BENSON 30, 60, 40, 120, 135 Installation And Operating Manual

...

BENS

Benson equipment must be installed and maintained in accordance with the relevant provisions of the Gas

Safety (Installations and Use) Regulations 1998 for gas red products. Due account should also be taken of any obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896 (Industrial & Commercial) and any other relevant British Standards and Codes of Practice by a qualied installer. All external wiring MUST comply with the current IEE wiring regulations.

Benson Gas Fired

Cabinet Heaters

installation and operatinG Manual

Part No. 20-45-159

INDEX Section

Introduction and Document Index

Installation Requirements ................................................................................. 1

Installation Instructions ................................................................................. 2

Commissioning Instructions ................................................................................. 3

Servicing Instructions ............................................................................................... 4

Spare Parts ............................................................................................... 5

Fault Finding Guide ............................................................................................... 6

Replacing Parts ............................................................................................... 7

User and Operating Instructions .................................................................... 8

WARNINGS

Doc No. 20-45-159 Page 2 of 60

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, Specications, 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. The Manufacturer 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 nal connections then we advise that installers consult with gas supplier or provider and satisfy themselves what additional precautions may be necessary

Doc No. 20-45-159 Page 3 of 60

Introduction.

elcome to the Gas Fired Cabinet Heater Range.

Local regulations may vary in the country of use and it is the installers responsibility to ensure that such regulations are satised

All installation, assembly, commissioning and service procedures must be carried out by suitable qualied competent persons to the statutory regulations in the country of use.

When installing, commissioning and servicing is undertaken

on these heaters due care and attention is required to ensure that working at height regulations are adhered to at the mounting heights specied.

All Dimensions shown are in mm unless

PLEASE READ this document prior to installation and

use. The safety of this heater is guaranteed only by the correct usage in accordance with these instructions, therefore it is recommended that they are retained for future reference.

The manufacturer reserves the right to alter specications without prior notice.

Document Index.

1 Installation requirements

1.1 Compliance notices

1.2 Certicates of conformity

1.3 General product information

1.4 General requirements

1.5 Delivery and pre-installation checks

1.6 Warranty

1.7 Health and Safety

1.8 Location / Positioning

1.9 Gas supply

1.10 Electrical supply - general

1.11 Air supply

1.11.1 Heaters installed within the heated space.

1.11.1.1 Natural ventilation openings to the heated space.

1.11.2. Heaters Installed within a plant room or enclosure.

1.11.2.1 Natural ventilation openings to plant rooms

1.11.2.2 Natural ventilation openings to enclosures

1.11.2.3 Mech ventilation - plant room or enclosure.

1.12 Air distribution system

1.13 Flue system.

1.14 Dimensions

1.15 Technical details

1.15.1 Reference information

1.15.2 Technical information 2 Installation Instructions

2.1 Packaging/siting

2.2 Flooring

2.3 Minimum clearances

2.4 Assembly

2.5 Flue installation

2.6 Gas Installation/Connection

2.7 Electrical Installation/Connection

2.8 Air distribution installation

2.9 Warm air registers

2.10 Heater control installation Wiring diagrams

3 Commissioning instructions

3.1 Commissioning - pretest

3.2 Commissioning - ignition

3.3 Commissioning - air delivery system.

3.4 Commissioning - hand over 4 Servicing instructions

4.1 Planned servicing.

4.2 Servicing procedure - Major component parts

4. 2 .1 Flue

4.2.2 Main fan motor

4.2.3 Main fan

4.2.4 Pulleys

4.2.5 Fan belts

4.2.6 Heat exchanger

4.2.7 Electrical supply

4.2.8 Gas supply

4.2.9 Burner

4.2.10 Air delivery system

4.2.11 Report

4.3 Service re-commissioning 5 Spare parts 6 Fault nding guide 7 Replacing parts

7.1 Burner

7.2 Controller

7.3 Electrode assembly

7.4 Contactor/Overload

7.5 MCB

7.6 Fan/Limit stat assembly

7.7 Fan belts

7.8 Blower motor

7.9 Fan blower 8 User and Operating Instructions

8.1 Commissioning and hand over

8.2 Servicing

8.3 Start up procedure

8.4 Stop procedure

8.5 Shut down procedure

8.6 Ventilation only

8.7 Lockout situations

Doc No. 20-45-159 Page 4 of 60

1. Installation Requirements.

1.1 Compliance notices

he Gas Fired Cabinet Heater range detailed herewith are manufactured 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 modication of then appliance to the conditions of use for the country.

The Gas Fired Cabinet Heater range have been tested and assessed for compliance with the following European Directives.

Machinery Directive: (2006/42/EC) Low Voltage Directive: (2006/95/EC) Electromagnetic Compatibility Directive: (2004/108/EC) Product Liability Directive: (85/374/EEC)

The manufacturer has taken reasonable and practical steps to ensure that all Gas Fired 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 Gas Fired Cabinet Heater range has 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.

The manufacturer supports all new products being supplied to their customers with a comprehensive information pack; this clearly denes mandatory instructions for the safe installation, use, and maintenance, of the appliance(s).

Where proprietary items are incorporated into any Gas Fired Cabinet Heaters, 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 Gas Fired Cabinet Heaters to ensure that they are familiar with the appropriate information/manuals supplied by the manufacturer 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 ecient use.

The manufacturer has a commitment to continuous improvement and therefore reserve the right to amend or change the specication of Cabinet Heaters subject to compliance with the appropriate European, national and local regulations

Contained within the text of the manual, the words ‘Caution’ and ‘Warning’ are used to highlight certain points.

Caution is used when failure to follow or

implement the instruction(s) can lead to

premature failure or damage to the heater or its

component parts.

Warning is used when failure to heed or

implement the instruction(s) can lead to not only

component damage, but also to a hazardous situation being created where there is a risk of personal injury.

The Gas Fired Cabinet Heater range conform to the following harmonised standards:

BS EN 292 -1 Safety of Machinery - Basic Concepts, General Principles for

Design Basic terminology, methodology BS EN 292-2

BS EN 292 -2 Safety of Machinery - Basic Concepts, General Principles for

Design Technical Principles and Specications

BS EN 60204-1 Safety of Machinery - Electrical Equipment for Machines

Specication for General Requirements

BS EN 60335-1 Safety of Household and Similar Electrical Appliances General

Requirements

BS EN 55014 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 Electrical Equipment of non-electric heating appliances for

household and similar purposes, safety requirements

1.2 Certicates of conformity

Certicates of conformity are available from the manufacturer, address details are shown on the back page.

Doc No. 20-45-159 Page 5 of 60

Notied body PIN reference is: 0558CM1312

1.3 General product information

The Gas Fired Cabinet Heater models have an output range from approximately 32.0 kW to 381kW, and are available in a conguration that will allow for down ow, horizontal, or oor mounting.

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 ue.

Each heater is tted with a forced draught burner which has been test red and pre-set prior to despatch. The safety functions of the burner are by way of a fully sequential control box tted to the burner.

Note

Neither asbestos nor soft soldered joints are used in the construction or manufacture of The Gas Fired Cabinet Heater range. 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.

1.4 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 qualied and competent persons.

Warning

Unauthorised modications 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 ecient 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.

Prior to installation the following points should be considered;

• The position of the heater for the optimum ecient distribution and circulation of warm air.

• The position of the heater relative to the route of the ue

• The position of the heater relative to the supply of gas

• The position of the heater relative to the electrical services, and if appropriate, any additional controls.

• The position of the heater relative to the supply of fresh air

• The height if applicable at which the heater is to be mounted and potential stratication /circulation problems.

• 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 aect 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.

1.5 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;

• The model is as per order.

• That it is undamaged.

• That it is suitable for the fuel supply.

• That it is suitable for the electrical supply

If any of these points are not satised then contact should be made with the suppliers sales oce as soon as possible by telephoning the number shown on the rear page. 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.

1.6 Warranty

The heater is supplied with a 1 year parts and labour warranty and a further year on all parts excluding consumable’s.

In addition to this there is a 10 year time related warranty on the combustion chamber.

The warranty commences from the date of dispatch from the manufacturer, and is subject to the terms detailed within the

Doc No. 20-45-159 Page 6 of 60

Manufactures ‘conditions of business’.

Note (i)

The warranty may be invalidated if -

• The installation is not in accordance with the general requirements of this manual.

• The ue arrangement and air supply for the heater are not in accordance with the manufacturers recommendations, codes of practice, or similar standards.

• Air ow through the heater is not in accordance with the manufacturers technical specications.

• Internal wiring on the heater has been tampered with or unauthorised service or repairs undertaken.

• The main electrical supply input to the heater has been interrupted during the heating mode.

• The heater has been subject to and aected by the ingress of water in any form.

• The heater is not operated at the rating(s) laid down in the manufacturers technical specications.

• The heater has not been operated or used within the normal scope of its intended application.

• The manufacturer’s recommended minimum service requirements have not been complied with

Note (ii)

All warranty claims must contain the following info to enable processing to take place

• Heater model

• Heater serial number

• Order reference/date of order, together with full installation details (name and address)

• Details or symptoms of fault

• Installers name and address.

Faulty parts must be returned to the supplier, the address of which is provided at the rear 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 specically not included within the scope of the warranty.

Note (iii)

Notication 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).

1.7 Health and Safety

The Gas Fired Cabinet Heater range must be installed in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998. Due account should also be taken of any obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896: (Industrial & Commercial) and any other relevant British Standards and Codes of Practice by a qualied installer. Isolate all electrical supplies to the heater & controller before proceeding.

For your own safety we recommend the use of safety boots and leather faced gloves when handling sharp or heavy items. The use of protective eye wear is also recommended.

Caution

Before using this appliance:

• Check that the voltage indicated on the type plate corresponds to the mains supply voltage.

• Ensure that the heater has been securely fastened in its nal mountain position.

UNDER NO CIRCUMSTANCES should any item be placed

on or above any part of the heater, whether the heater is being used or not.

WARNING: This appliance must be earthed.

1.8 Location / Positioning

Warning

All of the basic criteria must be satised prior to commencing installation and commissioning, additionally, the Gas Fired Cabinet Heater must be positioned and installed so as to comply with all the relevant standards and guide lines (see section 1.1), as well as meeting national and local re 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 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, uorides, salts, or other aggressive or volatile chemicals/compounds. Nor should the heater be positioned where the burner could be adversely aected by high winds or draughts.

The location chosen for the heater must allow for the tting of an eective ue system.

Doc No. 20-45-159 Page 7 of 60

The location must also allow for adequate clearance for the air supply, return air circulation, gas supply and electrical supply, whilst also providing good and safe working access. The heater must be installed on a at and level surface made from non-combustible material, which is suciently robust to withstand the weight of the heater and any ancillary equipment. Any combustible material adjacent to the heater or ue system must be so placed or shielded so that its surface temperature does not exceed 65°C.

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 oering the best heat distribution

All Gas Fired Cabinet Heaters are tted with a pressure relief facility, this is incorporated into the design of the ue 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.

1.9 Fuel supply - general

The Gas Fired Cabinet Heater range are all manufactured and pre-set for use with natural gas or LPG classied under the categories, based upon the destination of the heater see

se c tion 1.15.1

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 conrm 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 aect that such installations will have upon other plant sharing the gas supply.

If it is necessary to t a gas booster, the controls must include a low pressure cut-o switch which must be tted on the supply side of the booster. It is also a requirement that the gas supplier is contacted prior to the tting 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.

1.10 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.

Caution

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 o before any electrical work is carried out on the heater.

Caution

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.

Warning

All cabinet heaters must be earthed.

Caution

The main electrical supply must not be switched o 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 suciently 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.

Doc No. 20-45-159 Page 8 of 60

1.11 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 BS6230 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.

1.11.1 Heaters installed within the heated space.

Where heaters are installed within the space to be heated (i.e. not a plant room or enclosure) then:

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 satised by natural inltration 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 1.11.1.1. refers) or the mechanical ventilation of the heated space (section 1.11.1.2. refers)

1.11.1.1 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 oor level for natural gas but no higher than 250 mm.

The following table provides specic data for each heater model as -

Minimum Free Area of ventilation

opening

Model High Level cm² Low Level cm²

30 None 64

40 None 97

60 None 127

85 None 193

120 None 257

135 None 291

180 None 386

205 None 460

235 None 515

300 None 623

375 None 847

1.11.1.2 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.

1.12.2. Heaters Installed within a Plant Room or Enclosure.

A plant room means a room housing the heater plant and probably other items of building service plant and would generally have generous space for maintenance.

An enclosure is where the heater is installed within a compartment or conned area where space is limited.

Where heaters are installed within a plant room or enclosure then provision for both combustion air and air for general ventilation will be required by means of high and low level ventilation

Doc No. 20-45-159 Page 9 of 60

openings (sections 1.11.2.1 refers to plant room applications and sections 1.11.2.2 refers to enclosure applications).

Alternatively the plant room or enclosure may be mechanically ventilated (section 1.11.2.3 refers).

1.11.2.1 Natural Ventilation Openings to Plant Rooms

For plant room applications the minimum free area of ventilation opening shall be:

• At high level 2cm2 for each kW of rated heat input.

• At low level 4cm2 for each kW of rated heat input.

The high level ventilation opening should be sited on an external wall and positioned as high as is practical and always within the top 15% of the wall height.

The low level natural ventilation opening should be situated on an external wall and be within 1000 mm of oor level for natural gas installations but no higher than 250 mm.

The table below provides specic data for each heater model as -

Minimum Free Area of ventilation

opening

Model High Level cm² Low Level cm²

30 64 128

40 97 194

60 127 254

85 193 386

120 257 514

135 291 582

180 386 722

205 460 920

235 515 1030

300 623 1246

375 847 1694

1.11.2.2 Natural Ventilation Openings to Enclosures

For enclosure applications the minimum free area of ventilation opening shall be:

• At high level 5cm2 for each kW of rated heat input.

• At low level 10cm2 for each kW of rated heat input.

The high level ventilation opening should be sited on an external wall and positioned as high as is practical and always within the top 15% of the wall height

The low level natural ventilation opening should be situated on an external wall and be within 1000 mm of oor level for natural gas installations but no higher than 250 mm.

The table in the next column provides specic data for each heater model as:-

Minimum Free Area of ventilation

opening

Model High Level cm² Low Level cm²

30 159 318

40 244 488

60 317 634

85 483 966

120 643 128 6

135 726 1452

180 965 1930

205 1152 2304

235 1287 2574

300 1558 3116

375 2118 4236

1.11.2.3 Mechanical Ventilation to a Plant Room or Enclosure.

In the event that the installer prefers to mechanically ventilate the plant room or enclosure rather than provide ventilation openings then:-

• The plant room or enclosure needs to be mechanically ventilated at the rate of 4.14 m3/h of fresh air per kW or rated heat input.

• It is a requirement that the mechanical ventilation shall be of the ’input’ type with either natural or mechanical extraction. Where mechanical extraction is selected then the extraction rate should be 5%-10% less than the input rate.

• Systems of mechanical extraction with a natural inlet shall not be used

Doc No. 20-45-159 Page 10 of 60

It is necessary to provide an automatic means to safely inhibit heater(s) operation should mechanical air supply fail for any reason

The table to follow provides specic data for each heater model as -

Mechanical Ventilation Rate for Plant Room or Enclosure

Model M³/h

30 139

40 206

60 274

85 409

120 567

135 717

180 822

205 987

235 1131

300 1410

375 1830

1.12 Air distribution system

All materials used within the construction of the delivery and return air ducts must not represent a re 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 re resistant insulation material.

In installations where forced recirculation is a feature, a full and unobstructed return air path to the heater(s) must be provided, with return air grilles connected by ducting directly to the return air inlet on the heater.

The limit for recirculation should not be greater than 85% re-circulated air to 15% fresh air.

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 ue.

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 500mm above the outside oor or ground level, it must also be tted 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 re resistant material and constructed to prevent the likelihood of any re from spreading.

In ducted applications the ductwork must be designed so as to give a static pressure within the limits stated in section 15 of this manual. It should be noted that if the static pressure is too high, nuisance shut-down will occur when the heater goes out on the overheat limit thermostat, if the static pressure is too low, then damage can be caused to the fan motor.

Warm air outlets on ducted applications must be such that they cannot be closed or become blocked, which again would lead to an increase in static pressure and nuisance shut-down. The outlets must not be sited so that warm air can be discharged onto combustible materials, if necessary, guard rails should be used to ensure that eected areas are kept clear.

Return air intakes must not be located so that potentially harmful or hazardous contaminated air can be drawn into the system.

1.13 Flue system.

Warning

It is essential that the products of combustion are ued to the outside of the building. Each heater must have its own separate ue, with a ue diameter of not less than is detailed in section 15 within this manual.

The minimum vertical length of ue must not be less than 3m. The ue should rise vertically, and the number of bends should be kept to a minimum.

Flue pipes below a height of 2m should be guarded against the possibility of being accidentally touched when hot by personnel

Note:

It is strongly advised that BS 5854; 1980, and BS 5440; parts 1

Doc No. 20-45-159 Page 11 of 60

and 2, are used as consultative documents when considering ue requirements.

Care should be taken to ensure that the ue terminal is not situated in a high-pressure area, the proximity of buildings and other obstacles which will inuence this must be taken into account, preferably at the design stage. See pages 15 & 16

Provision must be made for the disconnection of the ue for inspection and service requirements, and it is strongly advised that where bends are tted inspection covers are included.

The materials from which the ue is constructed must be non-combustible, resistant to internal and external corrosion, and be capable of withstanding the stresses and loadings associated with normal use.

When designing the ue system the prevention of the formation and entrapment of condensation must be a key consideration.

Twin wall or insulated systems are recommended, as they tend to inhibit the formation of condensates.

Where condensation is unavoidable traps should be included to encourage the condensates to ow freely to a point from which they may be released, preferably into a gully.

The condensate pipe from the ue to the disposal point must be made from corrosion resistant pipe of not less than the internal diameter of the drain pipe.

If the ue passes through a wall, ceiling, or roof made from combustible material then it has to be sleeved so as to provide a minimum of a 25mm void between the exterior of the ue and the internal wall of the sleeve. The maximum permitted temperature of any adjacent combustible material is 65°C.

The position of the ue 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 ue gases without risk of their re-entering the property through windows, ventilation ports, etc. The ue should extend to at least 1m above the height of any object within 3.5m of the terminal.

Flue terminals should be tted on all ues, 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 ue.

Caution

It is imperative that the ue should be properly sealed where it passes through the roof, this can best be achieved by using the approved method of roof ashing 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 ue has not made provision for possible condensation problems.

Doc No. 20-45-159 Page 12 of 60

Flat roof with parapet

Flat roof envelope method

Flat roof where the ue height is more than 10 Heights (H) away from all structures

Flat roof with ue close to parapet

Doc No. 20-45-159 Page 13 of 60

Flat roof with no parapet

Flat roof with structure close to ue outlet

Pitched roof not greater than 45°

Doc No. 20-45-159 Page 14 of 60

Front View Side View

Top View - Nozzle Outlet

(also showing spigot Ø )

Top View - Duct Outlet

1.14 Dimensions

Doc No. 20-45-159 Page 15 of 60

Dimensions for Vertical Cabinet Heaters (all dims in mm)

Model 30 40 60 85 120 135 180 205 235 300 375

Unit height

1650 1650 1900 1900 2025 2025 2120 2120 2110 2110 2667

Unit width

660 660 660 660 790 790 1000 1000 110 0 1100 124 4

Unit depth

662 662 925 925 1085 1085 1282 1282 1550 1550 1550

Flue outlet ctr

95 95 170 170 170 170 213 213 195 195 203

Flue Spigot Ø

125 125 150 175 175 175 200 200 225 225 250

Stack Box depth

250 250 320 320 327 327 394 394 380 380 355

Burner depth

295 295 346 346 389 389 389 508 508 508 580

Nozzle outlet width

280 280 280 280 305 305 355 355 406 406 474

J J1

Nozzle height Std Nozzle height Ext

240 n/a

300 n/a

330 660

360 720

410 815

460 915

613 1115

Stack Box height

150 0 1500 1778 17 78 1865 1865 1980 1980 1965 1965 2610

Burner ctr/l height

835 835 984 984 971 971 1068 1068 1054 1054 1372

Outlet Spigot depth

570 570 770 770 944 944 1120 1120 1452 1452 1365

Outlet Spigot width

570 570 634 634 711 711 890 890 1002 1002 1086

Nozzles Spigot Ø

240 (2) 240 (2) 240 (2) 240 (3) 280 (3) 280 (4) 320 (4) 320 (4) 370 (4) 370 (4) 370 (4)

Dimensions of Return Air Spigots (all dims in mm)

Model 30 40 60 85 120 135 180 205 235 300 375

Side height

348 348 427 427 642 642 691 391 654 654 796

Side width

522 522 702 702 904 904 1077 1077 1145 114 5 115 0

Rear height

445 445 550 550 642 642 896 896 654 354 n/a

Rear width

620 620 520 520 687 687 691 691 935 935 n/a

Filterbox height

420 420 600 600 702 702 765 765 720 720 860

Filterbox width

660 660 800 800 990 990 1165 1165 1245 1245 1530

Filterbox depth

300 300 300 300 300 300 300 300 450 450 450

Side Inlet Spigot (L/H or R/H) Rear Inlet Spigot Side Inlet inc Filter box (L/H or R/H)

Doc No. 20-45-159 Page 16 of 60

Dimensions for Horizontal Cabinet Heaters (all dims in mm)

Model 85 135 205 300 375

Unit length

1865 1960 2057 2076 2667

Unit height

660 790 1000 110 0 124 4

Unit width

925 1085 1282 1550 1550

Flue outlet ctr to front

170 170 213 195 203

Outlet nozzle width

160 280 366 320 320

Flue outlet ctr/l to end

1660 1761 1858 1823 2426

Burner ctr/l to end

984 971 1068 1054 1372

Outlet Spigot width

770 944 1120 1452 1365

Outlet Spigot height

634 711 890 1002 1086

Outlet Flange depth

30 30 30 30 30

Inlet Flange depth

50 50 50 50 50

Feet centres length

1806 1895 1992 2020 2612

Feet width

1157 1365 1565 1826 1826

Feet centres width

1081 1289 1489 1750 1750

Doc No. 20-45-159 Page 17 of 60

Dimensions for Downturn Cabinet Heaters (all dims in mm)

Model 85 135 205 300 375

Unit height

1865 1960 2057 2076 2667

Unit width

660 790 1000 110 0 1244

Unit depth

925 1085 1282 1550 1550

Flue outlet ctr to front

170 170 213 195 203

Outlet nozzle height

160 280 366 320 320

Flue outlet ctr/l to top

1660 1761 1858 1823 2426

Burner ctr/l to top

984 971 1068 1054 1372

Outlet Spigot width

770 944 1120 1452 1365

Outlet Spigot height

634 711 890 1002 1086

Outlet Flange depth

30 30 30 30 30

Inlet Flange depth

50 50 50 50 50

Doc No. 20-45-159 Page 18 of 60

1.15 Technical Details

Model 30 40 60 85

Heat Output (max)

kW/hr Btu/hr

29.1 99,289

39.74 124,191

58.1 198, 237

82.5

282. 513

Heat Input (Gross)

kW/hr Btu/hr

35.4 120,785

48.9 166,847

70.3 239,864

102.1 348,365

Heat Input (Nett)

kW/hr Btu/hr

31.9 108,823

44.09

150.435

63.3 215,979

91.9 313,563

Nett Eciency

% 91.2 90.14 91.72 90.06

Burner Type

Riello GS5 GS5 GS10 GS10

Gas Connection

RC½ RC½ RC½ RC½

Fuel Consumption Nat Gas

m³/ hr ft ³/ hr

3.37 119

4.66 165

6.69 236

9.71 343

Burner Pressure Nat Gas

mbar Ins WG

2.3

0.9

3.6

1.4

2.5

1.0

5.3

2.1

Min Gas Inlet Pressure Nat Gas

mbar 17. 5 17. 5 17. 5 17. 5

Head Setting Nat Gas (no ue)

Number 2.0 5.0 2.0 4.0

Air Setting Nat Gas (no ue)

Number 2.8 4.5 2.8 6.0

Fuel Consumption LPG

m³/ hr ft ³/ hr l/h

1.3 46

4.9

1.78 63

6.7

2.56 91

9.7

3.7 131

14.0

Burner Pressure LPG

mbar Ins WG

3.1

1.2

4.6

1.8

3.5

1.4

5.5

2.2

Min Gas Inlet Pressure LPG

mbar 37.0 37. 0 37.0 37. 0

Head Setting LPG (no ue)

Number 1 5 2 3.5

Air Setting LPG (no ue)

Number 2.5 4 2.8 4

Available Outlet Pressure

Pascals Ins WG

0.3

100

0.4

144

0.6

105

0.4

Nozzle Discharge Velocity

m/sec ft/min

5.73 1124

4.53 888

6.8 1339

6.88 1354

Air Throw (approx)

mtrs ft

14 45

17.1 55

Air Delivery (std)

m³/sec ft ³/min

0.61 130 0

0.71 150 0

1.03 2180

1.39 2950

Temp Rise Through Heater

°C °F

39 70

50.3 90

47. 2 85

Combustion Chamber

mbar 0.21 0.21 0.24 0.34

Sound Level

dba 67 69 69 71

Flue Resistance

Min mbar Max mbar

-0.2

0.6

-0.2

0.6

-0.2

0.6

-0.2

0.6

Flue Diameter

mm 125 125 150 175

Electrical Supply

Standard 230/1/50 230/1/50 230/1/50 230/1/50

Rated Input

kW 0.55 0.55 0.75 0.75

Fused Isolator Size

Amps 16 16 20 20

Running Current

Amps 3.2 4.8 7.9 8.5

Electrical Supply

Optional n/a n/a 415/3/50 415/3/50

Rated Input

kW n/a n/a 1.5 1.5

Fused Isolator Size

Amps n/a n/a 16 16

Running Current

Amps n/a n/a 2.2 2.2

Weight

kg 196 196 245 247

Nozzle Amount

no. 2 2 2 3

Nozzle top Plate Outlet Dia

Ø mm 242 242 242 242

Flue Temperature (Gross)

@ 20°C Ambient

220 254 200 210

Doc No. 20-45-159 Page 19 of 60

Model 120 135 180 205

Heat Output (max)

kW/hr Btu/hr

117. 3 400,227

132.5 452,090

176. 8 603,241

205.5 701,200

Heat Input (Gross)

kW/hr Btu/hr

142.8 487, 23 4

161.2 550,014

214. 2 730,850

250.6 822,300

Heat Input (Nett)

kW/hr Btu/hr

128 .6 438,783

145,3 495,763

193.0 658,516

225.6 769,747

Nett Eciency

% 91.24 91.2 91.6 91.1

Burner Type

Riello GS20 GS20 GS20 RS34.1

Gas Connection

RC¾ RC¾ RC1 RC1¼

Fuel Consumption Nat Gas

m³/ hr ft ³/ hr

13. 6 480

15. 3 541

20.4 720

23.85 842

Burner Pressure Nat Gas

mbar Ins WG

4.0

1.6

4.6

1.8

5.9

2.3

7.2

2.9

Min Gas Inlet Pressure Nat Gas

mbar 17. 5 17. 5 17.5 17. 5

Head Setting Nat Gas (no ue)

Number 3 4 4 2

Air Setting Nat Gas (no ue)

Number 3.2 4.2 8 3

Fuel Consumption LPG

m³/ hr ft ³/ hr l/h

5.2 184

19.6

5.9 208

22.2

7.8 276

29.5

9.13 322

34.5

Burner Pressure LPG

mbar Ins WG

5.2

2.0

7.8

3.1

tba tba

Min Gas Inlet Pressure LPG

mbar 37.0 37. 0 37. 0 37. 0

Head Setting LPG (no ue)

Number 1.5 4.0 4.0 2.0

Air Setting LPG (no ue)

Number 4.5 4.2 8.0 3.0

Central Air Adjustment

Number n/a n/a n/a 2.8

Available Outlet Pressure

Pascals Ins WG

137

0.55

150

0.6

175

0.7

188

0.75

Nozzle Discharge Velocity

m/sec ft/min

7.55 1481

6.98 1369

6.13 1203

6.71 1315

Air Throw (approx)

mtrs ft

20.2 65

21.7 70

Air Delivery

m³/sec ft ³/min

2.15 4550

2.65 5620

3.11 6600

3.4 7200

Temp Rise Through Heater

°C °F

45.1 81

44.5 81

44.7 81

49.2 88

Combustion Chamber

mbar 0.56 0.88 0.54 0.62

Sound Level

dba 74 75 78 78

Flue Resistance

Min mbar Max mbar

-0.2

0.6

-0.2

0.6

-0.2

0.6

-0.4

1.6

Flue Diameter

mm 175 175 200 200

Electrical Supply

Standard 415/3/50 415/3/50 415/3/50 415/3/50

Rated Input

kW 1.5 2.2 3.0 3.0

Fused Isolator Size

Amps 16 16 25 25

Running Current

Amps 3.6 5.2 6.5 6.5

Electrical Supply

Optional 230/1/50 230/1/50 n/a n/a

Rated Input

kW 1.5 2.2 n/a n/a

Fused Isolator Size

Amps 40 40 n/a n/a

Running Current

Amps 12 14 n/a n/a

Weight

kg 330 332 525 540

Nozzle Amount

no. 3 4 4 4

Nozzle top Plate Outlet Dia

Ø mm 271 271 329 329

Flue Temperature (Gross)

@ 20°C Ambient

210 210 255 205

Doc No. 20-45-159 Page 20 of 60

Model 235 300 375

Heat Output (max)

kW/hr Btu/hr

236.8 807,961

283.67 967,9 00

380.5 1,298,300

Heat Input (Gross)

kW/hr Btu/hr

285.7 974,808

345.88 1,180,150

463.6 1,581,803

Heat Input (Nett)

kW/hr Btu/hr

257.4 878,244

311. 6 0 1,063,198

417. 3 1,423,827

Nett Eciency

% 92.0 91.08 91.1

Burner Type

Riello RS34.1 RS34.1 RS50

Gas Connection

RC1¼ RC1¼ RC2

Fuel Consumption Nat Gas

m³/ hr ft ³/ hr

27. 2 960

33.0 116 8

45.8 1617

Burner Pressure Nat Gas

mbar Ins WG

7.4

2.9

11. 5

4.62

tba

Min Gas Inlet Pressure Nat Gas

mbar 17. 5 17. 5 17. 5

Head Setting Nat Gas (no ue)

Number 2.5 4 tba

Air Setting Nat Gas (no ue)

Number 2.7 3.5 tba

Fuel Consumption LPG

m³/ hr ft ³/ hr l/h

10.4 368

39.3

14. 36 516

54.2

19.0 671

71.1

Burner Pressure LPG

mbar Ins WG

18.0

7.2

tba tba

Min Gas Inlet Pressure LPG

mbar 37.0 37. 0 37.0

Head Setting LPG (no ue)

Number 2.5 tba tba

Air Setting LPG (no ue)

Number 2.7 tba tba

Central Air Adjustment

Number 3.4 5.0 n/a

Available Outlet Pressure

Pascals Ins WG

125

0.5

175

0.7

250

1.0

Nozzle Discharge Velocity

m/sec ft/min

6.55 1285

7.39 1445

8.49 1665

Air Throw (approx)

mtrs ft

21.7 70

24.8 80

31.1 100

Air Delivery

m³/sec ft ³/min

4.32 9150

4.86 10,30 0

6.88 14,680

Temp Rise Through Heater

°C °F

44.2 79

48 86

45 81

Combustion Chamber

mbar 0.67 0.92 0.9

Sound Level

dba 79 81 81

Flue Resistance

Min mbar Max mbar

-0.4

1.6

-0.4

1.6

-0.4

1.6

Flue Diameter

mm 225 225 250

Electrical Supply

Standard 415/3/50 415/3/50 415/3/50

Rated Input

kW 4.0 5.5 7.5

Fused Isolator Size

Amps 32 32 64

Running Current

Amps 8.4 11 24

Electrical Supply

Optional n/a n/a n/a

Rated Input

kW n/a n/a n/a

Fused Isolator Size

Amps n/a n/a n/a

Running Current

Amps n/a n/a n/a

Weight

kg 630 646 1090

Nozzle Amount

no. 4 4 4

Nozzle top Plate Outlet Dia

Ø mm 380 380 471

Flue Temperature (Gross)

@ 20°C Ambient

205 200 233

Doc No. 20-45-159 Page 21 of 60

1.15.1 Technical Information

Appliance Type B23

PIN / report number 0558CM1312

Country Approved Gas Category

AT,CH,CZ,DK,EE,ES,FI,GB,GR,HU,IE,ITIS,LT,LV,NO,PT, RO,SE,SI,SK,TR

BE,CZ,NL,FR,DE,IE,IT,ES,CH,PT,GB,SE,SK,SL,PT,PL,TR I

PL,LU,DE,RO I

NL I

BE I

2E(R)B

FR I

2E(R)B

PL I

2LS

PL I

2LW

1.15.2 Reference Information

Doc/Ref Title/Subject

BS EN 1020 Non Domestic Gas Fired Forced Convection Air Heaters For Space Heating BS EN 292-1 &-2 Safety of Machinery BS EN 60204-1 Safety of Machinery - Electrical BS EN 60335-1 Safety of Electrical Appliances BS EN 55014 Electromagnetic Compatibility BS EN 50165 Safety of Electrical Equipment BS 5854 Code of Practice - Flues/Flue Structures BS 6891 Installation of Pipework < 35mm BS 5991 Indirect Gas Fired Heaters < 2 MW BS 715 Metal Flue Pipes and Fittings BS 5440-1 Specication/Installation of Flues BS 5440-2 Ventilation Requirements Gas Appliances ISO 7/1 Specication for Metric Pipe Threads (see also BS21 ) ISO 228/1 Pipe Threads Seals and Couplings See also BS 2779 and BS 5380) UP/1 Installation of Gas Appliances (Replaces IM/5 & IM/16 ) UP/2 Installation of Gas Appliances (Replaces IM/7 )

Doc No. 20-45-159 Page 22 of 60

2. Installation.

t is strongly advised that the installer reads Section 1 of

this manual prior to starting any installation work. It is a requirement that only qualied and competent personnel undertake installation, commissioning, and servicing.

Warning

Always ensure that the appropriate personal protective equipment is used.

2.1 Packaging/siting

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 scheduled to be sited.

Caution

It is strongly advised that when positioning the heater the lifting eyes are used, thereby reducing the risk of inadvertent damage being occasioned to the heater.

2.2 Flooring

The heater must be installed on a level non-combustible surface capable of supporting the weight of the heater and any ancillary equipment.

2.3 Minimum clearances

The following minimum clearances (in millimeters) are recommended when installing the heater.

Model Front Rear LHS RHS

30 - 40 500 700 150 150

60 - 85 500 1000 150 150

120 - 135 600 1200 150 150

180 600 1500 150 150

205 900 1500 150 150

235 - 300 900 2000 400 400

375 900 2000 500 500

2.4 Assembly

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 nal 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 airow.

Ensure louvres are adjusted outwards and ensure blades are not resonating. The nozzles should be securely xed in their desired position on completion of commissioning.

(b) Horizontal Nozzled Models

Remove packaging and secure the 90° Duct Outlet to the outlet on the heater using the bolts supplied.

Secure the nozzle spigot plate to the duct outlet using the bolts and prevailing torque nuts provided. Fit the securing brackets to each of the outlet nozzles, and lift the complete heater assembly and position on the pre-sited purpose built supports. Finish o the assembly by tting and securing the outlet nozzles to the spigots by way of previously tted brackets.

2.5 Flue Installation

An integral ue spigot is tted to all Cabinet Heaters thereby allowing the ue to connect directly to the heater. The design of the ue must ensure that it can be disconnected to allow for cleaning and servicing, furthermore, all of the ue section joint sockets must face upwards, and the seal between the sections achieved through mechanical joints or through the use of approved caulking string and grout.

Caution

It is strongly advised that BS 5854 and BS 5440 parts 1 and 2 are referred to. See also terminal details on page 15 & 16

Where condensation is likely to be a problem provision should be made preferably at the design stage (see section 1.13)

2.6 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 exible coupling, or rigid connection. Threaded connections must comply with ISO288/1 of ISO 7/1, further information concern-

Doc No. 20-45-159 Page 23 of 60

ing 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 1.15 )

Warning

The installation must be purged and tested for soundness prior to commissioning. Always ensure that the appropriate personal protective equipment is used.

2.7 Electrical Installation/connection

Cabinet heaters are available either for 415V 50Hz 3PH or 230V 50Hz 1PH supplies depending upon the model specied.

It is recommended that reference is made to the wiring diagrams contained within section 2.11 of this manual prior to installation or connection to the supply. The electrical supply must be as specied 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 ttings that are used to make the connection between the isolator and the heater must conform to the appropriate IEE regulations.

All heaters are supplied fused and pre-wired, all must be earthed.

Final connections for any additional external controls must be completed on site, and must be carried out according to IEE regulations.

Separate user information is provided for the time control unit and the burner, and forms part of the product information pack which accompanies every heater when despatched.

Warning

Always isolate from mains electrical supply before commencing work on the heater. Always ensure that the ap- propriate personal protective equipment is used.

2.8 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 sucient clearance must be left, irrespective of any re 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 ooring a permanent membrane must be used to isolate the ducting from the corrosive eect 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 insulation eectiveness.

2.9 Warm Air Registers

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 oor 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.

2.10 Heater Control Installation

Warning

Isolate heater from mains before undertaking any electrical work.

Unless specied all Cabinet Heaters are manufactured and supplied with a pre-wired Control panel as standard. Optional remote controllers are available to be wired back to the cabinet heater.

Refer to Controller instruction manual for full installation details.

A commissioning switch is provided on all cabinet heaters tted with a remote controller.

See following section for individual wiring diagrams.

Doc No. 20-45-159 Page 24 of 60

Wiring Diagram 20-45-600 30 - 40 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 25 of 60

Wiring Diagram 20-45-601 60 - 85 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 26 of 60

Wiring Diagram 20-45-602 120 - 135 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 27 of 60

Wiring Diagram 20-45-603 60 - 300 ON/OFF Riello Burner Integral SC³-SZ 415/50/3ph

Doc No. 20-45-159 Page 28 of 60

Wiring Diagram 20-45-616 30 - 40 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 29 of 60

Wiring Diagram 20-45-617 60 - 85 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 30 of 60

Wiring Diagram 20-45-618 120 - 135 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph

Doc No. 20-45-159 Page 31 of 60

Wiring Diagram 20-45-619 60 - 300 ON/OFF Riello Burner Remote SC³-SZ 415/50/3ph

Doc No. 20-45-159 Page 32 of 60

Wiring Diagram 20-45-604 30 - 40 ON/OFF Riello Burner Integral CP4 230/50/1ph

Doc No. 20-45-159 Page 33 of 60

Wiring Diagram 20-45-605 60 - 85 ON/OFF Riello Burner Integral CP4 230/50/1ph

Doc No. 20-45-159 Page 34 of 60

Wiring Diagram 20-45-606 120 - 135 ON/OFF Riello Burner Integral CP4 230/50/1ph

Doc No. 20-45-159 Page 35 of 60

Wiring Diagram 20-45-607 60 - 300 ON/OFF Riello Burner Integral CP4 415/50/3ph

Doc No. 20-45-159 Page 36 of 60

Wiring Diagram 20-45-620 30 - 40 ON/OFF Riello Burner Remote CP4 230/50/1ph

Doc No. 20-45-159 Page 37 of 60

Wiring Diagram 20-45-621 60 - 85 ON/OFF Riello Burner Remote CP4 230/50/1ph

Doc No. 20-45-159 Page 38 of 60

Wiring Diagram 20-45-622 120 - 135 ON/OFF Riello Burner Remote CP4 230/50/1ph

Doc No. 20-45-159 Page 39 of 60

Wiring Diagram 20-45-623 60 - 300 ON/OFF Riello Burner Remote CP4 415/50/3ph

Doc No. 20-45-159 Page 40 of 60

Wiring Diagram 20-45-612 30 - 40 ON/OFF Riello Burner No Controls 230/50/1ph

Doc No. 20-45-159 Page 41 of 60

Wiring Diagram 20-45-613 60 - 85 ON/OFF Riello Burner No Controls 230/50/1ph

Doc No. 20-45-159 Page 42 of 60

Wiring Diagram 20-45-614 120 - 135 ON/OFF Riello Burner No Controls 230/50/1ph

Doc No. 20-45-159 Page 43 of 60

Wiring Diagram 20-45-615 60 - 300 ON/OFF Riello Burner No Controls 415/50/3ph

Doc No. 20-45-159 Page 44 of 60

Wiring Diagram 20-45-292 HI/LOW option Riello Burner CP4 Control

Wiring Diagram 20-45-425 HI/LOW option Riello Burner SC3-MZ

Doc No. 20-45-159 Page 45 of 60

3. Commissioning.

Warning

It is a requirement that only suitably qualied and competent personnel are allowed to undertake the commissioning of the heater.

Note:

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 specic requirements of the installation /application.

Warning

All Cabinet Heaters undergo a rigorous test programme prior to being despatched, whilst such a programme does involve pre-commissioning and setting up the heater to operate eciently and well within its designed operational limits, this does not mean that on site commissioning is less important than might otherwise be the case.

The idiosyncrasies of each installation can only ever be allowed for, through the use of thorough on site commissioning carried out by trained and experienced personnel equipped with the correct tools and apparatus.

Note:

It is strongly recommended that equipment used for the sampling and analysis of ue gases is accurate to within +/-

0.1% and maintained so that it is regularly calibrated.

3.1 Commissioning - Pretest

Check to ensure electrical safety, and inspect and check the Gas installation, testing for leaks.

(a) Ensure that the electrical supply is turned o. (b) Ensure that the gas supply is turned o. (c) Check that all panels and fasteners are secure and in place. (d) Check that the heater is installed so that it is square and

that the support is adequate. (e) Ensure that warm air delivery outlets are open and that

ducting is adequately supported. (f) Ensure that if lter assemblies are tted 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 ue 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 ue gas sampling and that

this sample point can be plugged and sealed after commissioning.

(k) Check that the fan stat settings has not been disturbed. (l) Remove lower panel and check motor and fan drive system

for integrity of joints, check pulley alignment, fan rotation, and belt tension (see section 4.2).

(m) Ensure that the burner is securely attached to the heater. (n) Test for electrical earth continuity between the heater, gas

pipe work, and mains supply. (o) Turn on main electrical supply. (p) Enable fan on via controller by selecting ‘Fan only’; ‘Vent

only’; ‘Vent/Manual’.* (* dependent on control type supplied. Refer to individual controller operating manual.)

(q) Check to ensure burner is o but power remains to the fan. The fan will start enabling fan direction etc to be veried. Reset Fan on/standby switch to o.

(r) Set room thermostat and time clock to ‘demand’ positions. (s) Turn mains electrical supply to o, replace and secure lower

louvered panel covering fan and motor assembly.

3.2 Commissioning - Ignition

Warning

Do not proceed with commissioning unless all the criteria detailed within sections 3.0 and 3.1 have been satised.

(a) Ensure the electrical supply is turned o. (b) Ensure that the gas supply is turned o. (c) Turn on main electrical supply. (d) Enable burner via controller by selecting ‘Heat’ (Relay 2);

‘Heat On’; ‘Heat/Auto’. * (* dependent on control type supplied. Refer to individual controller operating manual.)

(e) Select ‘on’ position for heater on/standby switch. (f) Check for the following burner sequence

Interval Operation

1 <5s Combustion air damper actuated, burner fan motor initiates purge cycle...

2 <40s Pilot valve opens ignition transformer provides spark for burner ignition...

-------- E I T H E R --------

3 >40s Ignition failure caused by gas starvation resulting in burner lock-out/shut-down...

(g) Clear burner lockout using burner reset function. (h) Set heater on/standby switch to standby position (i) Open gas supply cocks. Repeat steps 3.1 q, and 3.2 c,e,f.

Doc No. 20-45-159 Page 46 of 60

----------- O R ----------

3 >40s Pilot ignition... Burner Ignition 4 <60s Burner ignition cycle complete

Note:

It is strongly recommended that the separate manual concerning the operational details of the burner supplied with the heater as part of the information package is studied prior to commissioning.

Time intervals within the ignition sequence will vary slightly from one model to another.

Warning

If burner ignition is not satisfactorily accomplished, commissioning must not proceed until the reason or fault has been identied and rectied, if necessary by reference to the separate burner information or to section 6 of this manual.

(j) Repeat steps 3.2 c,a, (k) Re-check all connections and joints for gas soundness

using an approved leak detection uid. (l) Remove burner cover and attach manometers to check

burner pressure settings. (m) Repeat steps 3.2 d,e,f, allowing the heater to reach thermal

equilibrium. (n) Check burner pressure settings are in line with the data as

per section 1.15 (if adjustment is necessary refer to separate burner information within section B)

Note (i) The gures quoted in section B are independent test gures

based upon zero ue resistance.

On completion mark the gas valve adjustment screw with paint/sealant to prevent tampering with valve

(o) Adjust room thermostat to its highest setting, and allow the heater to continue to re.

(p) Gradually reduce the temperature setting on the room thermostat until the burner shuts down, (@ < ambient) and then gradually increase the temperature setting on the thermostat until heat is called for, (@ > ambient) and the burner automatically re-res.

(q) Re-set time clock to a minimum o period, checking that the burner shuts down, and then automatically re-lights once the minimum o period has elapsed (Separate information on the time clock is contained within the information package supplied with the heater).

(r) Check fan and limit stat by depressing and holding in the fan motor overload re-set button, located on the heater electrical panel. The time between the fan stopping and burner shut down should be noted, once the burner has shut down the overload on the motor should be released.

On completion delete any override settings on optimised control and return temperature settings to customer requirements.

(s) Undertake ue gas analysis using approved and calibrated analysing equipment recording data on the commissioning card, ie, CO, CO2, net and gross ue temperatures. Record mains gas, and burner head pressure, ambient temperature, barometric pressure, and complete percentage eciency calculation using the formula detailed in section 1.15.

Note (ii) The burner air and gas pressure settings should be only very

nely adjusted to achieve a CO2 reading of 9.3% (+/- 0.1%).

Note (iii) The net eciency must not be lower than 79% for heaters

tted with a modulating or hi/lo burner.

In other cases he net eciency level must not be lower than 84%

Note (iv) All Cabinet Heaters are test red and pre-commissioned as

part of the manufacturing process, if however, during on site commissioning the data are found to be not in accordance with the manufacturers data, then the following action is recommended.

* Re-check all readings and calculations. * Adjust burner as per manufacturers instructions. * Consult the Technical Department, details on rear page.

(t) Complete commissioning card and provide operating instructions for the user, high-light the fact that the manufacturer recommends that in the interests of safety and eciency the heater is serviced on a regular basis only by qualied and competent persons.

The completed commissioning card must be returned to the supplier (details on rear page) immediately after the satisfactory completion of commissioning, failure to do so can invalidate any subsequent warranty claim.

(u) Set all controls to the requirements of the user.

3.3 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 ow from the nozzle hoods should be made, and the hoods should be secured in the required position by drilling through the two

Doc No. 20-45-159 Page 47 of 60

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 eciency 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 inecient heating/ ventilation system.

Check that the amount of fan produced air volume is in accordance with the heater specication, 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 conrm 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 insucient 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.

Caution

The Fan Belts must be rechecked on completion of commissioning ensuring that the tension is correct and the pulleys are in alignment

3.4 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 the supplier (details on rear page)

(b) The commissioning engineer must ensure that the user is familiar with the safe and ecient use of the heater, detailing the function of all controls, and main components.

(i) Lighting, shutdown, and operational information. (ii) Safety features, data plate, and labelling. (iii) The requirement for regular inspection - especially if the

heater is within a more demanding environment - and the need for regular servicing carried out by competent and

qualied persons. (d) Section 8 ‘User Instructions’ should be left with the

customer upon satisfactory completion of the commissioning and hand-over.

Caution

After approximately 100 hours of running, the tension of the fan belts must be checked to ensure that they are correct and that they have not stretched. See section 4.2.5 for further instructions.

4.0 Servicing.

ervicing must be carried out on a regular basis, the maximum interval between services being 1 year.

Warning

It is a requirement that only suitably qualied and competent persons are allowed to undertake servicing.

Warning

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 o at the supply valve and isolator respectively.

Caution

Certain component parts are factory sealed and are designed so as to be tamper proof. Usually such items do not require servicing, and therefore should not be tampered with.

Failure to comply with this can invalidate any warranty, and can also lead to premature failure.

The following parts fall within this category: room thermostat, time clock, frost thermostat, sequential controller, and fan and motor.

Reference should be made to the separate information covering the operational details of the burner and timer.

Only approved spare/replacement parts can be tted, failure to comply with this can compromise the safe and ecient running of the heater, and can also invalidate any warranty claim.

4.1 Planned Servicing

In order to maintain the ecient operation of the heater it is recommended that the following planned servicing and preventative maintenance programme is adopted by the user.

Doc No. 20-45-159 Page 48 of 60

Quarterly Inspection (a) Visual inspection of the burner (b) Clean and check ionisation probes (c) Check overheat safety is operational Bi-Annual Inspection (a) As per quarterly inspection, plus... (b) Combustion check Annual Inspection (a) As per half year inspection, plus... (b) Heat exchanger and cleaning (c) Electrical connections (d) Main fan motor (e) Main fan assembly (f) Pulleys (g) Fan belts (h) Gas supply (i) Burner (j) Air delivery system (k) Flue (l) Report

4.2 Servicing Procedure - Major Component Parts

4.2.1 Flue

A visual inspection should be carried out to ensure that the ue remains adequately supported, both internally as well as externally, and that the various joints are eectively sealed.

Inspection covers, where tted, should be removed and the ue checked to see whether cleaning is require If inspection covers are not tted the ue gas exit duct and ue spigot will provide not only an indication of the cleanliness of the ue, but will also enable access for cleaning.

The presence of the ue terminal should be checked. If a condensate trap and drain facility is tted this should be checked to ensure that it continues to function correctly, and the drainage of condensates is not impaired.

4.2.2 Main Fan Motor

Remove access panel. Dust and other foreign matter should be cleaned by blowing over with compressed air and through the use of a soft bristle brush and cloth. Solvent wipes may be used to remove heavy soiling from the motor casing.

Traces of surplus lubricants spreading from the bearings should also be cleaned away.

Where motors are tted with grease nipples bearings should be lubricated with the correct grade of lubricant. Motors

which do not have grease nipples feature sealed bearings which are lubricated during manufacture for their life.

The electrical connections should be checked as follows. (a) The cover to the terminal box should be removed by

undoing the screws which secure it. (b) Check connections for signs of corrosion, tightness, and

ensure that there are no stray strands which could form a short circuit.

(c Clean, tighten, and replace as necessary. Replace cover and secure.

4.2.3 Main Fan

Remove dust and other foreign matter by blowing o with compressed air or through the use of a soft bristle brush.

Check that the bearings do not show signs of excessive wear. It should be noted that these bearings do not require lubricating.

If the bearings require replacing the following procedure should be followed.

(a) Remove belt(s). (b) Loosen set screw on eccentric collar and tap collar in the

opposite direction to fan rotation. (c) Remove collar and bearing. (d) Check shaft for alignment and straightness. (e) Locate the bearing in its seat and place on the shaft with

the cam facing outwards. (f) Fit the eccentric collar and engage the cams. (g) Tighten initially by rotating, and then by tapping in the

direction of the fan rotation. (h) Replace fasteners and secure. (i) Turn by hand to ensure free fan rotation.

4.2.4 Pulleys

Check pulleys for alignment using a straight edge, if necessary reposition either or both of the pulleys and the fan motor.

Check for excessive wear within the root and sides of the grooves, and check for any other signs of wear or damage, if necessary replace the pulley as follows.

(a) Release tension on belts and remove. (b) Release the taper locks by slackening the securing screws

by several complete turns. (c) Fully remove one screw from the taper lock, and having

oiled it, insert into the threaded jacking point. (d) Tighten screw until the taperlock is free. (e) Remove taperlock and pulley. (f) Fit taperlock in new pulley, and provisionally position on

the shaft. (g) Remove the screw from the jacking point, and tighten both

screws in their clamping points until the pulley can just be moved on the shaft by hand.

Doc No. 20-45-159 Page 49 of 60

(h) Align pulleys using a straight edge, and by gradual alternate tightening of the screws clamp in position.

(i) Ret belts and check for the correct amount of tension.

4.2.5 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 motor towards fan to slacken belts. (d) Replace belts, pull fan motor away from fan until belts are

tight. (e) Tighten adjustment bolt to hold motor. (f) Tighten fan securing bolts ensuring that the fan is square

and the pulleys aligned. (g) Check belt tension, making nal adjustments as necessary. (h) Tighten and clamp fasteners to hold fan motor in position.

4.2.6 Heat Exchanger

The heat exchanger requires a visual inspection at least once per year, this should be accompanied by cleaning.

It is recommended that a ue brush and vacuum cleaner be used to facilitate this.

Access to the heat exchanger is gained through the removal of the rear upper panel and heat shield.

Servicing and cleaning should be performed as follows: (a) Remove brass nuts and cover from heat exchanger end

assembly to expose heat exchanger tubes. (b) Remove any accumulated deposits from the tubes. (c) Particular attention should be paid to the upper internal

surfaces of the tubes, where through convection heavier deposition is likely to occur.

(d) Any deposits which may have accumulated within the combustion chamber can be removed with a vacuum cleaner once the burner is removed.

Note:

It is most important that a build up of deposits is not allowed to occur as this can have an adverse eect upon the eciency of the heater and reduce the life of the heat exchanger.

(e) The heat exchanger and combustion chamber should be visually inspected for signs of splits, cracks, and distortion.

(f) All gaskets should be checked to ensure that they continue to provide a gas tight seal, if there is an element of doubt then they should be replaced.

If the condition of the heat exchanger gives cause for concern the suppliers Service Department should be advised pending a more detailed examination. Details on rear page

4.2.7 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.

4.2.8 Gas Supply

The gas supply pipework, and ttings should all be inspected to ensure that they are free from corrosion, and to ensure that where brackets have been tted these remain secure and oer adequate support.

The system should be soundness tested in accordance with Institute of Gas Engineers recommendations detailed in UP-1 & UP-2.

Warning

Any waste oil or sludge must be disposed of correctly. Never dispose of it by dumping or tipping it down drains or into watercourses where ground water can become polluted and environmental damage caused.

4.2.9 Burner

Service requirements for the burner tted to the cabinet heater are covered in the separate manual prepared by the burner manufacturer.

Note:

It is most important that the burner is serviced regularly and in accordance with the manufacturers instructions.

4.2.10 Air Delivery System

A visual inspection should be undertaken to ensure that the air delivery system is in good order, that it remains adequately supported and that the various joints are eectively sealed.

Doc No. 20-45-159 Page 50 of 60

Turbulator Positions in Heat Exchanger Model 60 Cabinets. 11 o

Turbulator Positions in Heat Exchanger Model 85 Cabinets. 22 o

Turbulator Positions in Heat Exchanger Models 120 & 135 Cabinets. 18 o

Turbulator Positions in Heat Exchanger Models 180 & 205 Cabinets. 40 o

Turbulator Positions in Heat Exchanger Models 235 & 300 Cabinets. 40 o

Turbulator Positions in Heat Exchanger Model 375 Cabinets. 28 o

4. 2.11 Rep ort

A full and detailed service report should be prepared, it is advised that the report is not completed until the heater has been re-commissioned, where upon the completed report can then be run through with the user.

4.3 Service Re-commissioning

The heater should be re-commissioned as follows, as per section 3.1 through to section 3.4 inclusive.

This must be regarded as a necessary part of the heater service. By the service engineer.

Doc No. 20-45-159 Page 51 of 60

5 Parts Lists

Doc No. 20-45-159 Page 52 of 60

Item

Heater Size / Description

30 40 60 85 120 135

Burner Nat Gas On/O + Gas Train

29-99-445 GS5 + GT

29-99-446 GS10 + GT

29-99-448 GS20 + GT

Burner Gasket 30- 05-787 30-05-787 30 -05-795 30 -05-795 30- 06-710 30-06-710

Gas Train (incl. valve & pipe)

39-70-569 39-70-569 39-70-530 39-70-530 39-70-531 39-70-531

Control Box 30-20-230 30-20-230 30-13-073 30-13-073 30-13- 073 30-13-073

Electrode 30 -06-704 30 -06 -704 30-06-943 30-06-943 30-06-706 30-06-706

Probe 30-06-707 30-06-707 30-06-708 30 -06 -708 30- 06-709 30 -06 -709

Rocker Switch Black

28 -40-104 28-40-104 28-40 -104 28-40 -104 28- 40-104 28-40 -104

MCB 1ph MCB 3ph

28-07-085 n/a

28-07-085 28-07-084

28-07-084 28-07-084

Overload 1ph Overload 3ph

n/a n/a

n/a 28 -11-125

28 -11-130 28 -11-127

28 -11-132 28 -11-128

Contactor 1ph Contactor 3ph

n/a n/a

28 -11-137 28 -11-131

n/a 28 -11-131

Fan/Limit Thermostat Assy

20-45-599 20-45-599 20-45-599 20-45-599 20-45-599 20-45-599

Fan/Limit Thermostat Gasket

20-45-589 20-45-589 20-45-589 20-45-589 20-45-589 20-45-589

Sight Glass 20-30-151 20-30-151 20-30-151 20-30-151 20-30-151 20-30-151

Propane Conversion Kit

30-00-882 30-00-882 30-00-884 30-00-884 30-00-886 30-00-886

Doc No. 20-45-159 Page 53 of 60

Item

Heater Size / Description

30 40 60 85 120 135

HTX Assy Aluminised S/Steel

31-28-128 31-28 -159

20 -45-154 20 -45-16 4

20-46-283 20-46-281

Turbulators n/a n/a 20-45-485 20-45-485 20- 45-780 20 -45-780

Burner Spigot Gasket

31-28-080 31-28-080 31- 40 -156 31-40-156 31-27-121 31-27-121

Stackbox Assembly Painted

31-28-078 31-28- 078 31-24-074/Z 31-27-123/ Z 37-27-123/Z 31-27-123/Z

Pressure Relief Gasket

31-28-080 31-28-080 31-27-121 31-27-121 31-27-121 31-27-121

Flue Box Cover Assembly

31-2 8 -115 31-28-115 20-45-094 20-45-094 20-45-094 20-45-094

Heatshield Panel Front Rear

31-28-124 31-28-123

20 -45-140 20 -45-141

20-46-291 20-46-290

Motorised Fan 1ph Motorised Fan 3ph

28-09-049 n/a

n/a

20-32-042

n/a

20-32-042

n/a n/a

Centrifugal Fan* n/a n/a 28-09-086 28-09-086 28-09-003 28-09-003

Fan Pulley* n/a n/a N6563 N6475 28-65-092 28-65-096

Fan Pulley Taperlock*

n/a n/a N6551 N6551 28-6 6-125 28 -66-125

Motor 1ph* Motor 3ph*

n/a n/a

28 -10-117

n/a

28 -10-117

n/a

28 -10-117 28 -10-127

28 -10-016 28 -10 -015

Motor Pulley* n/a n/a N6701 N6701 N6553 N6553

Motor Pulley Taperlock*

n/a n/a N6128 N6128 28-66-024 28-66-025

Pulley Belt* n/a n/a N6603 N6603 09-16 -110 09-16-106

Doc No. 20-45-159 Page 54 of 60

Item

Heater Size / Description

180 205 235 300 375

Burner Nat Gas On/O + Gas Train

29-99-449 GS20 + GT

29-99-552 RS34/1 + GT

29-99-561 RS44/MZ+GT

Burner Gasket 30- 06-710 30 -03-817 30- 03- 817 30 -03 -817 3 0- 03-817

Gas Train (incl. valve & pipe)

39-70-532 39 -70 -231 39-70-231 39-70-231 39-70-233

Control Box 30 -13- 073 30 -13- 073 30-13-073 30 -13- 073 30-13-073

Electrode 30-06-706 30-14-037 30 -14- 037 30 -14- 037 30 -14- 037

Probe 30-06-709 30 -13-725 30 -13-725 30 -13-725 30 -13-725

Rocker Switch Black

28 -40-104 28 -40 -104 28 -40-104 28 -40 -104 28 -40-104

MCB 1ph MCB 3ph

n/a 28-07-084

28-07-084 28-07-084 28-07-084

Overload 1ph Overload 3ph

n/a 28 -11-128

28 -11-129 28-11-130 2 8 -11-111

Contactor 1ph Contactor 3ph

n/a 28 -11-131

28 -11-131 n/a

n/a 28 -11- 045

Fan/Limit Thermostat Assy

20-45-599 20-45-599 20-45-599 20-45-599 20-45-599

Fan/Limit Thermostat Gasket

20-45-589 20-45-589 20-45-589 20-45-589 20-45-589

Sight Glass 20-30-151 20-30-151 20-30-151 20-30-151 20-30-151

Propane Conversion Kit

30-00-886 30-10-423 30-10-423 30-10-423 30-10-424

Doc No. 20-45-159 Page 55 of 60

Item

Heater Size / Description

180 205 235 300 375

HTX Assy Aluminised S/Steel

20-46-355 20-46-400

20-47-405 20-47-421

20-28-211 20-28-039

Turbulators 20-46-781 20-46-781 20-47-763 20-47-763 20-47-763

Burner Spigot Gasket

31-27-121 31-27-121 31-29- 046 31-29- 046 31-29- 046

Stackbox Assembly Painted

20-46-307/Z 20-46-307/Z 20-47-425/Z 20-47-425/Z 20-28-086/Z

Pressure Relief Gasket

20-46-354 20-46-354 20-46-354 20-46-354 31-27-121

Flue Box Cover Assembly

20-46-310 20-46-310 20-47-546 20-47-546 20-28-094

Heatshield Panel Front Rear

20-46-336 20-46-335

20-47-430 20-47-431

20-28-070 20-28-071

Motorised Fan 1ph Motorised Fan 3ph

n/a n/a n/a n/a n/a

Centrifugal Fan* 28-09-004 28-09-004 28-09-043 28-09-043 28-09-087

Fan Pulley* 28-65-105 28-65-105 28-65-074 28-65-075 N6103

Fan Pulley Taperlock*

N6131 N6131 N6131 N6131 N6139

Motor 1ph* Motor 3ph*

28 -10-117 28 -10-120

n/a 28 -10-120

n/a 28 -10-026

n/a 28 -10-021

n/a 28 -10-024

Motor Pulley* N6553 28-65-072 N6100 N6677 N6677

Motor Pulley Taperlock*

28-66-025 28-66-028 28-66-028 N6413 N6 413

Pulley Belt* 09 -16-126 09 -16-126 09 -16-116 09 -16-116 09 -16-138

Doc No. 20-45-159 Page 56 of 60

No Power

Burner fails

to run

No Demand

Check isolator

Check fuse

Check controls

Burner lockout

Check set temp

Check on time

Check air

pressure switch

Check ame

probe

Check burner

motor

6 Fault Finding Guide

Check gas

supply

Ensure gas cock

is open

Ensure start gas

valve opens

Fan starts

but burner

goes to lockout

Purge air

Check control

box and burner

Check as per

burner manual

Check

control box

Check HT lead

and connector

Check gap

Check insulation

Air in gas feed

Faulty air

pressure switch

Faulty ignition

transformer

Faulty electrode

Faulty control

box

Check gas

supply

Doc No. 20-45-159 Page 57 of 60

Burner lights

on start gas

but fails to

establish

mail ame

Check gas

supply

Excess air

Check that

ue gas CO

is as advised

Adjust damper

to suit

Check inlet

gas pressure

Check main

burner gas

pressure

Low gas

pressure

Check ame

probe

Signal

Position

Check

burner

Check

control

Check

controls

Check main

burner gas

pressure

Check inlet

gas pressure

Burner starts

but excess

temperature

shuts down

the burner

on overheat

Insucient

air passing

over heat

exchanger

High return

(inlet) air

temperature

Check air to

inlet is not

restricted

Remove

obstruction.

Clean lter

Resistance

too high

Fan belt slipping

Reset nozzles

away from

adjacent walls

Check for

warm air

short circuit

to air inlet

Impellor

slipping

Check outlet

grilles are open

Check nozzles

are open

Adjust and or

replace belts

Adjust and or

replace belts

Doc No. 20-45-159 Page 58 of 60

7. Replacement Parts.

Note

It is recommended that only suitably competent persons are allowed to undertake replacement of parts.

7.1 Burner.

• Disconnect electrical supply to the heater and shut o gas supply.

• Disconnect gas supply

• Detach electrical connections via plugs.

R40 series:

• Using an 13mm spanner, remove the nut holding the unit to the burner ange.

• Withdraw the burner from the throat of the heat exchanger.

RL34/44 series:

• Using a 6mm Allen key, remove the bolt holding the burner to the ange.

• Pull the burner forward on the two supporting bars. Caution - Heavy!

• Remove the two supporting bar bolts and carefully

remove the burner through the throat of the ange.

• Replace in reverse order.

7.2 Controller

• Disconnect electrical supply to the heater.

• Remove the burner cover.

• Remove the screw xing the controller to the base

and withdraw controller.

• Replace in reverse order.

7.3 Electrode and Probe

• Disconnect electrical supply to the heater.

• Remove the burner cover.

R40 series:

• Using an 13mm spanner, remove the nut holding the unit to the burner ange.

• Withdraw the burner from the throat of the heat exchanger, support on bracket/ange lugs.

• Remove the xing screw(s) holding the End Cone and withdraw from burner head.

• Loosen the screw clamping the electrodes.

RL34/44 series:

• Using a 6mm Allen key, remove the bolt holding the burner to the ange.

• Pull the burner forward on the two supporting bars.

• Loosen the screw clamping the electrodes.

• Withdraw electrodes forward and away from the burner.

• Replace in reverse order.

7.4 Contactor/Overload

• Disconnect electrical supply to the heater.

• Remove front panel (below burner)

The contactor and overload are located on the electrical panel plate situated on the right hand side of the unit.

For Overload:

• Disconnect all wiring to the to the overload noting which cables are connected to which terminals

• Loosen the three screws in contactor terminals 2, 4 and 6

• Pull the overload in a downwards movement and unclip from the back of the contactor.

• Replace in reverse order.

For Contactor:

• Disconnect all wiring to the to the contactor and overload noting which cables are connected to which terminals

• Unscrew the two screws xing the contactor to the electrical panel and remove.

• Loosen the three screws in contactor terminals 2, 4 and 6

• Pull the overload in a downwards movement and unclip from the back of the contactor.

• Replace in reverse order.

Doc No. 20-45-159 Page 59 of 60

7.5 MCB

• Disconnect electrical supply.

• Remove front panel (below burner)

The MCB is located on the electrical panel plate situated on the right hand side of the unit.

• Disconnect the two cables from the MCB noting which cables are connected to which terminals

• The MCB is attached to a DIN rail using a spring loaded din xing clip - using a small at head screwdriver, prise the clip downwards to release the MCB.

• Replace in reverse order.

7.6 Fan/Limit Stat Assembly

• Remove the cover plate by re4moving 4 screws.

• Loosen the cable gland then disconnect the three cables from the fan stat (left hand) and the two cables from the limit stat (right hand) noting which cables are connected to which terminals.

• Remove the two screws xing the assembly to the body of the heater.

• Carefully withdraw the assembly through the hole and replace in reverse order.

7.7 Fan Belts

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.

• Disconnect electrical supply.

• Remove front lower panel (below burner)

• Loosen fan motor securing bolts on chassis.

• Loosen fan motor slide adjustment bolt.

• Slide fan towards fan to slacken belts.

• Replace belts, pull fan motor away from fan until belts are tight.

• Tighten adjustment bolt to hold motor.

• Tighten fan securing bolts ensuring that the fan is square and the pulleys aligned.

• Check belt tension, making nal adjustments as necessary.

• Tighten and clamp fasteners to hold fan motor in position.

7.8 Blower Motor

• Disconnect electrical supply.

• Remove front lower panel (below burner) and side lower panel for ease of access.

• Loosen fan motor securing bolts on chassis.

• Loosen fan motor slide adjustment bolt.

• Slide motor towards fan to slacken belts and remove.

• Remove the four bolts and nuts securing the motor feet to the motor slide and withdraw motor for ease.

• Remove the motor electrical box cover by removing four screws

• Disconnect the electrical cables to the motor connections noting which cables to which terminals.

• Unscrew the cable gland on the side of the electrical box and withdraw the motor cables.

• Replace in reverse order.

7.9 Fan Blower

The fan blower is removed form the rear of the cabinet heater (opposing side to burner). Ensure there is enough room to work in and to withdraw the fan blower.

• Disconnect electrical supply.

• Remove all lower panels.

• Loosen fan motor securing bolts on chassis.

• Loosen fan motor slide adjustment bolt.

• Slide motor towards fan to slacken belts and remove.

• Remove the two bolts xing the painted rear lower edge tidy plate from the chassis and remove plate.

• Remove the six screws xing the rear air deection shield (three on the right, three on the left) two of which screw into the centre diaphragm plate and two each which screw into the side deection shields.

• Remove the four bolts xing the fan feet to the base plate.

• Withdraw the fan blower by sliding it out from the rear.

• Remove pulley assembly

• Replace in reverse order

NORTEK GLOBAL HVAC (UK) LTD

Fens Pool Avenue

Brierley Hill

West Midlands DY5 1QA

United Kingdom

Tel: 01384 489 250

Fax: 01384 489 707

bensonsales@nortek.com

www.bensonheating.co.uk

Norte k Global H VAC is a register ed tradem ark of Nor tek Glob al HVAC Limite d. Because of continu ous produc t innovat ion, Nor tek Glob al HVAC reser ves the right to change product speciﬁcation without due notice.

Registered in England No. 01390934. Registered office: The Colmore Building, Colmore Circus Queensway, Birmingham B4 6AT

8.4 Stop procedure

(a) Disable burner by selecting ‘Heat OFF’; ‘Standby’.* (* dependent on control type supplied. Refer to individual controller operating manual.)

(b) The burner will turn o. (c) 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 o the heater, to do so can cause damage to the heat exchanger and combustion chamber and thereby invalidate the warranty.

8.5 Shut down procedure

(a) Follow steps 8.4 (a), (b) and (c), when main fan stops turn main electrical isolator o, and shut gas cocks

8.6 Ventilation only

(a) Enable fan on via controller by selecting ‘Fan only’; ‘Vent only’; ‘Vent/Manual’.* (*dependent on control type supplied. Refer to individual controller operating manual.)

(b) Fan will operate without the burner for the set period of the controller.

8.7 Lockout situations

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.

Caution

Repeated or frequent lockouts must be investigated and their cause determined by a qualied and competent engineer.

8 User Instructions

8.1 Commissioning and hand over

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 labelling. (iii) The requirement for regular inspection - especially if the

heater is within a more demanding environment - and the need for regular servicing, carried out by competent and qualied engineers.

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

8.2 Servicing

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 qualied and competent persons are allowed to undertake the servicing.

The manufacturers advise that the planned service schedule as detailed in section 4.1 of the Installation, Commissioning and Servicing Manual is adopted by the user.

Further details are available from either the commissioning engineer or from the Manufacturer (details below)

8.3 Start Up Procedure

(a) Enable burner via controller by selecting ‘Heat’ (Relay 2); ‘Heat On’; ‘Heat/Auto’.*

(* dependent on control type supplied. Refer to individual controller operating manual.)

(b) Burner will re and establish within 60seconds. (c) As temperature of heater increases, fan will operate.

Document reference number: 20-45-159 Mar 2017 issue 19

replaces 20-45-160 Oct 2016 issue18

BENSON 30, 60, 40, 120, 135 Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual