INSTALLATION & SERVICING MANUAL FOR BENSON VARIANTE² TUBULAR HEATER NATURAL GAS (G20 I2H), PROPANE GAS (G31 I3P) WARNINGS Benson equipment must be installed and maintained in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired products. Due account should also be taken of any obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice.
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 6 1.6 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.
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.
1.0 Compliance notices The Benson Variante range of warm air heaters detailed herewith are manufactured by Benson Heating within a strictly controlled environment within the parameters of ISO9001 These instructions are only valid if the following country code is on the appliance GB. IE.
for Machines Specification for General Requirements These are detailed in following page’s Cabinet BS EN 60335 - Part 1 Safety of Household and Similar Electrical Appliances General Requirements Manufactured from electro-zinc coated steel, finished in a durable stove enamelled polyester powder paint.
to during foreseen normal use when installed in accordance with the manufacturers recommendations. 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.
Consumable items are specifically not included within the scope of the warranty. The warranty commences from the date of dispatch from the manufacturer, and is subject to the terms detailed within the Benson Heating 'conditions of business'. Note (iii) Note (i) Notification is required immediately a fault is suspected. The warranty may be invalidated if a) The installation is not in accordance with the general requirements of this manual.
Additionally the maximum temperature within the plant room should not exceed 32°C 2.0 Installation 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, gas supply, electrical supply, whilst also providing good and safe working access.
Clearances VRA in mm Model 12 20 30 42 50 60 72 95 120 145 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 12 20 30 42 50 60 72 95 120 145 Above 300 300 300 300 300 300 300 300 300 300 Below 300 300 300
• 2.3 Warm Air Circulation The air heater should be positioned to enable maximum circulation of discharged warm air within the area to be heated, whilst taking account of personnel within the area, sources of cold air ingress, and obstructions. If the design air change rate of the heated space is 0.5 air changes per hour or greater The design air change rate may be satisfied by natural infiltration or by mechanical ventilation.
Minimum Free Area Of Ventilation Opening MODEL High Level Low Level cm2 cm2 12 None 26 20 None 43 30 None 64 42 None 86 50 None 107 60 None 128 72 None 158 95 None 211 120 None 263 145 None 315 An enclosure is where the heater is installed within a compartment or confined area where space is limited.
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. 2.4.2.2 Natural Ventilation Openings to Plant Rooms for Flued Heaters 2.4.2.
gas and ideally at floor level for lpg gas installations but in any event no higher than 250 mm. 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 lpg gas installations but in any event no higher than 250 mm. 2.4.2.5 Mechanical Ventilation to a Plant Room or Enclosure 2.4.2.
operation should mechanical supply fail for any reason air The table below provides specific data for each heater model as MODEL Mechanical Ventilation Rate for Plant Room or Enclosure M3/h 12 54 20 88 30 133 42 177 50 221 60 265 72 327 95 436 120 543 145 652 air grille is supplied as standard. This MUST be fitted in place of the combustion air spigot. On VRA145 ONLY installed in flue only option (type B appliance) - a combustion air grille is supplied as standard.
For vertical flue installations the flue should rise vertically where possible bends should not exceed 45° and the number of bends should be kept to a minimum. Vertical flue installations: Distance from heater connection terminal must not exceed 10 Metres. to The temperature of the combustion products can be as high as 170° C and therefore tend to rise naturally within the flue. Unnecessary bends and restrictions should therefore be avoided.
C32 Vertical Co axial flue kit options L1 maximum combined flue length 6 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 16 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 17 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 18 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 Combined Length L1MAX. 12 m 0.50 3.00 20 m 0.50 6.00 30 m 0.60 6.00 42 m 0.70 6.00 50 m 0.
VRE Flueing options B22 Single pipe flue only and C32 Vertical coaxial Heater Unit Flue Exit Vertical Co/Axial Combined length Flue Exit VERTICAL MIN. MAX. MIN. MAX. 12 m 1,00 3.
2.6 Electrical Installation Electrical panel All electrical wiring and connections must be in accordance with the relevant European, National, and Local regulations as well as to IEE Standards. Warning Ensure that the mains isolator is turned OFF before undertaking any electrical work on the heater. Access to the electrical panel is gained by opening the right hand heater side panel. Ensure that the Electric and Gas supplies are turned off before any electrical work is carried out on the heater.
Fan/Limit Control 2.7 Gas installation ( Situated inside the right hand side panel) These settings may require slight adjustment on commissioning. Fan control (white button) FAN ON 50°C FAN OFF 30°C The fan control switch features normally open 230V contacts, and is wired to control the live supply to the fan motor. When the circuit is made the fan will switch on.
separate isolating cock positioned adjacent to and upstream of the union which must be sited outside the heater. The isolating cock should be of the 90° turn 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.
a) Test for earth continuity. b) Test for resistance to earth. c) Check live and neutral connections are correct. d) Check to ensure that when the external controls operate to switch the heater off, power remains to the fan. 3.2 Gas supply pre-test Ensure that the service pipework has been installed, purged and tested in accordance with the relevant regulations, and that the installation is served by an adjacent isolating cock.
Adjustment of Optional Hi-Low regulator • IMPORTANT Adjustments should be made by qualified persons only. • If the appliance manufacturer supplies checkout and/or service and maintenance instructions, carefully follow them. If such instructions are not provided, then follow the procedure as outlined below. • pressure (measuring point must be as near to burner as possible). Energize High-Low regulator, set gas control in operation and wait until an outlet pressure is recorded on pressure gauge.
When High and Low pressure settings are correct, replace cap and connect pressure feedback connection (if applicable). Checkout After any adjustment, set appliance in operation and observe through several complete cycles to ensure that burner system components function correctly. • • • • Adjustment of Optional modulation regulator IMPORTANT Adjustments should be made by qualified persons only.
• • maximum adjustment screw and hold it on. If maximum pressure setting needs adjustment turn the maximum rate adjustment screw clockwise for increasing or counter-clockwise for decreasing the maximum pressure, until the desired maximum outlet pressure is obtained. Release shaft. Mount cap and “O”-ring and reconnect pressure feedback connection (if applicable).
Example: • Potentiometer P2 is set at 0 %, and P3 at 5%, the hold-in voltage of the burner relay is adjustable between 5 % and 100 % of the input control signal. So, if input control signal is set at 0 to 10V DC, the hold-in voltage of the relay amounts to 0.5V DC. • Potentiometer P2 is set at 40 %and P3 at 5%, the hold-in voltage of the burner relay is adjustable between 45 %and 100 % of the input control signal.
q) Check that the gas pressure remains satisfactory for all appliances on the same circuit. r) Undertake combustion tests checking CO, CO2 and efficiency. CO should not exceed (20PPM). s) Check that the burners are extinguished when the thermostat is set to its lowest setting, and then remove the manometers. t) Turn the thermostat to its highest setting to re light the burner and replace the adjustment screw cover.
4.0 Servicing Warnings It is a requirement that only qualified personnel are allowed to carry out installation commissioning or servicing. In addition only spare parts recommended by the manufacturer may be fitted, and the installer should provide a list of recommended spare parts that are available through the manufacturer or his agent (see section 8).
Fan and Motor clear and free from dust. Check that the fan is secure and rotates freely without excessive play in the shaft. The fan blades and motor should be cleaned using a soft brush. Check that they are not kinked or damaged. Check electrical connections are intact. The fan and motor assembly can be removed from the heater by first disconnecting the leads from the terminal block and by removing the strain relief bush.
5.0 Fault finding Burner fails to light No Electric Supply ON No Turn on Electric Supply Yes Check fuse.
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 Yes Change fan motor or capacitor No Fan control Settings incorrect No Fan runs in manual mode No Faulty fan motor or capacitor 34 Yes Change fan control
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T 6.
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-707 VRC 42-50 Auto ignition On/Off
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-708 VRC 60 Auto ignition On/Off
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-696 VRA 72-145 Auto ignition On/Off SEQUENCE CONTROLLER 38
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T LINK ADDITIONAL FANS AS REQUIRED FAN MOTOR 3 (V²RE120/145 & V²RBD145) FAN MOTOR 4 (V²RE & V²RBD 45 ONLY) Wiring Diagram 33-67-697 VRC 72-95 VRE120-145 Auto ignition On/Off
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-698 VRC 72-145 3 Phase Auto ignition On/Off SEQUENCE CONTROLLER 40
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-699 VRA 12-60 VRC 12-30 Auto ignition Hi/Low
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-709 VRC 42-50 Auto ignition Hi/Low
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-710 VRC 60 Auto ignition Hi/Low
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-700 VRA 72-145 Auto ignition Hi/Low SEQUENCE CONTROLLER 44
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T LINK ADDITIONAL FANS AS REQUIRED FAN MOTOR 3 (V²RE120/145 & V²RBD145) FAN MOTOR 4 (V²RE & V²RBD 45 ONLY) Wiring Diagram 33-67-701 VRC 72-95 VRE 120-145 Auto ignition Hi/Low
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-702 VRC 72-145 3 Phase Auto ignition Hi/Low SEQUENCE CONTROLLER 46
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-703 VRA 12-60 VRC 12-30 Auto Ignition Modulation
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-711 VRC 42-50 Auto Ignition Modulation
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T Wiring Diagram 33-67-712 VRC 60 Auto Ignition Modulation
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-704 VRA 72–145 Auto Ignition Modulation SEQUENCE CONTROLLER 50
WARNING NEUTRAL RESET SEQUENCE CONTROLLER T T LINK ADDITIONAL FANS AS REQUIRED FAN MOTOR 3 (V²RE120/145 & V²RBD145) FAN MOTOR 4 (V²RE & V²RBD 45 ONLY) Wiring Diagram 33-67-705 VRC 72-95 VRE 120-145 Auto ignition Modulation
WARNING NEUTRAL RESET T T Wiring Diagram 33-67-706 VRC 72-145 3 Phase Auto ignition Modulation SEQUENCE CONTROLLER 52
Less Controls Connections On/Off (Hi/Low) 1 Phase 33-64-349T WARNING NEUTRAL RESET Less Controls Connections On/Off (Hi/Low) 3 Phase 33-67-014T WARNING NEUTRAL RESET 53
Less Controls Connections Modulation 1 Phase 33-64-584 WARNING NEUTRAL RESET Less Controls Connections Modulation 3 Phase 33-67-587 WARNING NEUTRAL RESET 54
7.0 Technical Data Appliance Type B22 C 32 C12 Electrical Protection IP20 7.
7.2 Technical Data - models 12-50 NAT GAS / LPG MODEL 12 20 30 42 50 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 5.8 19,700 9.4 32,100 14.2 48,400 18.9 64,400 23.6 80,800 kW Btu 6.5 22,200 10.6 36,200 16.0 54,600 21.3 72,700 26.
Technical Data - models 60-145 NAT GAS / LPG MODEL 60 72 95 120 145 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 28.3 96,700 34.9 119,100 46.6 158,900 57.7 197,000 69.3 236,500 HEAT INPUT (Nett) Low Fire kW Btu 32.
8.
Parts list cont’d Heater Size/ Description 12 20 30 42 Ionisation Probe 33-64-194 Overheat Red Neon 28-50-030 Burner On Green Neon 28-50-038 Reset Relay 230V 28-25-039 Relay Base 28-25-035 High Fire Timer Relay 28-15-027 60 28-07-084 (6A) 28-07-085 (10A) 28-07-046 (16A) MCB Lockout Reset Switch 20-40-118 Burner 33-64-158 Flue Fan 50 28-09-083 28-09-082 28-09-084 Fan Axial VRA 28-09-057 28-09-058 28-09-059 28-09-061 28-09-062 28-09-092 Fan Axial VRE 28-09-058 28-09-059 28-09-
Parts list cont’d Heater Size/ Description 72 95 120 145 Gas Valve 28-30-181 N/A Gas Valve N/A 28-30-184 Hi/Low Valve 28-30-188 N/A Hi/Low Valve N/A 28-30-189 Valve Gasket 33-64-227 N/A Valve Flange c/w ‘O’ Ring N/A 28-30-185 28-30-202 28-30-203 Modulating Valve Modulation Interface Board 28-30-198 Control Box 29-01-183 Pressure Switch 28-40-163 Fan Limit Stat 28-60-021 Overheat Stat 28-60-039 Injector Natural Gas 33-64-145 Injector Propane Gas 33-64-147 Electrode 33
Parts list cont’d Heater Size/ Description 72 95 120 Ionisation Probe 33-64-194 Overheat Red Neon 28-50-030 Burner On Green Neon 28-50-038 Reset Relay 230V 28-25-039 Relay Base 28-25-035 High Fire Timer Relay 28-15-027 28-07-084 (6A) 28-07-085 (10A) 28-07-046 (16A) MCB Lockout Reset Switch 20-40-118 Burner 33-64-160 Flue Fan 145 28-09-089 Fan Axial VRA 28-09-062* 28-09-092* Fan Axial VRE 28-09-062* 28-09-063* 28-09-097* Fan Centrifugal 28-09-049* 28-09-149* Std Fan Motor N
A 440 440 545 650 780 910 650 800 980 1150 Model 12 20 30 42 50 60 72 95 120 145 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 12 20 30 42 50 60 72 95 120 145 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 12 20 30 42 50 60 72 95 120 145 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.
Dimensions - Vertical Co/Axial Terminal AIR FLUE Heater A B C D E F G H J K 12-20 120 80 250 775 1075 1280 140 125 80 80 30– 60 140 75 270 815 1115 1360 170 150 100 100 72– 145 225 85 330 900 1630 1860 210 200 130 130 Dimensions in mm 65
Dimensions - Horizontal Co/Axial Terminal FLUE AIR TOP Ensure Terminal is located on the wall in this configuration BOTTOM Heater A B C D E F G B+C 12-20 170 360 250 120 125 80 80 610 30– 60 170 350 260 140 150 100 100 610 72– 145 180 420 340 225 200 130 130 750 Dimensions in mm 66
Dimensions - Wall Bracket VRA 12-60 Dimensions in mm Heater A B X Y øZ VRA12 330 105 31 142 125 VRA20 330 105 31 174 125 VRA30 400 175 28 191 150 VRA42 400 175 28 300 150 VRA50 400 175 28 430 150 VRA60 400 175 28 560 150 67
Dimensions - Wall Bracket VRA 72-145 VRC 12-60 Heater A B X Y øZ VRC12 653 755 31 142 125 VRC20 653 755 31 174 125 VRC30 653 755 28 261 150 VRC42 653 755 28 200 150 VRC50 653 755 28 330 150 VRC60 653 755 28 460 150 VRA72 1263 1365 5 185 200 VRA95 1263 1365 5 317 200 VRA120 1263 1365 7 489 200 VRA145 1263 1365 7 630 200 Benson Heating Ludlow Road Knighton Powys LD7 1LP United Kingdom.
