PORTABLE HEATER PARTS LIST AND SERVICE MANUAL
BENSON HEATING LTD
INTRODUCTION
The C.S.H heater is designed and manufactured within
the quality guidelines
of
ISO 9001
Care should be taken to ensure that the information used
from this manual is applicable to the model
of
heater.
This manual provides the necessary information for the
safe operation, cleaning, and servicing
of
the C.S.H.
Heater.
Whilst every care
is
taken to ensure that the information
in this manual is correct Benson Heating accept no
liabilityformisuse orfrom any loss, damage, or injury
caused by errors in, or omissions from the information
supplied.
HEALTH
AND
SAFETYATWORK
ACT
1974
Undersection 6
of
the Health & Safety at work act 1974
the manufacturer has taken reasonable and practical
steps to ensure that the Benson range
of
appliances are
safe and without risk when properly used.
These Heaters should therefore only be used in the
manner and purpose for which they were intended and in
accordance with the recommendations detailed herewith.
The Heaters have been designed, manufactured,
assembled, and inspected with safety in mind, there are
certain basic precautions which the user should be aware
of
and the useristherefore strongly advised to read the
operating instructions before operating the Heater
Contained within the text
of
this manual the words
CAUTION and WARNING are used to highlight certain
points.
CAUTION
Is
used when failure to adhere to the
instruction could result
In
premature failure or damage to
the heater.
WARNING
is
used when failure to heed or implement the
instruction can lead to component damage or risk
of
personal injury.
I PAGE
No2
SAFETY INFORMATION FOR HEATER
OPERATION
This equipment should only be used by a competent
person who has read and understood the following
instructions
Do
not
use
this
equipmentifyou
are ill feeling
tired
or
under
the
influenceofalcoholordrugs.
WARNING
Keep animals and children away from heater NEVER
leave them alone when heater is in use
Never
use the heater ifhighly flammable vapours are
present,
or
in a
dUSty
environment.
Never
stackorlean objects on or against the heater
whilst in operation
Never
restrict the air supply to the heater
Ensure the operating area is well ventilated restricted
combustion can cause carbon monoxide- concentrated
carbon monoxide kills
Never
Operate
the
heater
near
vehicle
exhaust
fumes
Never
fill the heater whilst itishot or running
Always wear protective ciothing when filling heater
(Gloves Goggles etc)
Never
smoke or allow naked light into the area when
refueling
Always mop up any spillage immediately
Never
breathe
any
unbumtgas oil vapours
Always ensure heater is standing on a firm level noncombustible surface
Never
move the heaterwhilst it is in operation
WARNING Before carrying out any work on the heater
ensure that electrical supply is isolated 110 Volt heaters
piug into a standard 110 volt generator ensure flex and
plugs are undamaged. Uncoil extension leads fully
Never
run leads through water or over sharp objects
Never
carry or
pUll
heater by the electrical cable
WARNING use
of
electrical equipmentindamp orwet
conditions can be dangerous
Ensure
that
the
sectionsonHeater
Controls
and
Heater
Operation
are read
and
understood
before
operationofthis
equipment.
Forfurther information contact and advice contact
Spares
I Service Depts. at Knighton Powys
TELEPHONE 01547 528534 FAX 01547 520399
~ECHNICAL
SPECIFICATION
CONFINED SPACE HEATER.
(DIESEL)
Heat Output
Air Delivery (cold)
Temperature Rise through Unit
Nozzle size
Pump Pressure (Diesel)
Max Fuel Throughput
Sound Level (D.b.a.)
Electricity Supply
Motorsize
Start current
Run current
Weight
FuelType
Tank Capacity
11
Kw
(37,500Btu)
@ 7mtrs
0.202m3/s
@ 14mtrs 0.185 m
@7mtrs
40°C
@ 14mtrs 30°C
Danfoss 0.30 Usg x 60° H
90 Psi
1.3ltrs/hr
70 D.b.a.
11
OVolt
150Hz
2550 Rpm
220 Watts
4.5
Amp
2.0 Amp
48 Kgs
Diesel
16
Us
PAGE No 3 I
PAGE No 2
P ARTS LIST
1 2 3
4
1A
13
14
15
16
5
6
7
8
9
10
11
1917
17A
18
20
21
22
23
2425
26
27
12
28
29
30
31
32
31A
33
35
36
34
37
38
39
40
41
42
43
43A
44
45
30
PAGE No 3
P ARTS LIST
Item No Parts Description No Off Part No
1 T op cover outer casing 1 21-30-01 1
2 Flue Pipe assembly 1 21-30-057
3 Burner cover 1
4 Pressure switch 1 E8010810000100
5 Photocell 1 E8010610000000
6 Allen screws - hexagon head 2 E8040017320000
7 Burner assembly including base 1
8 Electrode assembly 1 E8020003000001
9 Blast tube 1 E8000400100400
10 Blast tube mounting collar 1 E8000100500101
11 Burner Gasket 1 21-30-061
12 Nozzle 1
13 Heat exchanger 1 21-30-001
14 Heat shield assembly 1
15 Thermostat 1 28-16-049
16 Thermostat - reset type 1 28-16-050
17 Inlet valve solenoid assembly 1 E800104031 10300
18 Quick release valve 1 E8030120220200
19 Filter bowl complete with filter cartridge 1 E9030310110100
19A Filter cartridge 1
20 Elbow 3 E8030010420100
21 Fuel pump 1
22 Quick release valve 1 E80301 10430100
23 Ignition unit 1 E8010203210000
24 Fan cover assembly 1 21-30-012
25 Control Box 1 E801051 1003500
26 Fan and motor 1 28-09-070
27 Capacitor 1
28 Outer cover base panel 1 21-30-010
29 Outlet spigot assembly 1 21-30-022
30 3 core cable 1 10 V olt Y ellow 1 28-02-184
31 Thermostat 1 28-16-047
32 Thermostat mounting plate 1 21-30-030
33 Neon - Y ellow 1 28-50-022
34 Neon - Green 1 28-50-021
35 Neon - Red 1 28-50-020
36 Switch ON/OFF 1 28-40-127
37 Base cover - outer power inlet 1 21-30-032
38 Base mounting frame 1 21-30-023
39 Burner casing Lower panel 1 21-30-024
40 Base blanking panel 1 21-30-031
41 Front cover - Lower inner 1
42 1 10 Volt 3 pin connection plug - transformer 1 28-06-044
43 1 10 Volt 3 pin connection plug - heater 1 28-06-039
43A 1 10 V olt 3 pin socket - heater 1 28-06-035
44 T erry clip - Air ducting 1 28-01-079
45 Air ducting - Flexible 1 28-01-077
PAGE No 4
P ARTS LIST
5
6
8
7
3
4
4A
2
1
PAGE No 5
P ARTS LIST
Item No Parts Description No Off Part No
1 Fuel pipes 2 28-08-009
2 Fuel Elbows 2 29-00-258
3 Fuel tank 1 21-30-071
4 Heater mounts 2 21-30-070
5 Frame 1 21-30-045
6 Spindle 1 21-30-067
7 Locking dome - wheel 2 A30-01-030
8 Wheel 2 A30-01-002
IINSTALLATION
AND
CONTROLS
1 MOBILE HEATERS FUEL SUPPLY
All Mobile Heaters are set to operate on a two-pipe
system.
In
ordertopromote
trouble
free
operationitis
necessary
that
the
oil
does
not
fall
below
the
cold
filter
plugging
point
with
classDfuel
thisis-4°C
Summer
grade
and
-12°C
Winter
grade
All pipe work and fittings must be sealed so as to prevent
the ingress
of
air.
ELECTRICAL SUPPLY
110 Volt electrical supply connection is made to the
heatervia the generator
THERMOSTAT CONNECTION
A temperature control thermostat located within the
heater air discharge spigot can be adjusted to the
required temperature via the dial located on the heater
control panel.
FLUE INSTALLATION
C.S.H. Mobile Heaters are dispatched with the requisite
stack spigot and flue pipe.
It
is
recommended that O.5mm stainless steel flue be
fitted
In
general each indirect heatershould have its own flue,
which should terminate approximately 500mm above the
heater.
When siting the heaterand flue the proximity
of
other
buildings and obstacles should be considered.
FLEXIBLE
DUCTING
IMPORTANTThe flexible ducting supplied with the
heatershould be fitted with the direction
of
flow which is
indicated by an arrow on the duct pointing awayfrom the
heater
It should be secured to the outlet spigot with the pull strap
provided.
I
PAGENoB
HEATER
CONTROLS
1.
THREE POSITION SWITCH (
HEAT
I OFFI
VENT)
110
Volt
supply
indicatedbya
green
Neon
light
on
panel
(Heat position) Operates the bumer control circuit to the
control box
(Offposition) Breaks the
bumer
control circuit to the
control box
(Vent position) operates the fan only for ventilation
purposes
2. THERMOSTAT
CONTROL
KNOB
Enables the temperatureinthe air ducting to be regulated
to the desired temperature. The
orange
neon lightonthe
panel (bumer run
light)
will be on until the desired
temperature is reached and the burner switches off.
3. CONTROL
BOX
Situatedonthe control panel, monitors the combustion
process
of
the heater to ensure that all components are
operating correctly, it will shut down the heater ifa fault
occurs, a red light showing
in
the centerofthe Satronic
Control Box will flash periodically as the box monitors the
burneroperation
Ifthis light is permanently on it indicates that there is a
fault with the operation
of
the bumer and it has gone to
lockoutthe red button should be pressed (LOCKOUT
RESET)
See fault-finding chart
in
bumer manual.
4.
OVERHEAT
THERMOSTAT
Located on the heat shield
is
a safety overheat
thermostat, this thermostat will operate if the combustion
chamber becomes to hot
in
the eventofa fan failure or
restricted air flow.
The thermostat when it operates will immediately shut
down the bumer and a red ** neon lightwill be
illuminated on the control panel.
The thermostat can be reset by pushing the plastic reset
button located on the top
cover,
the red** neon will go
out when
reset.
IT MUSTBEMANUALLY
RESET
AND
THE CAUSE OF
THE
OVERHEAT
SHOULDBEINVESTIGATED
The above red**neonisdual purpose see
also operating instructions.
~PERATING
INSTRUCTIONS
The heater should be positioned
on
firm ground ensuring
that the air intake is clear ofvehicle exhaust fumes and
other hazardous conditions:
Connect the 110 Volt supply cable from the generator to
the heater.
The
green
neon will be illuminated.
Ensure fuel supply
is
clean.
Connectthe ducting to the duct spigot on the heater
using pull strap provided ensuring the correct direction
of
flow
Fit the flue pipe to the top
of
the heater
The
heaterisnow
ready
for
use
To VENT only, put three position switch to vent position,
the fan only will operate
To HEAT, put three position switch
in
heat position
The main fan will run and the red** neon on the controi
panel will illuminate indicating that the pre heaterfitted to
the burner is operating and pre heating the fuel prior to
the burner start .
NOTE
the
red**
neon
will
indicate
pre
heatatinitial
startuponly,ifthe
neonisilluminatedatany
other
time
the
heaterisat
overheat.
After approximately 150 seconds the
red"
neon will go
out and the bumer will fire, the
orange
neon on the
control panel will illuminate.
The heater will now operate controlled by the thermostat.
To
STOP put three position switch to
off
position.
The burner ON
orange
neon will go off, and the main fan
will continue to run for a further 5 minutes to sufficiently
cool the combustion chamber the fan will then switch
off
.
Only then rnay the electrical supply be safely
disconnected.
WARNING
Failure to cool the heater sufficiently will cause damage to
the combustion chamber and lead to nuisance overheat
lockout problems.
COMMISSIONING PROCEDURE
1 Ensure heater has fuel supply.
2 Ensure thermostat is at desired ternperature
3 Connect electrical supply
4 Switch to heat position
5 Ensure lockout button
on
control box is reset, burner
sequence should start immediately
6 Run heaterfor approx.15 minutes
7 Switch heaterto OFF check operation
of
overrun
thermostat
8 Restart heater to check correct operation
of
thermostat
MAINTENANCE INSTRUCTIONS
WARNING
Before carrying out any maintenance work
on
the heater
ensure that electrical supply is isolated and fuel supply
disconnected.
FUEL SYSTEM
FILTERS
All heaters are supplied with a filter located
in
the fuel line
the paper filter cartridge cannot be cleaned and must be
totally replaced during servicing or when contaminated,
FUEL
PUMP PRESSURE ADJUSTMENT
Ensure electrical supply
is
offand disconnected.
Remove rear lower base coveron heater
Remove vent plug located on the end
of
the brass
extension pipe on the pump body (in the center when
viewed from rear
of
heater)
Fit pressure gauge to brass extension
Re connect electrical supply
Switch Burner ON observe reading on gauge
Setpressure to (90 psi) diesel only
Ifadjustment is required situated above the fuel inlet
connection (left side when viewed from rear) is a screw
and locknut undo the locknut insert
PhiJlips
screw driver
into the screw head adjuster, turn clockwise to increase
anticlockwise to decrease the pressure.
When the pressure is correctly set tighten locknut
disconnect the electrical supply, remove gauge and
replace bleed screw and ensure it is tightly located
Replace rear cover
PAGE
Nog
I
[ MAINTENANCE
BURNER MAINTENANCE
Burner Maintenance should only be carried out by
competent personnel
and will require the complete rernoval
of
the Burnerfrom
the combustion chamber
BURNERASSEMBLY
see pages 15 & 16 for further detail
Disconnect the electrical supply to the heater
Disconnectfuel supply
Carefully roll heater on
to
its side and remove the 4 x M5
Screws from the base return unit to upright position
Remove top cover of heater 6 X M5 Screws
Remove bottom rear panel 4 x M5 Screws
Remove fan assernbly Screws 4 X M5 (lowertwo can be
accessed by inserting screw driver through the holes in
the base
of
the
heater)
and lift fan assembly out
Disconnect the wires from the block at the rear
of
the
burner head
Remove the thermostat capillary from the securing clips
in
nose cone and lowerinto the heater base through the
hole provided.
Remove the blanking panel 4 X M5 Screws
Rernove the two screws securing the burner to the
combustion chamber flange
The burner, blast tube, and control base can now be
cornpletely removed through the rear
of
the heater.
Maintenance
of
the Burnerisdetailed in the Installation
and Service Manual supplied separately.
Clean soot
or
carbon deposits from diffuser, end ring,
or
electrode tips
Clean and inspect electrodes for cracks replace if
necessary
Reset electrodes to dimensions shown in Burner manual
do not overtighten securing screw
A new Nozzle should be fitted every 12months
or
if
existing nozzle
is
damagedorworn.
Reassemble taking care that all parts are clean and dry.
Ensure fuel pipe
is
kept free from dirt whilst burner head
is dismantled
I PAGE No 10
PHOTOCELL
Ensure that the photocell is clean (wipe clean with a soft
cloth)
CONTROL
BOX
The control box cannot be repaired if the boxisfaulty it
should be replaced with a new box
WARNING
The control box should not be reset more than twice
before the fault is located and corrected,
or
any
surplus oil emitted into the chamber has been
mopped out through the burner entrance.
HEAT EXCHANGER REMOVAL
Remove complete burner assernbly
Ifrequired the combustion chamber can be removed by
bending up the chamber retaining clips and sliding the
chambertowards the rear
of
the heater
Chamber can now
be
cleaned by tapping the outside
of
the chamber with a hide hammerorpieceofwood. Care
should be taken notto damagethe burner flange.
Rernove any loose soot, carbon through the draught tube
aperture
or
the flue stack spigot
Re assemble
in
reverse orderofabove instruction.
IFAULT FINDING
Fault
Cause
Remedy
(a) No Electricity Supply
Check Supply
Heater Fails
to
start
when
heat
is
Fan
runs
supply correct
switched
ON
(b) Switch fan to manual
Check
thennostat
Thermostat calling for
heat
(c) Faulty Thermostat
Reset
red
buttonontrip,
(d) Overheat thermostat tripped
Investigate cause
Red light showing on satronic
(a) No fuel
Check fuel
(b) Air lock
in
fuel supply
Bleed Fuel system
control box
(c) Photocell not detecting
Check & clean Photocell
flame
(d) Faulty electrodes
Check electrode for cracks, check
(e)
Faulty control box
ignition leads
(afPhotocell notaetecting
~heck
photocell
Heaterruns for short period does
flame
hot
light control box goes to lockout
(b) No fuel
bheck
fuel supply
(c) Ignition failure
bheck
ignition leads
bheck
electrodes are clean & gap
~et
correctly
(d) Fuel pump failure
~heck
solenoid valve
(e)
Faulty solenoid valve
bheck
electrical connection to valve
Red neon light on fan not working
(a) Heater gone to overheat
Reset overheat thermostat
(a) Photocell not detecting light
~heck
photocell operation
Heater attempts to light up but
(b) Faulty photocell connection
/:heck
wiring connection
in control box
Burner Control box goes to lockout
(c) Faulty control box
bhange
control box
(d) Air pressure switch not
bheck
switch
bperating solenoid
(a) Air control incorrectly set Reset aircontrol
Heater runs but emits black smoke
(b) Nozzle loose or incorrect Check nozzle
rom stack box
(c) Incorrect fuel pressure Check fuel pressure
(d) Exhaust stack restricted Clear stack
(e)
Excess carboninthe Clean carbon from draught
tUbe
~raught
tube
Heaterruns butfan overrun does
(a) Loose wire on the overrun
hot
work when switched off******
Checkwiring
n order to check this fault the
device
lleater
should be run to ensure the
(b) Overrun device faulty
Replace overrun device
k;ombustion chamber is hot enough
(a) Air
in
the fuel supply
Check fuel pipe for cracks, check
pipe unions are tight
Heater runs but flame is intermitten
(b) Heater running out
of
fuel
Checkfuel supply
(c) Filter blocked
Clean filter
(d) Dirty nozzle
Check nozzle
PAGENo11
KEY·
X1
•
SATRONIC
DK0972
BASE
SW
•
SELECTOR
SWITCH
(HEAT/OFFNEND
M1
•
BURNER
MOTOR
M2
•
AIR
CIRCULATOR
MOTOR
(FAN)
L1 •
OVER
HEAT/STAND
BY
NEON
(RED)
L2
•
BURNER
RUN
(ORANGE)
L3
•
POWER
ON
(GREEN)
V1
•
OIL
VALVE
P
·OILPUMP
PH
•
OIL
PRE·HEATER
TS
•
THERMOSTAT
PT
•
PHOTOCELL
T •
IGNITION
TRANSFORMER
PA
•
AIR
PRESSURE
SWITCH
TSO
•
OVERHEAT
THERMOSTAT
cJw
RESET
TSR
•
RUN·ON
THERMOSTAT
LK1
•
BURNER
LINK
MIS
•
MAINS
INLET
SOCKET
M1
w
1---'7""'H-r-;H>-J
zl--....J
X1
r-----------------------r,~~~~;rL~r,~~~
t
M2
•
L-----------------------~_,L~~~~~L;J_,L~~
"
:E
~
L1
G')
~
m
Z
Z
0
G)
....
C
I\)
»
MAINS
G)
INLET
~
110V·50Hz
3:
PAGE No 6
NOTE:
FOR ALL SERVICE PROCEDURES EXCEPT
PRESSURE TESTING THE HEATER MUST BE
REMOVED FROM THE TRANSPORT CRADLE.
REMOVE THE 4 PHILIPS HEAD SCREWS
HOLDING THE HEATER TO THE CRADLE.
SERVICE MANUAL
1 TO REPLACE THE FAN UNIT AND/OR
CAPACITOR AND/OR TEMPERATURE
CONTROL THERMOSTATS
1:1 BEFORE REMOVING THE HEATER FROM THE
TRANSPORT CRADLE REMOVE THE LOWER
REAR COVERS (FIG. 2), BY REMOVING THE 4
ALLEN SCREWS ON THE OUTER COVER TO
GAIN ACCESS TO THE FUEL SUPPLY AND
RETURN PIPES, AND UNCLIP THE PIPES (FIG.
3), AND CAREFULLY FEED THEM THROUGH
THE CASING.
FIG. 2
FIG. 3
FIG. 1
4 PHILIPS HEAD
SCREWS
UNCLIP THE FUEL PIPES AND FEED
THEM THROUGH THE CASING
PAGE No 7
1:2 REMOVE THE FLUE COVER (FIG. 4) BY
LIFTING OVER THE FLUE
1:3 REMOVE THE TOP COVER (FIG. 4), BY
REMOVING THE 4 ALLEN SCREWS
FIG. 4
FIG. 5
1:4 TO REMOVE/REPLACE THE CAPACITOR,
REMOVE ITS LOCATION NUT, AND WIRING
FROM THE TERMINAL BLOCK.
REPLACE WITH A NEW UNIT AND CONNECT
ALL WIRING, AND REPLACE ALL COVERS.
UNSCREW THE
RETAINING NUT
AND WIRING FROM
THE TERMINAL
BLOCK
FIG. 6
1:5 TO REMOVE/REPLACE THE THERMOSTATS,
REMOVE THE LOCATION SCREWS, AND
SPADE CONNECTORS, AND REMOVE THE
THERMOSTATS (FIG. 6).
REPLACE WITH A NEW UNITS AND CONNECT
ALL WIRING, AND REPLACE ALL COVERS.
UNSCREW THE
RETAINING
SCREWS AND
REMOVE THE
SPADE TERMINALS
SERVICE MANUAL
PAGE No 8
1:7 PLACE THE HEATER IN ITS NORMAL
POSITION AND REMOVE THE REMAINING 2
ALLEN SCREW (FIG. 8)
1:8 UNPLUG THE MULTI WAY CONNECTOR AND
THE 4 THERMOSTAT LEADS (2 ORANGE 2
YELLOW)
1:9 UNPLUG THE PHOTOCELL (FIG. 9)
1:10CAREFULLY REMOVE THE FAN AND COVER
(FIG. 10) ASSEMBLY FROM THE CASING, AND
THEN REMOVE THE FAN FROM THE REAR
SLOTTED COVER BY REMOVING THE 4
ALLEN SCREWS.
1:11REPLACE WITH A NEW UNIT.
1:12RE ASSEMBLE BY REVERSING THE STRIP
DOWN PROCEDURE
(NOTE WHEN REPLACING THE PHOTOCELL
UNIT- IT ONLY FITS ONE WAY, DO NOT USE
EXCESSIVE FORCE WHEN REPLACING - IT
COULD BE DAMAGED)
SERVICE MANUAL
FIG. 8
FIG. 9
FIG. 10
1:6 TIP THE HEATER ON ITS SIDE TO EXPOSE
THE 2 LOWER FAN RETAINING SCREWS, AND
REMOVE THE TWO SCREWS (FIG. 7)
FIG. 7
PAGE No 9
SERVICE MANUAL
FOLLOW THE PROCEDURE FOR REMOVING THE
FAN (1:1 TO 1:9)
2:1 ROTATE THE HEATER ON TO ITS SIDE AND
REMOVE THE 4 ALLEN SCREW HOLDING THE
BURNER TRAY ASSEMBLY INTO POSITION
(FIG. 11).
2:2 REMOVE THE 2 LONG ALLEN SCREWS
HOLDING THE BURNER ON TO THE HEAT
EXCHANGER (FIG. 12).
2 TO REPLACE THE INJECTOR
2:3 REMOVE THE ‘P’ CLIP FROM THE GUARD,
AND REMOVE THE CAPILARY TUBE.
FROM THE CASING (FIG. 13), AND
CAREFULLY SLIDE THE COMPLETE BURNER
TRAY ASSEMBLY OUT OF THE BOTTOM
TRAY.
WHEN THE TRAY IS REMOVED THIS GIVES
ACCESS TO ALL OTHER SERVICEABLE ITEMS
(FIG. 13)
FIG. 11
REMOVE 4 SCREWS
FROM CASING
UNDERSIDE
FIG. 13
REMOVE THE
‘P’ CLIP
FIG. 12
PAGE No 10
FOLLOW STEPS FOR REMOVING THE FAN AND
INJECTOR
3:1 REMOVE THE BURNER COVER, BY
UNSCREWING THE 4 ALLEN SCREWS (FIG.
14)
3:2 REMOVE THE COVER RING (A), BY
UNSCREWING THE SINGLE BUTTON HEAD
ALLEN SCREW (FIG. 15), TO GAIN ACCESS TO
THE INJECTOR.
3:3 UNCLIP THE IGNITION LEADS AND REMOVE
THE ALLEN SCREW, AND REMOVE AND
REPLACE THE ELECTRODE ASSEMBLY.
4 TO REPLACE THE IGNITION UNIT
FOLLOW STEPS FOR REMOVING THE
INJECTOR
4:1 UNPLUG THE IGNITION LEADS (FIG. 16)
4:2 REMOVE THE 2 ALLEN SCREWS AND
REPLACE WITH A NEW UNIT
3 TO REPLACE THE IGNITION ELECTRODES
SERVICE MANUAL
2:3 REMOVE THE 3 SCREWS HOLDING THE
BLAST TUBE IN POSITION. (FIG. 14)
NOTE: THE BURNER TRAY PRESSING IS
SHOWN CUT AWAY FOR CLARITY
2:4 REMOVE THE INJECTOR, USING A 16MM
LOCK SP ANNER AND A 14MM SPANNER.
CARE MUST BE TAKEN NOT TO DAMAGE THE
IGNITION ELECTRODES WHEN
REMOVINGANDREPLACING THE INJECTOR.
REPLACEMENT IS THE REVERSAL OF
REMOVAL
BLAST RING
& 3
RETAINING
SCREWS
INJECTOR 14MM
LOCK
SPANNER
FLATS
FIG. 14
COVER RING
& ALLEN
SCREW
BURNER
COVER
BLAST
RING
ELECTRODE ASSY .
& ALLEN SCREW
IGNIGNITION
LEADS
FIG. 15
IGNITION
LEADS
ALLEN
SCREWS
FIG. 16
PAGE No 11
6 TO REPLACE THE THERMOSTA T, NEONS AND
ON/OFF SWITCH
FOLLOW STEPS FOR REMOVING CONTROL
BOX
6:1 TO REMOVE THE THERMOSTAT, REMOVE
THE CONTROL KNOB, AND UNSCREW THE 2
RETAINING SCREWS. REPLACE WITH A NEW
UNIT, AND REFIT ALL ITEMS (FIG. 18).
6:2 TO REMOVE AND REPLACE A NEON.
UNSCREW YTHE LEADS AT THE CONNECTOR
BLOCK (THEY ARE FLYING LEADS), NOTING
THEIR TERMINAL NUMBERS.
UNSCREW THE RETAINING NUT, WITHDRAW
THE NEON, AND REPLACE.
6:3 TO REPLACE THE ON/OFF SWITCH.
UNPLUG ALL WIRES FROM THE SWITCH,
NOTING THEIR TERMINAL NUMBERS, UNCLIP
THE SWITCH, AND FIT A REPLACEMENT .
REFIT ALL WIRES, AND OTHER COMPONENTS.
7 TO REPLACE THE POWER INPUT SOCKET
FOLLOW STEPS FOR REMOVING CONTROL
BOX
7:1 TO REMOVE THE POWER INPUT SOCKET,
NSCREW THE 3 POWER RING TERMINALS/
WIRES FROM THE SOCKET, AND THEN
UNSCREW THE 4 NUTS HOLDING THE
SOCKET IN PLACE (FIG. 19).
REPLACE WITH A NEW ITEM, REFIT
REVERSING THE REMOV AL PROCEDURE.
SERVICE MANUAL
5 TO REPLACE THE CONTROL BOX
FOLLOW STEPS FOR REMOVING THE
INJECTOR
5:1 TAKE OFF THE 2 ALLEN SCREWS HOLDING
THE CONTROL BOX ASSY TO THE BASE (FIG.
17)
5:2 REMOVE THE SINGLE SCREW RETAINING
THE CONTROL BOX TO THE BASE
MOULDING
5:3 REPLACE CONTROL BOX AND RE-ASSEMBLE
ALL COMPONENTS
2 ALLEN
SCREWS
RETAINING
CONTROL
BOX ASSY TO
BASE
SINGLE SCREW
RETAINING
CONTROL BOX
TO BASE
MOULDING
FIG. 17
FIG. 18
FIG. 19
PAGE No 12
8 TO REPLACE THE PRESSURE SWITCH
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
8:1 TO REMOVE THE PRESSURE SWITCH,
REMOVE THE NEGATIVE AND POSITIVE
PRESSURE TUBES FROM THE SWITCH -
NOTING THAT THE POSITIVE TUBE GOES TO
THE REAR INLET ON THE SWITCH (FIG. 20).
8:2 UNSCREW THE SINGLE SCREW AND
REMOVE THE SWITCH SO THAT THE COVER
CAN BE REMOVED.
8:3 REMOVE THE COVER, AND REMOVE THE
POWER LEADS - NOTING THAT BROWN
GOES TO COMMON AND BLUE TO
‘NORMALLY OPEN’ (NO ON SWITCH).
3:4 REPLACE ALL COMPONENTS - REVERSING
THE STRIP DOWN PROCEDURE.
9 TO REPLACE THE SOLENOID
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
9:1 UNPLUG THE 3 WAY SOCKET FROM THE
SOLENOID (FIG. 21).
9:2 REMOVE THE FUEL INLET CONNECTOR UNIT
9:3 REMOVE THE SOLENOID RETAINING CIRCLIP
9:4 SLIDE THE SOLENOID OFF THE FUEL INLET
9:5 REPLACE THE DEFECTIVE UNIT AND REFIT
ALL COMPONENTS, REVERSING THE STRIP
DOWN PROCEDURE
SERVICE MANUAL
POSITIVE
TUBE GOES TO
REAR INLET
NEGATIVETUBE
GOES TO
FRONT INLET
BROWN
TO
COMMON
REAR
INLET
FRONT
INLET
NEGATIVE
TUBE
BLUE
TO N.O.
FIG. 20
FIG. 21
PAGE No 13
FIG. 23
SERVICE MANUAL
10 TO REPLACE THE SOLENOID VALVE
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
10:1UNPLUG THE 3 WAY SOCKET FROM THE
SOLENOID (FIG. 22, 23)
10:2REMOVE THE FUEL INLET CONNECTOR UNIT
10:3REMOVE THE SOLENOID RETAINING CIRCLIP
10:4SLIDE THE SOLENOID OFF THE FUEL INLET
10:5UNFASTEN THE BURNER NOZZLE FUEL INLET
FROM THE SOLENOID VALVE USING A 10MM
AF OPEN ENDED SPANNER
10:6REMOVE THE SOLENOID VALVE USING A
12MM AF OPEN ENDED SPANNER
10:5REPLACE THE DEFECTIVE UNIT AND REFIT
ALL COMPONENTS, REVERSING THE STRIP
DOWN PROCEDURE
NOTE ON THE UNDERSIDE OF THE VALVE
THERE IS AN ARROW - THE VALVE MUST BE
FITTED WITH THIS POINTING TO THE
NOZZLE INJECTOR FUEL PIPE
FIG. 22
3 WAY
SOCKET
SOLENOID
CIRCLIP
VALVE
PAGE No 14
11 TO REPLACE THE FUEL PUMP
NOTE THIS IS A NON SERVICEABLE ITEM
AND MUST BE REPLACED AS A UNIT
FOLLOW STEPS FOR REMOVING THE
SOLENOID AND VALVE
11:1 TO REMOVE THE FUEL PUMP, UNSCREW THE
2 ALLEN SCREWS FASTENING THE PUMP TO
ITS MOUNTING BRACKET (FIG. 24).
2 ALLEN SCREWS
MOUNTING
BRACKET
FUEL PUMP
PRESSURE
TESTING ‘T’
SERVICE MANUAL
FIG. 24
FIG. 25
12 TO REPLACE THE FUEL FILTER.
NOTE:
THE HEATER CAN REMAIN IN ITS TRANSPORT
CRADLE FOR THIS OPERATION.
12:1REMOVE
BOTH REAR INNER AND OUTER
BOTTOM PANELS (FIG. 25).
12:2UNSCREW THE FILTER BOWL, REMOVE THE
FILTER, CLEAN THE BOWL IF DIRTY AND FIT A
NEW FILTER.
12:3 REFIT THE BOWL/FILTER ASSEMBLY, ENSURE
IT IS ADEQUATELY TIGHTENED TO AVOID
LEAKS, AND REPLACE BOTH BOTTOM
PANELS.
PAGE No 15
13 TO TEST FUEL PUMP PRESSURE
NOTE: FOR THIS OPERATION THE HEATER MUST
BE ON ITS CRADLE WITH THE FUEL LINES
CONNECTED.
13:1REMOVE BOTH REAR INNER AND OUTER
BOTTOM PANELS.
13:2UNSCREW AND REMOVE THE PRESSURE
TESTING POINT BLANKING PLUG (FIG. 26)
13:3CONNECT THE FUEL FEED PIPES
13:4SCREW
IN THE PRESSURE TESTING GAUGE
13:5TO ADJUST THE PRESSURE UNLOCK THE
LOCK NUT (A) AND ADJUST THE SCREW (B) IN
OR OUT TO ACHIEVE THE REQUIRED
PRESSURE. THE CORRECT PRESSURE 90
PSI.
13:6WHEN THE PRESSURE IS CORRECTLY SET
RE -FIT ALL COMPONENTS
ADJUSTING
SCREW (B)
LOCK NUT
(A)
PRESSURE
GAUGE
FIG. 26
BLANKING
PLUG
SERVICE MANUAL
BENSON HEATING LTD
LUDLOW ROAD
KNIGHTON
POWYS
LD7 1LP
TELEPHONE 01547 528534
FACIMILE 01547 520399
email information@bensonheating.co.uk
web www.bensonheating.com
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