BENSON 2 VARIANTE RANGE NATURAL GAS (G20 I2H) PROPANE GAS (G31 I3P) TUBULAR HEATER INSTALLATION COMMISSIONING SERVICING USER INSTRUCTIONS BENSON Issue 5 July 2010 33-64-695 THIS MANUAL SHOULD BE LEFT WITH THE END USER .
Section Contents Page No 1.0 Compliance Notices 4 1.1 Certificates of Conformity 5 1.2 General product Information 5 1.3 General Requirements 6 1.4 Delivery & Pre-installation Checks 6 1.5 Warranty 7 Special risk areas 7 2.0 Installation 8 2.1 Installation Clearances and Mounting Heights 8 2.2 Heater Mounting 9 2.3 Warm Air Circulation 10 2.4 Air Supply 10 2.5 Flue Installation 14 2.6 Electrical Installation 22 2.7 Gas Installation 23 3.0 Commissioning 24 3.
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.
Where proprietary items are incorporated into Benson Heating products, detailed The Benson Variante range of warm air heaters detailed herewith are manufactured information and instructions are also by Benson Heating within a strictly controlled provided as part of the information pack.
BS EN 60204 - Part 1 : 1993 Safety of Machinery - Electrical Equipment for Machines Specification for General Requirements BS EN 60335 - Part 1 : 1988 Safety of Household and Similar Electrical Appliances General Requirements BS EN 55014 - 1993 Limits and methods of measurement of radio disturbance characteristics of electrical motor-operated and thermal appliances for household and similar purposes, electrical tools and similar electric apparatus BS EN 50165 - 1997 Electrical Equipment of non-electric heat
1.3 General Requirements Caution Before installation, check that the local distribution conditions, nature of gas and pressure, and the current state adjustment of the appliance are compatible. Warning Unauthorised modifications to the appliance, or departure from the manufacturers guidance on intended use, or, installation contrary to the manufacturers recommendations may constitute a hazard.
following information to enable processing to take place; The heater is supplied with a 1 year parts and labour warranty and a further year on all (1) Heater model (2) Heater serial number parts excluding consumable’ s. (3) Order reference/date of order, together In addition to this there is also a 10 year with full installation details (name and time related warranty on the combustion address) chamber. (4) Details or symptoms of fault The warranty commences from the date of (5) Installers name and address.
In areas where it is proposed that more than Provided certain criteria are met it is possible one heater is to be installed, a general to install VRC (centrifugal fans) within a plant scheme of circulation should be drawn up room heaters installed in plant rooms should and maintained, thereby offering the best heat distribution.
Clearances VRA in mm Model 40 70 100 135 170 200 250 330 410 490 Above 300 300 300 300 300 300 300 300 300 300 Below 300 300 300 300 300 300 300 300 300 300 Right side 250 250 250 250 250 250 250 250 250 250 Left side 800 800 800 800 800 800 950 950 950 950 Rear 300 350 400 500 500 560 560 560 560 630 Clearances VRC in mm Model 40 70 100 135 170 200 250 330 410 490 Above 300 300 300 300 300 300 300 300 300 300 Below 300
capable of adequately supporting the weight of the unit and ancillary equipment . 2.4 Air Supply for Combustion and Ventilation 2.4.1.1 Natural Ventilation Openings to the Heated Space 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 the heaters are to be installed .
each heater model as - Room or Enclosure 2.4.1.
within 1000 mm of floor level for natural gas and ideally at floor level for l.p.g gas installations but in any event no higher than 250 mm. and ideally at floor level for l.p.g gas installations but in any event no higher than 250 mm. 2.4.2.3 Natural Ventilation Openings to 2.4.2.
15% of the wall height The low level natural ventilation opening should be situated on an external wall and be within 1000 mm of floor level for natural gas and ideally at floor level for l.p.g gas installations but in any event no higher than 250 mm. within 1000 mm of floor level for natural gas and ideally at floor level for l.p.g gas installations but in any event no higher than 250 mm. 2.4.2.5 Mechanical Ventilation to a Plant Room or Enclosure The table below provides specific data for 2.4.2.
means to safely inhibit heater(s) spigot if the heater is to be installed in the operation should mechanical air supply flue only option fail for any reason The flue assembly must comply with all the relevant regulations regarding height and The table below provides specific data for materials, and must terminate with an each heater model as approved flue terminal. Care should be taken to ensure that the flue terminal is not situated in a high pressure area, the proximity of buildings and other 2.
Provision for the disconnection of the flue for servicing and inspection purposes must also be made. The position of the flue and its terminal should be such that it does not impair the combustion process. It should terminate in an exposed position so as to allow the free escape of flue gases without risk of their reentering the building through windows, ventilation ports etc.
C32 Vertical Co axial flue Kit options L1 maximum combined flue length 10 metres Kit comprises Item (1) Co-axial flue terminal Ø 80 x Ø 80 Item (3) 900 by Ø 80 bend x 2 Part No 33-55-010 33-54-005 Extra pipes to extend the flue are available as an option Pipe Pipe Pipe Bend Ø Ø Ø Ø 80 x 1000 mm 80 x 250 mm 80 x 500 mm 80 x 450 33-54-001 33-54-002 33-54-003 33-54-004
C32 Vertical Co axial flue Kit options L1 maximum combined flue length 10 metres Part No Kit comprises Item (1) Co-axial flue terminal Item (2) Ø100 x 250 mm pipe Item (3) 900 by Ø100 bend x 1 Item (4) 450 by Ø100 bend x 2 33-55-107 33-54-103 33-54-105 33-54-104 Extra pipes to extend the flue are available as an option Pipe Ø 100 x 1000 mm Pipe Ø 100 x 500 mm Pipe Ø 100 x 250 mm 33-54-101 33-54-102 33-54-103
C32 Vertical Co axial flue Kit options L1 maximum combined flue length 10 metres Part No Kit comprises Item (1) Co-axial flue terminal Item (2) Ø130 x 250 mm pipe x 2 Item (3) 900 by Ø130 bend x 2 33-55-207 33-54-203 33-54-205 Extra pipes to extend the flue are available as an option Pipe Ø 130 x 1000 mm Pipe Ø 130 x 500 mm Pipe Ø 130 x 250 mm Bend Ø 130 x 450 33-54-201 33-54-202 33-54-203 33-54-204
Option B22 In this configuration the heater is connected to a single flue pipe to discharge the products of combustion outside the building either through the roof or through a wall. The air for combustion is taken from inside the building. Heater Unit Flue Exit HORIZONTAL Flue Exit VERTICAL MIN. MAX. MIN. MAX.
Option C12 In this configuration the heater is connected to a horizontal flue system discharging the products of combustion and bringing in the combustion air from outside the building in which the heater is located. The outlet / inlet must be through the wall and may be made with two separate pipes or with a horizontal coaxial concentric terminal Heater Unit Horizontal L1 MIN Concentric Flue L1MAX. 40 m 0.50 3.00 70 m 0.50 6.00 100 m 0.60 6.00 135 m 0.70 6.00 170 m 0.85 6.
VRE Flueing options B22 Single pipe flue only and C32 Vertical coaxial Heater Unit Flue Exit VERTICAL CO/AXIAL Flue Exit VERTICAL MIN. MAX. MIN. MAX. 40 m 1,00 3.
Caution It is imperative that the flue should be properly sealed where it passes through the roof, this can best be achieved by using the approved method of roof flashing plate and cravat. The flue spigot outlet on all Variante heaters is in horizontal configuration.
Any ancillary electrical items e.g. room thermostats , time switches, remote panels etc, must be wired into the heater electrical circuit in accordance with the diagrams provided Note When external controls operate to switch the heater OFF, power to the heater should remain to allow the fan to continue to operate to sufficiently cool the heater thereby preventing damage to the heat exchanger. 2.
type and should be clearly marked OPEN / CLOSED it should also be installed so as to fall to the closed position An approved gas jointing compound must be used on all joints and unions and the system purged and tested for soundness prior to final connection The connection to the heater can be made by way of either an approved flexible coupling or rigid connection .
In order to test that all controls are in good working order, the control sequence should first be tested with the gas supply turned Off. Ensure gas isolating cock is in the Off position Warning If during the following sequence of operations the heater fails to operate correctly the fault should be traced and rectified before proceeding, if necessary referring to section 5.0 fault diagnosis.
down v) Turn off the electrical supply w) Close the side panel x) Set thermostat to desired setting y) Ensure that the user is familiar with the heater and its controls and that the user is satisfied with the commissioning and testing, and that he is aware of the instructions within the manual It is strongly advised that the commissioning engineer runs through the lighting, shutdown, and general safe and efficient running of the heater before hand over. 3.
injectors are correctly aligned, and that they are clean, and that there are no contaminates restricting the orifices, if necessary clean carefully with compressed air and or lint free cloth and acetone. Caution The injector orifice is precision machined to fine tolerances, do not clean with hard sharp or abrasive instruments. If the injectors have been removed from the manifold, when they are replaced, and care should be taken not to over tighten. Ensure all joints are gas tight.
Fault Finding Burner fails to light Electric Supply ON Turn on Electric Supply No Check fuse Replace if required Yes Yes Flue fan running No Check flue fan connections Yes Replace flue fan Yes Air pressure switch made No Check flue is clear Yes Change air pressure switch d Limit thermostat operated Yes Reset Limit thermostat Yes Thermostat calling for heat Yes Yes Gas Supply ON No Turn on Gas Supply Yes Air in Gas Supply Purge Gas Line Yes No Spark ignition on No Check HT
Fault finding cont’d Fan will not run heater goes off on limit Yes Bad electrical connection Yes Check wiring connection Yes Reset fan control settings Yes Faulty fan control No Fan control settings incorrect No Fan runs in m anual m ode No Faulty fan m otor or capacitor Yes Change fan m otor or capacitor Yes Change fan control
WARNING NEUTRAL RESET Wiring Diagram 33-67-161 VRA 040-200 Auto ignition
WARNING NEUTRAL RESET Wiring Diagram 33-67-162 VRA 250-330 Auto Ignition
WARNING NEUTRAL RESET Wiring Diagram 33-67-163 VRA 410- 490 Auto Ignition
WARNING NEUTRAL RESET Wiring Diagram 33-67-164 VRC 250-330 VRE 410-490 Auto Ignition
WARNING NEUTRAL RESET Wiring Diagram 33-67-202 VRC 250-490 3 Phase Auto Ignition
SC3-SZ On/Off Control 1 Phase 33-67-568 WARNING NEUTRAL RESET SC3-SZ On/Off Control 3 Phase 33-67-590 WARNING NEUTRAL RESET
SC3-MZ Hi/Low Control 1 Phase 33-67-569 WARNING NEUTRAL RESET SC3-MZ Hi/Low Control 3 Phase 33-67-591 WARNING NEUTRAL RESET
CP4 Control 1 Phase 33-64-351T WARNING NEUTRAL RESET CP4 Control 3 Phase 33-67-247 WARNING NEUTRAL RESET
CP2 On/Off Control 1 Phase 33-64-350T WARNING NEUTRAL RESET CP2 On/Off Control 3 Phase 33-67-203 WARNING NEUTRAL RESET
CP2 Hi/Low Control 1 Phase 33-64-488T WARNING NEUTRAL RESET CP2 Hi/Low Control 3 Phase 33-67-204 WARNING NEUTRAL RESET
Less Controls Connections 1 Phase 33-64-349T WARNING NEUTRAL RESET Less Controls Connections 3 Phase 33-67-041T WARNING NEUTRAL RESET
7.0 Technical Data Appliance Type B22 C 32 C12 PIN / report no 0063BQ5461 Electrical Protection IP20 7.
Natural Gas (G20 I2H) Tubular Heater The minimum allowable pre-purge time requires calculating [BS EN1020:1998 clause 6.38]. To do this only the Carbon Dioxide CO2 figure needs to be measured. E.G. on a model 170 the calculated minimum time is = 354.8 / ((100 / CO2) + 1) If the measured CO2 is 6.7% Then 100 / 6.7 = 14.9 14.9 + 1 = 15.9 Therefore minimum pre-purge time is = 354.8 / 15.9 = 22.3 seconds The calculation to be conducted is given below for all models: Model 40 Minimum pre-purge time = 628.
Propane (G31 I3P) Tubular Heater The minimum allowable pre-purge time requires calculating [BS EN1020:1998 clause 6.38]. To do this only the Carbon Dioxide CO2 figure needs to be measured. E.G. on a model 170 the calculated minimum time is = 898.4 / ((300 / CO2) + 2.01) If the measured CO2 is 8.0% Then 300 / 8.0 = 37.5 37.5 + 2.01 = 39.51 Therefore minimum pre-purge time is = 898.4 / 39.51 = 22.
7.2 Technical Data NAT GAS / LPG MODEL 40 70 100 135 170 HEAT OUTPUT kW Btu 12.0 40.950 19.6 67,000 29.4 100,000 39.2 134,000 49.0 167,000 kW Btu 12.9 44,000 21.1 72,000 32.0 109,180 42.6 145,350 53.3 181,700 EFFICIENCY % Nett 92.8 92.7 92.0 92.1 92.0 EFFICIENCY %Gross 83.6 83.5 82.8 82.9 82.8 HEAT OUTPUT Low Fire kW Btu 6.8 23,2000 12.4 42,300 18.5 63,130 24.8 84.620 31.1 106.100 kW Btu 7.2 24,570 13.3 45,400 20.2 68.920 26.9 91,780 33.
7.2 Technical Data NAT GAS / LPG MODEL 200 250 330 410 490 HEAT OUTPUT kW Btu 58.8 201,000 72.0 246,000 96.0 328.000 120.0 409,000 144.0 491,000 HEAT INPUT (Nett) kW Btu 63.9 218,000 78.8 268,900 105.2 359,000 130.4 445,000 156.5 534,000 EFFICIENCY % Nett 92.0 91.4 91.2 91.5 91.5 EFFICIENCY % Gross 82.8 82.3 82.1 82.4 82.4 HEAT OUTPUT Low Fire kW Btu 37.2 126,900 46.6 159,000 62.2 212,250 77.5 264,430 93.0 317,300 HEAT INPUT (Nett) Low Fire kW Btu 40.
8.
Parts list con’td MODEL 200 250 330 410 490 Fan Axial VRA Standard 28-09-092 28-09-062* 28-09-092* 28-09-056* 28-09-056* Fan Axial VRE 28-09-056 28-09-062* 28-09-097* 28-09-063() 28-09-098(*) VRA ENHANCED THROW Fan Centrifugal 28-09-002 28-09-049* 28-09-144* 28-09-043 28-09-043 Fan Motor N/A N/A N/A 28-10-015 28-10-120 Fan Belts N/A N/A N/A 09-16-110 09-16-110 Fan Limit Stat 28-60-023 28-60-021 28-60-021 28-60-021 28-60-021 Gas Valve 28-30-180 28-30-181 28-30-181 28-30
A 440 440 545 650 780 910 650 800 980 1150 Model 40 70 100 135 170 200 250 330 410 490 1750 1750 1750 1750 1050 1050 1050 1050 1050 1050 B 1625 1625 1375.5 1304.5 1245.5 1245.5 1174.5 1174.5 1174.5 1133.
A 440 440 545 650 780 910 650 800 980 1150 Model 40 70 100 135 170 200 250 330 410 490 1750 1750 1750 1750 1050 1050 1050 1050 1050 1050 B 1022.5 1022.5 1022.5 1022.5 892.5 892.5 892.5 892.5 880.5 840.
A 440 440 545 650 780 910 650 800 980 1150 Model 40 70 100 135 170 200 250 330 410 490 1750 1750 1750 1750 1050 1050 1050 1050 1050 1050 B 1022.5 1022.5 1022.5 1022.5 892.5 892.5 892.5 892.5 880.5 840.
Vertical Co/Axial Terminal Dimensions AIR FLUE Heater A B C D E F G H J K 40-70 120 80 250 775 1075 1280 140 125 80 80 100- 200 140 75 270 815 1115 1360 170 150 100 100 250- 490 225 85 330 900 1630 1860 210 200 130 130 Dimensions in mm’s
Horizontal Co/Axial Terminal Dimensions FLUE AIR TOP Ensure Terminal is located on the wall in this configuration BOTTOM Heater A B C D E F G B+C 40-70 170 360 250 120 125 80 80 610 100-200 170 350 260 140 150 100 100 610 250-490 180 420 340 225 200 130 130 750 Dimensions in mm’s
Heater A B X Y øZ 2 330 105 31 142 125 2 V R070A 330 105 31 174 125 V2R100A 400 175 28 191 150 V R135A 400 175 28 300 150 V2R170A 400 175 28 430 150 400 175 28 560 150 V R040A 2 2 V R200A Dimensions in mm’s
Heater A B X Y øZ 2 653 755 28 200 150 2 V R170C 653 755 28 330 150 V2R200C 653 755 28 460 150 V R250A 1263 1365 5 185 200 V2R330A 1263 1365 5 317 200 V2R410A 1263 1365 7 489 200 1263 1365 7 630 200 V R135C 2 2 V R490A Dimensions in mm
Heater X Y øZ V2R040C 31 142 125 V R070C 31 174 125 V2R100C 28 261 150 2 Dimensions in mm
BENSON HEATING LTD LUDLOW ROAD KNIGHTON POWYS LD7 1LP Telephone +44 (0) 1547 528534 Facsimile +44 (0) 1547 520399 email information@bensonheating.co.uk Web www.bensonheating.
