Brivis Service Manual

Transcription

1 Brivis Service Manual EMS (2) Energy M anagem ent Syst em Servicing shall be carried out only by A uthorised Personnel. T his Service Manual must N O T be left with the O wner. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 1

2 Contents BULLETINS & SERVICING INSTRUCTIONS: EMS (2) Ignition Failure - EPRL Lockout TECHNICAL INFORMATION: Buffalo 85 EMS - Technical Data Sheet Buffalo 120 EMS - Technical Data Sheet Wombat 92 EMS - Technical Data Sheet Wombat 120 EMS - Technical Data Sheet Upflow 92 EMS - Technical Data Sheet Upflow 120 EMS - Technical Data Sheet Downflow 92 EMS - Technical Data Sheet Motor Wiring Diagram - 61S Motor Wiring Diagram - 61S Motor / Plug Wiring Diagram TEK Relay HSP Wiring Diagram Transformer Assembly Wiring Gas Valve - VR8601P Adjusting the Gas Pressure INTRODUCTION: Brivis Energy Management System (EMS) TEK 331 Control Board COMMISSIONING THE HEATER: Instructions to Adjust the Fan Speeds Setting the Fan Motor Minimum Voltage Outlet Chart HEATER OPERATION: Normal Heating Cycle Timed Safe Guard Period Cooling Cycle Pilot Ignition Failure Gas Supply Interruption Power Supply Interruption ELECTRONIC CONTROL (TEK 331) FUNCTION SUMMARY: DIAGNOSTIC LED IDENTIFICATION: ABNORMAL OPERATING CONDITIONS: If the Heater has NO Functions Test Procedure for Pilot Not Lighting Test Procedure for HSI Electrode Glows, But Pilot Flame Will Not Light If Pilot Flame Lights But Lock Out Occurs After 60 Seconds If Pilot Lights & Confirms Flame But the Main Burners Will Not Light If Both Pilot Lights & Main Burners Light but Turn OFF Again HSP Wiring Diagram Overtemperture Condition Over Temperature Switch Open Circuit Check List Flame Rollout Flame Rollout Check List Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 2

3 Contents (cont) Test Procedure for EMS Operation Delayed Ignition and Poor Ignition Fan Not Operating If Fan is Continually Running Abnormal Operation Due to 2 Amp Fuse Blown (open circuit) DISMANTLING PROCEDURE: TEK 331 Electronic Controller Burners / Manifold and Gas Valve Main Fan Heat Exchanger EMS2 Conversion (From HSP to Spark Ignition Full Instructions)..51 Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 3

4 Bulletins & Servicing Instructions EMS (2) Ignition Failure - EPRL Lockout No DESCRIPTION MODELS AFFECTED PART No REQUIRED 1 Ignition EMS (2) LPG 15283,14663,12921 Failure - EPRL Lockout EMS 2 Natural Gas 13388,14663,12921 Background: Early model EMS (2) version heaters are prone to an intermittent EPRL lockout condition, which may develop with the age of the unit. Action: All Service Technicians are required to carry out the following procedures when servicing EMS (2) models: 1.1 Natural Gas & LPG A Relay Adaptor 331 Assy (P/No 14663) and TEK331 Electronic Control (with a 47 Ohm resistor) (P/No 12921) must be fitted. The Chromatherm thermostat pins and contacts must be scratched and cleaned to remove tarnish resulting from operation without a relay adaptor. This may also result in intermittent NO-GO operation. Important It is essential ALL the terminal block screws are tightened onto the relay adaptor pins before reconnecting the wires into the relay adaptor terminals. 1.2 Pilot Bracket Natural Gas: Bracket is to be straight and BBF18 INJECTOR (P/No 13388) fitted. LPG: Pilot bracket is to be bent, as per drawing below, and pilot injector BBF10 INJECTOR (P/No 15283) fitted. See diagram on next page. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 4

5 Bulletins & Servicing Instructions LP Gas (propane) pilots only 10 FOR LPG ONLY (NATURAL GAS REMAINS UNBENT) Relay Adaptor Diagram P1 P2 P3 P4 P5 P6 a D1 RL1 R1 Loop T G EC W R 24V COOL ECON THST GND Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 5

6 Technical Information Buffalo 85 EMS AGA Approval No.: Energy Label Star Rating: 3.1 Stars Cabinet Width Height Depth Weight 395 mm 1120 mm 1090 mm 74.0 kg Gas Type N.G. L.P.G. 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 R.P.M Fan Wheel 240mm X 180mm Capacitor 4 uf 15 uf (9" x 7") Gas Valves:Honeywell VR8601P with operator HI/LO V8336A. Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24V, 1.75 Amp 50HZ. Overtemperature Switches: Fan Compartment: Texas Inst. Klixon Oil 1727 L57 (opens at 57C). Supply Air Compartment: Texas Inst Klixon Oil 1747 L90 (opens at 93C). Flame Roll-Out Sensor (AFRO): Cableco Sensor 340 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 6

7 Technical Information Buffalo 120 EMS AGA Approval No.: Energy Label Star Rating: 2.4 Stars Cabinet Width Height Depth Weight 565 mm 1160 mm 1320 mm 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 890 L/s XA 61S pa Ext. Stat. Pres. Watt Amps Fan Wheel 270mm X 270mm R.P.M (10" X 10") Capacitor 15 uf 15 uf Gas Valves: Honeywell VR8601P with operator HI/LO V8336A Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50HZ. Overtemperature Switches: Fan Compartment: Texas Inst. Klixon oil 1727 L57 (Opens at 57C). Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93C). Flame Roll-Out Sensor (AFRO): Cable Sensor 470 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 7

8 Technical Information Wombat 92 EMS AGA Approval No.: Energy Label Star Rating: 2.5 Stars Cabinet Width Height Depth Weight 400 mm 720 mm 1010 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 (9" X 7") Capacitor 4 uf 15 uf Gas Valves: Honeywell VR88601P with operator HI/LO V8336A. Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50 HZ. Overtemperature Switches: Fan Compartment: Texas Inst. Klixon oil 1727 L57 (Opens at 57C). Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93C). Flame Roll-Out Sensor (AFRO): Cableco sensor 340 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 8

9 Technical Information Wombat 120 EMS AGA Approval No.: 2593 Energy Label Star Rating: 2.1 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 (10" X 10") Capacitor 15 uf 15 uf Gas Valves: Honeywell VR8601P with operator HI/LO V8336A Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50HZ. Overtemperature Switches: Fan Compartment: Texas Inst. Klixon oil 1727 L57 (Opens at 57 o C). Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93 o C). Flame Roll-Out Sensor (AFRO): Cable Sensor 420 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 9

10 Technical Information Upflow 92 EMS AGA Approval No.: Energy Label Star Rating: 2.5 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 16.7 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 S Watt Amps Fan Wheel 240mm X 180mm R.P.M (9" X 7") Capacitor 4 uf 15 uf Gas Valves: Honeywell VR8601P with operator HI/LO V8336A. Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50 HZ. Overtemperature Switches: Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93C). Flame Roll-Out Sensor (AFRO): Cableco sensor 340 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 10

11 Technical Information Upflow 120 EMS AGA Approval No.: Energy Label Star Rating: 2.1 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) 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 0.50 mm Motor std X.A Air Quantity 825 L/s std Model Betts 125 pa Ext. Stat. Pres. 61S S Watt Amps Fan Wheel 270mm X 270mm R.P.M (10" X 10") Capacitor 15 uf 15 uf Gas Valves: Honeywell VR8601P with operator HI/LO V8336A Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50HZ. Overtemperature Switches: Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93C). Flame Roll-Out Sensor (AFRO): Cable Sensor 470 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 11

12 Technical Information Downflow 92 EMS AGA Approval No.: Energy Label Star Rating: 2.5 Stars Cabinet Width Height Depth Weight 395 mm 1122 mm 457 mm 53.0 kg Gas Type N.G. L.P.G. Input (max) 92.0 MJ 25.5 kw 84.0 MJ 23.3 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 400 L/s std Model Betts 50 pa Ext. Stat. Pres. 61S S Watt Amps Fan Wheel 240mm X 180mm R.P.M (9" X 7") Capacitor 4 uf 15 uf Gas Valves: Honeywell VR8601P with operator HI/LO V8336A. Pilot Burner: Honeywell Q3450 Hot Surface Pilot. Zip Tube Burner: For cross ignition of Burners. Pilot Injector: Honeywell, N/Gas - BCR18 or BCR16, LPG - BBR10. Heat Exchanger: Aluminised Steel. Control Fuse: 2 Amp type 3AG. Transformer: Multicontact 24 V, 1.75 Amp, 50 HZ. Overtemperature Switches: Supply Air Compartment: Texas Inst. Klixon oil 1747 L90 (Opens at 93C). Flame Roll-Out Sensor (AFRO): Cableco sensor 340 mm. Electronic Heater Controller: FEATURES: Tekelek Electronic TEK 331 with LED diagnostic display, Hot surface pilot, flame roll-out sense 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 12

13 Technical Information Motor Wiring Diagrams ORANGE ORANGE Motor No. 61S Amps CAPACITOR: 15uF CAPACITOR 15uF ORANGE WHITE BLUE/WHITE START 11.8 ORANGE BROWN BLUE RED BROWN BLUE MAIN 8.5 GREEN /YELLOW EARTH Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 13

14 Technical Information Motor Wiring Diagrams (cont) Part No. 411 MOTOR 750W 61S Amps CAPACITOR: 15 uf ORANGE WHITE START 15.5 BLUE/WHITE RED BROWN MAIN 3.6 BLUE GREEN / YELLOW EARTH NOTE: TO REVERSE ROTATION REVERSE PINS WHITE / BLUE AND WHITE Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 14

15 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 15

16 Technical Information TEK 331 Relay TEK T G EC W R Loop V COOL ECON THST GND AOG STAT FAN ECON EPRL ROLL O/HS O/HF EMS Switch Thermostat Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 16

17 a Technical Information HSP Wiring Diagram HSI 5.4 Ohms Max 10 Ohms White Terminals 1 - Earth No Flame= O V Flame confirmed = V TEK 331 Clear/Copper 1 Blue Blue HSP PCB O/HS O/HF ROLL EPRL 8 ECON 10 FAN STAT AOG D1 R1 Loop P6 P1 P2 RL1 P3 P4 P5 T G EC W R 24V COOL ECON THST GND Relay Where Fitted Orange Blue Brown Brown Red Red Gas Valve Fan Switch Pilot Valve 7.1 Ohms Economy Valve 55.2 Ohms Main Valve 59.4 Ohms EMS Switch Thermostat Orange Purple Terminals 4-5 = 15 Volt Ohm Terminals 6-7 = V (Pre Flame Confirmation) = V (Flame Confirmed) = 7.1 Ohm (Min 8 Volt) EMS low = 0 Volts Terminals 8-10 = EMS high = 24 Volts Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 17

18 Technical Information Transformer Assembly Wiring RED RED BLACK BROWN BLUE ELECTRICAL SPECIFICATION Primary Winding Voltage Exciting Current Secondary Winding Red to Red Open Volt 1.75A Red (either) to Black Open Volt 1.75A 240 VAC 40 ma max VAC 24 VAC ± 24 VAC % 13.6 VAC 12 VAC ± 12 VAC % Winding Resistance Blue to Brown Red to Red Red to Black 70 to 75 Ohms 1.4 to 1.9 Ohms 0.6 to 1.2 Ohms Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 18

19 Technical Information Gas Valve VR8601P H 7.1 V8336A V - 50Hz mbar EMS Hi /Lo Solenoid Pilot Solenoid Main Operator Solenoid 1 V804A V 50HZ. 0.2A Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 19

20 Technical Information Adjusting The Gas Pressure Step 1. Connect the Manometer to the pressure test point on the manifold. Step 2. For normal heating, set the outer sleeve of the regulator. Refer data plate for correct pressure for model and gas type. Step 3. For "Low" EMS, set the inner screw of the regulator. Refer data plate for correct pressure for model and gas type. NOTE: Adjusting the outer sleeve can affect the setting of the inner screw, so always check both in the above sequence. H Outer Sleeve Insulated Violet Inner Screw V8336A V - 50Hz mbar Insulated Orange REGULATOR 7 8 Green/Yellow Single Wire Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 20

21 Introduction Brivis Energy Management System (EMS) Energy Management System (EMS) units come standard with "Hot Surface Ignition Pilot" (intermittent pilot burner), and speed controllers with full fan speed variation in Normal heating, EMS low heating and Cooling fan operations. EMS allows the owner to switch the heaters capacity to a lower output. Using the thermostat's EMS switch, the heaters Electronic controller will automatically switch the gas valve and fan operation to a lower setting. i.e.- suitable for smaller heated area. The heater's pilot has a ceramic probe hot surface igniter that is heated to a temperature that will ignite the gas at the pilot burner. The pilot burner also has a flame confirmation device, to shut down the gas supply, if the pilot flame is not established or has been extinguished. Gas valve operation provides the initial gas flow to the pilot burner, and once the pilot has been confirmed, the gas valve opens the gas flow to the main burners. Most EMS models required 1mm2 cabling to the thermostat. The maximum current draw on the thermostat circuit is 1.5 Amp 24 Volt and therefore manual and/or thermostats with heat anticipators rated less the 1.5 Amp cannot be used. Later models were fitted with a relay board that did not require special wiring. The heaters electronic control module, the TEK 331, incorporates a 24 Volt transformer, and the Hot Surface Pilot ignition circuit board (Honeywell sv9500). The electronic controller also has a 8 LED light display to show the current status of operation and assist service diagnostics. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 21

22 Introduction (cont) The electronic controller has four fan speed potentiometers that are identified as follows. FAN SPEED - fan speed adjustment for normal heating mode. COOL - fan speed adjustment for fan recirculation or add on cooling. ECON - fan speed adjustment for EMS mode low. MIN - minimum Voltage speed adjustment for fan motor (factory set) Refer to the following instructions for the correct adjustment. TEK 331 PCB COOL Speed MIN Speed HSP PCB Electronic Heater Controller A N E COOL ECON MIN Transformer Connections ECON Speed a D1 R1 P6 P5 P4 P3 RL1 P2 P1 O/HS O/HF ROLL EPRL ECON FAN STAT AOG Loop T G EC W R 24V COOL ECON THST GND Diagnostic LED's Fan Speed Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 22

23 Commissioning the Heater Instructions to Adjust the Fan Speeds (if Required) 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. ECON (EMS Economy - Low) This speed adjustment potentiometer will operate in the low heat mode, and should be adjusted to achieve the same temperature rise as described above for normal heat mode operation. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 23

24 Commissioning the Heater (cont) Instructions to Adjust the Fan Speeds (if Required) (cont) 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. As mentioned above. Re - adjust 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 2 AMP FUSE MIN ECON COOL A N 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 24

25 Commissioning the Heater (cont) 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 EMS B 85 EMS Std / XA Std / XA [a] Minimum 8 / 8 5 / 5 [b] Ceiling 11 / 13 8 / 10 [c] Floor 16 / / 12 Classic - Internal Heaters Airflow (L/s) - Horizontal W 120 EMS W 92 EMS Std / XA Std / XA [a] Min 8 / 8 6 / 6 [b] Ceiling 11 / 13 8 / 10 [c] Floor 16 / / 13 Classic - Internal Heaters Airflow (L/s) - Vertical U 120 EMS U 92 EMS D 92 EMS [a] Min [b] Ceiling [c] Floor Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 25

26 Heater Operation When power is first applied to the unit, or the test reset button is pressed, the unit will go through a light sequence display, followed by a 5 second power up stabilisation time. Then the unit will be ready to operate from the thermostat. If EMS "low" has been selected then the ECON LED light will be displayed on the electronic control. Normal Heating Cycle When the thermostat is turned ON, the "STAT" LED illuminates, and the H.S.P ignition module goes to a 2 second self check operation. If the HSP Pilot Flame Sensor detects that flame is already present at the pilot, then the gas supply will be prevented from operating, and the no power will be supplied to the HSI electrode. After this self check operation, the gas supply to the pilot burner and the power to the ignition probe will commence. When the pilot flame is established and confirmed, the closed circuit through the flame to the sensing rod, signals to the controller to open the gas supply to the main burners, and the ignition process is completed. From the time the main gas valve was energised, the main fan is timed to commence operating 45 seconds later (60 seconds on EMS), and the "FAN" LED illuminates to show it is turned ON. When the thermostat turns OFF, the gas valve closes, and the gas to both the main burners and the pilot burner ceases. The main fan continues to operate to dissipate the residual heat from the heat exchanger for: 75 seconds for normal heating operation. 90 seconds for EMS heating operation. During this period of cooling down the "STAT" LED will be in a "flashing" status. If the thermostat turns OFF after 4 seconds of the gas valve opening and the main burners lighting, then the electronic control box will start the fan immediately, if the fan wasn't already operating, and run for the normal fan off cycle time. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 26

27 Heater Operation (cont) 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. Pilot ignition failure The TEK 331 PCB monitors the ignition operation and will LOCK OUT the ignition process, should the TEK 331 PCB detect the HSP ignition module has not powered the pilot electrode within 60 seconds of the thermostat calling for heat, or if the pilot flame is not established within 60 seconds of the electrode being energised. Ignition Lock Out will prevent any further operation of the unit, until the condition has been reset, and this condition is identified by the EPRL LED flashing on the TEK 331 PCB. Resetting a Ignition Lock Out is achieved by pressing the PCB reset button, or power up to the unit. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 27

28 Heater Operation (cont) Gas supply interruption If the gas supply is interrupted while the thermostat is turned OFF, then the units operation is not affected. If the thermostat is turned ON whilst the gas is interrupted, the unit will attempt a normal ignition, but, because the pilot will not be able to light due to lack of gas, the unit will go to a Lock Out as described previously and illuminate the EPRL LED. NOTE: The fan will be timed to commence operation at the normal time after the main gas valve is turned ON, but will be timed to turn OFF, at the normal interval (75 or 90 seconds), if the EPRL Lock Out is activated. If the gas supply is interrupted during the heaters operation, then the pilot flame will be extinguished and the unit will attempt re-ignition. Should the pilot not be reinstated within 60 seconds, the EPRL Lock Out is activated. If five (5) attempts for re-ignition are required within a 2 minutes period of a normal heating cycle with the thermostat is turned ON, then the TEK 331 controller will force a EPRL Lock Out on the sixth ignition attempt. Early model controls allow only 3 attempts in 1 minute. Power supply interruption If the power interruption occurs and is restored whilst the thermostat is turned OFF, then the unit will resume a normal power up. If a power interruption occurs when the thermostat is turned ON, and the unit is operating, the gas valve will close immediately. When the power supply is restored to the unit: If any excessive temperature has activated an over temperature switch, then the fan will be force to start immediately to clear the over temperature, and the ignition and gas valve operation will be prevented until the over temperature condition has been cleared. If the thermostat is still turned ON, the fan will start immediately and normal ignition will commence. If the thermostat is turned OFF, or is not calling for heat, then the unit will reset for the next normal heating cycle. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 28

29 Electronic Control (TEK 331) FUNCTION SUMMARY FAN ON delay time 50 seconds Normal heating 60 seconds EMS heating FAN OFF delay time 75 seconds Normal heating 90 seconds EMS heating Pre HSP ignition Time out 60 seconds Post HSP ignition Time out 60 seconds Timed Safe Guard Period 12 minutes Flame Roll Out Timer 10 seconds Roll Out Lock Out Timer 50 seconds Over Temperature FAN OFF delay time 60 seconds Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 29

30 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 repowered. 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 - Indicates the EMS low mode is turned ON. 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 30

31 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, 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 MIN Volts 250 WATT Volts 600 / 750 WATTS Volts CAPACITOR MAIN FAN A N E A N E Y T G EC W R MAINS IN 3 PIN PLUG TO A 240 Volt 10 Amp POWER OUTLET. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 31

32 Abnormal Operating Conditions (cont) If the Heater has No Functions Test procedure for the TEK 331 Controller Check the TEK 331 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 331 PCB. Check all terminal connections to the relay adaptor board (where fitted). Bridge the terminals R and W, and check that the STAT LED illuminates, and the ignition sequence commences. Check the contact pins on the Electronic thermostat are not tarnished preventing a closed circuit. Bridge terminals R and G, and check if the main fan operates. Check for 24 Volt at terminals R and T. Check the transformer for damaged windings or wire connections. If TEK 331 PCB will not operate, replace TEK 331. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 32

33 Abnormal Operating Conditions (cont) Test Procedure for Pilot Not Lighting Refer to Wiring Circuit Diagram for Terminal # references (See diagram Page 36) Check if the HSP electrode glows when the thermostat is turned ON, and the ignition sequence commences (60 seconds). If the electrode does not glow check the following: Check for 240 Volt power supply to the electronic controller. (see test procedure for TEK 331 PCB) Check the STAT LED is lit confirming thermostat circuit closed (stat ON). Check the EPRL LED is not flashing indicating an ignition lock out - reset the TEK 331 and retest. Check the unit has been upgraded as per Service Bulletin (page 4). Check the OH/S, OH/F or ROLL LED's are not flashing indicating a Lock Out condition. Check the 2 Amp fuse on the TEK 331 electronic controller. Check for 24 Volt output to the HSP - PCB at terminals 8 & 9. Check for Volt output to the HSP lead at terminals 2 & 3 on the HSP - PCB. If no power at terminals 2 & 3 replace faulty HSP - PCB. If power is present recheck or replace pilot electrode and lead. Disconnect the HSP lead from the electronic control box, and check for 5.4 Ohm resistance, on the 2 blue lead plug terminals. If the resistance is incorrect, check for damage to the electrode and or plug and leads. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 33

34 Abnormal Operating Conditions (cont) Test Procedure for HSI Electrode Glows, but Pilot Flame will Not Light Refer to Wiring Circuit Diagram for Terminal # references (See diagram Page 36) Check gas supply to unit. Check gas supply through gas valve to the pilot burner. Check the pilot injector is not blocked or damaged. Check the unit has been upgraded as per Service Bulletin (page 4). Check the pilot bracket is straight for Natural Gas or bent for LPG. Check for Volt power output at terminals 6 & 7 on the HSP - PCB If no power present replace HSP PCB. Note: When the pilot light is detected the power on terminals 6 & 7 is switched to a holding Voltage Volts (must be more than 8 Volt). Check the gas valve pilot solenoid (7.1 Ohm - see diagram) If Pilot Flame Lights but Lock Out Occurs After 60 Seconds Refer to Wiring Circuit Diagram for Terminal # references Check the pilot flame sensing rod is not coated or damaged. Check the pilot flame sensing rod wire lead and plug connection are good. Check the pilot burner has a good Earth connection to the cabinet (pilot tube to burner bracket). Check for power output at terminals 1 & Earth on the HSP. 0 Volts - without flame Volt - with pilot flame lit and confirmed. Check the 240 Volt mains power supply and polarity. Check the white wire and connection onto the HSP - PCB and the TEK 331 PCB. Replace HSP - PCB and retest. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 34

35 Abnormal Operating Conditions (cont) If Pilot Lights and Confirms Flame but the Main Burners Will Not Light Refer to Wiring Circuit Diagram for Terminal # references (See diagram Page 36) Check for 15 Volt power output at terminals 4 & 5 on the HSP - PCB. If no power present then replace HSP - PCB. Check for 15 Volt power on the main valve solenoid terminals Check gas valve main operator solenoid (59.4 Ohm - see diagram) If gas valve resistance incorrect or the valve will not function - replace gas valve. If Both Pilot and Main Burners Light but turn OFF Again Check for poor gas supply pressure. Check the pilot flame for stability and formation. Check the installation provides the required ventilation Check the unit s flue is functioning correctly. Check for delayed ignition interference to the pilot on start up. Check for air interference on the pilot flame after the main fan has started. Check the Voltage to the gas valve pilot solenoid does not drop below 8 Volt. Check all looms and plug connections. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 35

36 a Abnormal Operating Conditions (cont) HSP Wiring Diagram Pilot Malfunction Wiring Circuit Diagram HSI 5.4 Ohms Max 10 Ohms White Terminals 1 - Earth No Flame= O V Flame confirmed = V TEK 331 Clear/Copper 1 Blue Blue HSP PCB O/HS O/HF ROLL EPRL 8 ECON 10 FAN STAT AOG D1 R1 Loop P6 P1 P2 RL1 P3 P4 P5 T G EC W R 24V COOL ECON THST GND Relay Where Fitted Orange Blue Brown Brown Red Red Gas Valve Fan Switch Pilot Valve 7.1 Ohms Economy Valve 55.2 Ohms Main Valve 59.4 Ohms EMS Switch Thermostat Orange Purple Terminals 4-5 = 15 Volt Ohm Terminals 6-7 = V (Pre Flame Confirmation) = V (Flame Confirmed) = 7.1 Ohm (Min 8 Volt) EMS low = 0 Volts Terminals 8-10 = EMS high = 24 Volts Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 36

37 Abnormal Operating Conditions (cont) Over Temperature conditions The EMS unit has two over temperature switches to sense if over heating occurs: 1. Located in the supply air discharge and is activated at 93oC. 2. Located in the fan compartment and is activated at 57oC. 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. NOTE: If both over temperature switches open circuit then only the OH/F LED 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 (90 seconds for EMS Low). 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 37

38 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 331 PCB will go into an Over Heat Lockout mode. The power to the TEK 331 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 38

39 Abnormal Operating Conditions (cont) Over Temperature Switch Open Circuit Check List Check the air temperature rise at the outlet does not exceed 47oC. above ambient. Check that the supply air outlet temperature does not exceed 90oC. Check if enough duct outlets are open on the system (Minimum 6 outlets for 85 MJ and 8 outlets for 120 MJ). Check that all register transition/s (boots) disc/s has been properly balanced. Check the Over Temperature loom plug is correctly inserted into the TEK 331 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 39

40 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. The TEK 331 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 make contact to the flame roll out sensor the TEK 331 PCB immediately turns OFF the gas valve (burners) for a 10 second period, and then commences a re-ignition cycle to light the burners again. The fan will start immediately the flame roll out sensor detected flame. When the burners resume operation, if no further roll out is detected, then a normal heating cycle will be reinstated. During the 10 second shut down period the LED "ROLL" will be illuminated, then flash whilst the re-ignition period, until the gas valve has been energised again. If a subsequent " flame roll out " occurs within 60 seconds of the first roll out, the TEK 331 PCB will go to a Roll Out - Lock Out condition. The gas valve will permanently locked out ignoring any call for heating from the thermostat. This condition is indicated by the LED "ROLL" flashing continuously, and will remain until the power supply to the unit is turned off and reset. The fan OFF operation will operate as for a normal heating cycle, i.e. when the gas valve is de-energised the fan stops 75 second later (90 seconds for EMS). Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 40

41 Abnormal Operating Conditions (cont) Flame Roll Out Check List Check the external heaters balanced flue is not unbalanced, or obstructed, affecting the burners combustion. Check for an obstruction in the burner's venturi causing burn back. Check for a sooted or damaged heat exchanger chamber. Check for 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 or contaminated combustion ventilation. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 41

42 Abnormal Operating Conditions (cont) Test procedures for EMS operation Refer to Wiring Circuit Diagram for Terminal # references (See diagram Page 36) Gas will not vary from HI (normal) to LOW (EMS) Check for 24 Volt power output at terminals 8 & 10 on the TEK 331 PCB 0 Volts - gas valve in EMS - LOW mode. 24 Volt - gas valve in EMS - HI mode. If 24 Volt power is not present at terminals 8 & 10 on the PCB with the EMS switch in "Normal" heat position then check the following: Check the wiring to the thermostat is correct. Check the EMS switch circuit is closed i.e. bridge terminals R - EC. Check if the fan speed varies between FAN SPEED and ECON potentiometer settings. Check the potentiometers are set differently. Check wiring and terminal connections at the TEK 331 PCB and gas valve solenoid. Check the HI - LOW operator solenoid coil (55.2 Ohm - see diagram) Fan will not vary from HI (normal) to LOW (EMS) Check power output 24 Volt at terminals 8 & 10 (as above) Check EMS speed control setting: Set EMS (ECON) speed set to low and retest. Check MIN speed potentiometer is not set too high i.e. 140 Volt watt motor 120 Volt - 600/750 watt motor Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 42

43 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. 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 43

44 Abnormal Operating Conditions (cont) Delayed Ignition and Poor Ignition (cont) 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, and 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 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 44

45 Abnormal Operating Conditions (cont) Fan not operating Check that the Heaters Power Supply is plugged into the power point and 240 Volt power is turned ON. Check that 240 Volt power is present on the power supply / fan output loom plug at the TEK 331 PCB. Check that the FAN LED illuminates if terminals R and G are bridged, or the fan operation switch at the thermostat is turned ON. Check that all electrical connections are good and tight. Check that there is no obstruction to the fan motor or fan blades. Check that the fan motor has not overheated and its thermal overheat switch tripped. i.e. motor still hot. Check that the fan motor brackets are not broken and jamming fan blades. Check that the TEK 331 minimum Voltage potentiometer has been correctly set for the motor size. Check if the 240 Volt power is present at the motor's 9 pin plug Active (Brown) and the Common/Neutral (Blue) terminals. If there is no power at the motor's 9 pin plug Replace the TEK 331 Electronic Controller. If power is present at the motor's 9 pin plug Check the fan motor windings resistance (refer to motor diagrams pages 13 to 15). Replace the capacitor and retest. Replace the fan motor. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 45

46 Abnormal Operating Conditions (cont) If Fan is continually running Check if the gas valve is in the ON position, i.e. STAT LED illuminated Check that the thermostat is not in cooling mode and/or if the thermostat fan switch is ON. Check that an over temperature switch has not been tripped, and is open circuit i.e. OH/S or OH/F LED illuminated. Switch the 240 power supply to turn unit OFF for 10 seconds, and check again if the TEK 321 PCB has reset and resumed normal operation. Abnormal Operation Due to 2 Amp Fuse Blown (Open circuit) If the 2 Amp fuse is blown when the unit is not in operation, then the TEK 331 PCB will have no functions, and the diagnostic LED's will no light. If the 2 Amp fuse is blown during a heating operation then the following sequence will result: Immediately the OHF LED will be lit (solid) and the Fan will operate continuously with the FAN LED lit (solid) Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 46

47 Dismantling Procedures TEK 331 Electronic Controller Turn OFF the power supply and unplug the power supply lead. Remove the TEK 331 control cover plate screws and remove plate. Unplug the transformer wire loom from the TEK 331 PCB. Unplug the wiring looms from the over temperature switches, and flame roll out sensor, from the TEK 331 PCB. Unplug the power supply / fan output loom plug from the TEK 331 PCB, disconnect the Earth terminal, release the grommets, and remove the loom from the TEK 331 Controller. Unplug the gas valve wire loom from the TEK 331 PCB. Disconnect all wiring from the TEK 331 PCB terminal block i.e. thermostat. On later models, unscrew the relay board and remove from the terminal block. Remove the TEK 331 Control mounting screws (2) and retract the controller. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 47

48 Dismantling Procedures (cont) Burners / Manifold and Gas Valve Turn OFF the power and gas supply. Burners Remove the 3/16" brass nuts and washers (2) retaining the zip burner bracket and burner alignment bar. Push the zip burner forward into the burner chamber, to disengage the zip burners gas supply tube from it's injector, and the brackets from their retaining bolts. Remove the burner alignment bar. Lift the main burners up and release the burner retaining clip from the burner injectors, before withdrawing the burners from the heat exchanger. NOTE: It may be necessary on some models to, either, release a screw on one side of the burner manifold bracket for movement, or remove the burner compartment base tray, to release the centre burner. Manifold and Gas Valve Remove the burners as described above Disconnect the gas supply pipe from, either, the gas valve's feed pipe, or the gas valve. Unplug the gas valve wiring loom from the TEK 331 PCB. Remove the burner manifold bracket screws and retract the manifold assembly. Remove the gas valve from the burner manifold. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 48

49 Dismantling Procedures (cont) Main Fan Turn OFF the power supply. Buffalo models only, remove the weatherproof top panel, by removing the securing screws (4), then lift the top up and off. Downflow models only. Lift up and out the top front panel; remove the 2 screws in the opening of the draught diverter, then pull the bottom of the diverter out and down to remove. Upflow 92 model only, remove the bottom front panel. Upflow 120 and Wombat models, remove the fan compartment access panel. Unplug the fan supply lead. Remove the fan housing securing screws (where applicable), then remove the fan housing out of the cabinet. Remove the screws from the fan partition plate, and remove the plate. Remove the screws retaining the motor mounting plate (8) to the fan housing, and withdraw the fan assembly from the housing. Dismantle fan assembly if required as shown below. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 49

50 Dismantling Procedures (cont) Heat Exchanger Turn OFF the power supply and unplug the power supply lead. Remove the front panel. Disconnect the gas supply at gas valve's feed tube or the gas valve. External Models only Remove the weatherproof roof panel from the appliance, which is secured by hex-headed self tapping screws (4). Remove the self tapping screws from the flue terminal. Lift off the flue terminal. Internal Models only 120 MJ and Upflow 92 models Remove bolted sleeve securing break in flue. Remove the front top stay, then remove the self tapping screws (2) at the bottom of the draught diverter and pull it out. Wombat 92 MJ Remove bolted sleeve securing break in flue. Remove the self tapping screws (4) at the front of the draught diverter, then pull it straight out. Downflow 92 MJ Remove front top panel by first sliding it up, and then pull the bottom out and down to release. Remove the self tapping screws (2) securing the draught diverter, and then pull the bottom out and down to remove. Remove the self tapping screws (6) from around the perimeter of the heat exchanger. Unplug, and disconnect all wiring looms from the TEK 331 control. Remove the heat exchanger, complete with the burners, controls and electric's, by first lifting it up approximately 10 mm and pulling it forward and out. Note: When replacing the heat exchanger, it is necessary to seal around unit with fireproof (Stove) cement. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 50

51 EMS (2) Ignition Conversion, using the Honeywell S8605 Ignition Module. This conversion will require the removal of the TEK 331 Electronic Control HSP ignition PCB and wiring loom, and installing the Honeywell S8605 Ignition module (including the pilot burner igniter change over). First, isolate the power supply, and remove the TEK 331 Electronic control front cover. Remove the pilot burner igniter loom plug from the TEK 331 HSP circuit board. Remove the 2 screws retaining the HSP circuit board into the TEK 331, and then remove the circuit board complete with plastic mounting plate. Disconnect the 4 pin plug and loom from the HSP circuit board and cut the WHITE wire from the loom as close as possible to the plug. Strip back the insulation on the white wire in readiness to connect to the new wiring loom. Remove the wiring loom from the terminals on the gas valve and the TEK 331. Mount the Honeywell S8605 Ignition module and relay onto the heat exchanger front panel directly behind the gas valve as show in the diagram. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 51

52 On 92 MJ models it will be necessary to remove the 2 retaining screw on the TEK 331 Electronic control base and remove the control to provide access to fit the Honeywell S8605 behind the gas valve. On Buffalo 85 models, removing the gas valve head cap will provide access to fit the Honeywell S8605 behind the gas valve. Drill the heat exchanger panel and use the self tapping screws provided to secure the module ensuring the loom wires are within reach of the gas valve terminals. Fit the Honeywell S8605 Ignition module loom to the gas valve terminals and the TEK 331 as shown in diagram. Connect the loom white wire and joiner to the white wire on the TEK 331 Electronic control previously prepared. Refit the TEK 331 (if removed) and the TEK 331 control cover. Service Manual 19 Heater EMS (2) Series Aprroved Issue 1 Printed 13-Feb-14 11:53:52 AM 52