BENSON HEATING MH200 User guide

BENSON
MH200
( OIL FIRED MARQUEE HEATER )
I N S T A L L A T I O N C O M M I S S I O N I N G
S E R V I C I N G
U S E R I N S T R U C T I O N S

Section Contents Page No
1.0 Compliance Notices 4
1.1 Certificates of Conformity 5
1.2 General product Information 5
1.3 General Requirements 5
1.4 Delivery & Pre-installation Checks 6
1.5 Warranty 6
2.0 Location & Positioning 7
2.1 Fuel supply-general 7
2.2 Fuel 7
2.3 Fuel Storage 8
2.4 Single pipe system 8
2.5 Two pipe system 8
2.6 Pipe work & Fittings 8
2.7 Oil installation and Connection 8
2.8 Electrical Supply 9
2.9 Air Supply 9
2.10 Air Distribution 9
2.11 Flue System 10
3.0 Installation 11
3.1 Heater Siting 11
3.2 Electrical installation & Connection 11
3.3 Air Distribution 11
3.4 Heater Control Installation 12
4.0 Commissioning 12
4.1 Pre test 12
4.2 Ignition 13
4.3 Air Delivery System 14
4.4 Hand Over 15
5.0 Servicing 15
5.1 Planned Servicing 16
5.2 Servicing Procedure 16
6.0 Fault diagnosis by flow chart 19
7.0 Wiring Diagrams 20
8.0 Technical data 23
9.0 Reference Documents 25

1.0 Compliance notices
The Benson MH 200 oil fired Heater detailed
herewith is manufactured by Benson Heating
within a strictly controlled quality environment
within the parameters of ISO 9001.
The Benson MH 200 has been tested and
assessed for compliance with 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 Benson MH 200
Heaters are safe and without risk when
properly used. These heaters should therefore
only be used in the manner and purpose for
which they were intended, and in accordance
with the recommendations detailed herewith.
The heaters have been designed,
manufactured, assembled, inspected, and
tested, with safety and quality in mind, there
are certain basic precautions which the
installer and user should be aware of, and they
are strongly advised to read the appropriate
sections of the information pack accompanying
the heater, prior to installation or use.
Benson Heating supports all new products
being supplied to their customers with a
comprehensive information pack; this clearly
defines mandatory instructions for the safe
installation, use, and maintenance, of the
appliance(s).
Where proprietary items are incorporated into
Benson Heating 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 Heating to ensure that they are
familiar with the appropriate information/
manuals, supplied by the manufacturer, and
that they are suitably aware of the purpose of
the manuals and the safety instructions. In
addition, operators must be suitably trained in
the use of the appliance so as to ensure its
continued safe and efficient use.
Benson Heating has a commitment to
continuous improvement, and therefore
reserves the right to amend or change the
specification of the MH 200 Heater subject to
compliance with the appropriate European,
national, and local regulations.
Contained within the text of the manual, the
words 'Caution' and 'Warning' are used to
highlight 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 Benson MH 200 Oil fired heaters conform
to the following harmonized standards;
BS EN 292 - Part 1 : 1991
Safety of Machinery - Basic Concepts, General
Principles for Design Basic terminology,
methodology
BS EN 292 - Part 2 : 1991
Safety of Machinery - Basic Concepts, General
Principles 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, electrical
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 Heating.
1.2 General product information
The Benson MH 200 model has an output
range of 200kW.
The MH 200 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
Benson 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.
1.3 General requirements
Caution
Ensure that the fuel supply is in accordance
with the manufacturer's recommendations and
is as stated on the appliance data plate.
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.
Caution
The heater must not be installed where high
wind velocities may affect burner operation.
Suitable protection should be provided for the
appliance when it is located in a position where
it may be susceptible to external mechanical
damage from; for example, fork lift trucks,

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
If any of these points are not satisfied then
contact should be made with the Sales Office
at Benson Heating as soon as possible by
telephoning 01547-528534. 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 Heating '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 Heating
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
within 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
Faulty parts must be returned to the Knighton
Spares Department, the address of which is
provided on the rear cover of this manual. 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).
2.0 Location/positioning
Warning
All of the basic criteria must be satisfied prior
to commencing installation and
commissioning, additionally, the Heater must
be positioned and installed so as to comply
with all the relevant standards and guide lines
(see section 9.0), as well as meeting national
and local fire regulations and insurance
criteria, especially if it is proposed that the
heater is to be installed within a special risk
area (e.g. proximity to where petrol engined
vehicles are stored or parked, where cellulose
spraying takes place, where woodworking
machinery is operated, etc,).
Indirect fired heaters must not be located in
hazardous areas, however, it is permissible for
the heater to supply air to such areas.
The 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.
The location must also allow for adequate
clearance for the air supply, return air
circulation, oil supply, electrical supply, whilst
also providing good and safe working access.
Any combustible material adjacent to the
heater or flue system must be so placed or
shielded so that its surface temperature does
not exceed 65oC.
Warning
TRANSPORTATION
The heater should be kept in a
HORIZONTAL position at all times when
being transported by fork lift truck or other
mechanical devices
2.1 Fuel supply - general
The Benson MH 200 of oil fired heater 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.
All pipe work must be constructed and
installed so that it does not permit the ingress
of air.
The construction, size, and position of the oil
storage tank must take account of the current
regulations, as well as suiting the requirements
of the installation.
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.
2.2 Fuel
In order to promote trouble free operating it is
necessary that the oil within the storage tank
and oil line does not fall below the cold filter
plugging point (cfpp), in this country and with
class D fuel (also referred to as gas oil). The
critical temperature is -4oC for this summer
grade.
The cfpp critical temperature for the winter
grade is -12oC.
If summer grade fuel is stored for winter use in
areas prone to severe frosts and low
temperatures it will be necessary to insulate or
even heat the supply tank and pipe work.
Warning
The pump pressure must not exceed a
maximum of 0.4 bar, this is because beyond
this point gas is liberated from the oil.

2.3 Storage tank
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 installations 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.
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 100mm above the bottom of the
tank.
A none return valve with a metal to metal seat
should be fitted, especially if the return pipe
work is terminated at a level above the draw
off tube.
The non 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 Pipe work and fittings
Caution
Galvanised pipe work and fittings must not be
used.
All joints must be sealed properly, if necessary
using PTFE tape or other approved sealing
media.
The pipe work must be effectively sealed so
as to prevent the ingress of air.
It is advisable to check all pipe work 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.
2.7 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.
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 IEE
regulations.
The means of connection to the main electrical
supply must allow for complete electrical
isolation of the heater, furthermore, in the case
of a unit wired for a three phase supply, the
supply should only be used to serve the heater
itself and no other plant or equipment.
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 Benson 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.
Caution
Additionally, an automatic control interlocked
to the burner must be fitted to ensure burner
shutdown in the event of airflow failure or
restriction.
2.10 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% re-circulated air to 15% fresh air.

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 through which
the ductwork 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.
2.11 Flue system
Warning
Each heater must have its own separate flue,
with a flue diameter of not less than is detailed
in section 8 within this manual.
The minimum vertical length of flue must not
be less than 1m.
The flue should rise vertically, and the number
of bends should be kept to a minimum.
It is strongly advised that BS 5854; 1980, and
BS 5440; parts 1 and 2, are used as
consultative documents when considering flue
requirements.
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.
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 65oC.
The position of the flue and its terminal should
be such that it does not impair the combustion
process.
It should terminate in an exposed position so
as to allow the escape and dissipation of flue
gases without risk of their re-entering the
property through windows, ventilation ports,
etc.
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 with
a diameter of 200mm or less.
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.
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.
3.0 Installation
3.1 Flue Installation
An integral flue spigot is fitted to all Cabinet
Heaters thereby allowing the flue to connect
directly to the heater.
The design of the flue must ensure that it can
be disconnected to allow for cleaning and
servicing, furthermore, all of the flue section
joint sockets must face upwards, and the seal
between the sections achieved through
mechanical joints or through the use of
approved caulking string and grout. It is
strongly advised that BS 5854 and BS 5440
parts 1 and 2 are referred to.
Warning
Always ensure that the appropriate
personal protective equipment is used.
3.2 Heater Siting
The heater must be installed on a level surface
capable of supporting the weight of the heater
and any ancillary equipment.
3.3 Electrical Installation/
connection
Benson MH 200 cabinet heaters are
415V 50Hz 3PH NEUTRAL & EARTH
It is recommended that reference is made to
the wiring diagrams contained within section 7
of this manual prior to installation or
connection to the supply.
The electrical supply must be as specified and
suitable for the heater, and must be run within
conduit to a point adjacent to the heater, and
be terminated to provide an isolation point that
will prevent remote or inadvertent activation.
Cables, conduit, and fittings that are used to
make the connection between the isolator and
the heater must conform to the appropriate IEE
regulations. All heaters are supplied fused and
pre-wired, all must be earthed.
Final connections for any additional external
controls must be completed on site, and must
be carried out according to IEE regulations.
Separate user information is provided for the
time control unit and the burner, and forms part
of the product information pack which
accompanies every heater when dispatched.
Warning
Always isolate from mains electrical supply
before commencing work on the heater.
Always ensure that the appropriate personal
protective equipment is used.
3.4 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 airtight and
fastened securely and designed to remain so,
even when operating at high temperatures.
Adequate support must be designed into the
layout of the ductwork to ensure that the
integrity of the seams and joints is maintained.
The support must be independent and

separate from the heater and the ducting, to
allow for free movement during expansion and
contraction.
Where ducting passes through walls or
partitions sufficient clearance must be left,
irrespective of any fire stop requirement, to
allow for expansion and contraction.
Failure to adhere to these latter two points can
result in the generation and transmission of
excess noise.
Where ducting is installed in concrete flooring
a permanent membrane must be used to
isolate the ducting from the corrosive effect of
the alkaline salts within the concrete.
Care should be taken to ensure that soft
insulation material does not become
compressed and thereby lose its effectiveness.
3.5Heater Control Installation
Warning
Isolate heater from mains before undertaking
any electrical work.
(a) On/off switch
(b) Ventilation/heat switch (summer/winter
switch)
(c) Manual/automatic switch
(d) Thermostat
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 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.
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 (if fitted).
(j) Check that there is provision for flue gas
sampling and that this sample point can be

plugged and sealed after commissioning.
(k) Check that fan and limit stat settings have
not been disturbed and are as follows
Fan on - 60oC
Overheat limit - 100oC
Fan off - 30oC
Also check that the white button (automatic) is
pulled outward and that the red button (reset)
is pushed inwards to the reset position.
(l) Ensure that the burner is securely attached
to the heater.
(m) Test for electrical earth continuity between
the heater, oil pipe work, and mains supply.
(n) Turn on main electrical supply, select the
following switch settings
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.
(o) Turn mains electrical supply to off, replace
and secure lower louvred panel covering fan
and motor
assembly.
(p) Set thermostat to 'demand' position.
4.2 Commissioning - 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
On/Off - off
Heat/Ventilation - heat
Manual/Automatic - automatic
(d) Turn on main electrical supply.
(e) Select 'on' position for heater on/off switch.
(f) Check for the following burner sequence
Interval Operand
1 <5s Combustion air damper actuated,
burner fan motor initiates purge
cycle...
2 <15s Solenoid valve opens ignition
transformer provides spark for
burner ignition...
E I T H E R --------
3 >15s Ignition failure caused by oil
starvation resulting in burner lock-
out/shut-down...
(g) Set heater on/off switch to off position
(h) Attach oil manifold (bleed screw and
pressure gauge)
(i) Open oil supply valves and bleed air from
pipe work and adjust burner oil pressure as per
detailed in burner manual Repeat steps 4.1 q,
and 4.2 c,e,f.
--------- O R ------------
4 >15s Burner ignition.flame detection...
5 <20s 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 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 thermostat to its highest setting,
and allow the heater to continue to fire.
(n) Gradually reduce the temperature setting
on the thermostat until the burner shuts down,
(@ < ambient and then gradually increase the
temperature setting on the thermostat until
heat is called for, (@ > ambient) and the
burner automatically re-fires.
(o) 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 down 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 60oC, fan off 30oC, limit
100oC.
(ii) Check that the position of the unit is
correct, ie, equi-distant between heat
exchanger body and heat shield panel.
(iii) Check integrity of unit, ensuring that
neither the bi-metallic strip nor its casing is
damaged.
(p) Undertake flue gas analysis using
approved and calibrated analysing equipment
recording data on the commissioning card, ie,
CO, CO2, net and gross flue temperatures.
Record burner oil pump pressure, ambient
temperature, barometric pressure, and smoke
reading (0 - 1 Baccarach scale).
Note (i)
The burner air and oil pressure settings should
be only very finely adjusted to achieve a CO2
reading of 12.5%
(+/- 0.5%).
Note (ii)
The gross efficiency must be approximately
80%.
Note (iii)
All 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 Heating Technical
Department.
(q) 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 Heating Service
Department immediately after the satisfactory
completion of commissioning, failure to do so
can invalidate any subsequent warranty claim.
(s) Set all controls to the requirements of the
user.
4.3 Commissioning - air delivery
system
Caution
On ducted applications it is necessary that the
system is balanced in order to optimise the

efficiency of the heater and the air distribution
and delivery system
Failure to balance the system can result in fan
motor overloading and premature component
failure, it can also result in an inefficient
heating/ventilation system.
(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 Heating 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.
Caution
Certain component parts are factory sealed
and are designed so as to be tamper proof.
Usually such items do not require servicing,
and therefore should not be tampered with.
Failure to comply with this can invalidate any
warranty, and can also lead to premature
failure.
The following parts fall within this category:
thermostat, , fan and motor.
Additionally, the fan and limit stat has been

factory set, and must not be re-set without
formal consent from the manufacturer.
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 photocell
(d) Check overheat safety is
operational
Bi-Annual Inspection
(a) As per quarterly inspection,
plus...
(b) Combustion check
(c) Smoke test
Annual Inspection
(a) As per half year inspection,
plus...
(b) Heat exchanger and cleaning
(c) Electrical connections
(d) Main fan motor
(e) Main fan assembly
(f) Pulleys
(g) Fan belts
(h) Oil supply including filter
(i) Burner
(j) Air delivery system
(k) Flue
(l) Report
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 flue 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 lubricated with the correct
grade of lubricant. Motors which do not have
grease nipples feature sealed bearings which
are lubricated during manufacture for their life.
The electrical connections should be checked
as follows.
The cover to the terminal box should be
removed by undoing the screws which secure
it.
Check connections for signs of corrosion,
tightness, and ensure that there are no stray
strands which could form a short circuit.
Clean, tighten, and replace as necessary.
Replace cover and secure.

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 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.
(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 alternate 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 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 the pulleys 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
cleaner be used to facilitate this.
Access to the heat exchanger is gained
through the removal of the Front 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.
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.
(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.
If the condition of the heat exchanger gives
cause for concern the Service Department
at Benson Heating should be advised
pending a more detailed examination.
Electrical Supply
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 pipe work, tank, and fittings
should all be inspected to ensure that they are
free from corrosion, and to ensure that where
brackets have been fitted these remain secure
and offer adequate support.
The oil filter should be replaced with a new
one, and the system should be checked for
leaks.
If the oil level is such to allow removal of any
sludge or other contaminants form 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 heater are covered in the separate manual
prepared by the burner manual.

Burner
fails to
Run
No Power
No
Demand
Check Isolator Check Fuses
Check
Controls
Burner Lockout
Fan / Limit
Thermostat
Room
Thermostat
Timer
Heat / Ventilate
Switch
On / Off Switch
Burner
starts
Ignition
sequence
but fails to
light and
Lockout
Occurs
Fuel Feed
Incorrect
Check that the
Oil Pressure is
correct
Check that Head
of Gravity is
Sufficient
Check that the
suction Lift is not
too great (two
pipe system)
Check that the
Bypass Plug is
Present
Fuel / Air
Problem
Check Burner
Air Setting
Bleed S
y
stem
Air in S
y
stem
Restricted Fuel
Feed
No Spark Check
Electrode
Possible Fuel
Contamination
Check Valves,
Fuel Feed, Filter
Nozzle for
Blockages or
Restrictions
Check Control
6.0 Fault Finding

Burner gives a
sparky flame
Too Much Air
Air / Fuel Mix
Ratio Incorrect
Fuel Feed
Restricted
Adjust Air
Damper
Check for Air in
Fuel Line
Check Fuel
Pressure
Check Nozzle
Check Filter
Check Fuel
Lines
Check Valves
Burner
gives a
smokey
flame
Poor
Combustion
Insufficient
Combustion Air
Inadequate Flue
Draught
Check Oil
Pressure
Check Air Damper
Check Nozzles
Check if Correctly
fitted
Check if Correct
size
Check if Damaged
or Worn
Check Flue