Bentone BENTOFLEX ST 120 KA, Installation And Maintenance Instruction

Page 1: ...Providing sustainable energy solutions worldwide 178 150 15 1 2019 08 29 Installation and maintenance instruction BENTOFLEX ST 120 KA ...

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Page 3: ..._ 15 4 1 Example of basic settings _________________________ 15 5 Burner servicing ____________________________________ 18 5 1 Servicing _______________________________________ 18 5 2 Servicing the combustion device ___________________ 18 5 3 Replacing the oil pump ___________________________ 19 5 4 Replacing the fan motor and fan wheel ______________ 20 5 5 Servicing the air intake and intake con...

Page 4: ...relative humidity no condensation Temperature 20 to 60 C Check that the burner is compatible with the boiler s output range The label information on the rating plate refers to the burner s minimum and maximum power The power data on the type sign refers to the burner s min and max power All components must be installed without being bent twisted or subjected to mechanical or thermal forces which c...

Page 5: ...atch this must be equipped with a hatch opening switch connected to the burner s safety system When in operation the burner s noise level can exceed 85 dBA Use hearing protection The burner must not be put into operation without proper safety and protection devices A Class BE fire extinguisher is recommended It is forbidden to alter thedesign or use accessories which have not been approved by Ener...

Page 6: ...0h Change cleaning Brake plate 1 Year Change cleaning 3000h Change cleaning Motor 1 year 3000 hrs Cuppling chaft 1 year control change 3000h control change Fan wheel 1 Year Change when dirty unbalance 3000h Change when dirty unbalance The burner and its components must be recycled according to applicable regulations Burner servicing schedule Servicing must be carried out once a year or after 3000 ...

Page 7: ...l B10 heating oil biofuel blend as defined in DIN V51603 6 and is used for Water heating generators Hot air generators these require LMO 24 255 C2E 2 1 Dimensions ST 120 Min recommended distance to floor Ø B C D E F G H I ST120 89 194 169 54 229 148 275 200 C A øB D F E G H ...

Page 8: ... 5 Flange 1 d1 d 2 d 3 Combustion device d1 d2 d3 ST 120 KA ø 90 M10 ø 125 150 2 3 Burner installation 2 3 1 Hole patten Make sure the hole pattern on the boiler is designed for burner flange Length of blast tube Protrusion from flange measurement A Flange 1 2 94 76 60 147 129 113 ...

Page 9: ...g h 24 66 kW mbar Type Motor Complete burner Sound ST 120 KA 90W 0 75A 230V 50 60Hz 4µF 230V 0 8A 50Hz 70 dBA 0 5 dBA 2 5 1 Electric Specification Burner correspond to IP 20 a b c NB It is important that the spark does not strike against the brake plate or nozzle 0 3 0 0 0 3 0 6 0 9 1 2 1 5 1 8 20 0 30 0 40 0 50 0 60 0 70 0 kW ...

Page 10: ...30 39 3 42 40 0 85 2 83 33 3 00 36 3 16 37 3 32 39 3 47 41 3 61 43 3 74 44 3 87 46 1 00 3 33 39 3 53 42 3 72 44 3 90 46 4 08 48 4 24 50 4 40 52 4 56 54 1 10 3 66 43 3 88 46 4 09 48 4 29 51 4 48 53 4 67 55 4 84 57 5 01 59 1 20 3 99 47 4 24 50 4 47 53 4 68 55 4 89 58 5 09 60 5 29 63 5 47 65 1 25 4 16 49 4 40 52 4 65 55 4 88 58 5 10 60 5 30 63 5 51 65 5 70 68 1 35 4 49 53 4 76 56 5 02 59 5 27 62 5 50...

Page 11: ...ition cables 5 Nozzle assembly 6 Nozzle 7 Brake plate 8 Blast tube 9 Ignition electrodes 10 Connecting pipe 11 Air damper 12 Solenoid valve 13 Pump 14 Drive coupling 15 Indication air damper 16 Fan wheel 17 Adjustment air damper 18 Photoresistor 19 Motor 2 8 Description ...

Page 12: ...not pinched or otherwise damaged during installation or servicing 3 1 1 Installation and Maintenance Manual The maintenance instructions supplied with the burner must be kept at an easily accessible location in the boiler room 3 1 2 Instructions The user must be comprehensively instructed in the operation of the oil burner and entire system It is the responsibility of the supplier to instruct the ...

Page 13: ...jected to tensile stresses or become excessively bent when the burner is swung out or removed for servicing The oil filter should be installed so that the filter cartridge can easily be replaced or cleaned Parts in contact with oil must be selected in materials that are capable of withstanding the medium s physical properties When installing oil hoses check that the inlet and return hoses are fitt...

Page 14: ... of the oil filter 3 For single pipe systems the return plug must be removed refer to Pump instructions 4 When installing oil hoses check that the supply and return hoses are fitted to the appropriate connection on the oil pump The hoses must be located so that they do not bend or become subject to tensile load 5 Bleed the oil system Dry running will damage the oil pump 6 The vacuum in the suction...

Page 15: ...9 16 ST 120 RV 69 16 Burner output 30 kW Output calculation due to preheater for nozzle choice according to the table refer to Technical data Estimated nozzle output 30 x 1 06 31 8 kW 31 8 11 86 2 68 kg h Choice of nozzle according to the table refer to Technical data According to the nozzle table this results in the following nozzle Nozzle 0 75 GPH Pump pressure 9 5 bar 1 1 1 Basic settings The s...

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Page 17: ...e position affects airflow Therefore it is always necessary to fine tune airflow using the burner s airflow regulator 4 1 3 Air intake adjustment Setting the air intake is very important to achieve good combustion with neither too much nor too little air To adjust the combustion airflow turn the airflow regulator lever using an Allen key The extent to which the airflow lever must be open is determ...

Page 18: ...h off mains power and disconnect the Europlug from the burner 2 Remove the burner from the boiler by loosening the screw A 3 Loosen the housing screw B and remove the front cover C 4 Visually inspect the combustion assembly and check the various components for defects 5 Loosen and pull off the brake plate package from the oil pipe Clean the brake plate as necessary 6 Unscrew the nozzle 7 Fit the n...

Page 19: ...e pump 5 Disconnect the solenoid valve cable from the pump 6 Disconnect the connection tube D from the pump 7 Loosen the screws E and pull out the oil pump 8 Install the new oil pump on the burner Tighten the screws and fit the connection tube D It is important that the pump shaft splines align correctly in the pump coupling 9 Fit the front cover and insert the burner into the boiler 10 Fit the oi...

Page 20: ...heel 9 Fit the fan wheel to the motor tighten the locking screw The fan wheel must be fitted with a little play between the motor and the fan wheel Make sure that there are no scratching noises Refit the end of the drive coupling 10 Align the motor flange with the fan housing Make sure the drive coupling has not fallen out and that it is correctly inserted in the end of the drive coupling on the m...

Page 21: ...Switch on mains power start the burner and check the combustion 5 6 Replacing the entire electrical package 1 Switch off mains power and disconnect the Europlug from the burner 2 Remove the burner from the boiler by loosening the screw A 3 Remove the cover 4 Disconnect the electrical connector to the motor 5 Disconnect the electrical connector to the transformer 6 Disconnect the electrical connect...

Page 22: ...Remove the burner control and loosen the two bottom screws in the relay socket 4 The Europlug plate is firmly attached under the relay socket 5 Remove the cable of the component to be replaced 6 Connect the new cable 7 Refit the electrical package do not forget the Europlug 8 Turn on the burner control 9 Connect the Europlug and turn on the mains power 10 Start the burner and check the combustion ...

Page 23: ...ange 1 3 12 0 mm2 s Pressure range 7 15 bar Rated voltage of coil 220 240V 50 60 Hz Oil temperature max 60 C Components 1 Nozzle port G1 8 2 Pressure gauge port 3 Pressure adjustment 4mm allen key 4 Cartridge filter 5 Vacuum gauge port G1 8 6 Return line G 7 Suction line G 8 Return plug ...

Page 24: ...2 00 4 00 6 00 9 50 H m 4 4 4 4 4 6 4 6 4 6 8 4 6 8 4 6 8 10 A2L pumps sum up the 2 nozzles A2L Pumpen Summe der zwei Düsen pompeA2L sommedes2gicleurs PerlepompeA2Laggiungeren 2ugelli Two pipe system 0 2 15 50 124 0 5 2 16 56 138 1 2 18 61 150 2 3 22 73 150 3 4 26 85 150 4 4 30 97 150 11 38 96 150 7 27 71 150 20 54 116 150 16 46 100 150 12 42 107 150 8 31 79 150 23 61 130 150 19 52 112 150 13 47 1...

Page 25: ... line The valve P1 functions in the following way When the opening pressure has been reached the passage to the return side opens The diaphragm and the spring keep the pump pressure constant at set value If the pump is overloaded i e if you try to get out more oil than the gear set can supply under existing circum stances the oil pressure falls below the set value and the valve closes against the ...

Page 26: ...r plug in the cover by means of a 4 mm allen key and withdraw the cartridge filter If necessary put a screwdriver between the cartridge filter and the plug and turn the cartridge filter carefully until it comes off Reject the cartridge filter and replace it by a new one Press it on to the plug Ensure that the O ring is not damaged Then fit the new cartridge filter to the pump ...

Page 27: ...onnection and fuses in accordance with local regulations If there is no plug in contact X2 on the boiler connect to the contact enclosed In case the twin thermostat is in series on incoming phase L1 a loop between the terminals T1 and T2 is necessary µA DC Blå Svart LMO QRB 11 12 Blue Blau Bleue Black Schwarz Noir A1 ...

Page 28: ...for some reasons the flame disappears after this time limit the burner will make an attempt to re start 4 Full load thermostat ON 1 The ignition spark goes out 15 s after flame indication LOA24 171 2 The ignition spark goes out 2 s after flame indication when the ignition transformer is connected to terminal 7 LOA24 173 The burner is in operating position and can now change between high and low ca...

Page 29: ...ent light Check high voltage wiring and ignition electrodes Check preheater function Symptom Burner does not start Burner pre ventilates Burner stops Causes Fuse blown Boiler thermostat has not reset Preheater does not get up to temperature Overheating protection has deployed Defective preheater Defective oil burner control or flame monitor No oil supply Too great a pressure drop at brake plate To...

Page 30: ...ught Adjust the burner Check preheater function Adjust the preheater s set operating temperature Ensure that the new oil s physical parame ters are within the limits for which the burner is designed If not change the oil Indications The burner pump emits noise during start The burner pump emits noise during operation 8 4 Noise in pump Causes Insufficient negative pressure on the suction side pump ...

Page 31: ... Address Test performed by Postal address Company name Tel no Boiler Type Make Power kW Bentone Burner Type Model Serial no Fuel Step 1 Step 2 Step 3 Draught in fireplace Fan Press mbar Filter smoke number CO2 O2 NOx CO Flue gas temp C Setting brake disc Setting Air damper Pump pressure bar Nozzle ...

Page 32: ...mperature If the burner will not start Press the reset button on the relay Check that the thermostats are correctly adjusted Don t forget the room thermostat check that any fusesare intact and main switch is on If the burner starts but does not ignite Make an attempt to start the burner Never make close repeated start attempts Don t restart the burner until the boiler is free from oil gases If the...

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