Benson Ah150 Guide

PAKAWAY

OIL

FIRED CABINET

HEATER RANGE

INSTALLATION,

COMMISSIONING,

SERVICING

AND

USER

INSTRUCTIONS

((

C

...

Jrl

Lfi

cnh!

Number"

FM

1

4923

-CONTENTS-

SECTION A

1.0

1.1

1.2

1.3

1.4

1.5

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

3.0

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

4.0

4.1

4.2

4.3

4.4

5.0

5.1

5.2

5.3

6.0

7.0

8.0

9.0

9.1

31-28-054

Compliance

Notices

Certificates

of

Conformity

General

Product

Information

General

Requirements

Delivery

& Pre-installation

Checks

Warranty

Location

&

Positioning

Fuel

Supply

-

General

Fuel

Storage

Tank

Single

Pipe

System

-

Gravity

Feed

Two

Pipe

System

Pressurised

Ring

Main

System

Pipework

and

Fittings

Electrical

Supply

Air

Supply

Minimum

Space

Requirements

Air

Distribution

System

Flue

System

Ins

talla

tion

Packaging

& Siting

Flooring

Minimum

Clearances

Assembly

Flue Installation

Oil Installation &

Connection

Electrical Installation &

Connection

Air

Distribution

Installation

Warm

Air

Registers

Heater

Control

Installation

Commissioning

Pre-Test

Ignition

Air

Distribution

System

Hand

Over

Servicing

.

Planned

Servicing

Procedure

-Major

Component

Parts

Servicing -

Recommissioning

Fault

Diagnosis

by

Flow

Charts

Wiring

Diagrams

by

Model

and

Burner

Type

Technical

Data

Reference

Documents

-

Standards,

Codes

of

Practice

Parts

Listing

Page

No

.

3

4

5

7

8

9

12

13

14

15

19

20

21

22

23

25

27

28

29

31

32

35

38

41

42

03.96/ PM/CE (1)

SECTIONB

Warranty

Registration

Burner Information

Manual

Timer

Information

Manual

SECTION C

10.0 Introduction

10.1

Commissioning/hand

over

10.2 Servicing

10.3 Start

up

procedure

10.4 Stop

procedure

10.5

Shutdown

procedure

10.6 Ventilation

only

10.7 Lockout situations

10.8 Contact Information

ILLUSTRATIONS

Fig 1 Exploded

view

Fig 2 - 8 Fuel

systems

and

storage

Fig 9

-19

Flue

systems

Fig

20

Heater

control

panel

Fig

21

Time clock controls

Fig

22

Fan

and

limit

thermostat

Fig

23

-

25

Fan

and

motor

configurations

Fig

26

-

31

Fault diagnosis flow charts

Section A - Page No.

6

10-11

16-18

22

23

24

32-34

2

1.0 Compliance notices

The

Pakaway

range

of oil fired

Cabinet

Heaters

detailed

herewith

is

manufactured

by

Benson

Environmental

Limited

within

a strictly controlled

quality

environment

within

the

parameters

of

ISO 900l.

The

Pakaway

AH

range

has

been

independently

tested

and

assessed,

and

has

been

found

to

meet

The Essential

Requirements

of

the

following

European

Directives.

Machinery

Directive

(89/392/EEC)

Low Voltage Directive

(73/23/EEC

&

93/68/EEC)

Electromagnetic Compatibility Directive

(89/336/EEC

&

91/31

/EEC)

Product

Liability Directive

(65/374/EEC)

The

manufacturer

has

taken

reasonable

and

practical

steps

to

ensure

that

Pakaway

Cabinet

Heaters

are safe

and

without

risk

when

properly

used. These heaters

should

therefore

only

be

used

in

the

manner

and

for

the

purpose

for

which

they

were

intended,

and

in

accordance

with

the

recommendations

detailed herewith. The

heaters

have

been

designed,

manufactured,

assembled,

inspected,

and

tested,

with

safety

and

quality

in

mind,

there are certain basic

precautions

which

the

installer

and

user

should

be

aware

of,

and

they

are

strongly

advised

to

read

the

appropriate

sections of

the

information

pack

accompanying

the

heater,

prior

to installation

or

use.

Benson

Environmental

Limited

supports

an

new

products

being

supplied

to

their

customers

with

a

comprehensive

information

pack; this

dearly

defines

mandatory

instructions for

the

safe

installation, use,

and

maintenance,

of the appliance(s).

Where

proprietary

items

are

incorporated

into

Benson

Environmental

Ltd

products,

detailed

information

and

instructions are also

provided

as

part

of

the

information

pack.

It

is

the

responsibility of

the

installer, owner, user,

or

hirer, of

such

products

supplied

by

Benson

Environmental

Ltd, to

ensure

that

they

are familiar

with

the

appropriate

information/manuals,

supplied

by

the

manufacturer,

and

that

they

are

suitably

aware

of

the

purpose

of

the

manuals

and

the

safety instructions. In

addition,

operators

must

be

suitably

trained

in

the

use of

the

appliance

so as to

ensure

its

continued

safe

and

efficient use.

Benson

Environmental

Ltd

has

a

commitment

to

continuous

improvement,

and

therefore

reserves

the

right

to

amend

or

change

the

specification of

the

Pakaway

AH

Cabinet

Heater

range

subject to

compliance

with

the

appropriate

European,national

and

local regulations.

Contained

within

the

text

of

the

manua

l,

the

words

'Caution'

and

'Warning'

are

used

to

highhght

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

Pakaway

AH

range

of

gas

fired

cabinet

heaters

conform

to

the

following

harmonised

standards;

BS

EN 292 -

Part

1 : 1991

Safety of

Machinery

-Basic Concepts, General Principles for Design

Basic

terminology, methodology

3

BS

EN 292 -

Part

2:

1991

Safety of Machinery -Basic Concepts, General PrincipIes for Design

Technical

Principles

and

Specifications

BS

EN 60204 -Part 1 : 1993

Safety of Machinery -Electrical

Equipment

for Machines

Specification

for

General

Requirements

BS

EN 60335 -

Part

1 : 1988

Safety

of

Household

and

Similar Electrical Appliances

General

Requirements

BS

EN 55014 -1993

Limits

and

methods

of

measurement

of

radio

disturbance

characteristics

of

electrical

motor-operated

and

thermal

appliances

for

household

and

similar

purposes, electric tools

and

similar electric

apparatus

prEN

50165 -1995

Electrical

Equipment

of non-electric heating appliances for

household

and

similar

purposes,

safety requirements

1.1 Certificates

of

conformity

Certificates

are

available

from

the

Quality

Control

Department

at

Benson

Environmental

Limited.

1.2 General product information

The

Pakaway

AH

models

have

an

output

range

from approximately 30kW to 293kW,

and

are

available

in

a configuration

that

will allow for floor

mounting

only.

The

Pakaway

units

can

suit

either

ducted

applications,

or

be

used

as free

blowing

units,

but

each

heater

must

be

connected to its

own

individual

open

flue.

Each heater is fitted with a forced

draught

burner

which

has

been

test fired

and

pre-set

prior

to

dispatch. The safety functions of the

burner

are

by

way

of a fully sequential control box fitted to

the burner.

Note

Neither

asbestos

nor

soft

soldered

joints are

used

in the

construction

or

manufacture

of

the

Pakaway

range

of Cabinet Heaters. The materials selected for

use

can

withstand

the mechanical,

chemical,

and

thermal

stresses

which

they will be subject to

during

foreseen

normal

use

when

installed in accordance with the manufacturers recommendations.

4

1.3 General requirements

Caution

Ensure

that

the

fuel s

upply

is in accordance

with

the

manufacturer's

recommendations

and

is as

stated

on

the

appliance

data

plate.

Installation,

commissioning,

and

servicing

must

only

be

carried

out

by

appropriately

qualified

and

competent

persons.

Warning

Unauthorised

modifications

to

the

appliance,

or

departure

from

the

manufacturers

guidance

on

intended

use,

or

installation

contrary

to

the

manufacturers

recommendations

may

constitute

a

hazard

.

Note

To

ignore

the

warning

and

caution

notices,

and

to

ignore

the

advice

from the

manufacturer

on

installation,

commissioning,

servicing,

or

use, will

jeopardise

any

applicable

warranty,

moreover,

such

a

situation

could

also

compromise

the safe

and

efficient

running

of

the

appliance

itself,

and

thereby

constitute

a

hazard.

The

installation

of

the

appliance

must

meet

all

the

relevant

European,

national,

and

local

criteria. (See sections 3

and

9).

Prior

to installation

the

following

points

should

be

considered;

a)

The

position

of

the

heater

for the

optimum

efficient

distribution

and

circulation

of

warm

air

b)

The

position

of

the

heater

relative to the

route

of

the flue

c)

The

position

of

the

heater

relative to

the

supply

of

fuel

d)

The

position

of

the

heater

relative to the electrical services,

and

if

appropriate,

any

additional

controls.

e)

The

position of

the

heater

relative to the

supply

of

fresh

air

f)

The

position of

the

heater

relative to service

and

maintenance

requirements

Caution

The

heater

must

not

be

installed

within

an

area

where

the

conditions

are

unsuitable,

e.g.

where

the

atmosphere

is

highly

corrosive,

has

a

high

degree

of

salinity,

or

where

high

wind

velocities

may

affect

burner

operation.

Suitable protection

should

be

provided

for

the

appliance

when

it is

located in a

position

where

it

may

be

susceptible to external

mechanical

damage

from; for

example,

fork lift trucks,

overhead

cranes etc.

1.4

Delivery

and pre-installation checks

The

heater

is

supplied

wrapped

in

heavy

duty

protective

polythene

.

On

receipt

of

the heater,

the

following checks

should

be

carried

ou

t;

a) The

model

is as

per

order

b)

That

it is

undamaged

c)

That

it is

suitable

for

the

fuel

supply

d)

That

it is

suitable

for

the

electrical

supply

5

Fig 1 -

Exploded

View

6

If

any

of these

points

are

not

satisfied

then

contact

should

be

made

with

the

Sales Office

at

Benson

Environmental

Ltd as

soon

as possible

by

telephoning

01547-528534. In the case of claims

for

damage,

this

must

be

reported

in

writing

within

24

hours

of delivery,

in

order

to

comply

with

insurance

criteria.

1.5 Warranty

The

heater

is

supplied

with

a 2

year

warranty

made

up

as follows; first

year

covering

parts

and

labour,

and

second

year

covering

parts

only. In

addition

to this there is also a 10

year

time related

warranty

on

the

combustion

chamber

/

heat

exchanger

.

The

warranty

commences

from the

date

of

dispatch

from

the

manufacturer,

and

is

subject

to

the

terms

detailed

within

the

Benson

Environmental

Ltd '

conditions

of

busine

s

s'.

Note (i)

The

warranty

may

be

invalidated

if -

a)

The

warranty

registration

/

commissioning

card

has

not

been

completed

and

returned

to

Benson

Environmental

Ltd

b) The installation is

not

in accordance

with

the

general

requirements

of this

manual

c)

The

flue

arrangement

and

air

supply

for

the

heater

are

not

in

accordance

with

the

manufacturers

recommendations,

codes of practice,

or

similar

standards

d) Air flow

through

the

heater

is

not

in

accordance

with

the

manufacturers

technical specifications

e) Internal wiring

on

the heater

has

been tampered

with

or

unauthorised

service/repairs

undertaken

f)

The

main

electrical

supply

input

to the

heater

has

been

interrupted

during

the

heating

mode

g) The

heater

has

been

subject to

and

affected

by

the

ingress of

water

in

any

form

h) The heater is

not

operated

at the rating(s) laid

down

in the manufacturers technical specifications

i)

The

heater

has

not

been

operated

or

used

\vithin

the

normal

scope of its

intended

application

j)

The

manufacturer's

recommended

minimum

service requirements

have

not been complied

with

Note

(ii)

All

warranty

claims

must

contain

the

following

information

to

enable

processing

to

take

place; (1)

heater

model

(2)

heater

serial

number

(3)

order

reference/date

of

order,

together

with

full

installation

details

(name

and

address)

(4)

details

or

symptoms

of

fault (5) instaHers

name

and

address.

Faulty

parts

must

be

returned

to

the

Knighton

Spares

Department,

the

address

of

which

is

provided

on

the

back

cover

of

this

manual

and

section

10.8.

Any

such

parts

will

undergo

inspection

to verify the

claim

.

Replacement

parts

supplied

prior

to this

may

be

charged,

and

a

credit

supplied

upon

subsequent

validation

of

the

warranty

claim

.

Consumable

items

are

specifically

not

included

within

the

scope of the warranty.

Note

(iii)

Notification

is

required

immediately

a fault is

suspected.

The

manufacturer

will

not

accept

responsibility for

any

additional

damage

that

has

been

caused,

expense

incurred,

or

consequential

loss resulting from

any

failure of

the

heater(s).

7

2.0 Location/positioning

Warning

All of

the

basic criteria

must

be satisfied

prior

to

commencing

installation

and

commissioning,

additionally

,

the

Cabinet

Heater

must

be

positioned

and

installed

so

as

to

comply

with

all

the

relevant

standards

and

guidelines

(see section 9.0), as well

as

meeting

national

and

local fire

regulations

and

insurance

criteria, especially if it is

proposed

that

heater

is to be installed

within

a special risk area (e.g.

where

petrol

engined

vehicles are

stored

or

parked,

wher

e cellulose

spraying

takes place,

where

woodworking

machinery

is

operated,

etc,).

Indirect fired heaters

must

not

be located in

hazardous

areas, however, it is permissible for the

heater

to

supply

air to

such

areas.

The heater

must

not be installed within

an

environment

where

there is a high concentration of

chlorides, fluorides, salts,

or

other

aggressive

or

volatile chemicals/

compounds

.

Nor

should

the

heater

be positioned

where

the

burner

could

be adversely affected

by

high

winds

or

draughts

.

The location

chosen

for the

heater

must

allow

for the fitting of

an

effective flue system. The

location

must

also allow for

adequate

clearance for the air supply,

return

air circulation, oil supp]y,

electrical supply, whilst also

providing

good

and

safe

working

access.

The heater

must

be installed

on

a flat

and

level surface

made

from non-combustible material,

which

is sufficiently

robust

to

withstand

the

weight

of the he

ater

and

any

ancillary

equipment.

Any

combustible material adjacent to the heater

or

flue

system

must

be so placed

or

shielded

so

that

its surface

temperature

does

not

exceed

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 offering the best heat distribution.

All

Pakaway

Cabinet Heaters are fitted

with

a pressure relief facility, this is

incorporated

into

the design of the flue gas exit duct. Care

should

therefore be taken in siting service connections

and

controls well

away

from the pressure relief vent.

Warning

Under

no circumstances

must

the pressure relief be restricted, blocked,

or

have

the free exit of

exhaust

gas

impaired

or

re-directed.

2.1

Fuel supply -general

The

Pakaway

AH

range

of oil fired cabinet heaters are all

manufactured

and

pre-set for

use

with

35 second gas oil delivered to the

burner

via a suitable

piped

system

from the oil storage tank.

The constraints of the application will, to a large extent,

determine

whether

it is preferable to

use

a

single

pipe

gravity

feed

system

,

or

whether

the

two

pipe

pumped

system

is

more

appropriate.

Where

more

than

one

appliance

is to

share

a

common

supply

it will be necessary to

use

a pressurised

ring

main

system. All

pipework

must

be constructed

and

installed

so

that

it

does

not

permit

the ingress of air.

The

contruction,

size,

and

position

of

the

oil

storage

tank

must

take

account

of

the

current

regulations, as well as

suiting

the requirements of the installation.

Note

Please refer to figures 2 - 8 for

additional

information.

Caution

On

pumped

systems

always

check

that

the

pump

is correctly

set

up

prior

to

running

,

and

always

ensure

that

valves

are

open

allowing a free flow of oil

through

the

system

.

8

2.2 Fuel

In

order

to

promote

trouble free

operating

it is necessary

that

the

oil

within

the

storage

tank

and

oil line

does

not

fall

below

the

cold

filter plugging point (cfpp), in this

country

and

with

class 0

fuel (also referred to as

gas

om,

the

critical

temperature

is

-4

°C for

the

summer

grade.

The

cfpp

critical

temperature

for

the

winter

grade

is -12°

e.

If

summer

grade

fuel is

stored

for

winter

use

in

areas

prone

to

severe

frosts

and

low

temperatures

it will be necessary to

insulate

or

even

heat

the

supply

tank

and

pipework.

Note

The

fuel

supplier

should

be

contacted

prior

to installation

so

that

any

requirements

concerning

delivery,

transport,

storage

and

use

can

be

addressed

before

work

commences

.

Warning

The

pump

pressure

must

not

exceed a

maximum

of 0.4 bar, this is

because

beyond

this

point

gas

is liberated from

the

oil.

2.3 Storage tank

Any

externally

painted

steel

storage

tank

to

BS

799

part

5 1987 is

required,

and

must

include

the

following;

- a fuel level

gauge

(not

made

from glass)

- a

vent

pipe

with

a

diameter

greater

than

that

of

the

filler

and

featuring

a

weather

proof

termina

tion

- a

sludge

valve

-

an

outlet

valve

situated

at

the

opposite

end

of the

tank

to the

sludge

valve

- a filler

pipe

connection

situated

at

the

opposite

end

to the

outlet

valve

The size of

the

storage

tank

must

take

account

of the

estimated

consumption

and

any

quantity

price

breaks

offered

by

the oil supplier.

It

is preferable to install the

tank

outside,

however, if this

is

not

practicable

and

the

tank

has

to

be

installed

indoors

advice

must

be

sought

about

its siting,

especially so far as fire

regulations

are

concerned.

If

a

separate

fire resistant

chamber

cannot

be

provided

for

indoor

installations, a

catchment

pit

with

a capacity ten

percent

greater

than

that

of

the

storage

tank

must

be

provided

. Storage

tanks

can

if

necessary

be

sited

on

a roof,

but

this is

subject

to

special

regulations

as

well

as

local

authority

approval

and

compliance

with

fire

regulations,

reference to

BS

5410

part

2 1978 is

strongly

suggested.

It

is

advisable

to

leave

the

tank

unpainted

on

the

inside,

but

to

paint

the

outside

with

a

proprietary

grade

of

anti-corrosive

paint.

A

galvanised

or

open

topped

tank

is

strictly

not

allowed.

If

a

medium

density

polyethylene

oil

tank

is to

be

used

then

it

must

be

OFTEC certified to OFS

T-100. Local, national,

European

and

fire

regulations

must

also be

complied

with.

2.4

Single

pipe

system

(gravity feed)

For

installation

where

the

oil

tank

is

200mm

or

more

above

the

level

of

the

fuel

pump

the

principle

of

gravity

feed

may

be used.

The

draw

off

point

for

the

supply

to the

burner

must

not

be

positioned

any

lower

than

100mm

above

the

bottom

of

the

tank.

Where

a

return

valve

is fitted

this

must

be

tamper

proof

to

prevent

inadvertent

operation.

9

Drain

Valve

Fuel

Tank

lilled

to facilitate drainage

Vent

Pipe

Isolating

Air

Nozzles

Fusible

a--+--c::l"'---t

Link

Fire

Burner

Filler

Valve Valve

Fig

2.

Typical

arrangement

of

oil storage

tank

and

single

pipe

system

1.

Gate valve

2.

In-line tilter

3. Pump

4.

Reliet valve

5.

Pressure gauge

6. Pressure reducing valve

7.

Return to tank

7

I

.- --

--

I

Note:

1. Pump duty and pipe sizing depend upon

application.

If

no

doubt contact our

Technical Department.

2. Pressure reducing

vatve

6 must be set to

give a maximum outlet pressure

of

4 p

.s.

i.

2

Fig

3.

Pressurised

oil feed

system

Warning: Before starting the burner make sure that the return pipeline

Is

not clogged; any

obstruction would cause the pump seals to break.

0

A '

..

I[

t -

.,'.

Y n

::~:

y"ifD"

Nole: All burners are despatched suitable

for

gravity feed installations.

Fig

4.

Burner

oil

pump

details

for

heater

models

100 to 600 -

Oil

Lines

H=D

iff

erence

of

level; L=Length of

th

esuction line; I.D

.=

Intemal diameterof

th

eoil pi

pes.

~

L melres

H

-

--

m 1.0. 1.0.

--

---

-

Bmm

10mm

- I .=--==

-=:.

1

----

0.5 10 20

-

--

I

-1 20

40

-- -

-=-'

1.5

40

80

2

60

100

E

'"

J:

>i

'"

E I 0 I

0 I i

~"I:.

10

Fig 5.

,-----r

~

f--

-

-IH

f--

-.-

: -

---=

--'

---

r

LmetrH

H 1.0 .

m 1.0.

Smm 10mm

0 35 100

0.5

30

100

1

25

100

1.5 20 90

2 15 70

3 8 30

3.5 6 20

The

pump suction should not exceed a

maximum of 4

matre.

(13ft). Beyond Ihls

limit gas

is

released from the oil.

OH

line.

musl

be

complelely alrtighL

The

return

line

Ihould

terminate

within

the

oil tank at the same level

IS

the

sucllon

line; in this case a non-return valve

Is

not

required.

Should, however, the return /ine

terminate

ovef

the fuel

~evel,

a non-return valve

is

essential.

This solution, however, is less safe

than

the

previous one, due to the possibility

of

leakage

of

the

valve.

Priming the

pump

: start the

burner

and

await

priming.

Should

lock-out

occur

prior

to

the

ar

rival

01

the fuel, wait at least 20

seconds

before repeating the operation.

Burner

oil

pump

details

for

heater

models

100 to 600 -

Oil

Lines

1l=Differ

ence

of

l

evel;

L=Lcn

gth

of

th

e

suction

line; I.D.=

lnt

e

rnal

diameter

of

the

oi

l

pip

es.

Fig

6.

~

L

I

1~1

H I.D.8mm t.D.10mm

0.315" 0.394"

p m

It

m

II

m

ft

lL

II·[CJ

:J

0.5

l'

6" 5 16 10 33

1

3'

0" 10 33

20

66

~

1.5 4' 6" 15 49 30 99

2 6' 0" 20 66

40

130

The

dimension

P should

not

exceed 4m (13'),

v to avoid damage to the pump seal

s.

Burner

oil

pump

details

for

heater

mode

ls 800 &

tooo

-

Gravity

Feed

from

the

bottom

of

the

oil-storage

tank

l-1

=Differen

ce

in hei

gh

t; L=To

tall

eng

th

of

suction line,

including

the

ver

ti

cal le

ngth

wit

hin

the

tank

Fig

7.

The

dtmen

sio

n P

shoutd

nol

exceed

4m (13'),

to

avoid damage

to

the

pump

seals.

L

H

I.D

. Smm t.D.

l0mm

0.315" 0.394"

m II m

It

m

It

0 0 32 105 70 230

0.5 l ' 6" 28 92 62 200

1

3'

0"

24

79 55 180

1.5 4' 6" 20 65 48 157

2 6' 0" 16 52

40

130

3 9' 0" 7 23

25

83

3.5 10' 6" --10 33

Burner

oil

pump

details

for

heater

models

800 & 1000 -

Gravity

Feed

over

the

top

of

the

oil-storage

tank

H=Differen.ce in

height;

L=Total len

gth

of

su

ction

line, i

ncludi

ng

the

vertical

length

within

the

t,lnk

Fig

8.

The p

ump

suction

must

not

exceed 4m

(13');

beyond

Ihis value

the

pump

becomes

noisy.

The

return valve

must

terminate at the same

level

as

the

foot

valve, otherwise the pump may

become

air-locked.

H =Difference

In

heigh!; L =Totat length of

suction line,

including

the vertical length

within

the

tank.

Burner

oil

pump

details

for

heater

models

800 & 1000 -

Suction

Feed

II

:;

Difference

in height; L

;::;:

Totallen

g

th

of

suction

line,

includin

g

tlw

vertical

length

within

the

tank

11

Caution

If

the

valve is closed

when

the

pump

is

running

the oil pressure can be increased sufficiently so

as to cause

damage

to the seals within the

pump.

The return oil should preferably be discharged through an elbow onto a tank plate situated within

the tank, this

should

be positioned so as not to introduce air

or

air bubbles into the

draw

off pipe.

2.5 Two pipe system

This is used

where

the oil storage tank is lower than the

pump.

Access for the fuel feed to the

burner

should

be via a suitable

tapping

made

in the top of the tank,

and

the fuel feed pipe

should

extend to

not

less than

lOOmm

above the bottom of the tank. A none return valve

with

a metal to

metal seat

should

be fitted, especially if the return

pipework

is terminated at a level above the

draw

off tube.

The

none

return valve

must

be removable for service

and

maintenance purposes,

and

the

return

pipe

from the

pump

must

therefore

be

extended

down

into the tank to the

same

level as the

suction pipe. The presence of a

tamper

proof isolating valve fitted within the return

pipe

is only

required if there is a risk that oil will

siphon

out

of the tank if the return pipe is disconnected at the

pump

during

maintenance

or

servicing

and

if the none return valve has been omitted.

2.6 Pressurised ring main system

This

system

is

used

to

supply

a

number

of

units from a

common

storage tank. A booster

pump

is

used

to

provide

the

pressure

storage tank. A booster

pump

is

used

to

provide

the pressure to

push

the oil

around

the ring main

and

back to the tank. Pressure reducing valves

should

be fitted

on

the delivery

pipe

to each heater to ensure that

the

pressure at the

burner

pump

is less

than

6 psi.

Caution

The internal by-pass

plug

must

be

removed

from the

pump

when

used

in a pressurised ring

main application.

2.7 Pipework and fittings

Caution

Galvanised

pipework

and

fittings

must

not

be

used.

All joints

must

be

sealed

properly,

if

necessary

using

PTFE

tape

or

other

approved

sealing media. The

pipework

must

be

effectively

sealed so as to

prevent

the ingress

of

air.

It

is advisable to check all

pipework

prior

to installation to

ensure

that there is no loose debris or

scale present. Black iron pipes can be

hammered

to assist in the removal

of

these contaminants.

Note

The oil feed to each heater

must

be fitted

with

a fire check valve

and

isolating valve. The fire

check valve

must

be

operated

by

way

of a fusible link positioned so

that

it is above the burner.

2.8 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

lEE regulations.

The

means

of

connection

to

the

main

electrical

supply

must

allow

for

complete

electrical

isolation

of

the heater(s), furthermore, in the case of heaters wired for a three

phase

supply, the

12

supply

should

only

be

used

to

serve

the heater(s).

The

position of

the

isolation

switch

must

be

such

that

it is adjacent to the heater(s)

and

easily accessible

at

all times,

additionally

the

isolator itself

must

have

a contact

separation

of

not

less

than

3mm

(as

per

BS

5991 clause 20.2).

The

main

isolator

fuse ratings are

detailed

on

the

appliance

data

plate.

Warning

Ensure

that

the electric

and

oil

supplies

are

turned

off before

any

electrical

work

is carried

out

on

the heater.

Ensure

that

wiring

cannot

make

contact

with

any

surfaces liable to be subject to high

temperatures

or

where

the

insulation

of

the

wiring

could

be

impaired

as a result of

such

contact.

All

Pakaway

cabinet heaters

must

be

earthed.

Caution

The

main

electrical

supply

must

not

be

switched

off

or

disconnected

as a

method

for

stopping

the

heater,

the

exception to this is in

an

emergency,

or

during

servicing,

when

the

heat

exchanger

has

been

allowed

to cool sufficiently to

prevent

any

damage

from occurring.

Claims

for

damage

will

not

be

considered

if

they

have

resulted

from incorrect

wiring

or

the

incorrect

use

of

the

heater.

2.9

Air

supply

Provision

must

be

made

for

the

existence

of

an

air

supply

for both

combustion

and

ventilation.

It

is a

requirement

that

the

area

where

the air

heater

is located

must

have a

permanent

air

vent

of

negligible resistance direct to the

outside

air. Such air vents

must

be

positioned so as

not

to

become

blocked

or

flooded,

nor

should

they

be placed so as to introduce

undesirable

matter

(e.g. flammable,

volatile,

or

aggressive

chemicals/

compounds

or

potentially

hazardous

or

harmful

substances)

either direct from the outside,

or

through

their proximity to

an

adjacent extraction system.

The criteria necessary for establishing the

minimum

size of

natural

vents

is detailed below;

Position

of

vent

Low level

(inlet)

High

level

(outlet)

Area

of

vent

direct

to

outside

540cm2 + 4.5cm2

per

kW of

rated

input

per

heater

270cm2+2.25cm2

per

kW of

rated

input

per

heater

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.

Caution

Systems of ventilation

that

employ

mechanical extraction

and

natural

inlet

must

not

be

used.

Furthermore,

where

the air

supply

is

by

way

of a mechanical

means

the inlet

must

be

positioned

at

low

level

and

be

capable

of

providing

a

minimum

throughput

as

detailed

in

section

8 of this

manual.

The

natural

extraction

air

vents

must

have

a

minimum

area as

per

above,

and

it is

strongly

recommended

that

natural

extraction

vents

are

situated

at

high level. Additionally,

an

automatic

control interlocked to the

burner

must

be

fitted to

ensure

burner

shutdown

in

the

event

of

air

flow

failure

or

restriction.

If

the

heater

is to

be

installed

within

its

own

separate

building

or

plant

room, the

above

details

do

still apply, as

does

the

requirement

for

minimum

space.

13

2.10

Minimum

space requirements

The

minimum

space

requirements

for single

and

multiple

heater

applications

are

detailed

in

section 3.3

later

within

this

manual.

2.11 Air distribution

system

All materials

used

within the construction of the delivery

and

return

air

ducts

must

not

represent

a fire

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 fire 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

% recirculated

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

flue.

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

floor or

ground

level, it

must

also be fitted 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

duct

work

passes

must

be

of fire

resistant material

and

constructed to

prevent

the likelihood of

any

fire from

spreading

.

In

ducted

applications the

ductwork

must

be

designed

so as to give a static pressure within the

limits

stated

in section 8 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

effected 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.

14

2.12 Flue

system

Warning

It

is essential

that

the

products

of

combustion

are flued to the

outside

of the building. Each

heater

must

have its

own

separate flue,

with

a flue

diameter

of not less than is detailed in section 8

within this manual. The

minimum

vertical length of flue

must

not be less than 3m. The flue

should

rise vertically,

and

the

number

of

bends

should

be

kept

to a minimum.

It

is strongly

advised

that

BS

5854; 1980,

and

BS

5440;

parts

1

and

2,

are

used as consultative

documents

,,,,hen considering

flue requirements.

Care

should

be taken to

ensure

that the flue terminal is

not

situated in a high pressure area, the

proximity of buildings

and

other obstacles which will influence this

must

be taken into account,

preferably at the design stage. See figures 9 -

19.

Provision

must

be

made

for the disconnection of the flue for inspection

and

service requirements,

and

it

is

strongly advised that

where

bends

are fitted inspection covers are included.

The materials from which the flue

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

flue

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 flow freely to a

point

from

which

they

may

be

released, preferably into a gully. The condensate

pipe

from

the

flue to the disposal

point

must

be

made

from corrosion resistant

pipe

of

not

less

than

25mm internal

diameter

.

If

the flue 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 flue

and

the

internal

wall

of

the

sleeve. The

maximum

permitted

temperature

of

any

adjacent

combustible

material is 65°C.

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 escape

and

dissipation of

the

flue gases

without

risk of their re-entering the

property

through

windows,

ventilation ports, etc.

The flue

should

extend

to

at

least 1m above the height

of

any

object

within

3.5m of the terminal.

Flue terminals

should

be fitted

on

all flues, 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 flue.

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.

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 flue has

not

made

provision for possible condensation problems.

15

- - -

- -

Not less than

600

Not I

ess

than

600

~parapet

Greater

than

1500

I

..

..I

I

Fig

9.

Flat roof,

with

parapet

All

dimen

sions are in millimetre

s.

-y--,....-r-,-

Not

less than

600 Structure

--

~

-

.

-

I

..

Less than

10

h2

..

/1

r-

__

------=--L-,--e-ss-----:-t-,--h-a-n-1,-:0:-::h--=-,'-----_

..

--I1

Greater

than

1500

Fig 10. Flat roof,

envelope

method

All

dimensions

are in millimetres.

Structur~e

Not

I",

thO'

_

!50

l

"Jh,

n!

Greater than

10

h2 I I Greater

tha

~

O

hI

I

~~I~--

--

~"

Fig

11

Flat roof,

where

the

flue

outlet

is

more

than

10

heights

(h)

away

from all

structures

A

ll

dimensions

dT

e in millimetres.

Not less than

600

Parapet

-

~~--+-~-----------

U Less

than

1500

Fig 12. Flat roof,

with

flue close to

parapet

All

dim

ensions

are

in

millimetres.

16

--

;::::;-.-

Not

less

than

I

600

I Not

Less

than

250

Fig 13. Flat roof,

with

no

parapet

All

dim

e

n~i

o n

s

are in millimetres.

Not

Less

than

600

Structure

Fig 14. Flat roof,

with

structure

close to

flue

outlet

All

dimension

s

ar

e in millimetres.

600

Not less than

600

Fig 15.

Pitched

roof,

not

greater

than

45°

All linear

dim

ensions are in millimetr

es

.

Dormer

window

Fig 16.

Pitched

roof,

within

1.5m

of

a

structure

on

roof

All

dimensions

are in millimelres.

Not

less

than

600

17

Not

less

than

600

Not

Less

than I

1000

Dormer window

Fig 19. Pitch roof,

chimney

within

l.5m

from

dormer

window

measured

horizontally

All

dimensions

arE'

in millimetrE'S.

18

Not

less

than

1000

Not Iess

than

1000

Fig 17.

Pitched

roof, exceeding

45°

All linear

dimensions

are

in millimetres.

Termination

on

ridge

/'../

Fig 18. Pitch roof,

internal

route,

pitch

not

exceeding

45°

and

ridge

termination

All

linear

dim

ens

i

ons

are in millimetres.

3.0 Installation

It is strongly

advised

that

the

installer reads Section 2

and

Section 3 of this

manual

prior

to

starting

any

installation work.

It

is a requirement that only qualified

and

competent

personnel

may

undertake

instal1ation, commissioning,

and

servicing.

Warning

Always

ensure

that

the

appropriate

personal

protective

equipment

is

used.

3.1 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.

Prior to installation the heater

must

be

correctly positioned before

any

final assembly

work

is

completed. The

bonnet

top

and

outlet nozzles

must

be securely

attached

before installation can

commence.

3.2 Flooring

The

heater

must

be

installed

on

a level

non

combustible

surface

capable

of

supporting

the

weight of the heater

and

any

ancillary equipment.

3.3

Minimum

clearances

The following

minimum

clearances (in metres)

must

be observed

when

installing the heater.

'

Model

top

lhs

rhs

front

back

AH

100 -600

AH

700 -1000 0.9

2.0 0.9

0.9 0.9

0.9 0.5

2.0 1.35

2.0 [

3.4

Assembly

The following sub-assembly

parts

should

be assembled to allow installation to continue.

Place Nozzle Base plate

onto

the top

of

the heater, align holes,

and

secure. Fit the nozzles to the

spigots,

turning

the nozzles to give the required

approximate

direction for air flow. Adjust louvres

to

give

the

desired

angle

of

warm

air

down

flow.

Secure

nozzles

to

spigots,

when

correctly

positioned,

by

means

of drilling

and

inserting self

tapping

screws.

19

BENSON AH150 Guide

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