Benson ECA Gas Cabinet Heater Installation Commissioning Servicing User Instructions

BENSON ECA
CABINET
HEATER
(GAS F I R E D)
INSTALLATI ON COMMISSI ONING
SERVICING
USER INSTRUCTIONS
November 2005
Issue 1
PART NO 20-45-363
1
~ CONTENTS ~
SECTION 1
1.0 Compliance Notices
1.1 Certificates of Conformity
1.2 General Product Information
1.3 General Requirements
1.4 Delivery & Pre-installation Checks
1.5 Warranty
4
5
5
5
6
6
2.0 Location & Positioning
2.1 Gas Supply
2.2 Electrical Supply
2.3 Air Supply
2.4 Minimum Space Requirements
2.5 Air Distribution System
2.6 Flue System
7
9
9
9
10
10
11
3.0 Installation
3.1 Packaging & Siting
3.2 Flooring
3.3 Minimum Clearances
3.4 Assembly
3.5 Flue Installation
3.6 Gas Installation and Connection
3.7 Electrical Installation & Connection
3.8 Air Distribution Installation
3.9 Warm Air Registers
3.10 Heater Control Installation
15
15
15
15
15
15
16
16
16
16
17
4.0 Commissioning
4.1 Pre-Test
4.2 Ignition
4.3 Air Delivery System
4.4 Hand Over
17
17
18
20
20
5.0 Servicing
5.1 Planned Servicing
5.2 Servicing Procedure - Major Component Parts
5.3 Servicing - Re-commissioning
6.0 Fault Diagnosis By Flow Charts
7.0 Wiring Diagrams by Model and Burner Type
8.0 Technical Data Net Efficiency Calculations
8.1 Benson Cabinet Range Data
21
21
21
24
25
27
33
34
9.0 Reference Documents Standards, Codes of Practice
9.1 Parts Listing
37
38
2
SECTION 2
10.0 Introduction
10.1 Commissioning/hand over
10.2 Servicing
10.3 Start up procedure
10.4 Stop procedure
10.5 Shutdown procedure
10.6 Ventilation only
10.7 Lockout situations
10.8 Contact Information
ILLUSTRATIONS
Page No
8
12-14
22
25
27
Exploded view
Flue Systems
Fan and Motor Configurations
Fault Diagnosis Flow Charts
Wiring Diagrams
Any reference made to Laws, Standards, Directives , Codes of Practice or other recommendations governing the application and installation of heating appliances and which may be
referred to in Brochures, Specifications, Quotations, and Installation, Operation and Maintenance manuals is done so for information and guidance purposes only and should only be
considered valid at the time of the publication. Benson Heating cannot be held responsible
from any matters arising from the revision to or introduction of new Laws, Standards, Directives, Codes of Practice or other recommendations.
3
1.0 Compliance notices
The Benson Gas fired Cabinet Heaters
detailed herewith are manufactured by
Benson Heating Within a strictly controlled
quality environment within the parameters of
ISO 9001.
These instructions are only valid if the
following country code is on the appliance
GB. IE. If this code is not present on the
appliance, it is necessary to refer to the
technical instructions which will provide the
necessary information concerning the
modification of then appliance to the
conditions of use for the country.
The Benson range has been tested and
assessed for compliance with the following
European Directives.
Gas Appliance Directive (90/396/ EEC)
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC)
& (93/68/EEC)
Electromagnetic Compatibility Directive
(89/336/EEC & 91/31/EEC)
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 Cabinet Heater range
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.
Product Liability Directive (65/374/EEC)
The manufacturer has taken reasonable and
practical steps to ensure that Benson
Cabinet 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).
4
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.
NOTE
THE WARRANTY REGISTRATION CARD
SUPPLIED WITH THE HEATER MUST BE
COMPLETED AND RETURNED IN THE
PRE–PAID ENVELOPE TO BENSON
HEATING ON COMPLETION OF
COMMISSIONING
Warranty claims made without this
condition being fulfilled will not be
processed
The Benson range of Gas fired Cabinet
Heaters conform to the following harmonised
standards;
BS EN 1020 Requirements for non
domestic gas fired forced convection air
heaters for space heating incorporating a fan
to assist transportation of combustion air
and/or combustion products.
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
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 despatch. 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
BS EN 60335 - Part 1 : 1988
Safety of Household and Similar Electrical
Appliances General Requirements
Caution
Before installation, check that the local
distribution conditions, nature of gas and
BS EN 55014 - 1993
pressure, and the current state adjustment of
Limits and methods of measurement of radio the appliance are compatible.
disturbance characteristics of electrical
motor-operated and thermal appliances for
Installation, commissioning, and servicing
household and similar purposes, electrical
must only be carried out by appropriately
tools and similar electric apparatus
qualified and competent persons.
BS EN 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.
Notified body Pin reference is 63AQ0533.
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,
1.2 General product information
servicing, or use, will jeopardise any
applicable warranty, moreover, such a
The Benson range of indirect gas fired forced situation could also compromise the safe and
convection heaters have an output range
efficient running of the appliance itself, and
from approximately 29.3 kW to 381.0 kW and thereby constitute a hazard.
are available in a configuration that will allow
for down flow, horizontal, floor mounting, or The installation of the appliance must meet
above ground level on purpose built steel
all the relevant European, national, and local
supports.
criteria. (See sections 3 and 9).
Prior to installation the following points
The units can suit either ducted applications, should be considered;
5
a) The position of the heater for the optimum
efficient distribution and circulation of warm
air
b) The position of the heater relative to the
route of the flue
c) The position of the heater relative to the
supply of gas
d) The position of the heater relative to the
electrical services, and if appropriate, any
additional controls.
e) The position of the heater relative to the
supply of fresh air
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 despatch from
the manufacturer, and is subject to the terms
detailed within the Benson Heating
'conditions of business'.
f) The height if applicable at which the heater
is to be mounted and potential stratification / Note (i)
circulation problems.
The warranty may be invalidated if g) The position of the heater relative to
service and maintenance requirements
a) The warranty registration/commissioning
card has not been completed and returned to
Caution
Benson Heating
The heater must not be installed within an
area where the conditions are unsuitable, e. b) The installation is not in accordance with
g. where the atmosphere is highly corrosive, the general requirements of this manual
has a high degree of salinity, or where high
wind velocities may affect burner operation. c) The flue arrangement and air supply for
Suitable protection should be provided for
the heater are not in accordance with the
the appliance when it is located in a position manufacturers
where it may be susceptible to external
recommendations, codes of practice, or
mechanical damage from; for example, fork similar standards
lift trucks, overhead cranes etc.
1.4 Delivery and pre-installation
checks
The heater is supplied wrapped in heavy
duty protective polythene. On receipt of the
heater, the following checks should be
carried out;
a) The model is as per order
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
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 signed for
as damaged and reported in writing within 24
hours of delivery, in order to comply with
6
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
(5) Installers name and address.
Indirect fired heaters must not be located in
hazardous areas, however, it is permissible
for the heater to supply air to such areas.
The heater must not be installed within an
environment where there is a high
concentration of chlorides, fluorides, salts, or
other aggressive or volatile chemicals /
compounds. Nor should the heater be
positioned where the burner could be
adversely affected by high winds or draughts.
The location chosen for the heater must
allow for the fitting of an effective flue
system.
Faulty parts must be returned to the Knighton The location must also allow for adequate
Spares Department, the address of which is clearance for the air supply, return air
circulation, oil supply, electrical supply, whilst
provided in Section 2 of this manual. Any
also providing good and safe working
such parts will undergo inspection to verify
the claim. Replacement parts supplied prior access. The heater must be installed on a
to this may be charged, and a credit supplied flat and level surface made from noncombustible material, which is sufficiently
upon subsequent validation of the warranty
robust to withstand the weight of the heater
claim.
and any ancillary equipment. Any
Consumable items are specifically not
combustible material adjacent to the heater
included within the scope of the warranty.
or flue system must be so placed or shielded
so that its surface temperature does not
Note (iii)
Notification is required immediately a fault is exceed 65oC.
suspected.
In areas where it is proposed that more than
The manufacturer will not accept
responsibility for any additional damage that one heater is to be installed, a general
scheme of circulation should be drawn up
has been caused, expense incurred, or
consequential loss resulting from any failure and maintained, thereby offering the best
heat distribution.
of the heater(s).
All Benson Heaters are fitted with a pressure
relief facility, this is incorporated into the
design of the flue gas exit duct. Care should
Warning
All of the basic criteria must be satisfied prior therefore be taken in siting service
connections and controls well away from the
to commencing installation and
pressure relief vent.
commissioning, additionally, the Cabinet
Heater must be positioned and installed so
as to comply with all the relevant standards Warning
and guide lines (see section 9.0), as well as Under no circumstances must the pressure
relief be restricted, blocked, or have the free
meeting national and local fire regulations
exit of exhaust gas impaired or re-directed.
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,).
2.0 Location /positioning
7
8
2.1 Gas supply - general
The Benson range of gas fired cabinet
heaters are all manufactured and pre-set for
use with natural gas classified under the
following categories, based upon the
destination of the heater I2H , I2L, I2Es , I2E(R)B ,
I2Esi ,
The heater must be compatible with the gas
supply, and each heater must be installed
with a separate approved isolating gas cock
positioned adjacent to and upstream of the
union between the service pipe and the
heater.
The gas supplier should have been
contacted to confirm that the supply feed
(pipework and metering) is capable of
delivering the required dynamic volume of
gas, thereby ensuring that the minimum
burner pressure can be achieved.
Consideration should have also been given
to the pressure drop on single and multiple
heater installations, and the affect that such
installations will have upon other plant
sharing the gas supply.
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.
The position of the isolation switch must be
such that it is adjacent to the heater and
easily accessible at all times. In addition, the
isolator itself must have a contact separation
of not less than 3mm as per BS5991
clause 20.2.
The Control Fuse ratings are detailed on the
appliance data plate.
Warning Ensure that the electric and gas
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 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
If it is necessary to fit a gas booster, the
controls must include a low pressure cut-off an emergency, or during servicing, when the
heat exchanger has been allowed to cool
switch which must be fitted on the supply
sufficiently to prevent any damage from
side of the booster. It is also a requirement
that the gas supplier is contacted prior to the occurring. Claims for damage will not be
considered if they have resulted from
fitting of the unit.
incorrect wiring or the incorrect use of the
heater.
Note
Reference to the Institute of Gas Engineers
2.3 Air supply
publication UP-1 and UP-2 together with
BS6891 is strongly advised.
Consideration must be given to the provision
Service and Installation pipework must be of of air for the purposes of combustion and
a diameter equal to or greater than the inlet ventilation of the heated space, plant room or
enclosure where heaters are to be installed
connection on the heater, all joints must be
sealed using an approved sealing
compound, and the system purged and
Note
tested for soundness.
It is strongly recommended that BS 6230 :
2005 is referred to for further information
concerning ventilation requirements
2.2 Electrical supply
Where mechanical ventilation is used it is a
Wiring external to the cabinet heater must be requirement that the inlet is of the
mechanical type, and the outlet is either
installed in accordance with any local,
national, and European regulations, as well mechanical or natural.
as meeting the appropriate requirements of
IEE regulations.
The means of connection to the main
electrical supply must allow for complete
9
The table in the next column provides
specific data for each heater model as
2.3.1 Heaters installed within the
heated space
Where heaters are installed within the space
to be heated (I.e. not a plant room or
enclosure
Combustion air or heater related ventilation
air
Will not be required if
The design air change rate of the heated
space is 0.5 air changes per hour or greater
The design air change rate may be satisfied
by natural infiltration or by mechanical
ventilation
Combustion and General ventilation
will be required if
The design air change rate of the heated
space is less than 0.5 air changes per hour
Where the heated space has an air change
rate of less than 0.5 air changes per hour
then it will be necessary to provide either
natural ventilation openings to the heated
space (section 2.3.1.1. refers) or the
mechanical ventilation of the heated space
(section 2.3.1.2. refers)
MODEL
120
220
370
560
770
1020
2.3.1.2
Mechanical Ventilation to the Heated
Space
In the event that the heated space has a
design air change of less than 0.5 air
changes per hour and that installer prefers to
mechanically ventilate the heated space
rather than provide ventilation openings
then -
2.3.1.1 Natural Ventilation Openings to
the Heated Space
•
If the heated space design air change rate is
less than 0.5 air changes per hour then
provision for low level natural ventilation
openings will only be necessary
The minimum free area of the low level
•
natural ventilation opening shall be
•
2cm2 for each kW of rated heat input
The low level natural ventilation opening
•
should be situated on an external wall and be
within 1000 mm of floor level for natural gas
and ideally at floor level for l.p.g gas
•
installations but in any event no higher than
250 mm.
10
Minimum Free Area of
ventilation opening
The heated space needs to be
mechanically ventilated so that the
design air change is 0.5 air changes or
greater.
It is a requirement that the mechanical
ventilation shall be of the ’input’ type
with either natural or mechanical
extraction.
Systems of mechanical extraction with
a natural inlet shall not be used
It is necessary to provide an automatic
means to safely inhibit heater(s)
operation should mechanical air supply
fail for any reason
Mechanical ventilation systems where fitted
must be provided with safety interlocks to
prevent heater operation in case of air flow
failure
2.4.3 Ventilation openings and Grilles
Ventilation openings and grilles must
communicate directly with the outside air, be
of negligible resistance and shall be sited so
that they cannot easily be blocked or flooded
2.5 Air distribution system
Where the combustion air intake is not
ducted to atmosphere heater installed in
flue only configuration then ventilation can
be via a permanent ventilation opening /
grille situated at both Low level (Inlet) and
high Level (Outlet) and with the free area of
such grilles as :-
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.
Low level (Inlet)
For heaters with a rated input of less than
60 kW — 9.0 cm2 per kW of heat input
For heaters with a rated input of more than
60 kW — 540 cm2 plus for each kW of rated
input over the 60 kW threshold an additional
4.5 cm2
High Level (Outlet)
For heaters with a rated input of less than
60 kW — 4.5 cm2 per kW of heat input
For heaters with a rated input of more than
60 kW — 270 cm2 plus for each kW of rated
input over the 60 kW threshold an additional
2.25 cm2
Alternatively mechanical input (not extract)
ventilation may be used in association with
either mechanical or natural extract , and
with a ventilation flow rate of 3.24m3/h per
kW of total rated input
Where mechanical extract is used to
complement the above then the extract rate
shall be 2.06m3/h per kW of rated heat input
11
In installations where forced recirculation is a
feature, a full and unobstructed return air
path to the heater(s) must be provided, with
return air grilles connected by ducting directly
to the return air inlet on the heater. The limit
for recirculation should not be greater than
85% recirculated air to 15% fresh air.
Where the heater is installed within a
compartment or plant room the return air and
discharge air arrangement must be such that
the air circulation fan does not interfere with
the operation of the flue.
The return air intake and warm air outlet
should therefore be fully ducted to and from
the heater, respectively, within the
compartment or plant room.
If the inlet air is ducted to the outside, then
the lowest edge of the inlet air duct must be
at least 500 mm above the outside floor or
ground level, it must also be fitted with an
access point (s) to allow for cleaning and
servicing to occur. The openings in the
structure of the plant room, through which
the ductwork passes must be of fire resistant
material and constructed to prevent the
likelihood of any fire from spreading.
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.
Warm air outlets on ducted applications must When designing the flue system the
prevention of the formation and entrapment
be such that they cannot be closed or
become blocked, which again would lead to of condensation must be a key consideration.
an increase in static pressure and nuisance Twin wall or insulated systems are
recommended as they tend to inhibit the
shutdown.
formation of condensates.
The outlets must not be sited so that warm
Where condensation is unavoidable traps
air can be discharged onto combustible
materials, if necessary, guard rails should be should be included to encourage the
condensates to flow freely to a point from
used to ensure that effected areas are kept
clear. Return air intakes must not be located which they may be released, preferably into
a gully. The condensate pipe from the flue to
so that potentially harmful or hazardous
the disposal point must be made from
contaminated air can be drawn into the
corrosion resistant pipe of not less than
system.
25 mm internal diameter.
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.
2.6 Flue system
It is essential that the products of combustion
are flued to the outside of the building. Each
heater must have its own separate flue, with
a flue diameter of not less than is detailed in
section 8 within this manual.
the minimum vertical length of flue must not
be less than 3m. The flue should rise
vertically, and the number of bends should
be kept to a minimum.
Flue pipe should be supported at intervals
not exceeding 1.8mtrs
Flue pipes below a height of 2 m should
be guarded against the possibility of
being accidentally touched when hot by
personnel
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. See figures 2-12.
12
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 25 mm 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 200 mm 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.
Caution
It is imperative that the flue should be
properly sealed where it passes through the
roof, this can best be achieved by using the
approved method of roof flashing plate and
cravat.
Note
It should be noted that claims made under
warranty and attributed to the ingress of
water may not be considered especially if an
approved method of sealing has not been
used, or if the design of the flue has not
made provision for possible condensation
problems.
13
1RWOHVVWKDQ
PP
1RWOHVVWKDQ
PP
3DUDSHW
*UHDWHUWKDQPP
Flat roof with parapet
1RWOHVVWKDQ
PP
H1
H2
/HVVWKDQK2
/HVVWKDQK1
*UHDWHUWKDQPP
Flat roof envelope method
H2
1RWOHVVWKDQ
PP
6WUXFWXUH
6WUXFWXUH
2
H1
*UHDWHUWKDQK1
Flat roof where the flue height is more than 10 Heights (H) away from all structures
1RWOHVVWKDQ
PP
6WUXFWXUH
/HVVWKDQPP
Flat roof with flue close to parapet
14
1RWOHVVWKDQ
PP
1RWOHVVWKDQ
PP
Flat roof with no parapet
1RWOHVVWKDQ
PP
6WUXFWXUH
/HVVWKDQ
PP
Flat roof with structure close to flue outlet
1RWOHVVWKDQ
PP
1RWJUHDWHUWKDQ
°
Pitched roof not greater than 45°
15
1RWOHVVWKDQ
PP
2.4 Minimum space requirements
The minimum space requirements for single
and multiple heater applications are detailed
in section 3.3 later within this manual.
16
2.7 Flue Installation
3.3 Minimum clearances
An integral flue spigot is fitted to all Cabinet
Heaters thereby allowing the flue to connect The following minimum clearances (in
directly to the heater. The design of the flue millimeters) must be observed when
must ensure that it can be disconnected to
installing the heater.
allow for cleaning and servicing, furthermore,
all of the flue section joint sockets must face
upwards, and the seal between the sections
Model Size Front Rear Lhs
achieved through mechanical joints or
120
500
1,000 150
through the use of approved caulking string
and grout. It is strongly advised that BS 5854
220
600
1,200 150
and BS 5440 parts 1 and 2 are referred to,
370
600
1,500 150
see also figs 2-12.
Where condensation is likely to be a problem
provision should be made preferably at the
design stage (see section 2.5).
Rhs
150
150
150
560
900
1,500
150
150
770
900
2,000
400
400
1020
900
2,000
500
500
3.0 Installation
3.4 Assembly
It is strongly advised that the installer reads
Section 2 and Section 3 of this manual prior
to starting any installation work. It is a
requirement that only qualified and
competent personnel may undertake
installation, commissioning, and servicing.
Warning
Always ensure that the appropriate personal
protective equipment is used.
3.1 Packaging/siting
The following sub-assembly parts should be
assembled to allow installation to continue.
(a) Vertical Nozzled Models
For free blowing applications it will be
necessary to complete the final assembly
before continuing with the installation. The
bonnet top with nozzle spigots should be
attached to the heater and secured. The
nozzles should then be pushed home on the
spigots and positioned to provide the desired
airflow.
Ensure louvres are adjusted outwards
and ensure blades are not resonating
The nozzles should be securely fixed in their
desired position on completion of
commissioning.
The heater will usually be supplied wrapped
in heavy gauge polythene, non assembled
parts will be supplied separately. Prior to
installation, the assembly of the heater
should be completed, it is advisable that this
is undertaken in the area where the heater is (b) Horizontal Nozzled Models
scheduled to be sited.
Remove packaging and secure the 90o Duct
Outlet to the outlet on the heater using the
Caution
bolts supplied.
It is strongly advised that when positioning
Secure the nozzle spigot plate to the duct
the heater the lifting eyes are used, thereby outlet using the bolts and prevailing torque
reducing the risk of inadvertent damage
nuts provided. Fit the securing brackets to
being occasioned to the heater.
each of the outlet nozzles, and lift the
complete heater assembly and position on
3.2 Flooring
the pre-sited purpose built supports. Finish
off the assembly by fitting and securing the
The heater must be installed on a level non outlet nozzles to the spigots by way of
combustible surface capable of supporting
previously fitted brackets.
the weight of the heater and any ancillary
equipment.
17
3.5 Gas Installation/Connection
Service pipework must terminate at an
approved gas cock, and be adjacent to the
position of the heater.
The connection to the heater can be made
by way of either an approved flexible
coupling, or rigid connection. Threaded
connections must comply with ISO288/1 of
ISO 7/1, further information concerning the
accepted practice in European countries is
detailed in the June 1995 version of prEN
1020 annex A7 The diameter of the pipework
from the cock to the burner connection must
not be less than the diameter of the burner
connection inlet. (see section 8 )
The installation must be purged and tested
for soundness prior to commissioning.
Always ensure that the appropriate personal
protective equipment is used.
3.6 Electrical Installation/Connection
Benson cabinet heaters are available either
for 415V 50Hz 3PH or 230V 50Hz 1PH
supplies depending upon the model
specified.
It is recommended that reference is made to
the wiring diagrams contained within section
7 of this manual prior to installation or
connection to the supply.
The electrical supply must be as specified
and suitable for the heater, and must be run
within conduit to a point adjacent to the
heater, and be terminated to provide an
isolation point that will prevent remote or
inadvertent activation. Cables, conduit, and
fittings that are used to make the connection
between the isolator and the heater must
conform to the appropriate IEE regulations.
Warning
Always isolate from mains electrical supply
before commencing work on the heater.
Always ensure that the appropriate personal
protective equipment is used.
3.7 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.
All heaters are supplied fused and pre-wired,
all must be earthed.
3.8 Warm Air Registers
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 despatched.
18
In order that vertical temperature gradients
are minimal thereby providing a more even
heat distribution, it is preferable to install
warm air registers at low wall levels or at
floor level, with the size, number, and
position commensurate with the requirement
of the application.
To minimise noise levels the registers should
be set away from corners, additionally, a
good seal between the register frame and
the wall is important, particularly on high
level positions, if unsightly staining through
warm air/ particulate deposition is to be
avoided.
mean that on site commissioning is less
important than might otherwise be the case.
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.
3.9 Heater Control Installation
4.1 Commissioning - Pretest
Check to ensure electrical safety, and
Warning
Isolate heater from mains before undertaking inspect and check the installation, testing for
leaks.
any electrical work.
(a) Ensure that the electrical supply is turned
off.
All Cabinet Heaters from are manufactured
and supplied with a CP4 Optimised Control
(b) Ensure that the gas supply is turned off.
as standard .
Set CP4 Control as per Basic Setting
Guide Instruction Sheet Supplied
(c) Check that all panels and fasteners are
secure and in place.
The controls are located on a removable
panel which when separated from the heater
can be re-positioned so as to offer a remote
facility.
However, to facilitate this, it is necessary to
order and fit an electrical panel cover and
front panel blanking plate to the heater in
place of the control unit.
(d) Check that the heater is installed so that it
is square and that the support is adequate.
The controls for Horizontal Cabinets are
supplied as remote option.
4.0 Commissioning
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.
(e) Ensure that warm air delivery outlets are
open and that ducting is adequately
supported.
(f) Ensure that if filter assemblies are fitted
that they are secure and correctly located.
(g) Check that air inlets are clear and that
return air paths are adequate.
(h) Ensure that the flue is secure, adequately
supported, and that the various joints are
properly sealed.
(i) Check that condensate trap and drain
facilities are adequate.
(j) Check that there is provision for flue gas
sampling and that this sample point can be
plugged and sealed after commissioning.
(k) Check that fan and limit stat settings have
not been disturbed and are as follows
120/560
770/1020 Range
Warning
Fan
on
60oC
Fan
on 50oC
All Cabinet Heaters undergo a rigorous test
o
C
programme prior to being despatched, whilst Overheat limit -100oC Overheat limit -100
o
Fan
off
30oC
Fan
off
30
C
such a programme does involve precommissioning and setting up the heater to
operate efficiently and well within its
designed operational limits, this does not
19
Also check that the white button (automatic)
is pulled outward and that the red button
(reset) is pushed inwards to the reset
position. See fig 15.
Interval
1 <5s
(l) Remove lower panel and check motor and
fan drive system for integrity of joints, check
2 <40s
pulley alignment, fan rotation, and belt
tension (see section 5.2 and figs 17 and 18).
(m) Ensure that the burner is securely
attached to the heater.
Operand
Combustion air damper actuated,
burner fan motor initiates purge
cycle...
Pilot valve opens ignition
transformer provides spark for
pilot ignition...
-------- E I T H E R --------
3 >40s Ignition failure caused by gas
(n) Test for electrical earth continuity
starvation resulting in burner lockbetween the heater, oil pipe work, and mains
out/shut-down...
supply.
CP4 Control
Press FAN /Enter
The fan will start enabling fan direction etc to
be verified. Reset on/standby switch to
standby position
(h) Clear burner lockout using burner reset
function.
(p) Turn mains electrical supply to off,
replace and secure lower louvered panel
covering fan and motor assembly.
(j) Open gas supply cocks Repeat steps 4.2
c,e,f.
(i) Set heater on/standby switch to standby
position
----------- O R ---------3 >40s Pilot ignition... Burner ignition...
4 <60s Burner ignition cycle complete
Note
4.2 Commissioning - Ignition
It is strongly recommended that the separate
manual concerning the operational details of
Warning
the burner supplied with the heater as part of
Do not proceed with commissioning unless
the information package is studied prior to
all the criteria detailed within sections 4.0
commissioning.
and 4.1 have been satisfied.
Time intervals within the ignition sequence
(a) Ensure that the electrical supply is turned will vary slightly from one model to another.
off.
Warning
(b) Ensure that the gas supply is turned off. If burner ignition is not satisfactorily
accomplished, commissioning must not
(c) Select the following switch settings on the proceed until the reason or fault has been
identified and rectified, if necessary by
heater
reference to the separate burner information
or to section 6 of this manual.
(d) Turn on main electrical supply.
(q) Set controls to demand settings
(e) Prog 0000 Enter 1TEMP key in an
operating temp and Enter
Press RUN 3 times to return to main screen
Press OVER button Select 1 OVERIDE then
select 1 and key in 01 hour override this will
allow enough time to commission the heater
safely
(f) Check for the following burner sequence
20
( j ) Repeat steps 4.2
(k) Re-check all connections and joints for
gas soundness using an approved leak
detection fluid.
(l) Remove burner cover and attach
manometers to check burner pressure
settings.
(m) Repeat steps 4.2 d,e,f, allowing the
(iii) Check integrity of unit, ensuring that
neither the bi-metallic strip nor its casing is
(n) Check burner pressure settings are in line damaged.
with the data as per section 8.1 (if
(s) Undertake flue gas analysis using
adjustment is necessary refer to separate
approved and calibrated analysing
burner information within section B)
equipment recording data on the
Note (i)
commissioning card, ie, CO, CO2, net and
The figures quoted in section B are
gross flue temperatures. Record mains gas,
independent test figures based upon zero
and burner head pressure, ambient
flue resistance.
temperature, barometric pressure, and
complete percentage efficiency calculation
(o) Adjust room thermostat to its highest
using the formula detailed in section 8.
setting, and allow the heater to continue to
fire.
Note (ii)
(p) Gradually reduce the temperature setting The burner air and gas pressure settings
on the room thermostat until the burner shuts should be only very finely adjusted to
achieve a CO2 reading of 9.3% (+/- 0.1%).
down, (@ < ambient) and then gradually
increase the temperature setting on the
thermostat until heat is called for,
Note (iii)
(@ > ambient) and the burner automatically The net efficiency must not be lower than
79% for heaters fitted with a modulating or
re-fires.
hi / lo burner.
In other cases the net efficiency level must
(q) Re-set time clock to a minimum off
period, checking that the burner shuts down, not be lower than 84%
and then automatically re-lights once the
minimum off period has elapsed (Separate
Note (iv)
All Cabinet Heaters are test fired and preinformation on the time clock is contained
within the information package supplied with commissioned as part of the manufacturing
process, if however, during on site
the heater).
commissioning the data are found to be not
in accordance with the manufacturers data,
(r) Check fan and limit stat by depressing
and holding in the fan motor overload re-set then the following action is recommended.
button, located on the heater electrical panel. * Re-check all readings and calculations.
* Adjust burner as per manufacturers
The time between the fan stopping and
burner shut down should be noted, once the instructions.
* Consult Benson Heating Technical
burner has shut down the overload on the
Department.
motor should be released.
(t) Complete commissioning card and
If the time interval between fan stop and
burner shut down is greater than 90 seconds provide operating instructions for the user,
high-light the fact that the manufacturer
further checks should be made.
recommends that in the interests of safety
These are as follows:
and efficiency the heater is serviced on a
regular basis only by qualified and competent
(i) Check settings on fan and limit stat are
persons.
correct, ie, fan on 60oC, fan off 30oC, limit
100oC.
The completed commissioning card must be
returned to Benson Heating Service
On completion delete any override settings
on optimised control and return temperature Department immediately after the
satisfactory completion of commissioning,
settings to customer requirements
failure to do so can invalidate any
subsequent warranty claim.
(ii) Check that the position of the unit is
correct, ie, equi-distant between heat
exchanger body and heat shield panel.
(u) Set all controls to the requirements of the
heater to reach thermal equilibrium.
21
user.
For setting information
See Fan belt section page 23
4.3 Commissioning - air delivery
system
On free blowing applications the integrity of
the fastenings on the heater top and outlet
nozzles must be checked .
Final adjustment for the direction of the air
flow from the nozzle hoods should be made.
Ensure louvres are adjusted outwards
and ensure blades are not resonating
and the hoods should be secured in the
required position by drilling through the two
holes provided in the hood outer ring and
fastened in place using self tapping screws .
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.
On Completion of commissioning the fan
belts should checked for the correct
tension
22
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 Dept.
(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 labeling.
(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 2 'User Instructions' should be left
with the customer upon satisfactory
completion of the commissioning and handover.
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 gas and
electric supplies to it turned off at the gas
cock 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:
room thermostat, time clock, frost thermostat,
sequential controller, and fan and motor.
Additionally, the fan and limit stat has been
factory set, and must not be re-set without
formal consent from 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.
5.2 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
5.1 Planned Servicing
Remove access panel, dust and other
In order to maintain the efficient operation of foreign matter should be cleaned by blowing
over with compressed air and through the
the heater it is recommended that the
following planned servicing and preventative use of a soft bristle brush and cloth. Solvent
wipes may be used to remove heavy soiling
maintenance programme is adopted by the
from the motor casing.
user.
Traces of surplus lubricants spreading from
Quarterly Inspection
the bearings should also be cleaned away.
(a) Visual inspection of the burner
Where motors are fitted with grease nipples
(b) Clean and check ionisation probes
(c) Check overheat safety is operational bearings should be lubricated with the
correct grade of lubricant. motors which do
not have grease nipples feature sealed
Bi-Annual Inspection
bearings which are lubricated during
(a) As per quarterly inspection, plus...
manufacture for their life.
(b) Combustion check
The electrical connections should be
checked as follows.
Annual Inspection
The cover to the terminal box should be
(a) As per half year inspection, plus.
removed by undoing the screws which
(b) Heat exchanger and cleaning
secure it.
(c) Electrical connections
Check connections for signs of corrosion,
(d) Main fan motor
tightness,
and ensure that there are no stray
(e) Main fan assembly
strands
which
could form a short circuit.
(f) Pulleys
Clean,
tighten,
and replace as necessary.
(g) Fan belts
Replace
cover
and secure
(h) Gas supply
(i) Burner
(j) Air delivery system
(k) Flue
(l) Report
23
Motorised Fan
Assembly
120-220
Fan and Motor
Assembly
370-560
Fan and Motor
Assembly
770-1020
24
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 setscrew 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.
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.
Pulleys
Check pulleys for alignment using a straight (g) Check belt tension, making final
edge, if necessary reposition either or both of adjustments as necessary.
(h) Tighten and clamp fasteners to hold fan
the pulleys and the fan motor. Check for
motor in position.
excessive wear within the root and sides of
the grooves, and check for any other signs of
Heat Exchanger
wear or damage, if necessary replace the
The heat exchanger requires a visual
pulley as follows.
inspection at least once per year, this should
(a) Release tension on belts and remove.
(b) Release the taper locks by slackening the be accompanied by cleaning.
securing screws by several complete turns. It is recommended that a flue brush and
vacuum cleaner are used to facilitate this.
(c) Fully remove one screw from the taper
Access to the heat exchanger is gained
lock, and having oiled it, insert into the
through the removal of the rear upper panel
threaded jacking point.
(d) Tighten screw until the taper lock is free. and heat shield.
Servicing and cleaning should be performed
(e) Remove taper lock and pulley.
as follows.
(f) Fit taper lock in new pulley, and
provisionally position on the shaft.
(g) Remove the screw from the jacking point, (a) Remove brass nuts and cover from heat
exchanger end assembly to expose heat
and tighten both screws in their clamping
points until the pulley can just be moved on exchanger tubes.
(b) Remove any accumulated deposits from
the shaft by hand.
the tubes by pushing through the full length
(h) Align pulleys using a straight edge, and
by gradual alternate tightening of the screws with a flue brush.
(c) The flue brush should be withdrawn so as
clamp in position.
to pull any deposits back into the bottom of
(i) Refit belts and check for the correct
the flue box where they can then be removed
amount of tension.
25
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.
manufacturer.
Note
It is most important that the burner is
serviced regularly and in accordance with the
manufacturers instructions.
Air Delivery System
A visual inspection should be undertaken to
ensure that the air delivery system is in good
order, and that it remains adequately
supported and that the various joints are
effectively sealed.
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 Report
the heater and reduce the life of the heat
A full and detailed service report should be
exchanger.
prepared, it is advised that the report is not
completed until the heater has been re(f) The heat exchanger and combustion
commissioned, where upon the completed
chamber should be visually inspected for
report can then be run through with the user.
signs of splits, cracks, and distortion
(g) All gaskets should be checked to ensure
that they continue to provide a gas tight seal, 5.3 Service Re-commissioning
if there is an element of doubt then they
The heater should be re-commissioned as
should be replaced.
follows, as per section 4.1 through to section
4.4 inclusive.
If the condition of the heat exchanger gives
cause for concern the Service Department at This must be regarded as a necessary part
Benson Heating should be advised pending of the heater service by the servicing
engineer.
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.
Gas Supply
The gas supply pipework, 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 system should be soundness tested in
accordance with Institute of Gas Engineers
recommendations detailed in
UP-1 and UP-2.
Burner
Service requirements for the burner fitted to
the cabinet heater are covered in the
separate manual prepared by the burner
26
Check On/Off
Switch
Check
Isolator
No
Power
Check
Fuses
Burner fails
to Run
Check for
Lockout
Check Thermostat
No
Demand
Check Timer
Check Overheat
Check Voltage
Check Control
Box and Burner
Check Gas
Supply
Ensure Gas Cock is
Open
Fan Starts but
Burner goes to
Lockout
Air in Gas Feed
Faulty Air Pressure
Switch
Ignition
Failure
Check Air
Pressure Switch
Check Flame
Probe
Check Burner
Motor
Ensure start Gas
Valve Opens
Purge Air
Check as per
Burner Manual
Check Control
Box
Faulty Ignition
Transformer
Faulty Electrode
Control Box Fault
27
Check HT Lead
and Connector
Check Gap
Check Insulation
Check Gas
supply
Excess Air
Check that flue
Gas CO is as
advised
Adjust damper
to suit
Burner
lights on
start gas
but fails to
establish
main
flame
Check
Flame
Probe
Low Gas
Pressure
Signal
Check Inlet
Gas Pressure
Check Main
Burner Gas
Pressure
Position
Check
Controls
Check
Burner
Check
Control
Insufficient air
passing over
Heat Exchanger
Burner starts
but excess
temperature
shuts down the
burner on
overheat
lockout
Check air to
inlet is not
restricted
Resistance
too high
Check Low
Flame Switch
is On
Check Slow
Acting Valve
Remove
Obstruction
Clean Filters
Check Outlet
Grilles are Open
Check Nozzles
are Open
High Return (inlet )
Air Temperature
Fan Belt
Slipping
Adjust and or
replace Belts
Impellor
Slipping
Tighten
Couplings
Faulty or
incorrectly set Fan
Limit Control
Check for
warm air
short circuit
to Air Inlet
Reset Fan
Limit
Control
28
Reset Nozzles
away from
adjacent walls
Drawing 20-45-311
Riello ON / OFF Gas or Oil Fired Burner 230v/1ph/50Hz
CP4 Control
29
Drawing No 20-45-312
Riello ON / OFF Gas or Oil Fired Burner
230v/1ph/50Hz CP4 Control
30
Drawing No 20-45-313
Riello ON/OFF Gas or Oil Fired Burner 415v/3ph/50Hz
CP4 Control
31
32
8.0 Technical Data
Formulae for calculating efficiency are detailed as follows: where
q1 is the heat of the dry products of combustion (% of heat released per unit volume of gas)
q2 is the heat of the water vapour contained in the products of combustion ( % of heat released per unit volume of gas)
c1 is the mean specific heat of the dry products of combustion (in MJ / m3 K)
t1 is the average combustion air temperature (in 0 C)
t2 is the average temperature of the products of combustion (in 0 C)
Hi is the net calorific value of the gas at 1013 mbar and 150 C , dry (in MJ / m3)
Hs is the gross calorific value of the gas at 1013 mbar and 150 C , dry (in MJ / m3)
Vf is the volume of dry products of combustion per unit volume of gas (in m3)
Vf is calculated from the volume of CO2(V CO2) produced by the combustion of 1m3 of gas
(see table below), and from the CO2 content of the products of combustion (V CO2,M)
V CO2
Vf = ------------------ x 100
V CO2 M
Ref. Gas
V CO2
G110
0.26
G120
0.32
G20
1
G25
0.86
The net efficiency E (net) (in %) is given by:
where
t2 - t1
q1 = C1 x Vf ------------ x 100
Hi
G30
G31
4
3
E (net) = 100 - ( q1+ q2 )
and
Hs - Hi
q2 = 0.077 ------------ (t2 - t1 )
Hi
Note The required net efficiency must not be less than 84%
On heaters that are fitted with modulating or Hi / Lo burners the testing is carried out with
the appliance adjusted to give the minimum rate, and the following formula is used.
Qn
10 ( Qn - Qmin )
---------------------- in %
Qn
is the nominal heat input
Qmin
is the minimum obtainable heat input
Emin > E n -
En
is the net efficiency determined by the Notified Body
Note The minimum net efficiency for appliances fitted with modulating or Hi / Lo burners
must not be less than 79%.
33
8.1Technical Data Range
MODEL
120
220
370
HEAT
OUTPUT
kW/hr
Btu/hr
35.35
120,545
63.15
215,468
108.73
370,978
HEAT INPUT
(GROSS)
KW/hr
Btu/hr
43.05
146,900
76.73
261,800
131.71
449,394
GAS
CONSUMPTION
M3/hr
Ft3/hr
145.8
258
441
BURNER TYPE
RIELLO
GS5
GS10
GS20
BURNER GAS PRESSURE
(zero resistance cover fitted)
Mbar
2.7
4.1
3.1
MINIMUM GAS INLET
PRESSURE
Mbar
Ins WG
17.5
7
17.5
7
17.5
7
HEAD SETTING
(zero flue resistance)
Number
1.5
AIR SHUTTER SET
(zero flue resistance)
Number
3
GAS CONNECTION
RC½
RC½
RC¾
AVAILABLE OUTLET
PRESSURE
Pascals
Ins WG
100
0.4
100
0.4
150
0.6
NOZZLE DISCHARGE
VELOCITY
M/sec
Ft/min
4.53
888
5.91
1159
6.98
1369
AIR THROW
(APPROX)
Mtrs
Ft
14
45
17.1
55
20.2
65
AIR
DELIVERY
M3/sec
Ft3/min
0.71
1500
1.39
2950
2.65
5620
TEMPERATURE RISE THROUGH
HEATER
Deg C
Deg F
50.3
122
49.8
122
44.5
112
EFFICIENCY NET
%
91.18
91.38
91.68
SOUND LEVEL
Dba
69
72
76
COMBUSTION
CHAMBER (press)
Mbar
0.21
0.34
0.88
FLUE
RESISTANCE
Min Mbar
Max Mbar
-0.2
0.6
-0.2
0.6
-0.2
0.6
FLUE DIAMETER
Mm
125
175
175
ELECTRICAL SUPPLY
Standard
230/1/50
230/1/50
415/3/50
RATED INPUT
KW
0.55
0.99
2.2
FUSED ISOLATOR SIZE
Amps
16
20
16
RUNNING CURRENT
Amps
4.8
7.2
5.2
ELECTRICAL SUPPLY
Optional
N/A
415/3/50
230/1/50
RATED INPUT
KW
N/A
0.99
2.2
FUSED ISOLATOR SIZE
Amps
N/A
16
40
RUNNING CURRENT
Amps
N/A
2.2
14
WEIGHT
Kg
196
243
332
AIR NOZZLE SIZE
Ins
9.4
9.4
11
NOZZLE AMOUNT
No
2
3
4
209
200
194
FLUE TEMPERATURE
(GROSS)
0
@ 20 C
Ambient
34
Technical Data Range
MODEL
560
770
1020
HEAT
OUTPUT
kW/hr
Btu/hr
163.39
557,486
225.60
769,747
300.21
1,024,317
HEAT INPUT
(GROSS)
KW/hr
Btu/hr
196.80
671,480
274.91
938.000
366.01
1,248,826
GAS
CONSUMPTION
M3/hr
Ft3/hr
662
927
1230
BURNER TYPE
RIELLO
GS20
RS28.1
RS38.1
BURNER GAS PRESSURE
(zero resistance cover fitted)
Mbar
5.8
8.2
5.7
Mbar
Ins WG
17.5
7
17.5
7
17.5
7
3.5
5
4
6.5
3.5
4
RC1¼
RC1¼
RC2
MINIMUM GAS INLET PRESSURE
HEAD SETTING
(zero flue resistance)
Number
AIR SHUTTER SET
(zero flue resistance)
Number
GAS CONNECTION
AVAILABLE OUTLET PRESSURE
(STD)
Pascals
Ins WG
188
0.75
175
0.7
250
1
NOZZLE DISCHARGE
VELOCITY
M/sec
Ft/min
6.71
1315
7.39
1445
8.49
1665
AIR THROW
(APPROX)
Mtrs
Ft
21.7
70
24.8
80
31.1
100
AIR
DELIVERY(STD)
M3/sec
Ft3/min
3.4
7200
4.86
10,300
6.88
14,680
TEMPERATURE RISE THROUGH
HEATER
Deg C
Deg F
49.2
120
48
118
45
113
EFFICIENCY NET
%
92.2
91.13
91.09
SOUND LEVEL
Dba
78
81
81
COMBUSTION
CHAMBER (press)
Mbar
0.62
0.92
0.9
FLUE
RESISTANCE
Min Mbar
Max Mbar
-0.4
1.6
-0.4
1.6
-0.4
1.6
FLUE DIAMETER
Mm
200
225
250
ELECTRICAL SUPPLY
Standard
415/3/50
415/3/50
415/3/50
RATED INPUT
KW
3
5.5
7.5
FUSED ISOLATOR SIZE
Amps
25
32
64
RUNNING CURRENT
Amps
6.5
11
24
ELECTRICAL SUPPLY
Optional
N/A
646
1090
RATED INPUT
KW
N/A
14.6
18.5
FUSED ISOLATOR SIZE
Amps
N/A
4
4
RUNNING CURRENT
Amps
N/A
340
300
WEIGHT
Kg
540
330
332
AIR NOZZLE SIZE
Ins
12.6
11
11
NOZZLE AMOUNT
No
4
3
4
175
207
206
FLUE TEMPERATURE
GROSS
0
@ 20 C
Ambient
35
9.0 Reference Information
Doc/Ref
BS EN 1020 :1998
BS EN 292
Title/Subject
Non Domestic Gas Fired Forced Convection
Air Heaters For Space Heating
Parts 1 and 2; 1992
Safety of Machinery
BS EN 60204 Part 1; 1993
Safety of Machinery - Electrical
BS EN 60335 Part 1; 1988
Safety of Electrical Appliances
BS EN 55014 1993
Electromagnetic Compatibility
BS EN 50165 1995
Safety of Electrical Equipment
BS 5854
1980
Code of Practice - Flues/Flue Structures
BS 6891
1988
Installation of Pipework < 28mm
BS 5991
1989
Indirect Gas Fired Heaters < 2 MW
BS 715
1993
Metal Flue Pipes and Fittings
BS 5440
Part 1 ; 1990
Specification/Installation of Flues
BS 5440
Part 2 ; 1989
Ventilation Requirements Gas Appliances
ISO 7/1
(see also BS21 )
ISO 228/1
See also BS 2779 and BS 5380) Pipe Threads Seals and Couplings
Specification for Metric Pipe Threads
UP/1
(Replaces IM/5 & IM/16 )
Installation of Gas Appliances
UP/2
(Replaces IM/7 )
Installation of Gas Appliances
36
Parts list
DESCRIPTION
120
220
Heat Exchanger Assy
31-28-128
20-45-154
Stackbox Assy
31-28-078
31-27-123
Front Lower Inlet Panel
31-28-075
20-45-144
Front Top Panel
31-28-126
20-45-143
Back Top Panel
31-28-083
20-45-137
Heatshield Front Panel
31-28-124
20-45-140
Heatshield Back Panel
31-28-123
20-45-141
Flue Box Cover Assy
31-28-115
20-45-094
Rear Lower Inlet Panel
31-20-107
20-45-139
Fan/Limit Thermostat
28-60-023
28-60-021
Fan/ limit Stat Gasket
20-33-549
20-33-549
Burner Plate Gasket
31-28-080
30—40-156
Pressure Relief Gasket
31-27-121
31-27-121
Sight Glass
20-30-151
20-30-151
Sight Glass Holder
20-30-061
20-30-061
Sight Glass Gasket
31-28-084
31-24-084
Fuse 1ph
28-07-049
28-07-049
Nozzle Outlet Assy
31-30-167(2)
Tray Spigot Assy
31-30-176
Motorised Fan 1ph
28-09-049
Fan Restrictor
28-09-002
N/A
Burner c/w Gas Train
29-99-445
Control panel CP4
37
29-99-446
DESCRIPTION
370
560
Heat Exchanger Assy
20-46-283
20-46-355
Stackbox Assy
31-27-123
20-46-307
Front Lower Inlet Panel
20-46-311
20-46-327
Front Top Panel
20-46-312
20-46-332
Back Top Panel
20-46-289
20-46-338
Heatshield Front Panel
20-46-291
20-46-336
Heatshield Back Panel
20-46-290
20-46-335
Flue Box Cover Assy
20-45-094
20-46-310
Rear Lower Inlet Panel
20-46-315
20-46-326
Overload
28-11-056
28-11-055
Contactor
28-11-057
21-11-057
Fan/Limit Thermostat
28-60-021
28-60-021
Fan/ limit Stat Gasket
20-33-549
20-33-549
Burner Plate Gasket
31-27-121
31-29-046
Pressure Relief Gasket
31-27-121
20-46-354
Sight Glass
20-30-151
20-30-151
Sight Glass Holder
20-30-061
20-30-061
Sight Glass Gasket
31-28-084
31-28-084
Fuse 1ph
N/A
N/A
Fuse 3ph
28-07-048
28-07-048
Nozzle Outlet Assy
31-30-159(4)
31-30-157(4)
Motorised Fan 1ph
N/A
N/A
Fan
28-09-003
28-09-004
Fan Pulley
28-65-096
28-65-105
Motor
28-10-015
28-10-120
Motor Pulley
28-65-063
28-65-072
09-16-110(2)
09-06-126(2)
29-99-448
29-99-450
N/A
30-10-145
Belt
Burner
Air Head
38
DESCRIPTION
770
DESCRIPTION
1020
Heat Exchanger Assy
20-47-405
Rear Panel
20-27-013
Stackbox Assy
20-47-425
Top Rear Heat Shield
20-27-011
Front Lower Inlet Panel
20-47-021
Bottom Rear Heat Shield
20-27-010
Front Top Panel
20-47-426
Heat Exchanger Assy
20-27-946
Back Top Panel
20-47-429
Gas Exit Duct Assy
V
20-27-090
Heatshield Front Panel
20-47-430
Gas Exit Duct Assy
H
20-27-092
Heatshield Back Panel
20-47-431
Outlet Assy (Nozzled)
V
20-27-094
Flue Box Cover Assy
20-46-310
Outlet Assy (Nozzled)
H
20-27-148
Rear Lower Inlet Panel
20-47-022
Outlet Assy (Ducted)
20-27-028
Side Lower Inlet Panel
20-47-039
Nozzle Outlet Assy (4) V
20-27-034
Overload
28-11-111
Contactor
28-11-057
Fan/Limit Thermostat
28-60-023
Fan/ limit Stat Gasket
20-33-549
Fan Drive Assy (Nozzled)
20-27-526
Burner Plate Gasket
31-29-046
Fan Drive Assy (Ducted)
20-27-527
Pressure Relief Gasket
20-46-354
Motor (Nozzled)
28-10-024
Sight Glass
20-30-151
Motor (Ducted)
28-10-025
Sight Glass Holder
20-30-061
Drive Pulley (Nozzled)
28-65-047
Sight Glass Gasket
31-28-084
Drive Pulley (Ducted)
28-65-053
Fuse Holder
28-07-050
Driven Pulley (Nozzled)
28-65-049
Fuse 3ph
28-07-048
Driven Pulley (Ducted)
28-65-054
Nozzle Outlet Assy
20-47-402
Taper lock Drive (Nozzled)
28-66-013
Tray Spigot Assy
20-47-403
Taper lock Drive (Ducted)
28-66-042
Fan
28-09-043
Taper lock Driven (Nozzled)
28-66-013
Fan Pulley
28-65-043
Taper lock Driven (Ducted)
28-66-019
Fan Taper lock
28-66-136
V Belt (3)
09-16-126
Motor
28-65-043
Burner c/w Gas Train
29-99-476
Motor Pulley
28-65-042
Air Head
30-10-146
Motor Taper lock
28-66-028
V Belt (3)
09-16-112
Burner c/w Gas Train
29-99-450
Air Head
30-10-145
39
10.1 Commissioning and hand over
SECTION 2
BASIC USER
INSTRUCTIONS
10.0 Introduction
The following information is relevant to the
Gas fired Cabinet Heater range
manufactured by Benson Heating. These
heaters are manufactured within a strictly
controlled quality system to ISO 9001.
Warning
As part of the commissioning programme,
the commissioning engineer must go through
the following with the operator.
(i) Lighting, shutdown, and operational
information.
(ii) Safety features, data plate, and labeling.
(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 engineers.
All Benson Heating gas fired Cabinet
Heaters are CE marked, having been found
to satisfy the essential requirements of the
following European Directives.
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC & 93/68/
EEC)
Electromagnetic Compatibility Directive
(89/336/EEC & 91/31/EEC)
Product Liability Directive (65/374/EEC)
Caution
After approximately 100 hours of running, the
tension on the fan belts must be checked to
ensure that it is correct, and that the belts
have not stretched.
It is strongly advised that this is undertaken
by the commissioning engineer, and not the
operator
Benson Heating support all new products
being supplied to their customers with a
comprehensive information pack, and it is the
responsibility of the owner, user, or hirer, of
such products supplied by Benson Heating to
ensure that operators are provided with the
operator manual, and that they are suitably
instructed regarding the purpose of the
manual and safety instructions. In addition to
this, operators must also be suitably and
adequately trained in the use of the product.
Warning
Servicing must be carried out on a regular
basis, the maximum interval between
services being one year.
It is a requirement that only suitably qualified
and competent persons are allowed to
undertake the servicing.
Contained within the text of this 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 a
premature failure or damage being
occasioned to the heater or its component
parts.
Warning is used when failure to heed or
implement the instruction(s) can lead not
only to component damage, but can also
lead to a hazardous situation being created
where there is a risk of personal injury or
death
40
10.2 Servicing
Benson Heating advise that the planned
service schedule as detailed in section 5.1 of
the Installation, Commissioning and
Servicing Manual is adopted by the user.
Further details are available from either
Benson Heating or from the commissioning
engineer.
10.3 Start up procedure CP4 OPTION
(a) Ensure that the gas cocks are open, and
that the mains electrical supply is turned on
(b) Ensure that the CP4 has been correctly
programmed
(c) Ensure programme is displaying Heat On
setting
ANALOGUE OPTION
(d) Ensure On Standby switch ON
(e) Ensure heat vent switch is set for ‘heat’
(f) Check for the following burner sequence
interval
10.6 Ventilation only
CP4 OPTION
(a) Select FAN /Enter to confirm
ANALOGUE OPTION
(b) Set heat/ventilate switch to 'ventilate'.
operand
10.7 Lockout situations
1
2
3
4
<5s
Combustion air damper actuated
fan motor initiates purge cycle...
<40s Pilot valve opens ignition
transformer provides spark for
Pilot ignition and flame detection
<40s Pilot ignition and Burner ignition
If either the burner or the fan and limit stat go
to lockout, the lockout must be cleared
manually before the ignition sequence can
be re-initiated.
<60s Burner ignition start cycle
complete
Caution
Repeated or frequent lockouts must be
investigated and their cause determined by a
qualified and competent engineer.
Note
The time intervals within the ignition
sequence may vary slightly between models.
(f) The burner will continue to fire until heat is
no longer demanded.
10.4 Stop procedure CP4 OPTION
(a)
Select standby , option 2 standby
(b) The fan motor will continue to run until
heat dissipation allows the fan and limit stat
to shut down the fan.
Stop procedure Analogue OPTION
a) Set switch to standby' position.
(b) The fan motor will continue to run until
heat dissipation allows the fan and limit stat
to shut down the fan.
Caution
Do not use the main electrical isolator to turn
off the heater, to do so can cause damage to
the heat exchanger and combustion chamber
and thereby invalidate the warranty.
10.8 Contact information
Further information is available from :-
Benson Heating
Ludlow Road
Knighton
Powys
LD7 1LP
Telephone 01547 528534
Facsimile 01547 520399
10.5 Shut down procedure
(a) Follow steps 10.4 (a) and (b), when fan
stops turn main electrical isolator off, and
shut gas cocks
41
Benson Heating is a Division of
Benson Climate Systems Ltd