Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 1

Transcription

1 Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 1

2 Index Page Technical Information Buffalo 3-6 Wombat 7-11 Upflow Downflow Airflow Chart 17 Outlet Chart 18 Wiring Diagrams TEK Wiring Thermostats on Classic Models 20 Motor / Plug Wiring Diagram 21 Motor Model No. 855BPVA-A12 22 Motor Model No. 8558BNV-A13 23 Motor Model No. 61S Motor Model No. 61S Motor Model No. 61S Instructions to Adjust the Fan Speeds Setting the Fan Motor Minimum Voltage 28 Replacing and Adjusting the Pilot Injector 29 Introduction 30 Normal Heating Operation Tekelek 321 Electrical Controller Power Up 31 Pilot Ignition and Electronic Pilot Relight Operation (EPR) 31 Heating Cycle Time Safe Guard Period 32 Cooling Cycle 32 TEK Electronic Controller Function Summary 33 Diagnostic LED Identification 34 Abnormal Operating Conditions If Heater has No Functions 35 Electronic Pilot Relighter Not Operating 36 Electronic Pilot Relighter will Not Stop Sparking 36 If Pilot will Not Light 37 If Pilot Lights, But will Not Stay Alight 38 If the Pilot Flame will Not Light 38 If the Main Burner will Not Light 39 Delayed Ignition and Poor Ignition Flame Roll Out Over Temperature Conditions If Over Temperature Switch Open Circuit 46 Fan Not Operating 47 If Fan is Continually Running 48 Dismantling Procedures TEK 321 Electronic Controller 49 Burners / Manifold and Gas Valve 50 Main Fan 51 Heat Exchanger 52 Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 2

3 Technical Information Buffalo 120 AGA Approval No.: 3183 Energy Label Star Rating: 1.7 Stars Cabinet Width Height Depth Weight 565 mm 1160 mm 1320 mm kg Gas Type NG LPG Input (max) 120 MJ 33.5 kw MJ 32.5 kw Output (max) 94.0 MJ 26.0 kw 92.0 MJ 25.5 kw Input (min) 90.0 MJ 25.0 kw 90.0 MJ 25.0 kw Output (min) 70.5 MJ 19.5 kw 70.5 MJ 19.5 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 500 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.85 mm 0.50 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 775 L/s std Model Betts Betts 890 L/s XA 61S Pa Ext. Stat. Pres. Watt Amps Fan Wheel 270 mm X 270 mm RPM (max) (10" X 10") Capacitor 15 uf 25 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6771B Zip Tube Burner: For cross ignition of Burners Pilot Injector: Honeywell, NG - BBF18, LPG - BBF10 Thermocouple: Honeywell Q309A Heat Exchanger: Aluminised Steel Control Fuse: 2 Amps type 3AG Transformer: Multicontact 24 V, 1 Amp, 50HZ Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco sensor 420mm Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amps (max) terminals transformer and internal circuit 2 Amps fuse protection Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 3

4 Technical Information Buffalo 85 AGA Approval No.: 3183 Energy Label Star Rating: 2.0 Stars Cabinet Width Height Depth Weight 395 mm 1120 mm 1090 mm 74.0 kg Gas Type NG LPG Input (max) 85.0 MJ 24.0 kw 84.0 MJ 23.0 kw Output (max) 65.5 MJ 18.5 kw 65.0 MJ 18.0 kw Input (min) 60.0 MJ 16.5 kw 60.0 MJ 16.5 kw Output (min) 46.0 MJ 13.0 kw 46.0 MJ 13.0 kw Burner Pressure (max) 840 Pa 2600 Pa Burner Pressure (min) 450 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.75 mm 0.45 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 430 L/s std Model Betts Betts 540 L/s XA 61S Pa Ext. Stat. Pres. Watt Amps RPM (max) Fan Wheel 240mm X 180mm Capacitor 4 uf 8 uf (9" x 7") Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6671B Zip Tube Burner: For cross ignition of Burners Pilot Injector: Honeywell, NG - BBF18, LPG - BBF10 Heat Exchanger: Aluminised Steel Control Fuse: 2 Amps type 3AG Transformer: Multicontact 24V, 1.75 Amp 50HZ Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco Sensor 290 mm Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amps (max) terminals transformer and internal circuit 2 Amps fuse protection Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 4

5 Technical Information Buffalo 52 AGA Approval No.: 3183 Energy Label Star Rating: 1.1 Stars Cabinet Width Height Depth Weight 290 mm 1065 mm 1090 mm 58.0 kg GasType NG LPG Input (max) 52.0 MJ 14.5 kw 50.0 MJ 14.0 kw Output (max) 40.5 MJ 11.0 kw 39.0 MJ 11.0 kw Input (min) n/a n/a n/a n/a Output (min) n/a n/a n/a n/a Burner Pressure (max) 840 Pa 2600 Pa Burner Pressure (min) n/a n/a Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.55 mm 0.35 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 300 L/s std Model Betts n/a n/a L/s XA 61S Pa Ext. Stat. Pres. Watt 250 n/a Amps 2 n/a Fan Wheel 240mm X 140mm RPM 1340 n/a (9" X 5") Capacitor 4 uf n/a Gas Valves: Honeywell VR8201 (Stat to be set on.2 for LPG Stat to be set on 0.5) Pilot Burner: Honeywell Q314A6771B Zip Tube Burner: For cross ignition of Burners Pilot Injector: Honeywell, NG - BBF18, LPG - BBF10 Heat Exchanger: Aluminised Steel Control Fuse: 2 Amps type 3AG Transformer: Multicontact 24 V, 1 Amp 50 HZ Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cable sensor 220 mm Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amps (max) terminals transformer and internal circuit 2 Amps fuse protection Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 5

6 Technical Information Buffalo 52 *, Buffalo 85 ** and Buffalo 120 *** Dimensional Diagrams * 1080mm ** 1090mm *** 1320mm * 920mm ** 925mm *** 1145mm * 955mm ** 1010mm *** 1065mm Hot air supply closest to gas pipe Gas connection (Copper or Aluminium 19mm flared with nut) * 1055mm ** 1120mm *** 1160mm * 320mm ** 370mm *** 415mm * 770mm ** 770mm *** 750mm * 290mm ** 395mm *** 565mm Balanced Flue brivis Climate Systems Removable front cover panel Brivis Buffalo 120 Reversible Base Box * 290mm ** 395mm *** 565mm Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 6

7 Technical Information Wombat 120 AGA Approval No.: 2593 Energy Label Star Rating: 1.4 Stars Cabinet Width Height Depth Weight 560 mm 820 mm 1110 mm 89.0 kg Gas Type N.G. L.P.G. Input (max) 120 MJ 33.5 kw MJ 32.5 kw Output (max) 94.0 MJ 26.0 kw 92.0 MJ 25.5 kw Input (min) 90.0 MJ 25.0 kw 90.0 MJ 25.0 kw Output (min) 70.5 MJ 19.5 kw 70.5 MJ 19.5 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 500 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.85 mm 0.50 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 775 L/s std Model Betts Betts 880 L/s XA 61S pa Ext. Stat. Pres. Watt Amps Fan Wheel 270mm X 270mm R.P.M (max) (10" X 10") Capacitor 15 uf 25 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6771B. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BBF18, LPG - BBF10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1 Amp, 50HZ. Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco sensor 420mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amp (max) terminals transformer and internal circuit 2 Amp fuse protection. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 7

8 Technical Information Wombat 120 Dimensional Diagrams 665mm Return air PANEL MUST BE REPLACED DURING NORMAL OPERATION Supply air Fan access panel either L/H or R/H side 240 Volt electrical connection 55mm 985mm Gas inlet to suit 19mm copper 270mm 1116mm Flue spigot brivis Climate Systems 820mm Brivis ems 26i 560mm Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 8

9 Technical Information Wombat 92 AGA Approval No.: 2593 Energy Label Star Rating: 1.6 Stars Cabinet Width Height Depth Weight 400 mm 720 mm 940 mm 65.0 kg Gas Type N.G. L.P.G. Input (max) 92.0 MJ 25.5 kw 84.0 MJ 23.0 kw Output (max) 73.0 MJ 20.5 kw 66.5 MJ 18.5 kw Input (min) 60.0 MJ 16.5 kw 60.0 MJ 16.5 kw Output (min) 46.0 MJ 13.0 kw 46.0 MJ 13.0 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 450 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.75 mm 0.45 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 440 L/s Std Model Betts Betts 555 L/s XA 61S pa Ext. Stat. Pres. Watt Amps Fan Wheel 240mm X 180mm R.P.M (max) (9" X 7") Capacitor 4 uf 8 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6771B. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BBF18, LPG - BBF10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1 Amp, 50HZ. Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco sensor 290 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amp (max) terminals transformer and internal circuit 2 Amp fuse protection. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 9

10 Technical Information Wombat 52 AGA Approval No.: 4721 Energy Label Star Rating: 1.1 Stars Cabinet Width Height Depth Weight 270 mm 700 mm 870 mm 49.0 kg Gas Type N.G. L.P.G. Input (max) 52.0 MJ 14.5 kw 50.0 MJ 14.0 kw Output (max) 40.5 MJ 11.0 kw 39.0 MJ 11.0 kw Input (min) n/a n/s n/a n/a Output (min) n/a n/a n/a n/a Burner Pressure (max) 840 Pa 2600 Pa Burner Pressure (min) n/a n/a Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.55 mm 0.35 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 274 L/s std Model Betts n/a n/a L/s XA 61S pa Ext. Stat. Pres. Watt 250 n/a Amps 2 n/a Fan Wheel 240mm X 140mm R.P.M n/a (9" X 5") Capacitor 4 uf Gas Valves: Honeywell VR8201 (Stat to be set on.2 for LPG Stat to be set on 0.5) Pilot Burner: Honeywell Q314A6771B. Zip Tube Burner: For cross ignition of burners. Pilot Injector: Honeywell, N/Gas - BBF18, LPG - BBF10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1 Amp, 50HZ. Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco Sensor 220 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amp (max) terminals transformer and internal circuit 2 Amp fuse protection. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 10

11 Technical Information Wombat 52 * and Wombat 92 ** Dimensional Diagrams Return air * 940mm ** 1010mm Supply air 50mm * 700mm ** 720mm * 870mm ** 940mm Gas inlet * 260mm ** 395mm Flue spigot Fan access for serviceman Minimum 600 mm clearance * 700mm **700mm brivis Climate Systems Brivis EMS Volt electrical connection * 270mm ** 400mm Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 11

12 Technical Information Upflow 120 AGA Approval No.: 2820 Energy Label Star Rating: 1.4 Stars Cabinet Width Height Depth Weight 565 mm 1250 mm 485 mm 76.0 kg Gas Type N.G. L.P.G. Input (max) 120 MJ 33.5 kw MJ 32.5 kw Output (max) 95.0 MJ 26.0 kw 92.0 MJ 25.5 kw Input (min) 90.0 MJ 25.0 kw 90.0 MJ 25.0 kw Output (min) 70.5 MJ 19.5 kw 70.5 MJ 19.5 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 500 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.85 mm 0.50 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 825 L/s std Model Betts 125 pa Ext. Stat. Pres. 61S BPVA-A12 Watt Amps Fan Wheel 270mm X 270mm R.P.M (max) (10" X 10") Capacitor 15 uf 25 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6771B. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BBF18, LPG - BBF10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1 Amp, 50HZ. Overtemperature Switches: Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C). Flame Roll-Out Sensor (AFRO): Cableco sensor 420mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amp (max) terminals transformer and internal circuit 2 Amp fuse protection. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 12

13 Technical Information Upflow 92 AGA Approval No.: 2820 Energy Label Star Rating: 1.6 Stars Cabinet Width Height Depth Weight 395 mm 1122 mm 457 mm 53.0 kg Gas Type N.G. L.P.G. Input (max) 92 MJ 25.5 kw 84.0 MJ 23.0 kw Output (max) 73 MJ 20.5 kw 66.5 MJ 18.5 kw Input (min) 60 MJ 16.5 kw 60.0 MJ 16.5 kw Output (min) 46 MJ 13.0 kw 46.0 MJ 13.0 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 450 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.75 mm 0.45 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 440 L/s std Model Betts 50 pa Ext. Stat. Pres. 61S BNV-A13 Watt Amps Fan Wheel 240mm X 180mm R.P.M (max) (9" X 7") Capacitor 4 uf 8 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7). Pilot Burner: Honeywell Q314A6771B. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BBF18, LPG - BBF10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1 Amp, 50HZ. Over temperature Switches: Supply Air Compartment: Texas Inst. Klixon oil1747l90 (Opens at 93 o C). Flame Roll-Out Sensor (AFRO): Cableco sensor 290 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amp (max) terminals transformer and internal circuit 2 Amp fuse protection. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 13

14 Climate Systems Technical Information Upflow 92 * and Upflow 120 ** Dimensional Diagrams Duct outlet * mm x 305 mm ** mm x 340 mm * 1122mm ** 1250mm [*a]50mm 240 Volt [**]50mm electrical connection * 1292mm ** 1570mm Gas inlet to suit 19mm copper * 660mm ** 850mm * 457mm ** 485mm Flue spigot brivis Brivis Upflow 120 PANEL MUST BE REPLACED DURING NORMAL OPERATION Duct inlet underneath * mm x 340 mm ** mm x 435 mm * 395mm ** 565mm Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 14

15 Technical Information Downflow 92 AGA Approval No.: 2477 Energy Label Star Rating: 1.6 Stars Cabinet Width Height Depth Weight 395 mm 1122 mm 457 mm 53.0 kg Gas Type NG LPG Input (max) 92.0 MJ 25.5 kw 84.0 MJ 23.0 kw Output (max) 73.0 MJ 20.5 kw 66.5 MJ 18.5 kw Input (min) 60.0 MJ 16.5 kw 60.0 MJ 16.5 kw Output (min) 46.0 MJ 13.0 km 46.0 MJ 13.0 kw Burner Pressure (max) 872 Pa 2600 Pa Burner Pressure (min) 450 Pa 2000 Pa Injector Orifice Main Burner 1.95 mm 1.15 mm Zip Burner 0.75 mm 0.45 mm Pilot Burner 0.50 mm 0.25 mm Motor std X.A Air Quantity 400 L/s std Model Betts 50 Pa Ext. Stat. Pres. 61S BNV-A13 Watt Amps Fan Wheel 240mm X 180mm RPM (max) (9" X 7") Capacitor 4 uf 8 uf Gas Valves: Honeywell VR8301 (Stat to be set on.2 for LPG Stat to be set on 0.7) Pilot Burner: Honeywell Q314A6771B Zip Tube Burner: For cross ignition of Burners Pilot Injector: Honeywell, NG - BBF18, LPG - BBF10 Heat Exchanger: Aluminised Steel Control Fuse: 2 Amp type 3AG Transformer: Multicontact 24 V, 1 Amps, 50HZ Over temperature Switches: Fan Compartment: Texas Inst. Lixon Oil 1727 L57 (opens at 57 o C) - Prior 1/12/98. Fan Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) - After 1/12/98. Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C) Flame Roll-Out Sensor (AFRO): Cableco sensor 290 mm Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 321 with LED diagnostic display, flame roll-out sense, pilot relight operation and independent fan speed adjustment for Heat/Cool/Economy Heating modes. Wiring terminal connection for thermostat/system with heat, fan only, cooling and auxiliary 24 V. 0.3 Amps (max) terminals transformer and internal circuit 2 Amps fuse protection Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 15

16 Climate Systems Technical Information Downflow 92 Dimensional Diagrams Duct inlet 365 mm x 305 mm 1122mm 240 Volt electrical connection 50mm Gas inlet to suit 19mm copper 320mm 457mm Flue spigot rectangular to round brivis Brivis Downflow 92 Duct outlet underneath 365 mm x 340 mm 395mm Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 16

17 Technical Information Airflow Chart Classic - External Heaters Airflow (L/s) B 120 B 85 B 52 Std / XA Std / XA Std 50 pas 850 / / pas 825 / / pas 795 / / pas 775 / / Classic - Internal Heaters Airflow (L/s) - Horizontal W 120 W 92 W 52 Std / XA Std / XA Std 50 pas 860 / / pas 825 / / pas 800 / / pas Classic - Internal Heaters Airflow (L/s) - Vertical U 120 U 92 D pas pas pas pa Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 17

18 Technical Information Outlet Chart [a] minimum number of outlets, if the heater is to operate properly without overheating. Ceiling systems have a maximum number of outlets [b] that can remain fully open, to ensure that the velocity through each outlet is sufficient. These maximums only relate to fully open outlets, however, the system will operate effectively with more outlets open, if it has been properly balanced. There is no maximum number for floor outlets [c], so the chart below lists the usual number of floor outlets for each heater. Classic - External Heaters Airflow (L/s) B 120 B 85 B 52 Std / XA Std / XA Std [a] Minimum 8 / 8 5 / 5 3 [b] Ceiling 11 / 13 8 / 10 5 [c] Floor 16 / / 12 7 Classic - Internal Heaters Airflow (L/s) - Horizontal W 120 W 92 W 52 Std / XA Std / XA Std [a] Min 8 / 8 6 / 6 3 [b] Ceiling 11 / 13 8 / 10 5 [c] Floor 16 / / 13 7 Classic - Internal Heaters Airflow (L/s) - Vertical U 120 U 92 D 92 [a] Min [b] Ceiling [c] Floor Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 18

19 Technical Information Wiring Diagrams TEK 321 TE K 321 O H /F W hite O range A Fan O ut A Pow er In N Pow er In Fan N O ut COOL ECON MIN B row n B lue G reen P urple O H /S T G E C W R 24V C O OL E CO N THS T GN D AOG STAT FAN ECON EPRL ROLL O/HS O/HF White White Blue 9 Pin P lug R edundant M ain G as V alve O range C apacitor ORANGE BROWN (Run) BLUE (Neutral) WHITE RED (Active Out) BLUE / WHITE GREEN/YELLOW (Earth) R U N S TA R T Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 19

20 Technical Information Heating: Connect terminals "R" and "W" on the Heater to terminals "R" and "W" on the Wall Control Thermostat. CAPACITOR MAIN FAN A N E TEK 321. A N E SPARE T G EC W R E GAS VALVE MAINS IN 3 PIN PLUG TO A 240 VOLT 10 AMP POWER OUTLET RC W R STANDARD ROOM THERMOSTAT Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 20

21 CAPACITOR MAIN FAN A N E TEK 321. A N E SPARE T G EC W R E GAS VALVE O W G C R RC B Y MAINS IN 3 PIN PLUG TO A Fan Only - (Electronic Only): 240 VOLT 10 AMP POWER OUTLET Connect terminal "G" on the Heater to terminal "G" at the Electronic Thermostat. ELECTRONIC ROOM THERMOSTAT Wiring Thermostats on Classic Models Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 21

22 Technical Information Motor / Plug Wiring Diagrams A N 9 Pin Plug E Capacitor ORANGE BROWN (Run) BLUE (Neutral) WHITE (Earth) RED (Active Out) BLUE / WHITE RUN START Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 22

23 Technical Information Motor Wiring Diagrams Part No MOTOR 650W HUSH 855BPVA-A12 CAPACITOR: 25 uf ORANGE BLACK START 10.8 BROWN MAIN 6.6 BLUE GREEN / YELLOW EARTH Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 23

24 Technical Information Motor Wiring Diagrams MOTOR 315 WATT HUSH MOTOR BETTS 8558 BNVA - A13 ORANGE WHITE START 38.8 BLUE/WHITE RED BROWN MAIN BLUE GREEN / YELLOW EARTH Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 24

25 Technical Information Motor Wiring Diagrams MOTOR MODEL NO. 61S AMPS CAPACITOR: 4 uf ORANGE WHITE START 120 BLUE/WHITE RED BROWN MAIN 14.5 BLUE GREEN / YELLOW NOTE: TO REVERSE ROTATION REVERSE PINS WHITE / BLUE AND WHITE Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 25

26 Technical Information Motor Wiring Diagrams (cont) Motor No. 61S Amps CAPACITOR: 15uF ORANGE ORANGE CAPACITOR 15uF ORANGE WHITE BLUE/WHITE START 11.8 ORANGE BROWN BLUE RED BROWN BLUE MAIN 8.5 GREEN /YELLOW EARTH Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 26

27 Technical Information Instructions to Adjust the Fan Speeds (if Required) The TEK Controller has 4 fan speed potentiometers for different modes of operation. 1. Heating Locate the potentiometer, marked FAN SPEED on the PCB next to the wiring terminal block. Start the Heater and proceed to balance the outlets to give the desired heat distribution. Once the air temperature has stabilised, check to make sure the outlet temperature at the closest outlet to the Heater does not exceed 47oC. above the room ambient (return air intake) temperature. Increasing the fan speed will lower the outlet temperature and vice versa. Rotate the control to increase or decrease air volume to suit the duct system as follows: For floor outlet systems the temperature rise above ambient should be targeted around 35oC. - 40oC. For ceiling outlet systems, where higher outlet velocities and air quantities are generally required, a lower outlet temperature rise is expected (approx. 30oC.) due to the increased airflow. 2. Cooling Remove the Electronic Controller cover plate and locate the speed potentiometer marked COOL on the PCB. Adjust the COOL potentiometer until the required airflow for cooling or air recirculation is obtained. Turn ON the cooling operation i.e. fan switch on thermostat or bridge wire between "R" and "G" terminals at the heaters terminal block, and recheck the balance of the duct system. 3. Economy This speed adjustment potentiometer will not function on standard units. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 27

28 Technical Information Instructions to Adjust the Fan Speeds (if Required) 4. Minimum Fan Motor Voltage (Factory Set) The minimum fan Voltage setting is factory set, and should not require adjustment, however, when fitting a replacement Electronic Controller, the minimum Voltage will need to be set to suit the units motor size. Set the potentiometer according to the heaters fan motor size as follows: 250/315 watt = 140 Volt 500/600/750 watt = 120 Volt Setting the fan motor minimum Voltage Using a multimeter set on 240 Volt AC range, insert the meter leads in the power supply / fan output loom plug, located on the PCB as show. Rotate the FAN SPEED, COOL and ECON potentiometers on the PCB to their lowest setting. Adjust the potentiometer marked MIN to the required minimum Voltage for motor size. Readjust the Heating and Cooling fan speeds as required. ORANGE ORANGE MOTOR 240V~ CAP CAP CAP NEUTRAL T MULTI- METER EARTH MAIN START 1 START 2 MAINS LEAD TEK321 PCB 240 VOLT RE-IGNITION SOCKET E E A N 2 AMP FUSE MIN ECON COOL E oh/f A oh/s roll O/H eprl econ fan stat ELECTRONIC HEATER CONTROLLER AOG HIGH LOW Y FAN SPEED G TRANSFORMER CONNECTIONS EC W R FAN ACTIVE MAINS ACTIVE MAINS NEUTRAL FAN NEUTRAL J103 Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 28

29 Technical Information Replacing and Adjusting the Pilot Injector Adjust Pilot Flame 25mm - 32mm Adjust pilot flow adjustment screw to give soft, steady flame enveloping 8mm - 13mm of the tip of the thermocouple or generator. An excessively large pilot flame will shorten life. To replace pilot injector or thermocouple, first remove pilot assemble from unit (see Diagram). Insert Orifice Push-in MTG Clip To remove thermocouple from pilot burner assembly. 6mm Comp Fitting Supplied with Attachment Nut or Clip. 6mm O.D. Tubing To replace Pilot Burner Injector Insert Orifice Orifice Stamping (Typical) BCR 18 Ferrule breaks off here and clinches around tubing One Piece Comp (Tighten one turn beyond finger tight) Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 29

30 Introduction The standard Electronic range of Brivis heaters (Classics) use a Tekelek Electronic control module to control the heaters operation. The TEK 321 Electronic module has the facility to integrate refrigerative add-on cooling switching with separate fan speed operation. The module also provided the pilot with an automatic spark igniter with a relight mechanism to prevent accidental pilot outage. These units are standard efficiency, natural draught burner heaters with standing pilot ignition. The model range includes external (Buffalo) and internal (Wombat, Upflow & Downflow) units. The heater range is approved to be downrated to a reduced gas input and heat output operation. Standard (Classic) heaters are available in an XA version with a larger fan motor and duct take off pops for additional airflow capacity. EMS (Energy Management System) option was available on some models, to provide the facility to switch between the high (normal) heat output, to the low (downrated) heat output. The electronics gave provision to adjust the fan speed to correspond to both settings automatically. These heaters are supplied with a conventional standard thermostat, with an option of an electronic battery powered thermostat. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 30

31 Normal Heating Operation Tekelek 321 Electrical Controller Power Up When power is first applied to the unit, the test reset button is pressed or the power is restored following an interruption, the unit will go through a light sequence followed by a 2.5 second power up stabilisation time. The units LED's will indicate the status of the units operation at any time as described in the instructions following. Before the unit can be operated from the thermostat, the pilot burner operation must first be established. Pilot Ignition and Electronic Pilot Relight Operation (EPR) From power up, the EPR will 2 sparks/second for a period of 85 seconds or, until pilot flame is established. During this period the EPRL LED will be illuminated solid. When the pilot is lit from the electrode spark, the Electronic Controller stops the sparking operation, and the EPRL LED will no longer be illuminated. If the pilot is not lit within 85 seconds the EPR will stop sparking, and will illuminate the EPRL LED flashing, but will not lockout the controller. Note: The pilot can be lit manually, and the heater could commence normal heating cycle, however, if the EPRL has locked out, then the heater cannot attempt to relight a temporary outage, as designed, unless the EPRL is reset (power up). Heating Cycle When the thermostat is turned ON and calls for heat, the green STAT LED is illuminated solid, the gas valve opens allowing the burners to light, and the fan is timed to start 45 seconds later. Once the fan motor has been powered, the green FAN LED will be illuminated. The Heater will operate at this continuous rate, until the thermostat is turned OFF again. Then the gas valve closes, and the fan is also timed to turn OFF 75 seconds later. The STAT LED will remain illuminated flashing (indicating cooling down recovery status) whilst the fan is timed OFF. Then both the flashing STAT LED and the FAN LED will turn OFF. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 31

32 Normal Heating Operation (cont. Heating Cycle (cont. On Power Up, i.e. following a power interruption, if the thermostat is ON, then both fan and burners will start-up immediately, before resuming the normal heating cycle. If the thermostat is OFF; both the fan and burners will remain OFF. When the thermostat is turned ON and calls for heat, if the thermostat turns OFF again after 3 seconds, and before the end of fan on period, then the fan will start immediately. Timed Safe Guard Period On power up and at the end of any fan operation i.e. normal heating cycle, a 12 minute "TIMED SAFEGUARD PERIOD" will commence to monitor if an over temperature condition occurs. Should an over temperature condition occur after the Timed Safe Guard Period has expired, then the control system will ignore the condition, and regard it as a result of high ambient temperature NOT associated with the operation of a heating cycle. An example of this would be the typical high ambient temperature experienced in a ceiling cavity of a building in Summer time. Cooling Cycle When cooling mode is selected i.e. terminals R and G are bridged, the fan immediately operates via the COOL speed control. This will override all other conditions including Lockouts. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 32

33 TEK Electronic Controller Function Summary Power Up stabilisation time 2.5 seconds Ignition time out period 85 seconds FAN ON delay time 45 seconds FAN OFF delay time 75 seconds Timed Safe Guard Period 12 minutes Flame Roll Out Timer 10 seconds Roll Out / Lockout Timer 60 seconds Over Temperature FAN OFF delay time 60 seconds Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 33

34 Diagnostic LED Identification AOG - green - Appliance Operation Guide indicates an internal recoverable error has occurred, and a remains flashing until the unit is reset or re-powered. This indicator has no affect to the units operation. STAT - green - Solid identification indicates the thermostat is turned ON. Flashing indicates the thermostat has recently turned OFF, and the fan is still running. FAN - green - Indicates the fan is turned ON. ECON - (Not used on this model) ROLL - red - Solid identification indicates the unit is in a current 10 second Roll Out condition. Flashing indicates the period of re-ignition following a Flame Roll Out or Flame Roll out Lockout. OH/S - red - Solid identification indicates a current over temperature condition at the Supply Air over temperature switch. Flashing indicates the Supply Air over temperature switch has reset, and the fan is still operating, or the unit is in a Lockout condition, due to this switch being activated. OH/F - red - Solid identification indicates a current over temperature condition at the Fan over temperature switch. Flashing indicates the Flue Fan over temperature switch has reset, and the fan is still operating, or the unit is in a Lockout condition, due to this switch being activated. All LED's Illuminated continuously indicates a fault (Check main fan motor and/or wiring circuit). Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 34

35 Abnormal Operating Conditions If the Heater has No Functions Check for incoming 240 Volt power supply and polarity Check voltage reading at the power supply lead plug terminals at the PCB (see diagram pages 19), and power point, as follows: Terminals Active and Neutral = 240 Volts Terminals Active and Earth = 240 Volts Terminals Neutral and Earth = 0 Volts Active Neutral Switch Earth Test procedure for the TEK 321 Controller Check the TEK 321 PCB for light flashing sequence on Power Up. Check the 240 Volt power supply. Check the 2 Amp fuse. Check all wire looms and plugs are correctly connected to TEK 321 PCB. Bridge the terminals R and W, and check that the STAT LED illuminates, and the gas valve is energised (24 Volt). Bridge terminals R and G, and check if the main fan operates. Check for 24 Volt at terminals R and T. If TEK 321 PCB will not operate, replace TEK 321. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 35

36 Abnormal Operating Conditions (cont. Electronic Pilot Relighter not operating Check that the Heaters Power Supply is plugged into the power point, and 240 Volt power is turned ON. Check the EPR lead is correctly connected in the TEK 321 PCB socket terminal. Check the 2 Amp fuse has not blown. Check if the EPR electrode has not shorted to ground i.e. touching pilot burner hood. Check that the EPR lead is not damaged, and test for continuity. Replace TEK 321 Electronic Controller. Electronic Pilot Relighter will not stop sparking Check if the pilot light is ON. EPR lead is damaged. Check if the EPR probe is located correctly in the pathway of the pilot flame. Check if the EPR probe is damaged. Check the pilot flame for correct formation and contact on the EPR probe. Check that the pilot injector is not dirty, blocked or damaged. Check the pilot burner has correct gas flow adjustment. Check the gas supply pressure is correct and not fluctuating. Check the pilot flame is not affected by draught, or air disturbance from the fan operation. Check the 2 Amp fuse is not blown. Check for loose connections to the wiring circuit on the fan motor i.e. 9 pin plug. Replace TEK 321 Electronic Controller. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 36

37 Abnormal Operating Conditions (cont. If Pilot will not light Is the main gas turned ON at the appliance, and at the gas meter? Is the gas valve in PILOT position, and fully depressed? Is there any air in the gas line that needs to be bled? If there is gas at the pilot burner: Check ignition and operation of the pilot burner by manually lighting it with a match. Check the EPR electrode has a clearance of approximately 4 mm between the electrode and pilot body. Check the polarity of the power supply (if active and neutral terminals are reversed the EPR will not spark, even though the heater operates). Check the electrical connections at the electrode and the PCB. Check the high tension lead has not been damaged (use multi meter or continuity tester). Check the electrode is not damaged or cracked on the ceramic insulator. Check the electrode is not coasted with any substance preventing it from arcing the spark to the pilot. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 37

38 Abnormal Operating Conditions (cont. If Pilot Lights, but will Not Stay Alight Check pilot flame is: Large enough. Directed at the thermocouple. Not being disturbed by air. Check the thermocouple connection to gas valve is clean and tight. Check that the gas valve knob is fully depressed before releasing (allow 60 seconds for thermocouple to generate power to electromagnet). For the electromagnet to hold, a minimum of 11 millivolts should be generated from the thermocouple closed circuit to the electromagnet. Replace the thermocouple and/or the electromagnet. If the Pilot Flame will Not Light Check for gas output from gas valve pilot connection (disconnect the pilot tube). If no gas output in valve: Check if gas supply is turned ON. Check the gas valve pilot adjustment screw is open sufficiently. Check for blockage in gas valve (Replace). Check for blockage in the pilot feed tube. Check for blockage or damaged pilot injector (Replace if necessary). Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 38

39 Abnormal Operating Conditions (cont. If the Main Burner will Not Light Check that the Heaters Power Supply is plugged in to the power point and 240 Volt power is turned ON. Check the TEK 321 PCB displays a light sequence at initial Power Up. Check the gas valve is in the ON position, and the pilot light is lit. Bridge out R and W and check for ignition. Check the STAT LED illuminates, indicating a closed thermostat circuit (stat ON). Bridge out R and G, and check if the fan operates. Check for 24 Volts on the gas valve Orange and Blue terminals. Check the TEK 321 PCB 2 Amp fuse. Check if the Heater is currently in an overheat temperature, or Flame roll out condition, indicated by the TEK 321 PCB LED OH/F, OH/S or ROLL. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 39

40 Abnormal Operating Conditions (cont. Delayed Ignition and Poor Ignition Delayed Ignition This condition is usually the result of one or more of the main burners: Not igniting. Not igniting properly i.e. flame lifting OFF burner and then relighting again. Check list for Delayed Ignition: Check if the burners are dirty and require cleaning (See section below) Check for blockage in the main injectors. Check for blockage to zip injector and zip tube burner. Check if the burner alignment is correct, (burners / zip burner / pilot). Check the pilot flame has the correct formation and adjustment. Check the incoming gas pressure is correct. Check each burner is not faulty, damaged or distorted. Check there is no blockage in burner (foreign matter). Check the burner compartment is not subject to excessive draught i.e. front cover not on Buffalo. Check if the heat exchanger is split or has sooted. Check the flue is not down draughting. Check that the burner injectors are the correct size. Check that the combustion ventilation is adequate. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 40

41 Abnormal Operating Conditions (cont. Delayed Ignition and Poor Ignition Poor Ignition The most common reason for poor ignition is dirt, dust or fluff accumulating in the burner or the burner venturi. Each burner draws air in through the venturi, and mixes it with the injected gas, for proper combustion. As it draws air in, some of the dust or fluff present in the air starts to deposit on the venturi. If the dust build up accumulates to a point that it affects the air/gas mixture flow into the burner, then poor combustion and poor ignition will occur. To remedy: perform routine service maintenance to burners. Remove burners and wash with water, flushing out dirt and fluff from venturi and port holes. Important When replacing the burners, care must be taken to align the burners vertically within each heat exchanger clam or damage to the heat exchanger will result. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 41

42 Abnormal Operating Conditions (cont. Flame Roll Out The unit is fitted with a sensor rod just above the burner compartment, to detect if flame is present outside of the heat exchanger chamber/s. This condition may be due to: A balanced flue being unbalanced or obstructed affecting the burners combustion. An obstruction in the burner venturi causing burn back. A sooted or damaged heat exchanger chamber. Air disturbance from around the heat exchanger panel interfering with the burners operation. Note: An obstruction to the burners and subsequent sooting, may result through lack of service maintenance. Unbalanced or down draughting from the flue terminal could result from: Not having the front cover on the unit. An obstruction too close to flue terminal. A faulty flue installation. Inadequate combustion ventilation. Incorrect return air installation. The TEK 321 PCB will recognise the circuit (resistance) from the sensor rod through the flame to the burner (ground), therefore flame contact is required for the sensor to operate. When the flame from the burner makes contact with the flame roll out sensor, the TEK 321 PCB immediately turns off the gas valve (burners) for a 10 second period, then powers the gas valve, so that the burners light again. The fan will start at the normal timed interval from the first gas valve operation. When the burners resume operation, if no further roll out is detected then a normal heating cycle will be reinstated. The ROLL LED will be illuminated ONLY during the 10 second shut down period. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 42

43 Abnormal Operating Conditions (cont. Flame Roll Out If a subsequent flame roll out occurs within 60 seconds of the first roll out, then the TEK 321 PCB will go in to a Roll Out - Lockout condition. The Heater will lockout from any further heating operation. This condition is indicated by the ROLL LED flashing continuously, and will require the power supply to the unit to be turned OFF to reset. The fan will operate as for a normal heating cycle, i.e. when the gas valve is energised the fan starts 45 second later, when the gas valve is de-energisedthefan stops 75 second later. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 43

44 Abnormal Operating Conditions Over Temperature Conditions The heater has two over temperature switches to sense if over heating occurs: 1. Located in the supply air discharge and is activated at 90oC. 2. Located in the main fan compartment is activated at 90oC. (not on Upflows). Units manufactured prior to 1/12/98 used a 570C. switch mounted on a bracket, positioned above the fan motor. If either or both over temperature switches open circuit, indicating over temperature conditions within the Timed Safe Guard Period, then the following will occur during the over temperature condition: The power supply to the gas valve will be terminated. The fan will operate immediately, if not already operating. The LED OH/F (Over Heat / Main Fan), or OH/S (Over Heat Supply Air), or both will be illuminated. If an overheat condition occurs after the 12 minute Timed Safe Guard Period, then the Electronic Controller will regard the condition as being caused by abnormal high external ambient temperatures, and will ignore the condition. If over temperature occurs during a normal heating cycle (i.e. STAT ON), then the gas valve closes, the fan continues to clear the over temperature condition, then the unit will resume re-ignition to the gas valve and burners. If the thermostat turns OFF, whilst the unit is in an over temperature condition during a normal heating cycle, then the fan will have a normal time OFF period of 75 seconds. During an over temperature condition, the OH/F and or OH/S LED will be illuminated. If an over temperature condition is detected within the Timed Safe Guard Period, with the thermostat turned OFF, and the unit not in operation, then: The fan will start. The LED for the appropriate over temperature switch will light and stay lit, until the fan cools the over temperature condition. The LED will flash (indicating cooling down recovery status) while the fan continues a 60 second fan off cycle. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 44

45 Abnormal Operating Conditions (cont. Over Temperature conditions (cont. Following an over temperature condition with the thermostat turned OFF, if a subsequent over temperature condition with the thermostat OFF is detected within the Time Safe Guard Period, then: The fan will start immediately. The LED for the appropriate over temperature switch will be lit until the fan cools and clears the condition. The LED will flash while the fan continues a 60 second fan OFF cycle. The TEK 321 PCB will go into an Over Heat Lockout mode. The power to the TEK 321 requires a reset to restore the unit to normal operation. If an over temperature condition occurs while the unit is in an over heat lockout mode, then the fan will be brought on for the duration of the over temperature condition, followed by a 60 second fan off cycle period. Refer to check list on following page. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 45

46 Abnormal Operating Conditions (cont. If Over Temperature Switch Open Circuit - (As indicated by over temperature LED) Check the air temperature rise at the outlet does not exceed 47oC. Above ambient. Check that the supply air outlet temperature does not exceed 93oC. Check if enough duct outlets are open on the system (Minimum 3 outlets for 52 MJ, 5 outlets for 85 MJ and 8 outlets for 120 MJ). Checks that all register transition/s (boots) disc/s have been properly balanced. Check the Over Temperature loom plug is correctly inserted into the TEK 321 PCB terminals. Check if a filter is fitted at the return air grille, if so, is it clean and is it the correct size? (Refer installation instructions). Check the gas pressure does not exceed maximum hourly input for the unit. Check the fan speed is set to correspond to gas input. Check the fan motor and impellor are rotating in the correct direction. Check for any obstruction in the fan blades, housing, or in the heating cabinet. Check the fan motor temperature is not excessively hot, and has tripped the over temperature switch located on the fan (OH/F), i.e. worn motor bearings. Check that the ductwork has not been damaged, crushed, and has been sized correctly. Check that the pilot flame is not excessive, causing heat to vent up through the fan housing, and trip the over temperature switch i.e. due to incorrect injector or over pressured incoming gas supply. Service Manual - Heater - Electronic (TEK 300) Series - No.2 Issue 6 Printed 2/13/ :51:58 AM 46