure

that the flue terminal is

not

situated in a high pressure area, the

proximity of buildings

and

other obstacles which will influence this

must

be taken into account,

preferably at the design stage. See figures 9 -

19.

Provision

must

be

made

for the disconnection of the flue for inspection

and

service requirements,

and

it

is

strongly advised that

where

bends

are fitted inspection covers are included.

The materials from which the flue

is

constructed

must

be

non-combustible, resistant to internal

and

external corrosion,

and

be

capable

of

withstanding

the stresses

and

loadings associated

with

normal use.

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

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

.

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 65°C.

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

the

flue gases

without

risk of their re-entering the

property

through

windows,

ventilation ports, etc.

The flue

should

extend

to

at

least 1m above the height

of

any

object

within

3.5m of the terminal.

Flue terminals

should

be fitted

on

all flues, the terminal

must

be of the

approved

type,

and

have

outlet grilles

on

all sides giving a total free area of at least

double

that of the flue.

Caution

It

is imperative that the flue

should

be properly sealed

where

it passes

through

the roof, this can

best

be

achieved

by

using

the

approved

method

of roof flashing plate

and

cravat.

Note

It

should

be

noted

that claims

made

under

warranty

and

attributed

to the ingress of

water

may

not

be considered especially if

an

approved

method

of sealing has

not

been used,

or

if

the

design

of

the flue has

not

made

provision for possible condensation problems.

15

- - -

-

-

Not less than
600

Not I

ess

than

600

~parapet

Greater

than

1500

I

..

..I

I

Fig

9.

Flat roof,

with

parapet

All

dimen

sions are in millimetre

s.

-y--,....-r-,-

Not

less than

600

Structure

--

~

-.-

I ..Less than

10

h2

..

/1

r-

__

------=--L-,--e-ss-----:-t-,--h-a-n-1,-:0:-::h--=-,'-----_

..

--I1

Greater

than

1500

Fig 10. Flat roof,

envelope

method

All

dimensions

are in millimetres.

Structur~e

Not

I",

thO'

_

!50

l

"Jh,

n

!

Greater than

10

h2 I I Greater

tha

~

O

hI

I

~~I~--

--

~"

Fig

11

Flat roof,

where

the

flue

outlet

is

more

than

10

heights

(h)

away

from all

structures

A

ll

dimensions

dT

e in millimetres.

Not less than

600

Parapet

-

-

~~--+-~-----------

U Less

than

1500

Fig 12. Flat roof,

with

flue close to

parapet

All

dim

ens ions

are

in

millimetres.

16

--

;::::;-.-

Not

less

than

I

600

I

Not

Less

than

250

Fig 13. Flat roof,

with

no

parapet

All

dimen~i

o n

s

are in millimetres.

Not

Less

than

600

Structure

Fig 14. Flat roof,

with

structure

close to

flue

outlet

All

dimensions ar

e in millim e tres.

600

Not less than

Not less than

600

Fig 15.

Pitched

roof,

not

greater

than

45°

All linear

dim

ensions are in millimetres.

Dormer

window

Fig 16.

Pitched

roof,

within

1.5m

of a structure

on

roof

All

dimensions

are in millim elres .

Not

less

than

600

17

Not

less

than

600

Not

Less

than I

1000

Dormer window

Fig 19. Pitch roof,

chimney

within

l.5m

from

dormer

window

measured

horizontally

All

dimensions

arE'

in millimetrE'S.

18

Not

less

than

1000

Not I ess

than

1000

Fig 17.

Pitched

roof, exceeding

45°

All linea r

dimensions

are

in millimetres.

Termination

on

ridge

/'../

Fig 18. Pitch roof,

internal

route,

pitch

not

exceeding

45°

and

ridge

termination

All

linear

dim

ensions

are in millimetres.

3.0 Installation

It is strongly

advised

that

the

installer reads Section 2

and

Section 3 of this

manual

prior

to

starting

any

installation work.

It

is a requirement that only qualified

and

competent

personnel

may

undertake

instal1ation, commissioning,

and

servicing.

Warning

Always

ensure

that

the

appropriate

personal

protective

equipment

is

used.

3.1 Packaging/siting

The heater will usually be

supplied

wrapped

in heavy

gauge

polythene, non-assembled

parts

will be

supplied

separately. Prior to installation, the assembly of

the

heater

should

be completed, it

is advisable that this is

undertaken

in

the

area

where

the

heater is scheduled to be sited.

Caution

It

is

strongly

advised

that

when

positioning

the

heater

the

lifting

eyes

are

used,

thereby

reducing the risk of

inadvertent

damage

being

occasioned to the heater.

Prior to installation the heater

must

be

correctly positioned before

any

final assembly

work

is

completed. The

bonnet

top

and

outlet nozzles

must

be securely

attached

before installation can

commence.

3.2 Flooring

The

heater

must

be

installed

on

a level

non

combustible

surface

capable

of

supporting

the

weight of the heater

and

any

ancillary equipment.

3.3

Minimum

clearances

The following

minimum

clearances (in metres)

must

be observed

when

installing the heater.

'

Model

top

lhs

rhs

front

back

AH

100 - 600

AH

700 -1000

0.9

2.0

0.9

0.9

0.9

0.9

0.5

2.0

1.35

2.0

[

3.4

Assembly

The following sub-assembly

parts

should

be assembled to allow installation to continue.

Place Nozzle Base plate

onto

the top

of

the heater, align holes,

and

secure. Fit the nozzles to the

spigots,

turning

the nozzles to give the required

approximate

direction for air flow. Adjust louvres

to

give

the

desired

angle

of

warm

air

down

flow.

Secure

nozzles

to

spigots,

when

correctly

positioned,

by

means

of drilling

and

inserting self

tapping

screws.

19

3.5 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, see also figs 9 - 19.

Where

condensation

is likely to

be a problem

provision

should

be

made

preferably

at

the

design

stage

(see section 2.11).

3.6

Oil

Installation/connection

The oil

tank

must

be

positioned so

that

there is a fall of 7.5mm (+ / - 2.5mm) for

every

30mm

away

from

the

outlet

and

towards

the

sludge/

drain

valve,

which

must

be sited

at

the

lowest

point

in

the tank.

If

the

tank

is

positioned

on

supports

then

there must

be

an

adequate

protective layer

between

tank

and

support

to

prevent

damage

or

deterioration

through

corrosion.

It

is

strongly

suggested

that

reference is

made

to

BS

5410;

part

2;

1978.

It

is also

suggested

that

the installer is

familiar

with

the

detail

and

requirements

contained

within

sections

2.1

through

to section 2.6 of

this

manual

prior

to

commencing

installation.

Warning

Prolonged

exposure

and

contact

with

Gas Oil can result in

the

natural

oils

being

removed

from

the

skin, sensitisation can

result

in dermatitis.

Always

ensure

that

the

appropriate

personal

protective

equipment

is

used.

3.7 Electrical Installation/connection

Pakaway

cabinet

heaters

are available

either

for 415V 50Hz

3PH

or

230V 50Hz

1PH

supplies

depending

upon

the

model

specified.

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

lEE

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 lEE regula tions .

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

(see section

B).

Warning

Always

isolate from

the

electrical

supply

before

commencing

work

on

the heater.

Always

ensure

that

the

appropriate

personal

protective

equipment

is

used.

20

3.8 Air Distribution Installation

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 air tight

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.

3.9 Warm Air Registers

In

order

that vertical

temperature

gradients are minimal thereby

providing

a more even heat

distribution, it is preferable to install

warm

air registers at low wall levels

or

at floor level,

with

the

size, number,

and

position

commensurate

with

the

requirement of the application.

To

minimise

noise levels the registers

should

be set

away

from corners, a

good

seal

between

the register f

rame

and

the wall is important, particularly

on

high

level positions, if unsightly staining

through

warm

air

/particulate

deposition is to

be

avoided

.

3.10 Heater Control Installation
Warning

Isolate heater from mains before

undertaking

any

electrical work.

All Cabinet Heaters are

manufactured

with

the following controls pre-wired

and

installed. See figs

13

and

14.

(a)

On/

off switch

(b)

Ventilation/heat

switch

(summer/winter

switch)

(c)

Manual!

automatic switch
(d) Thermostat
(e)

Time clock

(f)

Frost

stat

All

of

the

above

controls

are

located

on a removable

panel

which

when

separated

from

the

heater

can

be re-positioned so as to offer a remote facility. However, to facilitate this, it is necessary

to

order

and

fit

an

electrical panel cover

and

front

panel

blanking plate to the heater

in

place

of

the

control unit.

21

4.0

Commissioning

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.

Warning

All Cabinet

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.

Fig 20 -

Heater

Control

Panel

J80lATE

COVER

OFF

VENTILATE MANUAL

~

~

D

ON

Fig 21 - Time Clock

Controls

Reset Button

Manual Switch Summer

and

Winter Time Setting

Enter Switching

Times

Input Times

Weekdays flash

Enter Weekday

I s

Enter minutes

22

4.1

Commissioning

- Pretest

Check

to

ensure

electrical safety,

and

inspect

and

check

the

oil

installation,

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.

(d) Check

that

the heater is installed so

that

it is

square

and

that

the

support

is adequate.

(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.

(i) Check

that

condensate

trap

and

drain

facilities are adequate.

(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

60

°C
overheat limit
fan off
Also check

that

the

white

buttom

(automatic) is pulled

outward

and

that

the red

button

(reset)

is

pushed

inwards

to

the

reset position. See fig

15.

(1)

Remove lower panel

and

check

motor

and

fan

drive

system for integrity

of

joints, check pulley

alignment, fan rotation,

and

belt tension (see section 5.2

and

figs 23,

24

and

25).

Fig 22-

Fan

and

Limit

Thermostat

23

Fig 23

Fan and Motor

Assemblies

Fig

25

(m) Ensure

that

the

burner

is securely

attached

to the heater.

(n) Test for electrical

earth

continuity

between

the heater, oil

pipework,

and

mains

supply.

(0)

Turn on

main

electrical supply, select the following switch settings

on/off

on

heat/ventilation

ventilation

manual/automatic

manual

The fan will

start

enabling fan direction etc to be verified. Reset

on/

off

switch

to off position.

(p) Turn

mains

electrical

supply

to off, replace

and

secure

lower

lourved

panel

covering fan

and

motor

assembly

.

(q) Set room

thermostat

and

time clock to

'demand'

positions.

24

4.2

Commissioing -Ignition

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.

(c)

Select the following switch settings

on

the heater

oo/oH

off

heat

I ventila tion

heat

manual!

automatic automatic

(d) Turn

on

main

electrical

supply

.

(e)

Select

'on'

position for heater

onloff

switch.

(f)

Check for the following

burner

sequence

I

Interval

Operand

1 <5s

Combustion

air

damper

actuated,

burner

fan

motor

initiates

purge

cycle

...

2

Solenoid valve opens, ignition transformer
provides

spark

for pilot ignition

...

<ISs

E

IT

HER

I

I

,

3

>15s

Ignition failure caused

by

oil starvation

I I

resulting in

burner

lock-outl

shut-down

...

(g) Set heater

onloff

switch to 'off' position

(h) Attach oil manifold (bleed screw

and

pressure gauge)

(i)

Open

oil

supply

valves

and

bleed

air

from

pipework

and

adjust

burner

oil pressure as datailed

in

burner

manual

(section

B)

(j) Repea t steps

4.1 q and

4.2

c,

e,

f.

3

4

>15s
<20s

OR

Burner ignition.

..

flame detection

...

Burner ignition cycle complete.

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

25

reason

or

fault

has

been

identified

and

rectified, if necessary

by

reference to

the

separate

burner

information

or

to section 6 of this

manual.

(k) Repeat

steps

4.2 c,a,

(l)

Repeat

steps

4.2 d,e,f,

allowing

the

heater

to reach

thermal

equilibrium.

(m)

Adjust

room

thermostat

to its highest setting,

and

allow

the

heater

to

continue

to fire.

(n)

Gradually

reduce

the

temperature

setting

on

the

room

thermostat

until the

burner

shuts

down,

(@

°C <

ambient)

and

then

gradually

increase

the

temperature

setting

on

the

thermostat

until

heat

is called for,

(@

°C > ambient)

and

the

burner

automatically

re-fires.

(0)

Re-set

time

clock to a

minimum

off

period,

checking

that

the

burner

shuts

down,

and

then

automatically

re-lights once

the

minimum

off

period

has

elapsed

. (Separate information

on

the

time clock is

contained

within

the

information

package

supplied

with

the heater).

(p)

Check

fan

and

limit

stat

by

depressing

and

holding

in the fan

motor

overload

re-set

button,

located

on

the

heater

electrical

panel.

The

time

between

the fan

stopping

and

burner

shut

down

should

be

noted,

once the

burner

has

shut

down

the

overload

on

the

motor

should

be

released.

If

the

time interval

between

fan

stop

and

burner

shut

dmvn

is

greater

than

90

seconds

further

checks

should

be

made.

These are as follows :

(i)

Check settings

on

fan

and

limit

stat

are correct, ie, fan

on

60°C, fan off 30°C, limit 100°C.

(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-metalic

strip

nor

its casing is

damaged.

(q)

Undertake

flue

gas

analysis

using

approved

and

calibrated

analysing

equipment

recording

data

on

the

commissioning

card, ie,

CO,

C02,

net

and

gross flue

temperatures.

Record

burner

oil

pump

pressure,

ambient

temperature,

barometric

pressure,and

smoke

reading

(0

- 1

Baccarach scale).

Note

(i)

The

burner

air

and

oil

pressure

settings

should

be

only

very

finely

adjusted

to achieve a C02

reading

of 12.5% (+ / - 0.5%

).

Note

(ii)

The

gross efficiency

must

be

approximately

80

percent.

Note

(iii)

All

Cabinet

Heaters

are

test fired

and

pre-commissioned

as

part

of

the

manufacturing

process, if

however,

during

on

site

commissioning

the

data

are

found

to

be

not

in

accordance

with

the

manufacturers

data,

then

the

following action is

recommended

:

* Re-check all

readings

and

calculations.

*

Adjust

burner

as

per

manufacturers

instructions.

*

Consult

Benson

Environmental

Ltd Technical

Department.

(r)

Complete

commissioning

card

and

provide

operating

instructions for the user, high-light the

fact

that

the

manufacturer

recommends

that

in

the

interests of safety

and

efficiency

the

heater

is

serviced

on a regular

basis

only

by

qualified

and

competent

persons.

The

completed

commissioning

card

must

be

returned

to

Benson

Environmental

Ltd

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.

26

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.

(a)

Check

that

the

amount

of

fan

produced

air

volume

is

in

accordance

with

the

heater

specification, if the

volume

is too great

the

fan can be overloaded.

Ensure

that

the

running

current

is as

per

that

stated

on

the

heater

data

plate. Alternatively, the static pressure

should

be

measured

at the start

of

the

ductwork

to confirm

that

it

is within the permissible tolerance.

(b)

If

the

current

drawn

is greater

than

the stated

running

current, in most probability this will be

caused

by

insufficient static

pressure

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 Environmental Ltd Service Department.

(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.

(c)

The

user

should

be

made

aware

of

the following in particular

(i)

Lighting,

shutdown,

and

operational information.

(ii) Safety features,

data

plate,

and

labelling.

(iii) The

requirement

for regular inspection - especially if the heater is within a more

demanding

environment -and

the need for regular servicing, carried

out

by

competent

and

qualified persons.

(d) Section C 'User Instructions'

should

be left

with

the

customer

upon

satisfactory completion

of

the commissioning

and

hand-over.

Caution

After approximately

100

hours

of running, the 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 instructions.

5.0

Servicing

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.

27

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

foDowing

parts

fall

within

this category:

room

thermostat,

time

clock, frost

thermostat,

sequential

controller,

and

fan

and

motor.

Additionally,

the

fan

and

limit

stat

has

been

factory set,

and

must not be re-set

without

formal

consent

from Benson

Environmental

Ltd.

Reference

should

be

made

to

the

separate

information

covering

the

operational

details of the

burner

and

timer.

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.

5.1 Planned Servicing

In

order

to

maintain

the

efficient

operation

of the

heater

it is

recommended

that

the following

planned

servicing

and

preventative

maintenance

programme

is

adopted

by

the

user.

Quarterly Inspection

(a)

Visual

inspection

of

the

burner

(b)

Clean

and

check

spark

electrode

(c)

Clean

and

check

photo

cell

(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

(1)

Report

28

5.2 Servicing Procedure - Major Component Parts

Flue

A visual inspection

should

be carried

out

to

ensure

that the flue remains adequately

supported,

both

internally as well as externally,

and

that the

various

joints are effectively sealed. Inspection

covers,

where

fitted,

should

be

removed

and

the flue checked to see

whether

cleaning is required.

If

inspection

covers

are

not

fitted

the

gas

exit

duct

and

flue

spigot

will

provide

not

only

an

indication of the cleanliness of the flue,

but

will also enable access for cleaning. The presence of the

flue terminal

should

be checked.

If

a condensate

trap

and

drain

facility is fitted this

should

be checked to ensure that it continues

to function correctly,

and

the

drainage

of condensates is

not

impaired.

Main Fan Motor

Remove access panel.

Dust

and

other

foreign

matter

should

be

cleaned

by

blowing

over

with

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. Traces

of

surplus

lubricants

spreading

from

the

bearings

should

also be cleaned away. Where motors are fitted

with

grease nipples bearings

should

be lubricatd

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.

Main Fan

Remove

dust

and

other

foreign

matter

by

blowing

off

with

compressed air

or

through

the

use

of

a soft bristle brush. Check

that

the

bearings

do

not

show

signs of excessive wear.

It

should

be

noted

that

these

bearings

do

not

require

lubricating.

If

the

bearings

require

replacing

the

following

procedure

should

be followed.
(a) Remove belt(s).
(b) Loosen set screw

on

eccentric collar

and

tap

the collar in the

opposite

direction to fan rotation.

(c)

Remove collar

and

bearing.

(d) Check shaft for alignment

and

straightness.

(e)

Locate the

bearing

in its seat

and

place

on

the shaft

with

the

cam

facing outwards.

(f)

Fit the eccentric collar

and

engage the cams.

(g) Tighten initially by rotating,

and

then by

tapping

in the direction of the fan rotation.

(h) Replace fasteners

and

secure.

(i) Turn

by

hand

to ensure free fan rotation.

Pulleys

Check pulleys for alignment using a straight edge,

if

necessary reposition either

or

both

of the

pulleys

and

the fan motor. Check for excessive

wear

within

the

root

and

sides of the grooves,

and

check for

any

other

signs of

wear

or

damage,

if necessary replace the pulley as follows.

(a) Release tension

on

belts

and

remove.

(b) Release the

taper

locks

by

slackening the securing screws by several complete turns.

29

(c)

Fully

remove

one

screw

from

the

taper

lock,

and

having

oiled it,

insert

into

the

threaded

jacking point.
(d) Tighten screw until the taperlock is free.
(e)

Remove taperlock

and

pulley.

(f)

Fit taperlock in

new

pulley,

and

provisionally position

on

the shaft.

(g) Remove the screw from the jacking point,

and

tighten

both

screws in their

clamping

points

until the pulley can just be

moved

on

the shaft

by

hand.

(h) Align pulleys using a straight edge,

and

by

gradual

alternative tightening of the screws

clamp

in position.

(i)

Refit belts

and

check for the correct

amount

of tension.

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

multi-belt

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

motor

towards

fan to slacken belts.

(d) Replace belts, pull fan

motor

away

from fan until belts are tight.

(e)

Tighten

adjustment

bolt to hold motor.

(f)

Tighten fan securing bolts

ensuring

that the fan is

square

and

that

the pulleys are aligned.

(g) Check belt tension,

making

final

adjustments

as necessary.

(h) Tighten

and

clamp

fasteners to hold fan

motor

in position.

Heat Exchanger

The

heat

exchanger

requires a visual

inspection

at

least

once

per

year,

this

should

be

accompanied

by

cleaning.

It

is

recommended

that

a flue

brush

and

vacuum

cleaning are

used

to

facilitate this. Access to the heat exchanger is

gained

through

the removal of the rear

upper

panel

and

heat shield. Servicing

and

cleaning

should

be

performed

as follows.

(a) Remove brass

nuts

and

cover from heat exchanger

end

assembly to expose heat exchanger tubes.

(b) Remove

any

accumulated deposits from the tubes

by

pushing

through

the full length

with

a

flue

brush

.

(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.

30

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

chamber

should

be

visually

inspected

for

signs

of

splits,

cracks,

and

distortion.

If

the

condition

of

the

heat

exchanger

gives

cause

for

concern

the

Service

Department

at

Benson

Environmental

Ltd

should

be

advised

pending a more

detailed

examination.

(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.

Electrical

Supply

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.

Oil

Supply

The

oil

supply

pipework,

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

as 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.

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.

Burner

Service

requirements

for

the

burner

fitted to

the

cabinet

heater

are

covered

in

the

separate

manual

prepared

by

the

burner

manufacturer.

Note

It

is

most

important

that

the

burner

is

serviced

regularly

and

in

accordance

with

the

manufacturers

instructions.

Air

Delivery

System

A

visual

inspection

should

be

undertaken

to

ensure

that

the

air

delivery

system

is

in

good

order,

that

it

remains

adequately

supported

and

that

the

various

joints are effectively sealed.

Report

A full

and

detailed

service

report

should

be

prepared,

it is

advised

that

the

report

is

not

completed

until

the

heater

has

been

re-commissioned,

where

upon

the

completed

report

can

then

be

run

through

with

the user.

5.3

Service

Re-commissioning

The

heater

must

be

re-commissioned

as

follows;

as

per

section

4.1

through

to

section

4.4

inclusive. This

must

be

regarded

as a necessary

part

of

the

heater

service

by

the

servicing engineer.

31

6.0 Fault

Diagnosis

Fig 26

-

Burner fails

II

to run

-

~

Room

r---

Thermostat

Check

Controls

Timer

~

Heat/Ventilate

No

Demand

r---

Switch

On/Off

Switch

~

No

Power

Check

Isolator

Check

Fuses

Burner

Lockout

Fan/Limit
Thermostat

Fig 27

-

Fuel Feed
Incorrect

I

Check

that

the

Oil

Pressure

is

Correct

I

Check

that

the

.

Head

of

Grav

ity

is Sufficient

'--

Check tha t the
Suction Lift is

not

too

great

(two

pipe

systems)

I---

Burner starts

ignition

sequence,

but

fails to

light

and

lockout

occurs

-

-

Fuel!

Air

Probl

em

-

Check

Burner

Air

Setting/

Bleed

System

Air

in

System

Check

that

the

By-pass

Plug

is

Present

,I Possible Fuel

I

Contamination

r----

-

~

Restricted Fuel
Feed

Check

Valves/

Fuel

Feed/

Filter/

Nozzle

for

Blockages

and

Restrictions

-

~~ ~-

\

No

Spark

Check

Control

Check

Efectrode

1---------1

1-------1

32

Fig

28

Burner

gives

a

Too

Much

Air

sparky flame

-

Air

/Fuel

Mix

,--------

r-

-

Ratio Incorrect

r---

;--

r-

r------

r---

I

L-

Fuel Feed

r- r-

Restricted

~

Adjust Air

I

Damper

I

Check for Air in
Fuel Line

I

Check Fuel Press

Check Nozzle

Check Filter

Check Fuel Lines

Check Valves

Fig

29

,-------

Check Oil Press

,---

Insufficient
Combustion

Air

~

Check Air
Damper

Check Nozzles

I---

Burner

gives

a

smokey

flame

Poor
Combustion

r-

Check if
Correctly Fitted

I Check if Correct

Size

Check if
Damaged

or

Worn

'---

-

-

-

Inadequate

Flue

Draught

I

Check Flue

33

Fig 30

Burner

giving

excessive

noise

Check Burner

-

Fan

Motor

I--

L--

Suction Lift Too
Great

r--

Check Burner

011

e----'---

Pump

Foreign

Matter

in

Fan

Worn / Dry
Bearing

Insecure Burner
Fan

Water in Fuel
Line

Fuel Feed
Restriction

Adjust

Warm Air

F

ig

30 Check for

High

Discharge

and

Warm Air Short
Circuit

Level

of

System

I--

-

Cool Air Inlet

Resistance

Accordingl y

Fan

and

limit

regularly

go

to

lockout

f-

Insufficient Air

-

Flow

over

the

Heat

Exchanger

Limit Control

"----

Incorrectly Set

,--

~

,----

Check Fan

and

Motor Assembly

-

L--

-

Reset to 100" C

I---

Check

Outlet

Grilles are

not
Closed or Severely
Restricted

Check Filter
System is Clear

Check Pulleys

f------

are Secure

Check for no

I----

Loose Contacts

ICheck for Belt

Slip

i-

Fan

and/or

Motor

not

up

to

f------

Correct Speed

Check Fan

and

I----

Motor are Secure

Check that Fan is
not

Blocked

or

I---

Restricted

Check that
Impeller is

not

Slipping

I---

34

--

VJ

CJl

-

~t.;;-;A~

-,

111, - I- I I

,

GENERAL

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CONTROL

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1.0

FAN

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,

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SIDE

or

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IMPDRTANT:-

THE

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415V

3ph

50Hz

Models

AH-800 - AH-I000

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MODEL

AHIOO

AH150

AH200

AH300

AH400

I

kW/hr

29.3 44.0

58.6 88.0

117.2

HEAT OUTPUT

Btu/hr

100,000 150,100 200,000 300,000 400,000

HEAT INPUT

kW/hr

36.3 54.9 73.2 109.8 146.8

(GROSS)

Btu /

hr

125,000

187,500 250,000 375,000 500,000

I

FUEL CONSUMPTION

Imp

gall/hr

0.76 1.14 1.52 2.28 3.

04

Gas Oil (Class

0,35

Sec)

litre /

hr

3.5 5.2

I

6.9

10.4

13.8

Reillo

40

Riello

40

Riello

40

Riello 40 I

Riello

40

BURNER TYPE

G5 G5 G10

G10

G20

OIL NOZZLE USGPH

.75x80'

'S

1.0x60"S 1.35x60"S 2.0x60

"S

2.75x60'

'S

Danfoss Danfoss Danfoss Danfoss Danfoss

OIL PRESSURE

psi

150

180

180 180 180

bar

10.0

12.2

12.2 12.2

12.2

I

-

HEAD

SETTING

I

at

Zero

Flue Resistance

Number

2.0 4.0 2.5 5.0 2.5

AIR SHUTTER SETTING

Number

3.5

5.0 3.5 5.0 8.5

at Zero Flue Resistance

OIL

CONNECTION

BSP

3

!

~

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s

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AVAILABLE OUTLET

pa

63 63

125

75

150

PRESSURE Ins WG 0.25

0.25

0.5

0.3 0.6

-

-

AH500

AH600

AH700

146.5 175.8 205.2

500,000 600,000 700,000

183.2 219.6

256.5

625,000 750,000 875,000

I

3.80 4.56 5.32

17.3

20.7 24.2

Riello

40

Riello

40

Riello

G20S

G20S

I

RL28.1

2.0x60"S

3.5x60('S

4.0x45"S 2.5x60

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Danfoss

Danfoss Danfoss

165 180 180

11.2

12.2 12.2

3.5

6.0

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L/F

3

L/F

4

-

H/F

5.5

H/F7

3/

x

3/

S

3/

s

175 200 200

0.7

0.8

0.8

AH800

AHIOOO

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234.5

293.0

800,000 1000,000

293.0

366.4

1000,000 1250,000

6.08 7.60

27.6

34.5

Riello Riello

RL28 RL38

2.0x60"S

2 off

I

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170

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AH150 AH200

AH300 AH400

AH500 AH600

AH700

I

AH800

AHIOOO

i

NOZZLE DISCHARGE VELOCITY

m / sec

ft/min

6.5
128

8.67
1708

6.57
1294

6.04
1190

7.62

1500

8.0

1575

9.52

1875

9.90

1950

7.46

1469

9.56

1883

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AIR

THROW

(approx)

m

ft

14

45

18
60

18
60

16
52

21
70

23
75

27
90

27

90

23
75

,

29
95

AIR DELIVERY

m

3

/

hr

fP /

min

1,911
1,125

I

2,548

1,500

3,694
2,175

5,096
3,000

7,644
4,500

10,701

6,300

12,740

7,500

13,249

7,800

13,589

8,000

17,411

10,250

TEMPERATURE

RISE

THROUGH

HEATER (nominal)

°C

of

40

72

50
90

50
90

50
90

50
90

50
90

50
90

50

90

50
90

50
90

SOUND

LEVEL Dba

64

I

64

I

72

72

74

I

76 78

I

I

78

78 80

COMBUSTION CHAMBER

INTERNAL PRESSURE

I

mm

2 3 4 4 6 6

I

6

I

10

5

9

FLUE RESISTANCE

Min

mbar

Max

mbar

-0.2

0.6

-0.2

0.6

-0

.2

0.6

-0

.2

0.6

-0.2

0.6

-0.2

0.6

-0.2

0.6

-0

.8

3.0

I

-0.8

1.6

-0.8

2.5

GROSS FLUE TEMPERATURE

(20°C AMBIENT)

°C

235

270

I

260 295 270 340 275 280

260 320

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AHISO

AH200

AH300 AH400

I

AHSOO

AH600 AH700

AH800

AHIOOO

FL

UE

DIAMETER

ELECTRICAL SUPPLY

R

UN

NING

CURRENT

RATED

INP

UT

WEIGHT

mm

Amperes

kW

kg

Ib

s

125

230V

Iph

50H z

2.5

0.63

208
458

125

230V

Iph

50H z

2.5

0.63

208
458

150

230V

Iph

50H z

6.0

1.1

I

407
H97

175

230V

Iph

50Hz

7.2

1.3

407
H97

175

415V

3ph

50Hz

3.9

1.5

496

1093

175

415V

3p

h

50Hz

4.9

2.4

5

11

112

6

175

415V

3p

h

50Hz

7.6

2.98

550

1212

225

415V

3ph

50Hz

H.2

2.98

572

1262

225

415V

3ph

50Hz

8.5

4.1

707

1558

225

415V

3ph

50

Hz

9.0

5.5

780

1720

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9.0 Reference Information

Details of

how

to obtain copies of the publications listed below are available from:

The

Standards

Engineer, Engineering

Department,

Benson Environmental Ltd.

Doc

/ Ref

Title / Subject

BS

5410

BS

EN

292

BSEN

60204

BS

EN 60335

BS

EN 55014

BS

EN 50165

BS

5854

BS799

OFTEC

BS

715

BS

5440

BS

5440

BS799

ISO 228/1

Part

1;

1977

and

part

2;

1978

Code

of Practice for Oil Firing

Parts 1

and

2;

1992

Safety of Machinery
Part

1;

1993

Safety of Machinery - Electrical

Part

1;

1988

Safety of Electrical Appliances
1993

Electromagnetic Compatibility
1995

Safety of Electrical

Equipment

1980
Code

of Practice -

Flues/Flue

Structures

Part

5;

1987

Oil Burning

Equipment

- Oil Tanks

OFS T-100
Polyethylene Oil Storage Tanks

1993
Metal Flue Pipes

and

Fittings

Part

1;

1990

Specification/Installation of Flues
Part

2;

1989

Ventilation Requirements Gas Appliances
Part

2;

1987

Oil Burning

Equipment

- Burners

(See also

BS

2779

and

BS

5380)

Pipe Threads Seals

and

Couplings

41

I

9.1 Parts Listing

Part/Description

100

150

200

300

Heat

exchanger assy

Cabinet

bonnet

assy
Stack box assy
Heat

shield side panel

Front

bottom

panel

Front

top

panel

Back top

panel

Heat

shield front panel

Heat

shield back

panel

Expansion spacer
Fluebox cover assy
Rear air inlet

btm

panel
Overload
Contactor
Fan/limit

thermostat

Fan/limit

stat

gasket

Heat

exchanger cover plate

Burner

plate gasket
Pressure relief gasket
Motorised fan
Fan restrictor
Digital time clock
Thermostat

room/

frost

Rocker switch -

red

neon

Rocker switch -

dual
Rocker switch
12-way terminal block
Fuse

holder
Fuse
6-way terminal block
Nozzle

outlet

assy
Tray spigot assy
Exit

duct

cover plate gskt
Fan
Fan pulley
Fan taperlock
Motor
Motor pulley
Motor taperlock
Belt
Fire check valve
Stud

coupling
Adaptor
Appliance

manual

Support

bracket
Oil Filter
Nozzle
Nozzle (US Gal)
Burner

I

31-28-056
31-20-113

31-28-078

31-28-060 (2)
31-28-075
31-28-073
31-28-083
31-28-061
31-28-062

31-27-111

(2)
31-28-058
31-20-107
28-11-053
28-11-057
28-60-021

20-33-549
31-28-052
31-28-080
31-28-080
28-09-001
31-30-017
28-15-030
28-16-031
28-40-072

28-40-073

28-40-074

A 20-09-136

28-07-050
28-07-049

28-03-007
31-20-128

(2)

31-30-176

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
28-30-102
29-00-094
29-00-166
31-28-054
31-30-095

(2)
29-15-017
27-00-413

N/A

29-99-452

common
common
common
common

(2)

common

common
common
common
common
common

(2)

common
common
common
common
common
common

common

common

common
common

N/A
common
common
common
common
common
common

common

common

common
31-30-167

(2)
common
N/A
N/A
N/A
N/A
N/A
N/A
N/A

I

N/A
common
common

common
common
common

(2)
common
27-00-418

N/A

common

31-24-056

31-20-019
31-24-074
31-24-054 (2)

31-24-057

31-24-059
31-24-060
31-24-061

31-24-062

common

(2)
31-27-126
31-20-012
28-11-056

common
common
common

20-30-207

31-40-156
31-27-121

(2)
28-09-002
31-30-016

common
common
common
common
common
common
common
common
common
31-30-167

(2)

31-30-177
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
common
common
common
common
common

(2)
common
27-00-427
N/A
29-99-453

common
common

31-27-123

common

(2)
common
common
common
common
common
common

(2)
common
common

28-11-055

common
common
common
common
common
common
common

(2)
N/A
common

-

common
common
common
common
common
common
common
common
common

(3)
31-30-178
N/A
N/A
N/A
N/A

-

N/A
N/A
N/A
N/A
common
common
common
common
common

(2)
common
27-00-032
N/A
common

I

(2)

denotes 2 off -

(3)

denotes 3 off -

(4)

denotes 4 off

42

400 500

600 700

800

1000

31-27-114

common

31-27-058 31-27-094

31-29-031

common

31-27-098

common

31-27-046

31-27-045

31-29-025

common

common

common

common

31-27-048

common common

31-27-105 (2)

common

(2) 31-27-060 (2)

common

(2)

31-29-017 (2)

common

(2)

31-27-110

common

31-27-075

common

1

31-29-020

common

31-27-073

common

common

31-27-091

31-29-012

common

31-27-083

common

common

common

31-29-015

common

31-27-061

common common

31-27-092

31-29-011

common

-

31-27-062

common common

common

31-29-014

common

common

(2)

common

(2)

common

(2)

common

(2)

common

(2)

common

(2)

common

common common

31-29-040

common

common

31-10-106

common

31-20-102

common

31-29-021

common

-

28-11-053 28-11-056 28-11-055

common

28-11-111

common

common

common

common common

common

common

-

common

common

common

28-60-023

common

common

common

20-31-036

common
common

common
common

common
common

common
common

-I

common
common

31-27-121

common common

31-29-046

common common

common

(2)

common

(2)

common

(2) 20-33-068 (2)

common

(2)

common

(2)

N/A

N/A N/A

N/A

N/A

N/A

N/A

N/A N/A N/A

N/A N/A

common

common

common

common

common

common

.-

common

common

common

common

common

common

common

common

common

common common

common

-

common

common

common common

common

common

common

common

common

common

common

common

common

common common common

common

common

common

common

common common common

common

-

28-07-048

common common

common

common

common

common

common

common common

common

common

31-30-159 (3)

common

(4)

common

(4)

common

(4) 31-30-157 (4)

common

(4)

31-27-120 31-27-119 31-27-072

common

~.

31-29-050

common

N/A

N\A

N\A

31-29-045

common

common

28-09-003

common

28-09-004

common

28-09-043

common

28-65-075

common

28-65-075

-.

common

28-65-049

-

28-65-054

N/A

N\A N/A

N\A

28-66-136

28-66-137

-

28-10-127 28-10-015 28-10-120

common

28-10-026

28-10-021

28-65-070 28-65-071 28-65-071

common

28-65-042

28-65-073

N/A

28-66-025 28-66-025

common

28-66-028

28-66-038

09-19-110 (2)

common

(2)

09-19-134 (2)

common

(2)

09-16-120 (3)

common

(4)

common

common

common

common common

common

common common

common

common common

common

common common common

common

common

common

common common common

common

common

common

common

(2)

common

(2)

common

(2)

common

(2)

common

(2)

common

(2)

29-15-012

common

common

common

29-15-020

common

-

27-00-044

27-00-078

27-00-054

27-00-079 27-00-078

common

N/A

N\A

N\A

N\A

27-00-032

~

common

-

29-99-454

common

29-99-455

29-99-456 29-99-457

29-99-458

43

BENSON

ENVIRONMENTAL LIMITED

LUDLOW ROAD, KNIGHTON, POWYS LD7 1LP

Telephone: [phone] Facsimile: 01547 520399