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Condensing low‐emission gas‐fired air heater
ULTRA
025(EC), 035(EC), 050(EC),
075(EC), 100(EC)
Please read this document carefully before commencing the installation and leave it with
the user or attached to the appliance or gas service meter after installation!
The manufacturer does not take any responsibility in the event of non‐observance of the
regulation concerning the connection of the apparatus causing a harmful operation
possibly resulting in damage to the apparatus and/or environment in which the unit is
installed.
Subject to modifications
This appliance meets the following EC Directives
DIR 2009/142/EC : GAD
DIR 2014/30/EU : EMC
DIR 2014/35/EU : LVD
DIR 2006/42/EC : MD
INSTALLATION
COMMISSIONING
SERVICING – USER
INSTRUCTIONS
size 050
ATTENTION
1701ULTRA(EC)GBEN
1701ULTRA(EC)GBEN, p. 1/29
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Related Manuals for BENSON ULTRA 035(EC)
Summary of Contents for BENSON ULTRA 035(EC)
- Page 1 1701ULTRA(EC)GBEN Condensing low‐emission gas‐fired air heater ULTRA 025(EC), 035(EC), 050(EC), 075(EC), 100(EC) size 050 This appliance meets the following EC Directives DIR 2009/142/EC : GAD DIR 2014/30/EU : EMC DIR 2014/35/EU : LVD DIR 2006/42/EC : MD INSTALLATION COMMISSIONING SERVICING – USER INSTRUCTIONS Please read this document carefully before commencing the installation and leave it with the user or attached to the appliance or gas service meter after installation! ATTENTION The manufacturer does not take any responsibility in the event of non‐observance of the regulation concerning the connection of the apparatus causing a harmful operation possibly resulting in damage to the apparatus and/or environment in which the unit is installed. ...
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Page 2: Table Of Contents
TABLE OF CONTENTS 1 Hazard intensity levels 2 2 General 3 Warnings 3 General ... -
Page 3: General
2. GENERAL 2.1 WARNINGS or your safety, if you smell gas : Do not try to light any appliance Do not touch any electrical switch, do not use any phone in your building WARNINGS Evacuate all personnel Contact your gas supplier immediately o not store or use petrol or other flammable vapours and liquids in the vicinity of the appliance. mproper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment. o not use this appliance if any part has been immersed in water. Immediately call a qualified service technician to inspect the appliance and replace any gas control that has been immersed in water. ... -
Page 4: General
2.2 GENERAL The instructions in this manual apply to the condensing gas‐fired air heater model ULTRA/ULTRA EC. All models and sizes are available for use with either natural, propane or butane gas within operating temperatures between ‐15°C and 40°C. These heaters are designed for use in domestic, industrial and commercial premises, suitable only for indoor installation The type of gas, the input rate and the electrical supply requirements are shown on the heater rating plate. ... -
Page 5: Heater Location
2.5 HEATER LOCATION Attention Flue requirements may affect location. Consult section 7 before making a final determination. Use the minimum clearances as illustrated in figure 2 and the throw data mentioned in table 1 (Technical Data) to define where to locate the heater. Also respect the recommended minimum height as given in table 1. For best results, the heater should be placed with certain rules in mind. Always ensure that minimum clearances ... -
Page 6: Technical Data
3. TECHNICAL DATA Table 1 ULTRA/ULTRA EC Gas category Cat. I2H or I3P Comb. air & flue, type B instal (1) B22p Comb. air & flue, type c instal (1) C12, C32, C42, C52, C62, C82 Maximum heat input (Hs) 28,3 37,0 56,0... -
Page 7: Dimensions & Clearances
4. DIMENSIONS & CLEARANCES 4.1 DIMENSIONS Figure 1a :ULTRA/ULTRA EC 025, 035, 050 & 075 (all dimensions in mm, tolerance 3mm) ... - Page 8 Figure 1b : ULTRA/ULTRA EC 100 (all dimensions in mm, tolerance 3mm) Combustion air inlet ( 100mm) 4. Electrical connections Flue connection ( 100mm) 5. Service panel External gas connection (3/4”G) 6. Condensate drain 1701ULTRA(EC)GBEN, p. 8/29...
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Page 9: Internal Layout
4.2 CLEARANCES Figure 2 : ULTRA/ULTRA EC Z(*) (*) Heaters can be mounted on suitable non‐combustible supports. 5. INTERNAL LAYOUT Figure 3 : Metal mesh burner Zero pressure regulator Venturi Differential pressure switch Burner controller Flue gas extraction fan Inspection window + ignitor+ionisation electrode Limit control LC3 Limit control LC1 1701ULTRA(EC)GBEN, p. 9/29... -
Page 10: Installing
6 INSTALLING Check the supporting structure to verify that it has sufficient load‐carrying capacity to support the unit weight. WARNING Suspend the heater only from the threaded nut inserts. Do not suspend from the heater cabinet panels. Do not place or add additional weight to the suspended heater. The location where the air heater is to be installed must provide sufficient space around the heater for servicing and clearances for safety (see figure 2). When the unit is lifted for suspension, leave the unit on the pallet. Before hanging verify that all screws originally used to fix the shipping supports are re‐screwed into the cabinet. Ensure that the heater is installed in a level plane and vibration free. The air heater must be fastened securely to any base mounting arrangement. The heater is supplied with four point suspension. All points must be used. Threaded nut inserts are provided on each side of the top of the heater. See figure 4. After suspension the air heater should be rigid so as to avoid placing a strain on the flue system, gas services, electrical wiring and duct work. 1” BSP mounting cap nuts are optional. In case of a type C installation, the distance between the floor and the underside of the air heater must be at least 1.70m. Combustion air should be taken from a height that exceeds the above mentioned height of 1.70m. Also thermostats and switches which are not sparkless have to be installed at a minimum height of 1.70m. Figure 4 Be sure that the threaded hanger rods are locked to the heater as illustrated in ... -
Page 11: Air Supply & Flue Systems
7 AIR SUPPLY & FLUE SYSTEM 7.1 GENERAL The flue must be in accordance with all international and national rules and regulations in force. Local requirements may apply in addition to national requirements. Failure to provide proper flueing could result in death, serious injury and/or property damage. The products of combustion must be flued to outside atmosphere. Common flues (for more WARNING than one appliance) must not be used. Single wall flue pipe exposed to cold air or run through unheated areas should be insulated to avoid condensation. If the flue passes through a combustible element of the building it must be enclosed by a sleeve of non‐combustible material and separated from the sleeve by at least a 25mm air break. The temperature of any combustible material near to the flue must not exceed 65°C when the heater is in operation. The flue must be at least 50mm away from any combustible material. Provision must be made for condensation to flow freely to a point to which it can be released, i.e. drain. odel ULTRA/ULTRA EC heaters may be installed as type B or type C installations. The unit heaters are designed to operate safely and efficiently with either a horizontal or vertical flue system when installed according to the specific requirements and instructions. If this heater is replacing an existing heater, be sure that the flue is of the correct size and that the existing flue is in good condition. A correctly sized flue system is required for safe operation of the heater. An improper sized flue system can cause unsafe conditions and/or create condensation. ... - Page 12 Condense drain A condensation drain must be fitted to both the unit and the flue outlet to properly drain all condensation. Attention The condensation drain from the flue must be constructed from non‐corrodible material not less than 20mm diameter. Copper or copper based alloys must not be used for condensation drain. Consult section 8 : Condensation drain pipe connections 7.2 POWER VENTED INSTALLATIONS (type B appliances) If the air heater is to be installed as a type B appliance, Figure 6 : air for combustion will be taken from within the space Approved appliances type B where the heater is installed. Ensure that an adequate air supply for combustion and ventilation is provided B22p within ...
- Page 13 Figure 7 : Type C appliances : combustion air and flue pipe sockets ERTICAL FLUE KIT OPTION ORIZONTAL FLUE KIT OPTION ...
- Page 14 Figure 8 :Approved appliances type C C12 C42 wall roof roof C52 roof roof 7.4 DIAMETER & MAXIMUM FLUE PIPE LENGTHS Flue pipe diameters and maximum pipe lengths in table 2 apply to both horizontal and vertical systems. Add all straight sections and equivalent lengths for elbow. The total combined length must not exceed the maximum flue length. Model ULTRA/ULTRA EC Table 2 : Heater socket & pipe dia flue/inlet pipe ...
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Page 15: Condensation Drain Pipe Connection
Proper combustion air supply for a power vented type B installation requires ventilation of the heated space. Natural infiltration of air may not be adequate. Use of exhaust fans aggravates this situation. It is important to ensure that there is adequate combustion air supply at all times. Reliance on doors and windows is not permitted. Always ensure that en adequate inlet for fresh air for combustion is provided sized to suit the total installation of any combustion apparatus. 8 CONDENSATION DRAIN PIPE CONNECTIONS All ULTRA/ULTRA EC units are designed with a built‐in siphon (PN 70 61761) (figure 9). Attention : in case replacement of siphon is necessary, ensure that siphon is correctly installed. (see figure 10). Figure 9 ... - Page 16 9 GAS SUPPLY & GAS CONNECTION We refer to table 1 of section 3 for all gas specifications Connection to a gas service installation may only be carried out by suitably qualified persons. The gas installation must comply with all rules in force. Only materials appropriate for gas service installation may be used. Do not rely on the heater to support the gas pipe. NEVER USE A FLAME TO TEST FOR GAS SOUNDNESS. ALL COMPONENTS OF A GAS SUPPLY WARNING SYSTEM MUST BE LEAK TESTED PRIOR TO PLACING EQUIPMENT IN SERVICE. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY, PROPERTY DAMAGE OR DEATH! 9.1 GENERAL ULTRA/ULTRA EC heaters are designed to operate on either natural gas (G20), propane (G31) or butane (G30) gas. Check that gas supply, gas category & gas inlet pressure is in accordance with the data described on the air heater .To let the unit function at maximal heat output, the gas supply pipe MUST be correctly sized. Close to the air heater a gas tap with coupling must be mounted for servicing (see figure 11). It is strongly recommended to place a gas filter and clean the gas tube with nitrogen. The whole of the gas service installation including the meter must be inspected, tested for soundness and purged in accordance with appropriate requirements by a qualified person. Figure 11 9.2 GAS CONNECTION REMARK : Do not over tighten and do not rotate the ...
- Page 17 9.4 GAS CONVERSION The ULTRA/ULTRA EC heaters are designed to operate on natural, propane or butane gas and will be supplied for the gas type ordered. In the event a site conversion is required, it is necessary to change the burner jet and gas valve. Affix new data plate and gas type label. Upon completion of conversion recommission the heater. We hereto refer to the section ‘Ignition system’ Figure 13 Changes to carry out : 1. From natural gas to propane : Gas valve A propane conversion kit [part number 03 49950 ‐‐‐‐‐‐] will have to be purchased in order to perform the conversion. The conversion kit consists of the propane restrictor and the connector (see item 3 for more details) ...
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Page 18: Electrical Connections
10 ELECTRICAL SUPPLY & CONNECTIONS 10.1 ELECTRICAL SUPPLY THIS APPLIANCE MUST BE EARTHED. The electrical installation may only be carried out by suitably qualified persons observing the rules in force. DANGER Check that the electrical specifications are in accordance with the data on the air heater. All electrical connections should be in accordance with the terminal markings and the wiring diagram affixed to the air heater. The minimum external controls required for the air heater are a room thermostat. It is essential that the main input line and neutral to terminals L and N remains live at all times even when the appliance is switched off, this is to ensure correct operation of the unit. ... - Page 19 Possible control systems By means of option 954 = Individual on/off control (0% or 100% functioning) By means of option 952 = weekly programming digital chronothermostat (GA11) used for remote control of several units (consult option 952 instruction for more details) Example By means of 0‐10V power signal (to be performed by customer) Example 1701ULTRA(EC)GBEN, p. 19/29...
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Page 20: Commissioning, Lighting & Operation
COMMISSIONING, LIGHTING & OPERATION Final testing after production ensures that, if the installation has been carried out strictly in accordance with this document, the appliance is ready to be taken into service. 11.1 LIGHTING 1. Ensure that the air discharge louvres are open. 2. Turn on the gas supply. 3. Switch on the electrical supply. 4. Set the room thermostat to ‘ON’ position. 5. If the indicator light on the burner relay glows and/or the room thermostat display flashes, press the reset button. 6. The burner will now automatically light after about 15 sec and within 60 sec the air circulation fan will run. 7. If the installation is new, 3 start‐up cycles may be necessary due to air still being present in the gas pipe. Should the air heater still not light, refer to section 12 : ‘Fault Finding’. 8. The gas pressure must correspond to the data in table 1. If the gas pressure (G20) is higher than 60mbar, a pressure regulator with constant terminal pressure must be installed. If the gas pressure is lower than 20mbar/17.50mbar, check the supply pipework to ensure it is correctly sized. 11.2 OPERATION During start up all gas services (up to the gas meter) must be checked again for gas soundness to Attention ensure no leaks are present. The condensation drain pipe and siphon, both already filled with water, must be visually tested for water tightness. 1. If, for any reason, the burner flame is extinguished during a run cycle, an automatic attempt for re‐ignition will take place. If the burner does not relight, safety shut down and lockout will occur. Manual intervention to reset ... - Page 21 Ignition system – time table Definitions Start position The system is not in lock‐out position and can proceed with the start‐up sequence upon a demand for heat. Pre‐purge time This is a period of 20 sec during which the combustion fan operates prior to activation of the ignition device. Safety time The safety time is the delay between the gas valve being energised and the flame sensor checking for the presence of a flame. This is a period of 5 seconds. Note : if no flame is sensed, the burner relay will attempt ignition 5 times before going into lock‐out mode. Post‐purge time This is the time of 10 seconds between burner shut‐down and the moment the combustion fan (venter) is de‐energized. 1701ULTRA(EC)GBEN, p. 21/29...
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Page 22: Maintenance
MAINTENANCE It is recommended that maintenance is carried out at least once a year. More frequent servicing Attention may be required dependent upon the environmental circumstances where the air heater is installed. Regular inspection is necessary, especially in dirty areas, to assess the servicing frequency. Removal of service panel 1. Remove door lock at upper and underside. 2. Lift the panel holding it at the bottom. Substitution of combustion air fan 1. Turn off the main gas supply. 2. Set the room thermostat so there is no heat demand. 3. Wait until the air circulation fan has stopped running. 4. Check that the electrical supply is turned off. 5. Remove the service panel (see ‘removal of service panel’). 6. Disconnect the plugs from the combustion air fan. 7. Remove the bolts between the combustion air fan and the (bent) gas supply tube. Remove the gasket. 8. Remove the fixing screws (or the assembly in case of a ULTRA 075/100 EC) connecting the air intake restriction and the combustion air fan. 9. The combustion air fan can now be removed. 10. Remove all the dust from the combustion air fan with a soft cloth or brush. 11. Check that the motor and the turbine are undamaged. 12. - Page 23 Substitution of gas valve (differs according to the application and has to be ordered at your distributor) 1. Check that the air circulation fan has stopped running. 2. Before starting ensure that the electrical supply is turned off and locked. 3. Check that the gas supply is turned off. 4. Remove the service panel (see ‘removal of the service panel’). . 5. Disconnect the burner relay from the gas valve unscrewing the fixing screw. 6. Take a short screw driver and remove the screws connecting the gas valve and the air intake restriction. 7. Disconnect the gas valve from the gas connection. 8. Replace the gas valve in reverse order. Substitution of one of the relays 1. Check that the air circulation fan has stopped running. 2. Before starting, ensure that the electricity supply is turned off and locked. 3. Remove the service panel (see ‘removal of the service panel’). 4. Disconnect all the relay connections. 5. Remove the fixing screws of the contactor. 6. Replace the relay in reverse order. Substitution of air circulation fan (entirety) 1. Check that the air circulation fan has stopped running. 2. Before starting, ensure that the electricity supply is turned off and locked. 3. Remove the service panel (see ‘removal of the service panel’). 4.
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Page 24: Fault Finding
FAULT FINDING Fault finding may only be carried out by appropriately qualified persons! In case of a Check if the Check LL net, swap Call for heat igniter presence of sparks! flame! the 2 lines Check if the Check if the Check if control flame sensor Replace flame ionisation probe module reads the is not sensor! registers the min measured value! - Page 25 Check if the Check Call for heat igniter presence of sparks! flame! Check if flame is maintained and unit goes past the stabilisation time! Check copper Check if the pipe inside the pressure switch Unclog and blow dry! Replace Pressure switch! unit is not works within its clogged!
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Page 26: User Instructions
14. PARTS LIST Description Part number Reference Application motor+ventilator 01 26060 FN040-4EW.0F.A7P1 025 ULTRA AC motor+ventilator 01 26061 FN040-4EW.0F.A7P2 035 ULTRA AC motor+ventilator 01 26040 FN045-4EW.4I.A7P1 050 ULTRA AC motor+ventilator 01 26063 FN063-6EW.4I.A7P1 075 ULTRA AC motor+ventilator 01 26040 (2x) FN045-4EW.4I.A7P1 100 ULTRA AC motor+ventilator... - Page 27 At the end of a heating cycle the burner is switched off, the air circulation fan will continue to run until the air heater has cooled to a safe level. Thereafter the fan will remain off until the next cycle is initiated. Safety: 1. Flame failure is detected by the ionisation probe which is the sensor and will immediately result in gas valve shut down. 2. Safety against overheating is assured by two overheat controls. The first is an automatic resetting control which protects against low air flow i.e. clogged air ways, fan failure etc. The second, which ...
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Page 28: Declaration Of Conformity
16. DECLARATION OF CONFORMITY 1701ULTRA(EC)GBEN, p. 28/29... - Page 29 NORTEK GLOBAL HVAC (UK) LTD Fens Pool Avenue Brierley Hill West Midlands DY5 1QA United Kingdom Tel 01384 489250 Fax 01384 489707 ambiradsales@nortek.com www.ambirad.co.uk Registered in England N° 1390934. Registered office: 10 Norwich Street, London, EC4A 18D Nortek Global HVAC is a registered trademark of Nortek Global HVAC Limited. Because of continuous product innovation. Nortek Global HVAC reserves the right to change product specification without due notice 1701ULTRA(EC)GBEN, p.
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