BENSON ULTRA 035(EC) Manual

1701ULTRA(EC)GBEN, p. 1/29
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!
1701ULTRA(EC)GBEN
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Condensinglow‐emissiongas‐firedairheater

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ULTRA
025(EC),035(EC),050(EC),
075(EC),100(EC)
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

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
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
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
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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


Subjecttomodifications
size050

1701ULTRA(EC)GBEN, p. 2/29
TABLEOFCONTENTS

1 Hazardintensitylevels2
2 General3
Warnings3
General4
Warranty4
Uncrating&preparation4
Heaterlocation5
3 Technicaldata6
4 Dimensions&clearances8
5 Internallay‐out10
6Installing11
7 Airsupply&fluesystems12
8 Condensationdrainpipeconnection16
9 Gasconnection/Gassupply17
10Electricalconnections19
11Commissioning,lighting&operation21
12Maintenance23
13Faultfinding25
14Sparepartslist27
15Userinstructions27
16Declarationofconformity29
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1.HAZARDINTENSITYLEVELS
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DANGER
Failuretocomplywillresultinseverepersonalinjuryordeathand/or
propertydamage.
WARNING
Failuretocomplycouldresultinseverepersonalinjuryordeathand/or
propertydamage.
CAUTION
Failuretocomplycouldresultinminorpersonalinjuryand/orproperty
damage.
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1701ULTRA(EC)GBEN, p. 3/29
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2.GENERAL
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2.1WARNINGS
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
WARNINGS
For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
Evacuateallpersonnel
Contactyourgassupplierimmediately

Donotstoreorusepetrolorotherflammablevapoursandliquidsinthevicinityof
theappliance.

Improper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.

Do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.

Thisapplianceisnotintendedforusebypersons(includingchildren)withreduced
sensoryormentalcapacitiesorlackofexperienceandknowledgeunlesstheyhave
beengivensupervisionorinstructionsconcerninguseoftheappliancebyaperson
responsiblefortheirsafety.
Childrenshouldbesupervisedtoensurethattheydonotplaywiththeappliance.

Shouldoverheatingoccurorthegassupplyfailstoshutoff,shutoffthemanualgas
valvetotheappliancebeforeshuttingofftheelectricalsupply.

Gas‐firedappliancesarenotdesignedforuseinhazardousatmospherescontaining
flammablevapoursorcombustibledust,inatmospherescontainingchlorinatedor
halogenatedhydrocarbonsorinapplianceswithairbornesiliconesubstances.
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Themanualshouldbekeptinasafeplaceforfuturereference.
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Unauthorisedmodificationofthisapplianceordeparturefromuseinthemanner,
forwhichitwasintendedbythemanufacturerorinstalledinamannercontraryto
theseinstructions,mayconstituteahazardandjeopardizeallwarranties.
Deviationsshouldonlybecarriedoutafterformalconsenthasbeenobtainedfrom
themanufacturer.

Useonlyfactory‐authorizedpartswhenreplacementisrequired.
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Incaseofpersistingproblems,contactyourdistributor
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1701ULTRA(EC)GBEN, p. 4/29
2.2GENERAL
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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.
Theinstructionsareonlyvalidforthecountryofuseindicatedontheappliance.Ifnotcorrectcontactyour
supplier.
Installationshouldbedonebyasuitablyqualifiedinstallerinaccordancewiththeseinstructionsandwithall
rulesinforce.
Theinstallationmanualisshippedwiththeheater.Verifythattheliteratureiscorrectfortheheaterbeing
installed.Ifthemanualisincorrectfortheheater,contactthesupplierbeforebeginninginstallation.
Ensuretheenvironmentinwhichtheairheaterwillbeinstalledwillnotcreateahazardi.e.whereexcessive
dust,flammableorcorrosivesubstancesand/orvapoursandcombustiblematerialsmaybepresent.
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2.3WARRANTY
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Warrantyisvoidif:


Heatersareusedinatmospherescontainingflammablevapoursoratmospherescontaining
chlorinatedorhalogenatedhydrocarbonsoranycontaminant(silicone,aluminiumoxide,etc....).
Theinstallationisnotinaccordancewiththeseinstructions.
Wiringisnotinaccordancewiththediagramfurnishedwiththeheater.
Unitisinstalledwithoutproperclearancetocombustiblematerialsorwithoutproperventilation
andairforcombustion.
Airthroughputisnotadjustedwithintherangespecifiedontheratingplate.



2.4UNCRATING&PREPARATION

Theunitwastestoperatedandinspectedatthefactorypriortocratingandwasinproperoperatingcondition.
Iftheheaterhasincurreddamageinshipment,documentthedamagewiththetransportcompanyand
contactyoursupplier.Beforeinstallationcheckthattheapplianceasdescribedonthepackaginglabelisin
accordancewiththecorrecttypeandmodelasspecifiedonthedataplateandcomplieswithyourcustomer
order.Afterunpackingtheappliance,leaveitfastenedtoanybasepackingfortransportationuntilithasbeen
suspendedoruntiljustbeforebasemounting.Thisaffordsprotectiontotheunderside.
Checktheratingplatetodetermineiftheheaterisappropriatefortheintendedinstallation.
Readthemanualthoroughlyandbecomefamiliarwiththeinstallationrequirementsofyourheater.Ifyoudo
nothaveknowledgeoflocalrequirements,checkwiththegassupplierandanyotherlocalagenciesthatmight
haverequirementsconcerningthisinstallation.
Beforebeginningmakepreparationsfornecessarysupplies,toolsandmanpower.Iftheinstallationincludes
optionalparts,installtheseoptionsbeforetheheaterissuspended.Followtheinstructionsincludedinthe
optionpackage.
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1701ULTRA(EC)GBEN, p. 5/29
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aremaintained.Locatingaunitheaterabovethemaximumrecommendedheightcanresultin
significantairstratification.Whenpossible,heatersshouldbearrangedtoblowtowardoralongexposedwall
surfaces.
Suspendedheatersaremosteffectivewhenlocatedasclosetotheworkingzoneaspossible,butcareshould
beexercisedtoavoiddirectingthedischargedairdirectlyontotheroomoccupants.
Partitions,columns,countersorotherobstructionsshouldbetakenintoconsiderationwhenlocatingtheunit
heatersothataminimumquantityofairflowwillbedeflectedbysuchobstacles.
Whenunitsarelocatedinthecentreofthespacetobeheated,theairshouldbedischargedtowardthe
exposedwalls.Inlargeareas,unitsshouldbelocatedtodischargeairalongexposedwallswithextraunits
providedtodischargeairtowardsthecentreofthearea.Foroptimumresultsheatersarebestusedin
conjunctionwithrecirculatingairfanssuspendedathighlevel.
Atthosepointswhereinfiltrationofcoldairisexcessive,suchasentrancedoors...itisdesirabletolocatethe
unitsothatitwilldischargedirectlytowardsthesourceofcoldair,typicallyfromadistanceof4.5mto6mor
installadownflownunitoverthedooropening.



WARNING
Iftouched,theventpipeand
internalheatersurfacesthatare
accessiblefromoutsidetheheater
willcauseburns.Suspendthe
heatersothatthesecomponents
cannotbetouched!
CAUTION
Donotlocatethe
heaterwhereitmay
beexposedtowater.


Attention
Hazardsof
chlorine
applyto
the
locationof
the
combustion
airinlet

Thepresenceofchlorinevapoursinthecombustionairofgas‐firedheatingequipment
presentsapotentialcorrosionhazardCareshouldbetakentoseparatethesevapoursfrom
thecombustionprocess.
Thismaybedonebywiselocationoftheunitflueandcombustionairterminalswithregard
toexhaustersorprevailingwinddirections.
Chlorineisheavierthanair.Keepthisfactinmindwhendetermininginstallationlocationof
theheaterinrelationtobuildingexhaustsystems.
Wherechlorinevapoursareprevalent,heaterswithspecialgrade316AISIstainlesssteel
heatexchangersarerecommended.



1701ULTRA(EC)GBEN, p. 6/29

3.TECHNICAL DATA

Table1
ULTRA/ULTRA EC 025 035 050 075 100
Gas category Cat.
Comb. air & flue, type B instal (1)
Comb. air & flue, type c instal (1)
Maximum heat input (Hs) kW 28,3 37,0 56,0 78,4 106,3
Maximum heat input (Hi) kW 25,5 33,3 50,4 70,6 95,7
Minimum heat input (Hs) kW 5,7 7,2 11,4 15,9 20,9
Minimum heat input (Hi) kW 5,2 6,5 10,3 14,3 18,9
Maximum heat output kW 25,0 32,7 49,4 69,2 93,8
Minimum heat output kW 5,5 7,0 11,0 15,3 20,2
% 98,30 98,00 98,60 98,60 98,60
% 109,20 108,80 108,70 106,50 108,90
NatgasG20(H)vol%8,438,428,448,428,42
PropG31 vol%9,819,819,819,809,80
Propane restrictor diameter mm3,46666
NatgasG20(H)m³/h2,593,395,077,279,76
Prop G31 kg/h 1,99 2,6 3,93 5,51 7,47
NatgasG20(H)m³/h0,550,691,091,522,00
Prop G31 kg/h 0,4 0,51 0,8 1,12 1,47
Nat gas G20 (H) mbar
Prop G31 mbar
Air volume (15°C) m³/h 2900 3700 5600 7900 10500
Temperature rise at max load K2526262626
Horizontal throw (4) m 20 23 30 30 36
Max sound pressure level Lp (5) dB(A) 44 49
52 47 58
Min sound pressure level Lp (5) dB(A) 38 34
35 35 40
Noise free field conditions(max) dB(A) 37 42
45 40 51
Noise free field conditions (min) dB(A) 31 27
28 28 33
Maximum absorbed power W 200 300 500 600 1240
Gas connection (2)
Electrical connection mm 80 80 80 100 100
Condensation connection/outlet
Condensate quantity l/h 1,3 1,5 2 2,5 3,5
Recommended mounting heigth (3) m3 3,53,5 4 4
Weight kg 120 129 147 199 231
Protection grade IP
Revolutions per minute main fan rpm 950 1260 1340 820 1400
CE Approval number PIN
1/2" G 3/4" G
I2H or I3P
B22p
C12, C32, C42, C52, C62, C82
Max thermal efficiency at max heat input (G20)
Max thermal efficiency at min heat input (G20)
CO
2
gas at max heat input
230/240 V 1N50Hz
Connection diameter for flue gas and combustion air
32
IP 20
0461CO1016
Gas consumption at maximum heat input
Gas consumption at minimum heat input
Inlet pressures 20
30

(1)Gas Appliance Classifications for Approved Venting Methods based on CEN-report CR1749:2001
(2)Gasconnectionsizeisnotnecessarilythesupplylinesize.Thereisadifferencebetweenthegasconnectiondiameterandthediameterofthesupplyline.
Alwaysusethemostadequatediaofthesupplylinetominimizethepressuredropthroughthegaspipes–ifnecessaryreducethediameterofthesupplylineat
theinletoftheunit.
(3)Heightfromthefloortobottomsurfaceofheater.Thesearerecommendationsonly.Positioningofunitheatersforproperperformanceisapplication
dependent.Operationisaffectedbyotherairmovingequipmentinthespace,obstructionstotheairflow,draughtsand/orcloseproximitytodoorsor
windows,etc…Careshouldbetakentoavoidmountingtheheatersabovetheserecommendations,unlessdownturnnozzleoptionsareused,assignificant
stratificationmayoccurresultinginpoorfloorcoverageandhigherenergylossesthroughtheroofstructure.
(4)Isothermalconditionsat20°Cambientairtemperature,dischargelouvrezerodeflection,v=0,5m/s.
(5)SoundpressurelevelindB(A):measuredat5metersfromtheunitwithA=160m²&Q=2

1701ULTRA(EC)GBEN, p. 7/29

4.DIMENSIONS&CLEARANCES

4.1DIMENSIONS

Figure1a:ULTRA/ULTRAEC025,035,050&075(alldimensionsinmm,tolerance3mm)






































1. Combustion air inlet (D) 4. Electrical connections
2. Flue connection (D) 5. Service panel
3. External gas connection (C) 6. Condensate drain
ULTRA/ULTRAEC
ABC
DE F I J K L M
025 738 1217 1/2"G 80 82 405 55 449 135 311 120
035 738 1217 1/2"G 80 82 405 55 449 135 311 120
050 865 1216 3/4"G 80 74 531 50 576 140 311 120
075 1177 1274 3/4"G 100 129 760 78 860 143 294 140
(all dimensions in mm, tolerance 3mm)

1701ULTRA(EC)GBEN, p. 8/29
Figure1b:ULTRA/ULTRAEC100(alldimensionsinmm,tolerance3mm)








1. Combustion air inlet ( 100mm) 4. Electrical connections
2. Flue connection ( 100mm) 5. Service panel
3. External gas connection (3/4”G) 6. Condensate drain

1701ULTRA(EC)GBEN, p. 9/29
4.2CLEARANCES

Figure2:


ULTRA/ULTRA EC X Y Z(*) U V
025 400 100 100 100 820
035 400 100 100 100 820
050 400 100 100 100 820
075 500 100 100 100 820
100 500 100 100 100 820


(*)Heaterscanbemountedonsuitablenon‐combustiblesupports.




5.INTERNALLAYOUT

Figure3:




1Metalmeshburner
2Zeropressure
regulator
3Venturi
4Differential
pressureswitch
5Burnercontroller
6Fluegasextraction
fan
7Inspectionwindow
+ignitor+ionisation
electrode
8LimitcontrolLC3
9LimitcontrolLC1
9 8

1701ULTRA(EC)GBEN, p. 10/29

6INSTALLING

WARNING
Checkthesupportingstructuretoverifythatithassufficientload‐carryingcapacityto
supporttheunitweight.
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thisfigure.Recommendedmaximumhangerrodlengthis1.8m.Where
longerdropsarerequired,ensurethatrestraintsarefittedtopreventexcess
lateralmovementandsupportsareadequatelysized.Alternativelytheunit
canalsoebasemountedonanon‐combustiblesupport.Inthiscaseensure
thatunitissecurelyfixedonthebase.

1701ULTRA(EC)GBEN, p. 11/29

7AIRSUPPLY&FLUESYSTEM

7.1GENERAL






WARNING
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
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.

Model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.
TheunitsmaybeinstalledasabalancedfluetypeCheaterrequiringbothacombustionairinletpipeandafluepipe
orasapowerventedheatertypeBwherethecombustionairistakenfromthespacewhereheaterisinstalledand
whichrequiresonlyafluepipeexhaustingtooutdoors.Allproductsofcombustionmustbefluedtooutdoor
atmosphere.
EachheaterinstalledasatypeBappliancemustbefittedwithanindividualfluepipeandthecombustionairinlet
openingmustbeprovidedwithaprotectiongrill.
EachheaterinstalledasatypeCappliancemustbefittedwithanindividualcombustionair/fluepipesystem.TypeC2
appliance,withsinglepipesystemforsupplyofcombustionairandevacuationoffluegasses,arenotallowed.
Fortesting,thefluepipeshouldincludeasealabletestpoint.Ideallythetestpointshouldbeatleast450mmaway
fromtheairheaterflueconnectionsocket.Howeverifaconcentricflueisattacheddirectlytotheconnectionsockets
thenthecombustionshouldbetestedthroughtheflueoutletcollarviaadrilledtestpointwhichmustbesecurely
pluggedoncompletion.
Followthefluepipemanufacturer’sinstallationinstructionsformakingjoints,includingconnectionstotheairheater,
forpassingthroughabuildingelementandforsupportrequirements.

Figure5:
Combustionairandfluepipesockets
(standardversion)




Remark:
Acoverplatecanbeinstalledontherearor
toppanel.Theplatewiththefreshairinlet
andtheflueoutletsocketisfactoryinstalled
onthetoppanelbutcaneasilybereplacedon
therearpanelifrequired.Incaseofchange,a
separatekitmustbeorderedatthesupplier.

Combustionairinlet
Flueconnection

1701ULTRA(EC)GBEN, p. 12/29

Attention

Condensedrain
Acondensationdrainmustbefittedtoboththeunitandtheflueoutlettoproperly
drainallcondensation.
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,
airforcombustionwillbetakenfromwithinthespace
wheretheheaterisinstalled.Ensurethatanadequate
airsupplyforcombustionandventilationisprovided
withinthebuildinginaccordancewithBS6230or
BS5440plusallotherrelevantregulations&rulesin
force.
Singlewallfluepipeseamlessaluminium/stainlesssteel
pipesarerequired.Alljointsmustbesealedtoprevent
productsofcombustionfromleakingintothebuilding.
Donotinstallventpipingnearanysourceofheat
AprotectiongrilltypeIP20mustbemountedonthe
combustionairintake.
Table2showsthefluepipesizesandmaximumpipe
lengths.

Figure6:
ApprovedappliancestypeB


B22p
roof
B22p



7.3BALANCEDFLUEINSTALLATION(typeCappliances)

Balancedflueairheatersaredesignedtobefittedwithacombustionairinletpipethatobtainsoutdoorairanda
fluepipethatexhaustsflueproductstooutdoors.
Boththeflueandcombustionairpipesmustbesealed.Usegasketsealedseamlessaluminiumpipeorequivalent.
Ifmorethanoneairheaterisbeinginstalledinthesameplace,eachheatermusthaveaseparatefluesystem.


Attention

C2appliancesmustnotbeapplied!


1701ULTRA(EC)GBEN, p. 13/29
Figure7:TypeCappliances:combustionairandfluepipesockets

VERTICALFLUEKIT,OPTION302



























HORIZONTALFLUEKIT,OPTION301



1701ULTRA(EC)GBEN, p. 14/29
Figure8:ApprovedappliancestypeC
C12
wall

C32
roof
C42
roof

 
C52
roof

C82
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.

Table2:















IMPORTANT:OnlyuseMuelink&GroltypeSkyline3000forwallorroofterminalorequivalenttype

7.5AIRSUPPLY

WARNING
WhentheseairheatersareinstalledastypeBappliances,theytaketheirairforcombustion
fromthespaceinwhichtheyareinstalled.Donotrestrictthecombustionairintake.

Itisimportanttoensurethatthereisanadequateairsupplyatalltimesforbothcombustionandheating
requirements.Modernbuildingsinvolvegreateruseofinsulation,improvedvapourbarriersandweatherproofing.
Thesepracticesmeanthatbuildingsaresealedmuchtighterthaninthepast.
Model ULTRA/ULTRAEC 025 035 050 075 100
Max. straight concentric length
for combustion air inlet pipe & flue outlet pipe (1) m flue/inlet pipe 15 15 15 15 15
Equivalent length of 45° concentric elbow m flue/inlet pipe 0,85 0,85 0,70 1,10 0,75
(1) : ULTRA(EC) 025,035,050 : dia 80/125mm / ULSA(EC) 075,100 : dia 100/150mm
-use same diameter for all flue pipes
-recommened minimum flue = 1m
2,20 1,50
Equivalent length of 90° elbow m flue/inlet pipe 1,50 1,50 1,50 1,50 1,50
Equivalent length of 90° concentric elbow m flue/inlet pipe 1,70 1,70 1,40
30 30
Equivalent length of 45° elbow m flue/inlet pipe 0,75 0,75 0,75 0,75 0,75
Max. straight length1 pipe B23P(flue outlet
pipe)(w ith w all or roof terminal) m flue/inlet pipe 30 30 30
100 100
Max. straight length 2 pipes (combustion air inlet
pipe & flue outlet pipe)(w ith wall or roof terminal)
(Cappliance) m flue/inlet pipe 20 20 20 20 20
Heater socket & pipe dia mm flue/inlet pipe 80 80 80

1701ULTRA(EC)GBEN, p. 15/29
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Figure10










ItisrecommendedtouseaPVCdischargepipe.
Thecondensationconnectionbetweentheairheaterandthesiphonhasa32mmdiameterandmustbe
glued(leakproof)ontothesiphoninlet.
Toensurethecondensationwaterdoesnotfreeze,itisrecommendedtomountthedrainpipeinsidethe
building.Ifthereisnootherchoicebutmountingitoutside,itisstronglyrecommendedtoequipitwithfrost
proofinsulation.
Whenconnectingthesiphon,itisnecessarytousesealingrings(inthesiphonoutlet).Ensurethesesealing
ringsarecorrectlymounted.
Condensationdrainpipeconnectionsmustbeglued,topreventcondensationwaterdrippingfromthedrain
pipe.
Ifyouwanttoopenthesiphon(e.g.tocleanit),theairheatermustbeshutdown.
Forsecurityreasonsitisrecommendedtoweargloveswhencleaningthesiphon.
Thesiphonhastobecleanedyearlyandalsocheckedformetalsludge.Intheeventthatthereisalotofmetal
sludgepresent,theairheatermustbeservicedmorefrequently.
ThecondensationwatercomingfromtheairheaterhasapH‐levelofapprox4.6andcanaffectmaterials
madefrom
zincand/orcopper.
Hence,itisstronglyadvisedagainstlettingthecondensationwaterflowoffthroughthegutter.
Condensationwaterdoesnotbelonginarain‐watertank!
Downstreamfromthetrapsthecondensatedrainsmaybejoinedandbothmustbeconnectedtoasanitary
drainwithinthebuilding.Checkcodestobecertainthatthisispermitted(condensatefromtheheaterhas
abouttheacidityofsodapopandisnotharmfultoasanitarydrain).ULTRA/ULTRAECheaterswillproduce
condensatedependingonsizeandgastype(seetable3).
Acondensatedisposalsystemthatreliesongravityshouldbesatisfactoryformostinstallationssinceunit
heatersarenormallyinstalledseveralmetresabovethefloor.
Ifagravitysystemisnotpossible,acondensatepumpmustbeinstalled.Thereareanumberofcommercially
availablepumpsmadeforthispurpose.Ifusingacondensatepump,followthepumpmanufacturer’s
installationrecommendations.

Table3:
Condensedrainratesofflow




ULTRA/ULTRAEC 025 035 050 075 100
Natural gas/
Propane l/h 1,2 1,3 1,8 2,1 3,7

1701ULTRA(EC)GBEN, p. 16/29

9GASSUPPLY
&
GASCONNECTION

Werefertotable1ofsection3forallgasspecifications


WARNING
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
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.


9.2GASCONNECTION










9.3ADJUSTMENTGASVALVE

Toadjusttheoffset,removetheprotectionscrewon
thetopandregulatetheoffsetbyusingtheexposed
screw.Offsetvalueswillbemeasuredintheindicated
points.
ToadjusttheCO2,useascrewdriverintheindicated
spotandturnthescrewdriverclockwisetodecrease
themeasuredCO2orturnitcounterclockwiseto
increasethemeasuredCO2.TheCO2measurement
shouldbedoneinthefluedischargepipe.

Allunitsaresetaccordingtothedataplatebefore
leavingthefactory.Anymodificationtothegasvalve
mustbedonebyaqualifiedtechnician.


1h
2Inletpressuremeasuringpoint
3CO2adjustmentpoint(throttle)
4Offsetmeasuringpoint
REMARK:
Donotovertighten
anddonotrotatethe
gasvalveinsidethe
heatercontrol
com
p
artmen
Figure12
Figure11

1701ULTRA(EC)GBEN, p. 17/29
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’

Changestocarryout:

1. Fromnaturalgastopropane:
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)
thatwillprovidethenecessaryspeedfortheexhaust
blower.Inorderfortheunittobesetforpropane,thegas
valvewillberemovedfromtheventuribyremovingthe
threefixingscrews.Thebrassrestrictionwillbeplaced
insidetheO‐ringasdepictedinfigure13andthegas
valvewillberepositionedontheventuri.
ThrottleadjustmentsandCO2measurementswillhaveto
bemadeinordertoobtaintherecommendedCO2value.
FordetailspleaseseetheCO2/Throttleadjustmentsection
9.3.
Attention:Alwaysconsulttheappropriateinstruction
withreferencexxxx03111/xxxx03112‐ENprovidingallneeded
dataandinformationtoperformtheconversion..
2. Frompropanetonaturalgas
Inorderforaheatersetonpropanetobeconvertedtonaturalgas,thebrassrestrictionwillberemovedand
throttleadjustments*andCO2adjustments(*)remadeinordertoachievethenormalvaluesfornaturalgas.

Figure14:NaturalgasFigure15:Propane

(*)Ifanerrorismade,andtheunithasonlythebrasspropanerestrictorremovedwithouthavingthe
combustionvalueschecked,permanentdamagetotheunitwilloccur.
3.Connector
Inscriptionontheconnector
indicatesthesizeoftheunitand
thetypeofgastobeused.
Example:inphoto16theunitisa
ULTRA/ULTRAEC50setfor
naturalgas.
Theconnectorforpropaneuseis
providedwitharedwire
mentioningtheinscriptionPROP
(seephoto17).
Figuur16 Figuur17


Propane
restriction
Gas valve
Venturi
Rubber
O-ring
Fixing
screws
Figure13
Propane
restriction

1701ULTRA(EC)GBEN, p. 18/29

10ELECTRICALSUPPLY&CONNECTIONS

10.1ELECTRICALSUPPLY

DANGER
THISAPPLIANCEMUSTBEEARTHED.
Theelectricalinstallationmayonlybecarriedoutbysuitablyqualifiedpersonsobserving
therulesinforce.

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.

Theminimumclearancedistancebetweenthecontactsmustbemorethan3mm.Checkthattheairheateriswell
earthedandthatanearthleakagetestiscarriedout.Theelectricalsupplylinetotheheatershouldincludeamain
isolatingswitch.
AnexternalorangeindicatorlightisfittedontheheatertosignifywhentheburnerisON.
Anexternalburnerresetswitchwithredindicatorlightisfittedontheheater.Toaddaremoteresetbutton,make
connectionstotheterminalsintheelectricboxasindicatedonthewiringdiagram.
Ensurethatallcablesandinstallerswiringareappropriatelyfixedandthattheydonottouchthefluecombustion
collectorbox.
Toensurethattheunitisairtight,allunusedcablecouplingsmustbehermeticallysealed.

Attention

‐ Permanentdamagecanoccurto the burnerrelaywhenfaulty/incorrectconnectionstothe
thermostat,resetswitchorburnerfailurelamparemade!
‐ Switchingofwiresforresetswitchandflamefailurewilldestroytheburnerrelay.
‐ Iftheresetbuttonrequiresactivatingforanyreason,thecausemustbedetermined.After
determiningandcorrectingtheproblem,restarttheheaterandmonitorlongenoughto
ensureproperoperation(approx.5minutes).



10.2THERMOSTATLOCATION

General
Donotattempttocontrolmorethan1heaterfromasinglethermostatorcontrolpanelunlessaproperlywiredrelayis
fitted.Followtheinstructionssuppliedwithsuchpanels.
Thelocationoftheroomthermostatorsensorisveryimportant.Itshouldnotbepositionedonacoldwallorcold
surface.Avoidlocationindraughtyareasorwhereitmaybeinfluencedbyheatsourcese.g.thesun,processplant,
etc...
Thethermostatshouldbemountedonavibrationfreesurfaceandmountedabout1.5mabovefloorlevel.
Followthethermostatmanufacturer’sinstructions.

1701ULTRA(EC)GBEN, p. 19/29
Possiblecontrolsystems
1. Bymeansofoption954=Individualon/offcontrol(0%or100%functioning)

2. 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



3. Bymeansof0‐10Vpowersignal(tobeperformedbycustomer)
Example

1701ULTRA(EC)GBEN, p. 20/29

11.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

Attention

Duringstartupallgasservices(uptothegasmeter)mustbecheckedagainforgassoundnessto
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
willbenecessarytoputtheairheaterbackintoservice.
2. Intheeventofoverheatingforanyreason,overheatcontrolsoperatetoswitchofftheburner.Incasetheheat
exchanger’stemperatureistoohigh,theburnerwillbeswitchedoffbytheLC1limitcontrol(firstsafety).The
burnerautomaticallyswitchesonagainaftercoolingdownandre‐startwilltakeplace.ThelimitcontrolLC3,which
operatesatahighertemperaturesetting,switchesofftheburneranditselftoalockoutconditionrequiringa
thoroughcheckoftheheaterandamanualresetviatheburnerrelayortheremotecontroltorestoretheheater
tooperationalcondition.Acoolingtimeofabout1minuteisnecessarybeforeresetting.
3. Whenthesettemperaturehasbeenreached,thecomfortregulationensuresmodulationontheburner.To
compensatepossibleheatlosses,warmthisstilldissipatedbytheairheateritself.
4. Toturnofftheairheaterforashortperiod,turntheroomthermostattoalowersetting.Torelight,resetthe
thermostat.
5. Toturnofftheheaterforaprolongedperiod,turntheroomthermostattolowestsettingandturnoffthegas
supplytotheappliance.Switchoffelectricalsupplytotheairheateronlyaftertheaircirculationfanhasstopped.
Torelight,followthelightinginstructions.
6. Gasandelectricitymustonlybeturnedoffincaseofemergencyorforprolongedperiodsofshutdownoftheair
heater.
11.3LEDSTATUS