BENSON 30 Installation And Operating Manual

Gas fired cabinet heaters

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INDEX

Introduction and Document Index

Installation Requirements

Installation Instructions

Commissioning Instructions

Servicing Instructions

Spare Parts

Fault Finding Guide

Replacing Parts

User and Operating Instructions

WARNINGS

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

Safety (Installations and Use) Regulations 1998 for gas fired 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 qualified installer. All external wiring MUST comply with the current IEE wiring regulations.

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BENSON

ired

eaters

anual

Section

Part No. 20-45-159

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Summary of Contents for BENSON 30

Page 1 ..............WARNINGS Benson equipment must be installed and maintained in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired 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 &...
Page 2 Any reference made to Laws, Standards, Directives, Codes of Practice or other recommendations governing the application and installation of heating appliances and which may be referred to in Brochures, Specifications, Quotations, and Installation, Operation and Maintenance manuals is done so for information and guidance purposes only and should only be considered valid at the time of the publication.
Page 3 Introduction. on these heaters due care and attention is required to ensure that working at height regulations are adhered to at the elcome to the Gas Fired Cabinet Heater Range. mounting heights specified. Local regulations may vary in the country of use and it is the installers responsibility to ensure that such regulations are All Dimensions shown are in mm unless satisfied...
Page 4: Installation Requirements
1. Installation Requirements. The manufacturer has a commitment to continuous improvement and therefore reserve the right to amend or change the specification of Cabinet Heaters subject to Compliance notices compliance with the appropriate European, national and local regulations he Gas Fired Cabinet Heater range detailed herewith are manufactured within a strictly controlled quality Contained within the text of the manual, the words ‘Caution’...
Page 5: General Product Information
Notified body PIN reference is: 0558CM1312 Prior to installation the following points should be considered; • The position of the heater for the optimum efficient distribution and circulation of warm air. • The position of the heater relative to the route of the General product information flue •...
Page 6: Health And Safety
Health and Safety Manufactures ‘conditions of business’. The Gas Fired Cabinet Heater range must be installed Note (i) in accordance with the relevant provisions of the Gas Safety The warranty may be invalidated if - (Installations and Use) Regulations 1998. Due account should •...
Page 7: Electrical Supply
The location must also allow for adequate clearance for the Service and Installation pipework must be of a diameter equal air supply, return air circulation, gas supply and electrical to or greater than the inlet connection on the heater, all joints supply, whilst also providing good and safe working access.
Page 8: Air Supply
1.11 Air supply Minimum Free Area of ventilation opening Consideration must be given to the provision of air for the purposes of combustion and ventilation of the heated space, Model High Level cm² Low Level cm² plant room or enclosure where heaters are to be installed. None Note: None...
Page 9 openings (sections 1.11.2.1 refers to plant room applications • At high level 5cm2 for each kW of rated heat input. and sections 1.11.2.2 refers to enclosure applications). • At low level 10cm2 for each kW of rated heat input. Alternatively the plant room or enclosure may be mechanically ventilated (section 1.11.2.3 refers).
Page 10: Air Distribution System
It is necessary to provide an automatic means to safely inhibit such that the air circulation fan does not interfere with the heater(s) operation should mechanical air supply fail for any operation of the flue. reason The return air intake and warm air outlet should therefore be The table to follow provides specific data for each heater fully ducted to and from the heater, respectively, within the model as -...
Page 11 and 2, are used as consultative documents when considering Note: flue requirements. It should be noted that claims made under warranty and attributed to the ingress of water may not be considered Care should be taken to ensure that the flue terminal is not especially if an approved method of sealing has not been situated in a high-pressure area, the proximity of buildings used, or if the design of the flue has not made provision for...
Page 12 Flat roof with parapet Flat roof envelope method Flat roof where the flue height is more than 10 Heights (H) away from all structures Flat roof with flue close to parapet Doc No. 20-45-159 Page 12 of 60...
Page 13 Flat roof with no parapet Flat roof with structure close to flue outlet Pitched roof not greater than 45° Doc No. 20-45-159 Page 13 of 60...
Page 14 1.14 Dimensions Front View Side View Top View - Nozzle Outlet Top View - Duct Outlet (also showing spigot Ø ) Doc No. 20-45-159 Page 14 of 60...
Page 15 Dimensions for Vertical Cabinet Heaters (all dims in mm) Model 30 1650 1650 1900 1900 2025 2025 2120 2120 2110 2110 2667 Unit height 1000 1000 1100 1100 1244 Unit width 1085 1085 1282 1282 1550 1550 1550 Unit depth Flue outlet ctr Flue Spigot Ø...
Page 16 Dimensions for Horizontal Cabinet Heaters (all dims in mm) Model 85 1865 1960 2057 2076 2667 Unit length 1000 1100 1244 Unit height 1085 1282 1550 1550 Unit width Flue outlet ctr to front Outlet nozzle width 1660 1761 1858 1823 2426 Flue outlet ctr/l to end...
Page 17 Dimensions for Downturn Cabinet Heaters (all dims in mm) Model 85 1865 1960 2057 2076 2667 Unit height 1000 1100 1244 Unit width 1085 1282 1550 1550 Unit depth Flue outlet ctr to front Outlet nozzle height 1660 1761 1858 1823 2426 Flue outlet ctr/l to top...
Page 18 1.15 Technical Details Model kW/hr 29.1 39.74 58.1 82.5 Heat Output (max) Btu/hr 99,289 124,191 198,237 282.513 kW/hr 35.4 48.9 70.3 102.1 Heat Input (Gross) Btu/hr 120,785 166,847 239,864 348,365 kW/hr 31.9 44.09 63.3 91.9 Heat Input (Nett) Btu/hr 108,823 150.435 215,979 313,563...
Page 19 Model kW/hr 117.3 132.5 176.8 205.5 Heat Output (max) Btu/hr 400,227 452,090 603,241 701,200 kW/hr 142.8 161.2 214.2 250.6 Heat Input (Gross) Btu/hr 487,234 550,014 730,850 822,300 kW/hr 128.6 145,3 193.0 225.6 Heat Input (Nett) Btu/hr 438,783 495,763 658,516 769,747 Nett Efficiency 91.24 91.2...
Page 20 Model kW/hr 236.8 283.67 380.5 Heat Output (max) Btu/hr 807,961 967,900 1,298,300 kW/hr 285.7 345.88 463.6 Heat Input (Gross) Btu/hr 974,808 1,180,150 1,581,803 kW/hr 257.4 311.60 417.3 Heat Input (Nett) Btu/hr 878,244 1,063,198 1,423,827 Nett Efficiency 92.0 91.08 91.1 Burner Type Riello RS34.1 RS34.1...
Page 21: Technical Information
1.15.1 Technical Information Appliance Type 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 2E(R)B 2E(R)B 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...
Page 22: Flue Installation
Front Rear are referred to. See also terminal details on page 15 & 16 30 - 40 Where condensation is likely to be a problem provision should be made preferably at the design stage (see section 1.13) 60 - 85...
Page 23: Electrical Installation/Connection
ing the accepted practice in European countries is detailed in are prime considerations. Joints and seams must be airtight the June 1995 version of prEN 1020 annex A7 The diameter of and fastened securely and designed to remain so, even when the pipework from the cock to the burner connection must operating at high temperatures.
Page 24 Wiring Diagram 20-45-600 30 - 40 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 24 of 60...
Page 25 Wiring Diagram 20-45-601 60 - 85 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 25 of 60...
Page 26 Wiring Diagram 20-45-602 120 - 135 ON/OFF Riello Burner Integral SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 26 of 60...
Page 27 Wiring Diagram 20-45-603 60 - 300 ON/OFF Riello Burner Integral SC³-SZ 415/50/3ph Doc No. 20-45-159 Page 27 of 60...
Page 28 Wiring Diagram 20-45-616 30 - 40 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 28 of 60...
Page 29 Wiring Diagram 20-45-617 60 - 85 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 29 of 60...
Page 30 Wiring Diagram 20-45-618 120 - 135 ON/OFF Riello Burner Remote SC³-SZ 230/50/1ph Doc No. 20-45-159 Page 30 of 60...
Page 31 Wiring Diagram 20-45-619 60 - 300 ON/OFF Riello Burner Remote SC³-SZ 415/50/3ph Doc No. 20-45-159 Page 31 of 60...
Page 32 Wiring Diagram 20-45-604 30 - 40 ON/OFF Riello Burner Integral CP4 230/50/1ph Doc No. 20-45-159 Page 32 of 60...
Page 33 Wiring Diagram 20-45-605 60 - 85 ON/OFF Riello Burner Integral CP4 230/50/1ph Doc No. 20-45-159 Page 33 of 60...
Page 34 Wiring Diagram 20-45-606 120 - 135 ON/OFF Riello Burner Integral CP4 230/50/1ph Doc No. 20-45-159 Page 34 of 60...
Page 35 Wiring Diagram 20-45-607 60 - 300 ON/OFF Riello Burner Integral CP4 415/50/3ph Doc No. 20-45-159 Page 35 of 60...
Page 36 Wiring Diagram 20-45-620 30 - 40 ON/OFF Riello Burner Remote CP4 230/50/1ph Doc No. 20-45-159 Page 36 of 60...
Page 37 Wiring Diagram 20-45-621 60 - 85 ON/OFF Riello Burner Remote CP4 230/50/1ph Doc No. 20-45-159 Page 37 of 60...
Page 38 Wiring Diagram 20-45-622 120 - 135 ON/OFF Riello Burner Remote CP4 230/50/1ph Doc No. 20-45-159 Page 38 of 60...
Page 39 Wiring Diagram 20-45-623 60 - 300 ON/OFF Riello Burner Remote CP4 415/50/3ph Doc No. 20-45-159 Page 39 of 60...
Page 40 Wiring Diagram 20-45-612 30 - 40 ON/OFF Riello Burner No Controls 230/50/1ph Doc No. 20-45-159 Page 40 of 60...
Page 41 Wiring Diagram 20-45-613 60 - 85 ON/OFF Riello Burner No Controls 230/50/1ph Doc No. 20-45-159 Page 41 of 60...
Page 42 Wiring Diagram 20-45-614 120 - 135 ON/OFF Riello Burner No Controls 230/50/1ph Doc No. 20-45-159 Page 42 of 60...
Page 43 Wiring Diagram 20-45-615 60 - 300 ON/OFF Riello Burner No Controls 415/50/3ph Doc No. 20-45-159 Page 43 of 60...
Page 44 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 44 of 60...
Page 45: Operation
3. Commissioning. this sample point can be plugged and sealed after commissioning. (k) Check that the fan stat settings has not been disturbed. Warning (l) Remove lower panel and check motor and fan drive system It is a requirement that only suitably qualified and for integrity of joints, check pulley alignment, fan rotation, and competent personnel are allowed to undertake the belt tension (see section 4.2).
Page 46 ----------- O R ---------- On completion delete any override settings on optimised control and return temperature settings to customer requirements. 3 >40s Pilot ignition... Burner Ignition 4 <60s Burner ignition cycle complete (s) Undertake flue gas analysis using approved and calibrated analysing equipment recording data on the commissioning Note: card, ie, CO, CO2, net and gross flue temperatures.
Page 47: Commissioning - Hand Over
holes provided in the hood outer ring and fastened in place qualified persons. using self tapping screws. (d) Section 8 ‘User Instructions’ should be left with the customer upon satisfactory completion of the commissioning and hand-over. Caution On ducted applications it is necessary that the system is balanced in order to optimise the efficiency of the heater and Caution the air distribution and delivery system Failure to balance the...
Page 48: Servicing Procedure - Major Component Parts
Quarterly Inspection which do not have grease nipples feature sealed bearings which are lubricated during manufacture for their life. (a) Visual inspection of the burner (b) Clean and check ionisation probes The electrical connections should be checked as follows. (c) Check overheat safety is operational (a) The cover to the terminal box should be removed by Bi-Annual Inspection undoing the screws which secure it.
Page 49 (h) Align pulleys using a straight edge, and by gradual alter- Note: nate tightening of the screws clamp in position. It is most important that a build up of deposits is not allowed (i) Refit belts and check for the correct amount of tension. to occur as this can have an adverse effect upon the efficiency of the heater and reduce the life of the heat exchanger.
Page 50: Service Re-Commissioning
4.2.11 Report 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. Service Re-commissioning The heater should be re-commissioned as follows, as per section 3.1 through to section 3.4 inclusive.
Page 51: Parts Lists
5 Parts Lists Doc No. 20-45-159 Page 51 of 60...
Page 52 GS5 + GT GS10 + GT GS10 + GT GS20 + GT 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. 39-70-569 39-70-569 39-70-530 39-70-530 39-70-531 39-70-531 valve & pipe) Control Box 30-20-230 30-20-230 30-13-073 30-13-073 30-13-073 30-13-073...
Page 53 Heater Size / Item Description HTX Assy Aluminised 31-28-128 31-28-128 20-45-154 20-45-154 20-46-283 20-46-283 S/Steel 31-28-159 31-28-159 20-45-164 20-45-164 20-46-281 20-46-281 Turbulators 20-45-485 20-45-485 20-45-780 20-45-780 Burner Spigot 31-28-080 31-28-080 31-40-156 31-40-156 31-27-121 31-27-121 Gasket Stackbox 31-28-078 31-28-078 31-24-074/Z 31-27-123/Z 37-27-123/Z 31-27-123/Z Assembly Painted Pressure Relief 31-28-080 31-28-080 31-27-121...
Page 54 29-99-449 29-99-552 29-99-552 29-99-552 29-99-561 On/Off + Gas Train GS20 + GT RS34/1 + GT RS34/1 + GT RS34/1 + GT RS44/MZ+GT Burner Gasket 30-06-710 30-03-817 30-03-817 30-03-817 30-03-817 Gas Train (incl. 39-70-532 39-70-231 39-70-231 39-70-231 39-70-233 valve & pipe)
Page 55 Heater Size / Item Description HTX Assy Aluminised 20-46-355 20-46-355 20-47-405 20-47-405 20-28-211 S/Steel 20-46-400 20-46-400 20-47-421 20-47-421 20-28-039 Turbulators 20-46-781 20-46-781 20-47-763 20-47-763 20-47-763 Burner Spigot 31-27-121 31-27-121 31-29-046 31-29-046 31-29-046 Gasket Stackbox 20-46-307/Z 20-46-307/Z 20-47-425/Z 20-47-425/Z 20-28-086/Z Assembly Painted Pressure Relief 20-46-354 20-46-354...
Page 56: Fault Finding Guide
6 Fault Finding Guide No Power Check isolator Check fuse Burner lockout Burner fails Check set temp to run Check on time Check controls Check on time No Demand Check air pressure switch Check flame Check control probe box and burner Check burner motor Check gas...
Page 57: Check Control
Check that Check gas Excess air flue gas CO supply is as advised Adjust damper to suit Burner lights Low gas Check inlet on start gas pressure gas pressure but fails to Check main establish Signal burner gas mail flame Check flame pressure probe...
Page 58: Replacement Parts
Replacement Parts. R40 series: • Using an 13mm spanner, remove the nut holding the unit to the burner flange. Note • Withdraw the burner from the throat of the heat It is recommended that only suitably competent persons are exchanger, support on bracket/flange lugs. allowed to undertake replacement of parts.
Page 59: Blower Motor
• Tighten and clamp fasteners to hold fan motor in position. Blower Motor • Disconnect electrical supply. • Remove front panel (below burner) The MCB is located on the electrical panel plate situated on • Disconnect electrical supply. the right hand side of the unit. •...
Page 60: Ventilation Only
User Instructions 8.4 Stop procedure Commissioning and hand over Warning (a) Disable burner by selecting ‘Heat OFF’; ‘Standby’.* As part of the commissioning programme, the (* dependent on control type supplied. Refer to individual commissioning engineer must go through the following with controller operating manual.) the operator.

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