BENSON HEATING G20 I2H Manuel utilisateur

BENSON CABINET

HEATER

NATURALGAS (G20 I2H)

PROPANE GAS (G31 I3P)

I N S T A L L A T I O N C O M M I S S I O N I N G

S E R V I C I N G

U S E R I N S T R U C T I O N S

July 2010

Issue 11

THIS MANUAL SHOULD BE LEFT WITH THE END USER .

TO ENSURE SERVICE AND MAINTENANCE INFORMATION IS AVAILABLE ON SITE

1.0 Compliance Notices 4

1.1 Certificates of Conformity 5

1.2 General Product Information 5

1.3 General Requirements 5

1.4 Delivery & Pre inspection 6

1.5 Warranty 6

2.0 Location & Positioning 7

2.1 Gas Supply 9

2.2 Electrical Supply 9

2.3 Air Supply 9

2.4 Minimum Space Requirements 12

2.5 Air Distribution System 12

2.6 Flue System 13

2.7 Flue Installation 17

3.0 Installation 17

3.1 Packaging & Siting 17

3.2 Flooring 17

3.3 Minimum Clearances 17

3.4 Assembly 17

3.5 Gas Installation & Connection 18

3.6 Electrical Installation & Connection 18

3.7 Air Distribution Installation 18

3.8 Warm Air Registers 18

3.9 Heater Control Installation 19

4.0 Commissioning 19

4.1 Pre test 19

4.2 Ignition 20

4.3 Air Delivery System 22

4.4 Hand Over 22

5.0 Servicing 23

5.1 Planned Servicing 23

5.2 Servicing procedure Major Components 23

5.3 Service Re commissioning 27

6.0 Fault Diagnosis By Flow Chart 28

7.0 Wiring Diagrams 30

8.0 Technical Data 36

CONTENTS

8.1 Cabinet Range Technical Data 39

9.0 Reference Documents Standards & Codes of Practice 43

9.1 Parts Listing 44

~ C O N T E N T S ~

S E C T I O N 1

1.0 Compliance Notices 4

1.1 Certificates of Conformity 5

1.2 General Product Information 5

1.3 General Requirements 5

1.4 Delivery & Pre-installation Checks 6

1.5 Warranty 6

2.0 Location & Positioning 7

2.1 Gas Supply 9

2.2 Electrical Supply 9

2.3 Air Supply 9

2.4 Minimum Space Requirements 12

2.5 Air Distribution System 12

2.6 Flue System 13

2.7 Flue Installation 13

3.0 Installation 16

3.1 Packaging & Siting 16

3.2 Flooring 16

3.3 Minimum Clearances 16

3.4 Assembly 16

3.5 Gas Installation and Connection 17

3.6 Electrical Installation & Connection 17

3.7 Air Distribution Installation 17

3.8 Warm Air Registers 17

3.9 Heater Control Installation 18

4.0 Commissioning 18

4.1 Pre-Test 18

4.2 Ignition 19

4.3 Air Delivery System 21

4.4 Hand Over 21

5.0 Servicing 22

5.1 Planned Servicing 22

5.2 Servicing Procedure - Major Component Parts 22

5.3 Servicing - Re-commissioning 25

6.0 Fault Diagnosis By Flow Charts 26

7.0 Wiring Diagrams by Model and Burner Type 28

8.0 Technical Data Net Efficiency Calculations 35

8.1 Benson Cabinet Range Data 36

9.0 Reference Documents Standards, Codes of Practice 39

9.1 Parts Listing 40

S E C T I O N 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

I L L U S T R A T I O N S

Page No

Exploded view 8

Flue Systems 14-15

Fan and Motor Configurations 23

Fault Diagnosis Flow Charts 26

Wiring Diagrams 28

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.

IMPORTANT NOTICE TO INSTALLERS

Installers should satisfy themselves that the gas pipework installation is carried out in

accordance with all current legislation, Codes of Practice and

recommendations .

Additionally it may be necessary to protect the gas valves which form part of

the heater or burner assembly from potential pipe contamination particularly,

but not exclusively , where copper gas pipework is used.

In instances where copper pipework is to be used for all or part of a gas

pipework installation, including short length final connections then we advise

that installers consult with gas supplier or provider and satisfy themselves what

additional precautions may be necessary

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)

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).

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.

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

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

BS EN 60335 - Part 1 : 1988

Safety of Household and Similar Electrical

Appliances General Requirements

BS EN 55014 - 1993

Limits and methods of measurement of radio

disturbance characteristics of electrical

motor-operated and thermal appliances for

household and similar purposes, electrical

tools and similar electric apparatus

BS EN 50165 - 1997

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.

1.2 General product information

The Benson range of indirect gas fired forced

convection heaters have an output range

from approximately 29.3 kW to 381.0 kW and

are available in a configuration that will allow

for down flow, horizontal, floor mounting, or

above ground level on purpose built steel

supports.

The units can suit either ducted applications,

or be used as free blowing units, but each

heater must be connected to its own

individual open flue.

Each heater is fitted with a forced draught

burner which has been test fired and pre-set

prior to 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

Caution

Before installation, check that the local

distribution conditions, nature of gas and

pressure, and the current state adjustment of

the appliance are compatible.

Installation, commissioning, and servicing

must only be carried out by appropriately

qualified and competent persons.

Warning

Unauthorised modifications to the appliance,

or departure from the manufacturers

guidance on intended use, or, installation

contrary to the manufacturers

recommendations may constitute a hazard.

Note

To ignore the warning and caution notices,

and to ignore the advice from the

manufacturer on installation, commissioning,

servicing, or use, will jeopardise any

applicable warranty, moreover, such a

situation could also compromise the safe and

efficient running of the appliance itself, and

thereby constitute a hazard.

The installation of the appliance must meet

all the relevant European, national, and local

criteria. (See sections 3 and 9).

Prior to installation the following points

should be considered;

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

f) The height if applicable at which the heater

is to be mounted and potential stratification /

circulation problems.

g) The position of the heater relative to

service and maintenance requirements

Caution

The heater must not be installed within an

area where the conditions are unsuitable,

e.g. where the atmosphere is highly

corrosive, has a high degree of salinity, or

where high wind velocities may affect burner

operation. Suitable protection should be

provided for the appliance when it is located

in a position where it may be susceptible to

external mechanical damage from; for

example, fork lift trucks, 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

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

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'.

Note (i)

The warranty may be invalidated if -

a) The warranty registration/commissioning

card has not been completed and returned to

Benson Heating

b) The installation is not in accordance with

the general requirements of this manual

c) The flue arrangement and air supply for

the heater are not in accordance with the

manufacturers

recommendations, codes of practice, or

similar standards

d) Air flow through the heater is not in

accordance with the manufacturers technical

specifications

e) Internal wiring on the heater has been

tampered with or unauthorised service or

repairs undertaken

f) The main electrical supply input to the

heater has been interrupted during the

heating mode

g) The heater has been subject to and

affected by the ingress of water in any form

h) The heater is not operated at the rating(s)

laid down in the manufacturers technical

specifications

i) The heater has not been operated or used

within the normal scope of its intended

application

j) The manufacturer's recommended

minimum service requirements have not

been complied with

Note (ii)

All warranty claims must contain the

following information to enable processing to

take place;

(1) Heater model

(2) Heater serial number

(3) Order reference/date of order, together

with full installation details (name and

address)

(4) Details or symptoms of fault

(5) Installers name and address.

Faulty parts must be returned to the Knighton

Spares Department, the address of which is

provided in Section 2 of this manual. Any

such parts will undergo inspection to verify

the claim. Replacement parts supplied prior

to this may be charged, and a credit supplied

upon subsequent validation of the warranty

claim.

Consumable items are specifically not

included within the scope of the warranty.

Note (iii)

Notification is required immediately a fault is

suspected.

The manufacturer will not accept

responsibility for any additional damage that

has been caused, expense incurred, or

consequential loss resulting from any failure

of the heater(s).

2.0 Location / Positioning

Warning

All of the basic criteria must be satisfied prior

to commencing installation and

commissioning, additionally, the Cabinet

Heater must be positioned and installed so

as to comply with all the relevant standards

and guide lines (see section 9.0), as well as

meeting national and local fire regulations

and insurance criteria, especially if it is

proposed that the heater is to be installed

within a special risk area (e.g. proximity to

where petrol engined vehicles are stored or

parked, where cellulose spraying takes

place, where woodworking machinery is

operated, etc,).

Indirect fired heaters must not be located in

hazardous areas, however, it is permissible

for the heater to supply air to such areas.

The heater must not be installed within an

environment where there is a high

concentration of chlorides, fluorides, salts, or

other aggressive or volatile chemicals /

compounds. 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.

The location must also allow for adequate

clearance for the air supply, return air

circulation, oil supply, electrical supply, whilst

also providing good and safe working

access. The heater must be installed on a

flat and level surface made from non-

combustible material, which is sufficiently

robust to withstand the weight of the heater

and any ancillary equipment. Any

combustible material adjacent to the heater

or flue system must be so placed or shielded

so that its surface temperature does not

exceed 65oC.

In areas where it is proposed that more than

one heater is to be installed, a general

scheme of circulation should be drawn up

and maintained, thereby offering the best

heat distribution.

All Benson Heaters are fitted with a pressure

relief facility, this is incorporated into the

design of the flue gas exit duct. Care should

therefore be taken in siting service

connections and controls well away from the

pressure relief vent.

Warning

Under no circumstances must the pressure

relief be restricted, blocked, or have the free

exit of exhaust gas impaired or re-directed.

2.1 Gas supply - general

The Benson range of gas fired cabinet

heaters are all manufactured and pre-set for

use with natural gas or LPG classified under

the categories, based upon the destination of

the heater see section 8.0

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.

If it is necessary to fit a gas booster, the

controls must include a low pressure cut-off

switch which must be fitted on the supply

side of the booster. It is also a requirement

that the gas supplier is contacted prior to the

fitting of the unit.

Note

Reference to the Institute of Gas Engineers

publication UP-1 and UP-2 together with

BS6891 is strongly advised.

Service and Installation pipework must be of

a diameter equal to or greater than the inlet

connection on the heater, all joints must be

sealed using an approved sealing

compound, and the system purged and

tested for soundness.

2.2 Electrical supply

Wiring external to the cabinet heater must be

installed in accordance with any local,

national, and European regulations, as well

as meeting the appropriate requirements of

IEE regulations.

The means of connection to the main

electrical supply must allow for complete

electrical isolation of the heater, furthermore,

in the case of a unit wired for a three phase

supply, the supply should only be used to

serve the heater itself and no other plant or

equipment.

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

an emergency, or during servicing, when the

heat exchanger has been allowed to cool

sufficiently to prevent any damage from

occurring. Claims for damage will not be

considered if they have resulted from

incorrect wiring or the incorrect use of the

heater.

2.3 Air supply

Consideration must be given to the provision

of air for the purposes of combustion and

ventilation of the heated space, plant room or

enclosure where heaters are to be installed

Note

It is strongly recommended that BS 6230 :

2005 is referred to for further information

concerning ventilation requirements

Where mechanical ventilation is used it is a

requirement that the inlet is of the

mechanical type, and the outlet is either

mechanical or natural.

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)

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

 2cm2for 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.

The table in the next column provides

specific data for each heater model as -

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

 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

Minimum Free Area of

ventilation opening

High Level Low Level

cm2cm2

100 None 64

125 None 79

150 None 97

200 None 127

250 None 160

300 None 193

400 None 257

500 None 291

600 None 386

700 None 460

800 None 515

1000 None 623

1200 None 769

1300 None 847

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