Bentone ST 120 KA
Bentone ST 120 KA
Bentone ST 120 KA
2 Bentone
General
Table of contents
1. General Information __________________________________ 4
2. Technical data _______________________________________ 7
2.1 Dimensions ST 120 _______________________________ 7
2.2 Dimensions, flanges _______________________________ 8
2.3 Burner installation _________________________________ 8
2.5 Working field ST 120KA ____________________________ 9
2.4 Setting of brake plate and air flow ___________________ 9
2.6 Recommended nozzles and pressures ______________ 10
2.7 Nozzle table, 8-15 bar ____________________________ 10
2.8 Description______________________________________ 11
3. General instructions _________________________________ 12
3.1 General instructions ______________________________ 12
3.2 Delivery inspection _______________________________ 13
3.3 Preparing for installation ___________________________ 13
3.4 Oil distribution ___________________________________ 13
3.5 Electrical connection______________________________ 13
3.6 Burner installation ________________________________ 14
4. Basic settings ______________________________________ 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 cone ______________ 21
5.6 Replacing the entire electrical package ______________ 21
5.7 Replacing individual electrical package components ___ 22
6. Instructions Pump __________________________________ 23
6.1 SUNTEC AS ____________________________________ 23
7. Oil burner control ___________________________________ 29
7.1 Wiring diagram _________________________________ 29
7.2 List of components _______________________________ 30
7.3 Colour codes LMO14/24 __________________________ 31
7.4 Fault codes LMO14/24 ___________________________ 31
8. Fault Location ______________________________________ 32
8.1 Burner will not start _______________________________ 32
8.2 Burner will not start after normal use ________________ 32
8.3 Delayed ignition __________________________________ 33
8.4 Noise in pump ___________________________________ 33
8.5 Pump pressure __________________________________ 33
9. Log of flue gas analysis ______________________________ 35
10. Oil burners maintenance instructions _______________ 36
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1. General Information
This Installation and Maintenance manual:
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• The electrical installation must be professionally carried out in
accordance with applicable high voltage regulations, as per Enertech’s
recommendations.
• Before servicing, shut off the fuel supply and turn off the power to the
burner.
• Leak checks must be performed during installation and servicing to
prevent fuel leakage.
• Care should be taken by the installer to ensure that no electrical cables
or fuel lines are crushed or otherwise damaged during installation or
servicing.
• If the boiler is equipped with an access hatch, 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 Enertech in writing.
• Prior to operation, the following points must be checked:
- fitting and installation work has been completed and approved
- electrical installation has been correctly performed
- flue gas ducts and combustion air ducts are not blocked
- all actuators and control and safety devices are in working order and
correctly set
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Burner servicing schedule
Servicing must be carried out once a year or after 3000 hours of operation
The burner and its components must be recycled according to applicable regulations.
Delivery check
• Make sure everything is delivered and the goods have not been
damaged during transit.
• If something is wrong with a delivery, report it to the supplier.
• Transport damage must be reported to the shipping company.
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2. Technical data
The burner is intended for:
• Light oil, B10 heating oil/biofuel blend (as defined in DIN V51603-6)
A
E
øB
F
D
G
C H
ØB C D E F G H *I
ST120 89 194 169 54 229 148 275 200
165 205 23
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2.2 Dimensions, flanges
Protrusion from flange,
Length of blast tube measurement A
Flange
1 2
94 76 60
147 129 113
Flange 1 Flange 2
5 ø89,7
ø90 25
,3
10
10,3
130-150
125-150
Combustion d1 d2 d3
device
d3
d1
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2.5 Working field ST 120KA
2,0-5,6 kg/h
24-66 kW
mbar
1,8
1,5
1,2
0,9
0,6
0,3
0,0
-0,3
20,0 30,0 40,0 50,0 60,0 70,0 kW
!
b c *NB It is important that
the spark does not strike
against the brake plate or
nozzle
a b c
ST 120 KA 8,0-9,0 2,7-3,3 0,5-1,5
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2.6 Recommended nozzles and pressures
Because of the different types of boiler in existence, with varying furnace
geometries and furnace loads, it is not possible to commit to any given spray
angle or spay pattern. Note that spray angles and spray patterns change
with pump pressures.
The table applies to oils with a viscosity of 4.4 mm2/s (cSt) at a density of 830 kg/m3.
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2.8 Description
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3. General instructions
3.1 General instructions
Oil burners must be installed in accordance with local regulations. The
installer must therefore be knowledgeable of the regulations pertaining to oil
and combustion.
Only oil suitable for the burner must be used and then in combination with a
suitable oil filter installed before the burner’s oil pump.
If the burner is replacing an existing burner, ensure that the oil filter is
replaced or cleaned. Installation may only be performed by qualified
personnel.
Care should be taken by the installer to ensure that electrical cables and oil
lines are not pinched or otherwise damaged during installation or servicing
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
user.
3.1.4 Start-up
In order to obtain the correct setting, a flue gas analysis and temperature
measurement must be carried out. Otherwise, there is a risk of soot build up,
poor efficiency or condensation in the chimney. The system must be fine-
tuned at start-up. The temperature in the chimney at a depth of 0.5 m must
be at least 60 °C to prevent condensation.
165 205 19
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3.2 Delivery inspection
Make sure everything is delivered and the goods have not been damaged
during transit. If something is wrong with a delivery, report it to the supplier.
Transport damage must be reported to the shipping company.
!
- Pipelines are to be laid with the fewest possible number of glands. The oil filter must
- The pipes are to be laid so that the oil supply hoses are not subjected be installed before
to tensile stresses or become excessively bent when the burner is the burner’s oil
swung out or removed for servicing. pump
- 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
Be sure to fill the
of withstanding the medium’s physical properties. burner oil system
- When installing oil hoses, check that the inlet and return hoses are
before starting it for
fitted to the appropriate connection on the oil pump. The hoses must the first time.
be located so that they do not bend or become subject to tensile
load.
- Bleed the oil system. The oil pump/oil preheater may be damaged if
run dry. The vacuum in the suction line should not fall below 0.3 bar
during start-up.
! If any electrical connection is used other than that recommended by Enertech, there may be a risk of
damage to property and personal injury.
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3.6 Burner installation
3.6.1 Hole pattern
Make sure the hole pattern on the burner corresponds to the supplied flange
(refer to Technical data).
X2
165 201 20
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4. Basic settings
4.1 Example of basic settings
4.1.1 Choice of nozzle
ST 120 R 69-16
Burner output 30 kW
Estimated nozzle output: 30 / 11.86* = 2.53 kg/h
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
165 205 21
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4.1.2 Insert control
The burner is equipped with a lever that changes the position of the brake
plate in the burner tube. This is used to set the correct pressure drop across
the combustion assembly, thereby obtaining good combustion without
pulsation.
The setting to be used depends on, among other things, the output settings
and overpressure in the boiler
Insert control
Air control
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5. Burner servicing
5.1 Servicing
Servicing must be carried out after 3,000 operating hours, but at least once
yearly. A
Only authorised personnel may perform service.
Before any type of servicing is carried out, shut of the power at the main
switch and turn off the oil.
Be careful: certain parts exposed after separation of the burner can be hotter
than 60 °C. Care should be taken by the installer to ensure that electrical
cables and oil lines are not pinched or otherwise damaged during installation
or servicing.
5.2 Servicing the combustion device
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. Loosen the housing screw (B) and remove the front cover (C).
B
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 nozzle. Do not clean the nozzle. If the nozzle is defective, it must
be cleaned.
8. Check the ignition electrodes. Replace as necessary (refer to Technical
data for electrode settings). C
9. Install the brake plate and electrode package (see Fig. 1.2). Check that
the distance between the nozzle and brake plate is correct (refer to
Technical data).
10. Fit the front cover and insert the burner into the boiler.
11. Connect the Europlug and turn on the mains power.
12. Start the burner and check the combustion.
1 2
B
! When servicing/replacing components that affect combustion, an analysis and soot test must
be carried out on the installation.
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5.3 Replacing the oil pump
1. Switch off mains power and disconnect the Europlug from the burner.
2. Undo the oil hoses from the pump.
3. Remove the burner from the boiler by loosening the screw (A)
4. Loosen the housing screw (B) and remove the front cover (C). This will
make it easier to install the 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 oil hoses (for conversion between single-pipe and double-pipe
systems, see Pump instructions).
11. Connect the Europlug and turn on the mains power.
12. Turn on the burner, air the pump, adjust the pressure, and check the
combustion.
! When servicing/replacing components that affect combustion, an analysis and soot test must
be carried out on the installation.
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5.4 Replacing the fan motor and fan
wheel
1. Switch off mains power and disconnect the Europlug from the burner. F
G
2. Remove the burner from the boiler by loosening the screw (A).
3. Loosen the housing screw (B) and remove the front cover (C). This will
make it easier to fit the motor and fan wheel.
4. Disconnect the electrical connector to the motor.
5. Loosen the spring (G) holding the transformer.
6. Loosen the screws (F) (x2) holding the motor flange.
7. Lift out the motor.
8. Remove the end of the drive coupling from the motor axle, loosen and
remove the fan wheel.
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. F
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 motor and
pump. Also ensure that no cables are pinched.
11. Re-assemble the motor and fan housing. Alternately tighten
the screws. This is done to ensure the fan housing and the
motor flange are aligned in the correct position.
12. Connect the motor cable.
13. Refit the spring (G) holding the transformer.
14. Assemble the fan housing and front cover and insert the burner into the
boiler.
15. Connect the Europlug and turn on the mains power.
16. Start the burner and check the combustion.
! When servicing/replacing components that affect combustion, an analysis and soot test must
be carried out on the installation.
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5.5 Servicing the air intake and intake
cone
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. Loosen the housing screw (B) and remove the front cover (C). Air intake
Oil pipe
4. Loosen the motor and oil pipes.
5. Remove the air intake.
6. Check the functionality and appearance of the various components in
the air regulator. Clean and replace components as necessary.
7. Assemble the burner. Make sure to refit in the same position as before
disassembly.
8. Insert the burner into the boiler and connect the Europlug.
9. Switch on mains power, start the burner and check the combustion.
Motor
! When servicing/replacing components that affect combustion, an analysis and soot test must
be carried out on the installation.
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5.7 Replacing individual electrical
package components
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 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.
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6. Instructions Pump
6.1 SUNTEC AS
Components
1. Suction line G 1/4”
2. Return line G 1/4”and internal by-
3.
pass plug
Nozzle outlet G 1/8”
4. Pressure gauge port G 1/8”
5.
6.
Vacuum gauge port G 1/8”
Pressure adjustment
165 105 20
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Applications for SUNTEC AS47C pressure and return sides of the valve is open. No
The SUNTEC AS oil pump has a built in solenoid valve pressure will then be built up to open the valve; it does
which controls the regulator cut-off valve giving fast not matter which speed the gear set has.
cut-off and cut-on function independent of the rotational
When the solenoid is activated, this by-pass channel is
speed.
closed and because of the full speed of the gear set, the
pressure necessary to open the valve will be built up very
Applications rapidly, which gives a very sharp cut-on function.
Light oil, B10 heating oil/biofuel blend (as defined in DIN
V51603-6) and kerosene. Cut-off
- One or two-pipe system.
When the burner stops, the solenoid opens the by-pass
at the same moment, which drains all the oil down to the
Pump operating principle return, and the nozzle valve closes immediately.
The gear set draws oil from the tank through the built-
in filter and transfers it to the valve that regulates the This gives a very sharp cut-off function. The cut-on and
oil pressure to the nozzle line. All oil that does not go cut-off can be actuated regardless of motor speed and
through the nozzle line will be dumped through the valve have an extremely fast response.
back to the return line in two pipe installation or, if it is a
When the solenoid is not activated, the torque
one-pipe installation, back to suction port in the gear set.
requirement is low up to full motor speed.
In that case, the by-pass plug must be removed from the
return port, and the return port sealed by steel plug and
washer.
Solenoid valve
Solenoid valve Solenoidvalve
Solenoid
(NO) (NO)
open
open
valve closed
closed
Pressure
Pressure
adjustment To
To nozzle
nozzle
adjustment
Shaft seal
Shaft seal Pressure
Pressure
gauge port
gauge ports
Back to
Back Gear-set
suction Gear set
to suction Vacuum gauge
port Oil
Oil under suction
under suction
Vacuum
By-pass
By-pass By-pass gauge port Oil
Oil under pressure
under pressure
By-pass
plug
plug plug plug By-passed
By-passed oiloil
removed inserted returned to tank,
removed inserted returned to tank,
or to suction
ReturnReturn
pluggedONE PIPE TWO PIPE
or to suction
plugged INSTALLATION INSTALLATION Return
Return Inlet
Inlet
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6.1.1 Suction line tables
6.1.1.1 Overlying tank
1-pipe system
pe Nozzle*/Düse*
One pipe siphon feed system
Gicleur*/Ugello* 0,50 0,60 0,80 1,00 1,50 2,00 4,00 6,00 9,50 Einstranginstallation - Tank höher als Pumpe
(US GPH) Installation monotube en charge
Impianti monotubo a sifone
d (mm) 4 4 4 4 4 6 4 6 4 6 8 4 6 8 4 6 8 10
H (m)
4 172 144 108 86 57 150 43 218 21 109 150 14 72 150 8 45 144 150
*A2L pumps : sum up the 2 nozzles / A2L-Pumpen : Summe der zwei Düsen
pompe A2L : somme des 2 gicleurs / Per le pompe A2L aggiungere n.2 ugelli
Two-pipe system
Two pipe siphon feed system
Pump/Pumpe Zweistranginstallation - Tank höher als Pumpe
e 35/45 55 65 75 95
Pompe/Pompa Installation bitube en charge
Impianti bitubo a sifone
Q** (l/h) 60 77 102 130 150
H (m) d (mm) 4 6 8 10 6 8 10 12 6 8 10 12 8 10 12 14 8 10 12 14
d
**Q = pump capacity @ 0 bar / Pumpenleistung bei 0 bar Two pipe lift system
capacité de l'engrenage à 0 bar/portata della pompa a 0 bar.
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6.1.1.2 Underlying tank
1-pipe system
With an underlying tank a 1-pipe-system is not recommended
Two-pipe system
Pump/Pumpe
e Pompe/Pompa 35/45 55 65 75 95
Q** (l/h) 60 77 102 130 150
3 3 14 37 79 10 28 60 6 20 44 4 14 33 65 11 28 55
4 8 19 5 14 9 6 14 4 11 H
d
H max. = 4,5 m
The suction line tables consist of theoretically calculated values where the
pipe dimensions and oil velocity have been matched so that tur-bulences will
not occur. Such tur-bulences will result in increased pressure losses and in
acoustic noise in the pipe system. In addition to drawn copper piping a pipe
system usually comprises 4 elbows, a non-return valve, a cut-off valve and
an external oil filter.
The tables apply to a standard fuel oil of normal commercial quality accor-
ding to current standards. On commis- sioning with an empty tube system
the oil pump should not be run without oil for more than 5 min. (a condition is
that the pump is being lubricated during operation).
The tables state the total suction line length in metres at a nozzle capacity of
9,5 Gph. Max. permissible pressure at the suction and pressure side is 2,0
bar.
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6.1.3 Check oil line seals
Once the burner has been installed and commissioned, the seals of the
various coupling elements should be checked (A).
!
When servicing oil bearing components, check for
oil leakage when the burner is commissioned after
servicing.
Filter
Gasket
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6.1.4 Replacing the solenoid valve (pump)
Removal and installation
Components
11
1. Pressure regulator
2. Shaft seal kit (lip seal + protective cone)
3. By-pass plug
4. G 1/4 gasket
5. G 1/4 steel plug (1-pipe system)
6. Filter 2
7. Cover gasket
8. Cover
9. Pressure gauge port or vacuum
gauge port screw, O-ring
10. Coil 3 6
4 7
11. Tube assy 1 5
9
8
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7. Oil burner control
7.1 Wiring diagram
LMO
A1 12 11
Bleue
Blau
µA DC
Blue
+ Svart
-Blå
QRB
Outer electrical connection
X1
X2
165 105 21
Bentone 29
7.2 List of components
A1 Oil burner control S3 Main switch
A2 Twin thermostat T1 Ignition transformer
F1 Fuse, max. 10A Y1 Solenoid valve
H1 Alarm lamp X1 Plug-in contact, burner
H2 Signal lamp (optional) X2 Plug-in contact, boiler
M1 Burner motor
P1 Time meter (optional)
R1 Flame detector
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7.3 Colour codes LMO14/24
When the burner starts, three signal lights in the reset switch indicate the
normal sequence, as well as provide indication if something abnormal is
happening in accordance with the following table:
* In order for this fault code to occur, the preheater shall not reach its
cut-off temperature within 10 mins. from switch on.
To return to normal operation: Press the reset button for 1 second.
If the reset button is instead kept pressed a second time for at least 3
seconds, you can, via an interface, obtain the corresponding information on
a computer or flue gas analyser.
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8. Fault Location
8.1 Burner will not start
Symptom Causes Remedies
Motor starts Unstable flame
Burner pre-ventilates Excess air Adjust the damper
Low oil pressure Check the oil pressure
Flame formed Check the nozzle in relation to the
Burner trips Incorrect combustion apparatus settings combustion apparatus dimensions and the
ignition electrode position
Check the flame monitor is clean and can
Motor starts Flame monitor does not register light register light
Burner pre-ventilates Defective flame monitor Check with using new photocell
No flame formed Defective oil burner control Check using new oil burner control (Note:
replacement of photocell recommended if oil
Burner trips
burner control replaced)
Check the oil supply to the burner and that
No oil there are no air bubbles in the pump
False light Check function of solenoid
Check flame monitor does not register
ambient light
No spark
Check high voltage wiring and ignition
electrodes
Burner pre-ventilates Overheating protection has deployed Reset the overheating protection.
Investigate the cause of its deploying.
Defective preheater Remedy fault
Defective oil burner control or Check by replacing with new
flame monitor
Check that tank, oil lines, solenoid valves,
Burner stops No oil supply pump and nozzle are in good condition
Too great a pressure drop at brake plate Adjust the burner
Too strong draught prevents flame forming Correct the boiler draught
No spark Check the ignition transformer. Check the
ignition electrode settings and ceramics
165 105 09
32 Bentone
8.3 Delayed ignition
Replace
Pump coupling loose or worn
Check the ignition electrode setting,
Preheater blocked (see technical data)
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171 905 28
9. Log of flue gas analysis
Owner Adresss Tel. no:
Boiler
Type Make Power kW
Bentone Burner
Type Model Serial no. Fuel
Draught in fireplace
CO2
O2
NOx
CO
Nozzle
165 105 66
10. Oil burners maintenance instructions
General information If the burner starts but does not ignite
Keep the boiler room clean. Ensure that the boiler Make an attempt to start the burner.
room has permanent fresh air intake. Switch off before Never make close repeated start attempts.
dismantling the oil burner. Don´t restart the burner until the boiler is free from oil
At hinged mounting, make sure that an automatic safety gases.
switch is fitted, so that the burner cannot start when If the burner still does not ignite send for the service
theswing door is open. engineer.
Don´t use the oil fired boiler to burn paper or
When switching off during summer
rubbish,unless the boiler is especially fitted with a hinged
door tomake this possible. Always use the main switch to cut out the burner even
Don´t fill tank while burner is working. when adjusting the burner or cutting off the heating for
ashort time. For longer periods of shut down, close all
Starting precautions
valves and the oil supply stop-cock.
Make sure that the oil tank is not empty Clean the filter and nozzle by washing in petrol or
Make sure that the valves on oil and water supply pipes paraffin.
areopen. Make sure the filter medium is not damaged or defective.
Make sure that the boiler flue damper is open. Protect electrical gear from damp.
Make sure that the boiler thermostat is set at the correct
Warning
temperature.
Switch on the current. Most relay systems have a Never stand too near or put your face to the inspection
delayed action so that the burner will not start for or fire door, when the burner is about to start.
perhaps 20 seconds. Never use a naked flame to ignite oil if the electrical
With heavy oil the delay will be longer as the burner ignition fails.
will notstart until the oil in the preheater reaches the Always wait for about 10 minutes for the unburnt gases
requiredtemperature. to disperse before restarting the oil burner if it has failed
to ignite previously.
If the burner will not start
Installed by:
Tel:
Enertech AB. P.O Box 309, SE-341 26 Ljungby.
www.bentone.se, www.bentone.com