Vulcan Installation Manual

Installation Instru Instructio ctions ns

High Efficiency Gas Ducted Central Heating

HIGH EFFICIENCY DUCTED G AS HEATING

Introduction Introduction

PURCHASERS IMPORTANT NOTICE TO AGENTS, INSTALL ERS AND PURCHASERS

Climate Technologies manufactures appliances of World-Class standard. It’s important that you’re aware that problems can occur if these appliances are not properly installed. There are standards covering installation set down by the Australian Gas Association AS5601 (AG601). The guidelines for installation in this document are in accordance with those standards. If an appropriately qualified person is not used to install the equipment or if it’s not installed according to the guidelines, then Climate Technologies will not accept responsibility for any problems that occur as a result. ACCESSIBILITY ITY RESPONSIBILITY RESPONSIBILITY S AFETY & ACCESSIBIL

The manufacturer and its agents reserve the right to refuse service unless the safety and accessibility to the unit can be guaranteed. The cost of any extra equipment required to provide access to the unit for servicing is the responsibility of the owner.

WIRING - DEDICATED CIRCUIT It is Climate Technologies recommendation that all its Ducted Central Heaters are wired with a dedicated circuit from the distribution board with a separate suitable circuit breaker. It is the requirement of AS3000 (Wiring Rules) that if a ducted central heater is fitted with a Dual Cycle Refrigerative Air conditioner, the heater must be fitted with a dedicated circuit and circuit breaker.

INCORRECT COMMISSIONING If a Warranty Service Call is required because the system has been incorrectly installed or commissioned the cost of the service call will be charged to the dealer responsible for the installation. i nstallation.

Installation Instructions - 2006

Page 2


Introduction Introduction

PURCHASERS IMPORTANT NOTICE TO AGENTS, INSTALL ERS AND PURCHASERS

Climate Technologies manufactures appliances of World-Class standard. It’s important that you’re aware that problems can occur if these appliances are not properly installed. There are standards covering installation set down by the Australian Gas Association AS5601 (AG601). The guidelines for installation in this document are in accordance with those standards. If an appropriately qualified person is not used to install the equipment or if it’s not installed according to the guidelines, then Climate Technologies will not accept responsibility for any problems that occur as a result. ACCESSIBILITY ITY RESPONSIBILITY RESPONSIBILITY S AFETY & ACCESSIBIL

The manufacturer and its agents reserve the right to refuse service unless the safety and accessibility to the unit can be guaranteed. The cost of any extra equipment required to provide access to the unit for servicing is the responsibility of the owner.

WIRING - DEDICATED CIRCUIT It is Climate Technologies recommendation that all its Ducted Central Heaters are wired with a dedicated circuit from the distribution board with a separate suitable circuit breaker. It is the requirement of AS3000 (Wiring Rules) that if a ducted central heater is fitted with a Dual Cycle Refrigerative Air conditioner, the heater must be fitted with a dedicated circuit and circuit breaker.

INCORRECT COMMISSIONING If a Warranty Service Call is required because the system has been incorrectly installed or commissioned the cost of the service call will be charged to the dealer responsible for the installation. i nstallation.


Page 2

HIGH EFFICIENCY DUCTED G AS HEATERS

Quick Start QuickStart

Climate Technologies produces one of the world’s most advanced gas heating systems, incorporating the latest technology designed for complete comfort. It’s designed in Australia to suit Australian conditions. This document contains the installation and quick start operating instructions for both internal and external units using either LPG or NG. If all you need to do is use the heater then this page and ‘Safety Precautions’ on page 6 is probably all you need to read.

OPERATING THE DUCTED GAS CENTRAL HEATER To operate the heater the following steps must be followed: 1.

Check that there is gas gas supply supply to to the the unit. unit.

2. Check the the unit is plugged into into the power power point and is turned turned on to to the unit. unit. 3. If a radio frequency (RF) control is fitted, ensure it is in the OFF mode. 4. Wait for the thermostat to code itself to the control board. For RF systems, the thermostat thermostat will have to be manually manually coded. See the owner’s manual manual for details. 5. Turn the control ON and adjust the thermostat to a setting higher than the room temperature. 6.

The heater should fire up within 30 seconds.

7.

For programmable thermostats refer to the thermostat instructions instruction s included. If the Heater does not light, carry out steps 1 to 4 again.

NOTE: For products where a radio frequency (RF) control has been fitted, ensur ensur e the uni t cont rol s have been been coded. NOTE: Fault Fault Conditi on Lock Switching the controller OFF then ON again will reset the Heate Heaterr after a fault condi tion has caused caused it to go to lockout. or press th e RES RESET ET butt on(s) on the wall contr ol.


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Table Ta ble of Contents TableofContents

INTRODUCTION........................................................................................................................................2 QUICK START...........................................................................................................................................3 TAB LE OF CONTENTS ..................................................................................... ............................................................................................................................4 .......................................4 GENERAL INSTALL ATION ................................................................................................... ......................................................................................................................6 ...................6 ELECTRICAL CONNECTIONS ......................................................................................................................8 G AS CONNECTIONS ..................................................................................................................................9 COMBUSTION AIR REQUIREMENTS ..........................................................................................................10 EXHAUST FLUE LOCATION ......................................................................................................................12 POSITIONING THE FLUE TERMINAL ...........................................................................................................12 DUCTING ...............................................................................................................................................13 Return & Discharge Spigot Sizes .............................................................................................. ....................................................................................................13 ......13 General............................................................................................................................................13 Ducting & duct fittings................................................................................................... fittings......................................................................................................................14 ...................14 ROOM THERMOSTAT CONTROLS .............................................................................................................15 THE HEATER CONTROL MODULE ............................................................................................................16 HIGH EFFICIENCY EFFICIENCY HEATER HEATER – INDUCED DRAFT / INTERNAL INTERNAL / NATURAL NATURA L GAS .............................17 INSTALLATION REQUIREMENTS................................................................................................................18 UNIT DIMENSIONS ..................................................................................................................................19 UNIT INSTALLATION REQUIREMENTS .......................................................................................................20 In Roof Units .................................................................................... ....................................................................................................................................20 ................................................20 Under Floor Floor Units ............................................................................ ............................................................................................................................22 ................................................22 Exhaust flue piping requirements requirements ............................................................................................... ....................................................................................................24 .....24 Pipe Connection ............................................................................ ..............................................................................................................................25 ..................................................25 WIRING DIAGRAM ...................................................................................................................................26 UNIT COMMISSIONING ............................................................................................................................27 Commissioning Commissioning Procedure .................................................................................. ..............................................................................................................27 ............................27 Setting The Burner Pressures .............................................................................. .........................................................................................................28 ...........................28 Startup Sequence.......................................................... Sequence............................................................................................................................30 ..................................................................30 HIGH EFFICIENCY EFFICIENCY HEATER – INTERNAL / FORCED DRAFT LPG ONLY .......................................31 INSTALLATION REQUIREMENTS................................................................................................................32 UNIT DIMENSIONS ..................................................................................................................................33 UNIT LOCATION & INSTALLATION .............................................................................................................34 Under Floor Floor Units ............................................................................ ............................................................................................................................34 ................................................34 In Roof Units - LPG LPG ..................................................................................... .........................................................................................................................36 ....................................36 Exhaust flue piping requirements requirements ............................................................................................... ....................................................................................................39 .....39 WIRING DIAGRAM ...................................................................................................................................39 Installation Instructions - 2006

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Table Ta ble of Contents

COMMISSIONING ....................................................................................................................................39 HIGH EFFICIENCY EFFICIENCY HEATER – EXTERNAL / FORCED FORCED DRAFT NG & LPG .......................................40 UNIT DIMENSIONS ..................................................................................................................................41 UNIT LOCATION AND INSTALLATION .........................................................................................................42 Safety & accessibility responsibility.......................................................................................... responsibility.................................................................................................42 .......42 External Unit Location Location ............................................................................................. .....................................................................................................................42 ........................42 External Unit Installation.................................................. Installation..................................................................................................................43 ................................................................43 External base and wall preparation.................................................................................................44 Duct Connection to Heater .................................................................................... ..............................................................................................................45 ..........................45 Flue Terminal..................................................................................................... Terminal...................................................................................................................................45 ..............................45 WIRING DIAGRAM ...................................................................................................................................46 COMMISSIONING ....................................................................................................................................47 Commissioning Commissioning Procedure .................................................................................. ..............................................................................................................47 ............................47 Burner Pressure Setting................................................................................................... Setting ..................................................................................................................48 ...............48 Checking the System Performance.................................................................................................50 Performance.................................................................................................50 Startup Sequence.......................................................... Sequence............................................................................................................................51 ..................................................................51 TROUBLE-SHOOTING ............................................................................................. ...........................................................................................................................52 ..............................52 F AULT CODES ........................................................................................................................................53 COMMISSIONING CHECKLIST CHECKL IST ........................................................................................ .............................................................................................................54 .....................54 UNIT ......................................................................................................................................................54 DUCTWORK AND GENERAL ......................................................................................................................54 SITE ......................................................................................................................................................54 CUSTOMER HAND OVER ..........................................................................................................................54 SERVICE .................................................................................... .................................................................................................................................................55 .............................................................55


Page 5


General Installation GeneralInstalla tion

PLEASE READ THESE SAFETY PRECAUTIONS •

Do not connect the heating appliance to any power point that hasn’t been checked by a qualified electrician to ensure correct earthing and polarity. (This should be arranged by the installer.)

•

Do not use any type of gas other than that specified for the heating appliance. Each Gas Central Heater is factory set to operate on a particular type of gas.

•

Do not place any articles in front of or over the return air grille of the central heater.

•

Do not place any articles on or against the heating appliance.

•

Do not use or store flammable materials near the appliance.

•

Do not spray aerosols in the vicinity of the appliance while it is in operation.

INSTALLATION Requirements for installation under the floor or externally are quite different from those within a roof space. Please read the correct sections of this guide and make sure you understand them before commencing the installation.

CONDITIONS Installation of the Gas Central Heater must be carried out by an authorised person in accordance with: •

The manufacturer’s instruction.

•

Building regulations

•

Electrical supply authority regulations

•

Installation Code for Gas Burning Appliances and Equipment AS5601 (AG601).

CHOOSING THE HEATERS LOCATION Consider the following when choosing location for the heater: •

Access and clearances required for installation and service. Refer AS5601 (AG601), Sections 6A, 6B, 6C & 8 of this manual

•

Gas and electrical connections. Refer AS5601 (AG601) & AS3000

Noise

• •

A best practice guideline for heating and cooling systems is available from AIRAH

•

Base requirements

•

Ducting system layout


Page 6


General Installation •

Flue products

IMPORTANT 1. Do not install the heater in a location where combustible vapors from flammable or combustible liquids may be ignited. 2. Do not install the heater in any location where noise from its operation will disturb occupants or neighbors. Check local council regulations to ensure compliance. 3. Do not install the heater downstream of an evaporative air conditioner, air washer or refrigeration coil.


Page 7


Electri cal Connectio ns ElectricalConn ections

WIRING - IMPORTANT NOTE It is a Climate Technologies recommendation that all Gas Ducted Central Heaters are wired with a dedicated circuit from the distribution board with a separate circuit breaker. It is the requirement of AS3000 (Wiring Rules) that if a ducted central heater is fitted with a Dual Cycle Refrigerative Air conditioner, the heater must be fitted with a dedicated circuit and circuit breaker.

ELECTRICAL 1. Have a licensed Electrician install a 10 Amp 3 pin GPO (general-purpose outlet) within 600mm of the heater, electrical entry.

Note:

Ensure the polarity of the outlet is correct otherwise the flame can’t be sustained and the heater won’t operate.

2. Plug the pre-wired service lead into the GPO. Note:

Do not use an extension cord to reach the GPO. This is illegal and unsafe. An Electri cian must relocate the GPO

3. Follow the wiring diagram printed on the appliance to connect to thermostat cables to the control board. 4. The room air fan high speed is factory set to the maximum speed.


Page 8


Gas Connecti ons GasConnection s

G AS - IMPORTANT NOTE When connecting the gas supply inlet pipe to the gas valve, hold the connection nipple on the valve with a spanner while tightening the inlet pipe compression nut. This ensures the nipple is not over tightened. Cracked gas valves or regulator castings due to over tightening during installation or service are not th e manufacturer s r esponsibility. Gas Connections

1. A gas cock is not supplied. The installer must supply an AGA approved gas cock to suit the gas specified. Natural Gas: The connection on heater is a ¾” BSP compression fitting onto which the inlet pipe and ¾” gas cock is to be fitted. LP Gas: The connection on the heater is a ½” BSP compression fitting onto which the Inlet pipe and ½” gas cock is to be fitted.

A Liquefied Petroleum gas regulator, approved to AG205, must be fitted according to the installation code AS5601 (AG601) when using a LPG burning heater. It must be capable of providing the heater with 1.4 m 3/h minimum flow rate at 2.75kPa pressure with all other gas appliances operating at full demand. 2. The gas cock must be fitted outside the heater casing where it can be easily and quickly turned on or off. 3. Use gas copper pipe to AS 1432 Type B 4. Do not saddle gas pipe to heater. 5. Refer to the specification label on the appliance for burner pressure information.


Page 9


Combust ion Requirements CombustionAirRequirem ents

VENTILATION AIR INLETS Refer AS5601 (AG60I) Sec 5.4 and associated clauses

Locate the ventilation air inlet as far as possible from a swimming pool or swimming pool pump house. Chlorine fumes when burning in the heater will attack the heat exchanger. If the heater is installed in a ventilated enclosure (e.g. in the roof or under the floor) the space must meet the minimum volumes shown below. Model - m inimum enclosure (m3) Model

Minimum Enclosur e (m3)

15kW - 60MJ

20

21kW - 85MJ

30

30kW - 120MJ

40

35kW - 140MJ

50

If the volume is less than required then one of the following methods of ventilation must be used. Venti lation d irect fr om out side (A = 3 x MJ/hr) Two permanent ventilation openings must be provided directly to outside. The minimum free ventilation area ‘A’ required for each model is shown in the table below and is the sum of all holes, slots and other apertures. Model - free ventilatio n area (cm2) Model

Minimu m Venti lation Area (cm2)

15kW - 60MJ

180

21kW - 85MJ

270

30kW - 120MJ

360

35kW - 140MJ

450

Any holes, slots or other apertures in the ventilation openings must be 6mm or more. Dimension ‘a’ plus dimension ‘b’ must not be greater that 5% of the total height h of the enclosure (see diagram on opposite page).


Page 10


Combust ion Requirements Venti lation via an adjacent room (A = 6 x MJ/hr) Two permanent ventilation openings must be provided in the enclosure. The minimum free ventilation area ‘A’ required for each model shown in the table below Model

Minimu m Venti lation Area (cm2)

15kW - 60MJ

360

21kW - 85MJ

540

30kW - 120MJ

720

35kW - 140MJ

900

Any holes, slots or other apertures in the ventilation openings must be 6mm or more. Dimension ‘a’ plus dimension ‘b’ must not be greater that 5% of the total height ‘h’ of the enclosure (see diagram). These requirements must apply to all adjacent enclosures until an enclosure is ventilated outside or until the enclosure is larger than the minimum size required for the unit rating.

Ventilation air inlet requirements for units installed in spaces smaller than the rated minimum enclosure figure.


Page 11


Exhaust Flue Location ExhaustFlueLocatio n Positioningthefluetermin al

Refer AS5601 (AG60I) Section 5.13.6.5 Fig 5.3

The flue terminal must be positioned using the following guidelines.

IT IS IMPORTANT THAT FLUE GASSES DO NOT ENTER THE BUILDING OR PRESENT A THREAT TO LIFE. Installation Instructions - 2006

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Ducting Ducting

RETURN & DISCHARGE SPIGOT SIZES Model

Retur n & Discharge Duct Connectio n Spigot

15 kW – 60 MJ

12" (305mm)

21kW – 85MJ

12" (305mm)

21kW XA – 85MJ

14" (355mm)

30 kW – 120MJ

14" (355mm)

30kW XA – 120MJ

14" (355mm)

35kW – 140MJ

14" (355mm)

PLEASE NOTE: The spi got s izes provid ed above are unit co nnectio n details only. The duct sizes required for th e discharge and return air should be selected as per the product sizing guide recommendations to achieve best air flows.

GENERAL The heater will operate at its optimum with a correctly designed, efficient ducting system. Avoid over-sizing the heater. The best and most economical central heating is obtained by selecting the correct sized unit for the job. Over sizing can shorten the life of the heater, create stratification and increase noise levels and running costs. The following points all have some effect on the total system efficiency. •

Ensure that a door, movable partition, furniture, curtain or other items cannot block the return air grille.

•

The return air grille must be sized to accept the full air capacity of the system at low noise level. Refer to product sizing guide.

•

Do not place the return air grille in a location where the returning air is drawn over people.

•

Warm air flowing from the outlets in each room must be able to return freely back to the return air grille. This is achieved by cutting 25mm from the bottom of each door or by fitting door relief grilles.

•

Where possible, the return air grille should be installed close to floor level for best system performance.

•

If a filter is to be fitted in the return air duct, it should be easily accessible for cleaning.


Page 13


Ducting

DUCTING & DUCT FITTINGS •

Do not place an outlet register near the controller/thermostat as this can cause false readings

•

Do not place registers so that air is blown over people e.g. under tables, or a skirting register mounted horizontally under a sink or wash basin

•

To avoid exceeding maximum allowable air pressure drop in ducted system, do not use excessive lengths of duct. If a duct run exceeds 6 metres always install the next size larger ductwork. Note:

Duct register in small rooms with partially closed baffles to limit airflow mu st be consi dered as half a register.

•

Flexible ductwork must be run as straight as possible between the heater outlet and warm air outlets. Make sure there is at least 1500mm of straight ducting at the heater outlet.

•

The airflow through each outlet must be individually set to air balance the system.

•

The maximum discharge air temperature should not exceed 60-65C at 300mm from the unit discharge with the room at normal operating temperature.

•

Use a minimum of one outlet in every average sized room. A second outlet will be required for unusually large rooms or a bedroom with ensuite.

•

Refer to product sizing guide for the ductwork sizing guide.

•

All ductwork should be streamlined avoiding sharp angles that will reduce airflow.

•

Ensure all ductwork is taped airtight so that there is no leakage.

•

Balancing dampers maybe required to ensure even air distribution.

•

Always install damper blades in the branch take off fittings.

•

Ensure that the final ductwork bend to each ceiling register is a smooth radius so that the airflow is even from the register into the room. The minimum radius bend is 1.5 times the duct diameter.

•

Do not squash ductwork to fit through opening, as airflow will be restricted. Find a better location.

•

If more than 6m of flexible ductwork is required in one length, the next available size flexible duct must be used.


Page 14


Room Thermost at Contr ols RoomThermosta tControls

Refer to the Owner’s Manual supplied with the controls for operating, installation and commissioning instructions.


Page 15

HIGH EFFICIENCY

The Heater Control Module TheHeater ControlModule

Direct Spark Igni tio n (DSI) The design of the control module conforms to the Australia Gas Association AG206 and AG210 Standards and is classified as a Class 2Ca device. It receives instructions via a wired controller / thermostat or an optional radio frequency (RF) wireless thermostat.

High Efficiency (Tubular) Internal NG

High Efficiency Internal L PG External NG & LPG

Electric al rating 220-240V, 50/60 Hz, 10 VA input Electric al protection 1A fast or quick blow M205 type fuses.

The fuse is located on the electronic controller in the heater electric compartment Installation Instructions - 2006

Page 16

HE INTERNAL - NG (TUBULAR)

High HighEfficiencyHeater–InducedDraft/Internal/NaturalGas

HIGH EFFICIENCY Internal Tubular Natural Gas Induced Draft Combustion


Page 17


Installation Requirements InstallationRequ irements

WHAT YOU WILL NEED Items suppli ed with unit 1. Duct connectors (2).

2. Installation instructions. The installer will need to su pply 1. Suitable base material for heater (under floor or external units)

2. Platform / walkway for roof installations (heat resistant material not required) 3. Electric lighting above the central heater and switch to be placed next to the access opening (internal under-floor installations). 4. AGA approved gas cock (¾” for NG heaters and ½” for LPG gas heaters). 5. 65mm UPVC plastic flue pipe. For 35kW heaters where the flue length is greater than 5 metres, the flue size will have to increase to 100mm with a maximum of 2 x 90º bends 6. Plastic PVC vent cowl for tubular NG units. The vent cowl must not allow a 16mm diameter or larger object pass through it as per AS4556 standard, Clause 2.10.5 7. 20mm electrical conduit condensate drain on all external units and LPG Internal Units 8. 20mm PVC pressure pipe for NG tubular units


Page 18


Unit Dimensio ns UnitDimensions

(New Tubular)

MODEL

A

B

C

D

E

F

G

I

H

J

K

L

M

N

O

15kW

40

385

43

560

375

1430

710

734

159

891

314

217

286

300

300

21kW

40

385

43

560

375

1430

710

734

159

891

314

217

286

300

300

21kW x/a

40

385

43

560

375

1430

710

734

159

891

314

217

286

350

350

30kW

40

450

43

560

375

1430

710

734

192

891

314

217

286

350

350

30kW x/a

40

450

43

560

375

1430

710

734

192

891

314

217

286

350

350

35kW

40

515

43

560

375

1430

710

734

224

891

314

217

286

350

350


Page 19


Unit Location & Installation UnitInstallationRequ irements

IN ROOF UNITS (New Tubular)


Page 20


Unit Location & Installation

IN ROOF INSTALLA TION DETAILS (New Tubular) AS5601 5.3.11 Do not install directly above a source of cooking vapor or grease. Location of ducting should not interfere with access to the heater. 1.

The roof section, in which the unit is to be installed, shall be capable of supporting the additional load. A minimum clearance above the unit of 200mm is required.

2.

The unit is to be supported and placed so that the weight of the unit will not cause deformation of any part of the building structure.

3.

The location of the unit is to allow access for lighting and servicing. Permanent fixed means of access is required where the unit location is beyond the extent of the normal steps or ladder

4.

A walkway (crawl board) is to be provided with the access point to the unit and shall extend around the unit to the point where access may be required for lighting or servicing. The walk way is to be:4.1.1. At least 600mm wide from the access point to the unit 4.1.2. Where required around the appliance at least 750mm 4.1.3. Permanently fixed to the building 4.1.4. Capable of supporting the person

5.

Insulated supply air duct to have a 1500mm minimum straight section before any bends

6.

Duct temperature thermistor is supplied with a 3 metre cable. The thermistor must be installed as far as possible from the unit with a minimum of 1.5 metres or the first BTO / Y piece. Pierce the duct, and place the thermistor with the leading edge facing into the air stream of the duct. Secure the thermistor holder to the duct work.

7.

The top of the flue cowl must be a minimum distance of 500mm from the nearest part of the roof.

8.

A 10amp GPO power supply must be located within 600mm of the units control board.

9.

Plastic vent pipe flue cowl - not provided.

10.

65mm UPVC flue pipe required. Maximum length of flue shall not exceed 10 metres and 3 x 90o bends. See details below for the 140Mj / 35kW unit.

NOTE: - DO NOT GLUE FLUE PIPE TO THE HEATER CONNECTION. 11.

Condensate drain required using rigid 20mm PVC water pipe taking condensate to waste.

140MJ / 35kW Unit Flue Requirements Where using 65mm UPVC, the maximum length of the flue shall not exceed 5 metres with a maximum number of bends to the equivalent of 2 x 90º. Where the maximum length of the flue exceeds 5 metres, the flue size must be increased to 100mm. The total flue length shall not exceed 10 metres with a maximum number of bends to the equivalent of 3 x 90 º. See diagram for correct installation procedure.


Page 21



UNDER FLOOR UNITS (New Tubular)


Page 22



UNDER FLOOR INSTALLATION DETAILS (New Tubular) 1.

Under floor base. •

The heater must be located on a level concrete or bonded brick base underlying the entire heater

•

Provision must be made to drain any seepage or ground water so that water cannot enter the heater.

2.

Insulated supply air duct 1500mm minimum straight section before any bends.

3.

Where vertical clearance between the underside of the floor joists and the ground level is 1.2m or less, the heater must be i nstalled within 2m of the access door. If clearance exceeds l.2m the heater maybe installed at any distance from the access door subject to maximum flue length. Duct should not impede access to the unit.

4.

Duct temperature thermistor is supplied with a 3 metre cable. The thermistor must be installed as far as possible from the unit with a minimum of 1.5 metres or the first BTO / Y piece. Pierce the duct, and place the thermistor with the leading edge facing into the air stream of the duct. Secure the thermistor holder to the duct work.

5.

Artificial lighting must be provided to assist installation and servicing. The operating switch must be next to the access.

6.

The flue can be installed with a maximum of 3 x 90o bends. See details below for the 140Mj / 35kW unit. DO NOT GLUE FLUE PIPE TO THE HEATER CONNECTION.

7.

Flue Pipe: - A minimum clearance of 200mm plus allowance for flue pipe installation is required for service access between the top of the heater and the underside of the floor joints.

8.

A clearance of 700mm is required on the sides of the service side of the heater.

9.

Electrical connection is via a 3-pin plug and cable set. The unit requires a 10Amp GPO power supply located within 600 mm of the unit.

10.

Plastic vent pipe flue cowl - not provided.

11. Maximum length of flue shall not exceed 10 metres. See details below for the 140Mj / 35kW unit. 12. Condensate drain required using rigid 20mm PVC water pipe. 140MJ / 35kW Flue Requi rement s

Where using 65mm UPVC, the maximum length of the flue shall not exceed 5 metres with bends to the equivalent of 2 x 90º. Where the maximum length of the flue exceeds 5 metres, the flue size must be increased to 100mm. The total flue length shall not exceed 10 metres with a maximum number of bends to the equivalent of 3 x 90 º. See diagram for correct installation procedure. Installation Instructions - 2006

Page 23



EXHAUST FLUE PIPING REQUIREMENTS •

•

65Mj / 15kW – 120Mj / 30kW Unit Fl ue Requir ements

-

65mm UPVC piping should be used.

-

Maximum length of 10 metres without air inlet piping (single flue). This is the length of the pipe, not the distance between heater and terminal.

-

The maximum number of right angle bends in the flue pipe is 3 or proportionally more for smaller angles e.g. 6 x 45°.

140MJ / 35kW Unit Flue Requirements

-

Where using 65mm UPVC, the maximum length of the flue shall not exceed 5 metres with bends to the equivalent of 2 x 90º.

-

Where the maximum length of the flue exceeds 5 metres, the flue size must be increased to 100mm. The total flue length shall not exceed 10 metres with a maximum number of bends to the equivalent of 3 x 90 º.

•

Ensure the heater end of the flue pipe is cut square and then fit into the flue spigot. There is no requirement for a clamp to be fitted at the spigot.

•

Ensure the pipe work is correctly support, especially where there are horizontal pipe runs.

•

All flue pipe joints are to be solvent sealed. The flue terminal is to be secured with one screw. NOTE: DO NOT GLUE FLUE PIPE TO THE HEATER CONNECTION.

•

•

The pipe must have continuous fall (1 in 10) to the heater and be supported at 1500mm spacing.

The flue pipe should clear electrical wiring by at least 75mm and combustible material (wall studs, joists, etc) by at least 25mm.

Flue Termi nal

Ensure all roof penetrations are waterproof (In ceiling units).


Page 24



PIPE CONNECTION CONDENSATE PIPE INSTALLATION 1. Remove the condensate pipe, complete with ¾” nut and tail connection, from the inside of the heater for connection to the PVC condensate drain pipe. 2. Glue a ¾” x 20mm pressure pipe socket to the PVC pressure pipe and connect to the heater. 3. Glue all pipe joints of the condensate drain pipe. 4. Pipe should be firmly supported and saddled between the heater and outlet point. 5. Ensure the pipe has a continuous fall, without sags, to the outlet point. NOTE:

Failu re to drain cond ensate wil l prevent the heater from operating correctly and may damage the heater.

6. Connect condensate piping to a suitable waste point in accordance with AS3500. NOTE:

For in ceiling inst allation, do not direct the condensate outlet to gutters or down pipes. Do not allow condensate to be discharged under house or onto c oncr ete / paved pathways.

CHECKING FOR LEAK S. Pour a maximum of ½ litre of water slowly into the flue outlet and check for leaks in flue and condensate disposal piping.


Page 25


Wiring Diagram WiringDiagram


Page 26


Unit Commissioning UnitCommissionin g

COMMISSIONING PROCEDURE The heater may be temporarily operated from commissioning without the electrical access panel in place. NOTE: Do NOT attempt to operate heater with any other panels removed. 1

Press and release the ON/OFF button on the thermostat control until the control is in the OFF mode.

2

Remove the electrical service access panel

3

Turn on the gas cock on the supply line. Check all joints for leaks

4

Switch on the power at the power point

5

Press the ON/OFF button to switch the thermostat control on.

6

Select heat in thermostatic mode.

7

Using the up / down arrows, make the set temperature greater than the room temperature.

8

The combustion fan will start and after approximately 22 seconds the igniter will operate and the burning flame will be visible. The room air fan will commence operation after a timed delay.

9

Run the unit for 5 minutes in heating mode as part of the commissioning process. This will confirm that all sensors have been registered as operation in the ignition and control modules. During this commissioning period, the red light on the modulating control board will flash for up to 3 minutes. This LED will stop flashing once it confirms the sensor activity. If a sensor is not correctly register a fault code will be indicated on the main board and possibly on the modulating boards. NOTE: At first start up the ignition module can be in lockout and the unit will not st art.

If unit does not fir e up. 10 Press the RESET button(s) on the thermostat or the reset button on the control board. 11

Ensuring the set temperature is greater than the room temperature the unit will restart the lighting sequence.

12 The burner pressure is factory set and should not require adjustment. It is mandatory to check the dynamic (unit operating) supply pressure when the unit is running to ensure the correct gas supply. The test point is located on the inlet side of the valve as indicated below. 13 To check the dynamic gas pressure, refer to next section “Setting the Gas Pressures”. 14 Using the thermostat control, switch the unit OFF. Wait for the room air fan to complete its run down cycle and then switch the unit ON again to check its Installation Instructions - 2006

Page 27


Unit Commissioning running sequence. The run down cycle time can vary up to 4 minutes subject to a low discharge temperature of 38 °C being achieved. 15 Before leaving, make sure the customer understands how to operate the heating system and the thermostat control.

SETTING THE B URNER PRESSURES Dynamic (Supply) Pressure To check dynamic gas pressure

1

Remove the test point screw.

2

Fit the manometer tube and check the reading against the stated supply pressure on the customer’s supply regulator.

3

If the correct supply pressure is not available, contact the local gas authority to obtain the correct pressure.

4

Remove the manometer tube, replace test point screw and check for leaks.

Burner Pressures Model

Gas Type

Burner Pressure High

Burner Pressure Low

NG

0.80Kpa

0.40Kpa

LPG

-

-

NG

0.80Kpa

0.40Kpa

LPG

-

-

NG

0.80Kpa

0.40Kpa

LPG

-

-

NG

0.80Kpa

0.40Kpa

LPG

-

-

15KW – 60Mj

21KW – 85Mj

30KW – 120Mj

35KW – 140Mj


Page 28


Unit Commissioning To reset the unit , turn pow er OFF then ON or t urn t he thermost at OFF then ON or press th e RESET but tons on th e thermostat.Burner Pressure - Modulating

Setting the burner pressure is done in 2 parts. The high pressure must always be set before the low pressure can be correctly established. When adjusting either maximum or minimum gas rate, ensure the adjuster not being set is secured e.g. when adjusting the maximum gas rate, use a screwdriver to hold the minimum gas rate adjuster from moving. Setting the Maximum Burner Pressure 1. To adjust the maximum burner pressure, use a spanner on the hexagon nut and adjust in small increments. 2. Screw the adjuster clockwise to increase pressure, anti-clockwise to decrease burner pressure. 3. If the heater has been running for a while, the thermistor may be turning down the gas rate. To check the full gas rate, press down the pin in the middle of the minimum gas rate screw head. You will need something the diameter of a 1/8” rivet shank. Setting the Low Burner Pressure 1. To check and or set the minimum gas rate, remove one of the black gas modulating leads from the gas valve. 2. Adjust the gas rate in small increments using a Philips head screw. 3. Once checked replace the black gas modulating lead onto the valve. RETIGHTEN TEST POINT SCREW AND CHECK FOR GAS LEAKS. Installation Instructions - 2006

Page 29


Unit Commissioning

STARTUP SEQUENCE 1.

Turn gas supply on

2.

Turn on power supply to unit.

3.

A 2-second self-diagnosis is performed and, if successful, the green “DIAG” Led will be continuously illuminated. RF ONLY. Code thermostat. To code the thermostat •

Turn the power at the unit OFF then ON. This will provide a 4-minute coding period.

•

Turn the thermostat to the OFF position

•

Press the UP button and the ON/OFF button till the word code flashes.

•

Release buttons and wait 15 seconds until the word CODE disappears to start unit.

4.

To start unit set the thermostat temperature above the room temperature.

5.

Combustion air fan will commence operation for approximately 30 seconds.

6.

When combustion fan reaches required pressure level, the pressure switch closes.

7.

A further 24 seconds elapses as purge time.

8.

Igniter function commences.

9.

Gas valve is energised allowing 5 seconds for the gas to ignite.

10. Flame detected by sensor. The gas valve remains energised. 11. Room air fan will commence 30 seconds after the gas valve is energised. 12. The gas valve will modulate to maintain a constant discharge temperature of approximately 600C. 13. The person commissioning the unit can adjust the discharge temperature. This will alter the duty cycle of the system. 14. At the end of the heating cycle, the room air fan will have a run down period varying up to 4 minutes subject to a low temperature of 38ºC being achieved. 15. Should the flame not ignite after the 3rd attempt, the unit will go to lockout. Reset unit to restart.


Page 30

HE INTERNAL - LPG

High HighEfficiencyHeater–Internal/ForcedDraftLPGOnly

HIGH EFFICIENCY Internal LPG Forced Draft Combustion


Page 31

HE INTERNAL - LPG

Installation Requirements InstallationRequ irements

WHAT YOU WILL NEED Items suppli ed with unit 1. Duct connectors (2).

2. Installation instructions. 3. 65mm plastic flue cowl. 4. Balanced flue terminals for 120Mj units. The installer will need to su pply 1. Suitable base material for heater (under floor or external units).

2. Platform / walkway for roof installation (heat resistant material not required). 3. Electric lighting above the central heater and switch to be placed next to the access opening (internal under-floor installations). 4. AGA approved ½” gas cock. 5. 65mm UPVC plastic flue pipe. 6. 20mm electrical conduit for condensate drain.


Page 32

HE INTERNAL - LPG


MODEL

A

B

C

D

E

F

G

H

I

J

K

L

M

N

15kW

305

405

-

575

68

220

55

100

1300

635

305

30

245

368

21kW

305

405

-

575

68

220

55

100

1300

635

305

30

245

368

21kW x/a

355

405

-

575

68

220

55

100

1300

635

355

30

245

368

30kW

355

405

-

575

68

220

55

100

1300

635

355

30

245

368

30kW x/a

355

405

555

575

68

220

55

100

1300

635

355

30

245

368


Page 33

HE INTERNAL - LPG

Unit Location & Installation UnitLocation&Installation

UNDER FLOOR UNITS 60 & 85MJ

120MJ


Page 34

HE INTERNAL - LPG


UNDER FLOOR INSTALLATION DETAILS 1.

Under floor base. The heater must be located on a level concrete or bonded brick base underlying the entire heater

•

•

Provision must be made to drain any seepage or ground water so that water cannot enter the heater.

2.

Insulated supply air duct 1500mm minimum straight section before any bends.

3.

Where vertical clearance between the underside of the floor joists and the ground level is 1.2m or less, the heater must be i nstalled within 2m of the access door. If clearance exceeds l.2m the heater maybe installed at any distance from the access door subject to maximum flue length. Duct should not impede access to the unit

4.

If a remote control is installed, install the antenna at least 1 metre from metal masses.

5.

Artificial lighting must be provided to assist installation and servicing. The operating switch must be next to the access.

6.

The flue can be installed with a maximum of 3 x 90 o bends.

7.

A minimum of 300mm vertical clearance between the top of the heater and the underside of the floor joints is required for service access.

8.

A clearance of 700mm is required on the sides of the service side of the heater.

9.

Electrical connection is via a 3-pin plug and cable set. The unit requires a 10Amp GPO power supply located within 600 mm of the unit.

10. Flue cowl provided. 11.

Maximum length of flue shall not exceed 10 metres.

12. Condensate drain required using rigid PVC pipe (20mm electrical PVC).

120MJ Heaters Variations 13. Combustion air intake pipe to be fitted and terminated with cowl provided. Must not exceed 4 metres.

14.

Grate must be fitted to the flue pipe to maintain system pressure balance.

15. Alternate Combustion air intake can be fitted. Must be at least 2.5 metres long and terminated vertical with 300mm and air intake cowl supplied.


Page 35

HE INTERNAL - LPG


IN ROOF UNITS - LPG 60 & 85MJ

120MJ


Page 36

HE INTERNAL - LPG


IN ROOF INSTALLA TION DETAILS AG601 5.3.11 Do not install directly above a source of cooking vapor or grease. Location of ducting should not interfere with access to the heater. 1.

The roof section, in which the unit is to be installed, shall be capable of supporting the additional load. A minimum clearance above the unit of 300mm is required.

2.

The unit is to be supported and placed so that the weight of the unit will not cause deformation of any part of the building structure.

3.

The location of the unit is to allow access for lighting and servicing. Permanent fixed means of access is required where the unit location is beyond the extent of the normal steps or ladder

4.

A walkway (crawl board) is to be provided with the access point to the unit and shall extend around the unit to the point where access may be required for lighting or servicing. The walk way is to be:4.1.1. At least 600mm wide from the access point to the unit 4.1.2. Where required around the appliance at least 750mm 4.1.3. Permanently fixed to the building 4.1.4. Capable of supporting the person

5.

Insulated supply air duct to have a 1500mm minimum straight section before any bends

6.

The top of the flue cowl must be a minimum distance of 500mm from the nearest part of the roof.

7.

If a RF unit is fitted, the antenna should be at least 1 metre from any metal masses.

8.

A 10amp GPO power supply must be located within 600mm of the units control board.

9.

Flue cowl provided.

10.

65mm UPVC flue pipe required. Maximum length of flue shall not exceed 10 metres and 3 x 90o bends.

11.

Condensate drain required using rigid PVC pipe (20mm electrical PVC) taking condensate to waste.

120MJ Heater Variations 12.

Combustion air intake pipe to be fitted and terminated with cowl provided. Must not exceed 4 metres.

13.

Flue pipe to not exceed 4 metres.

14.

Grate must be fitted to the flue pipe to maintain system pressure balance.

15.

Alternate combustion air intake can be fitted. Must be at least 2.5 metres long and terminated vertical with 300mm and air intake cowl supplied.


Page 37

HE INTERNAL - LPG


CONDENSATE PIPE INSTALLATION 1. Fit 20mm PVC electrical conduit to the drain connector. Ensure bore end of PVC conduit is free of burrs to prevent damage to connector. The connector has an ‘O’ ring seal for simple connection of the correct sized piping. Do not use the flared end of the conduit to make the connection. 2. Use suitable sealant on pipe joints. Pipe should be firmly supported with clamps between the heater and outlet point. 3. Ensure the pipe has a continuous fall, without sags, to outlet point. NOTE:

Failu re to drain cond ensate wil l prevent the heater from operating correctly and will damage the heater.

4. Connect condensate piping to waste. NOTE:

For in ceiling inst allation, do not direct the condensate outlet to gutters or down pipes. Do not allow condensate to be discharged under house or onto c oncr ete / paved pathways.

5. Checking for leaks. Pour a maximum of ½ litre of water slowly into the flue outlet and check for leaks in flue and condensate disposal piping.


Page 38

HE INTERNAL - LPG

Exhaust Flue Pipe Requirements

EXHAUST FLUE PIPING REQUIREMENTS (Internal LPG units only) •

65mm UPVC piping should be used.

•

Maximum length of 10 metres without air inlet piping (single flue). This is the length of the pipe, not the distance between heater and terminal.

•

Ensure the heater end of the flue pipe is cut square and then fit over the flue spigot. There is no requirement for a clamp to be fitted at the spigot.

•

Ensure the pipe work is correctly support, especially where there are horizontal pipe runs.

•

All flue pipe joints are to be solvent sealed. The flue terminal is to be secured with one screw.

•

The pipe must have continuous fall (1 in 10) to the heater and be supported at 1500mm spacing.

•

The maximum number of right angle bends in the flue pipe is 3 or proportionally more for smaller angles e.g. 6 x 45°.

•

The flue pipe should clear electrical wiring by at least 75mm and combustible material (wall studs, joists, etc) by at least 25mm.

Flue Termi nal

Ensure all roof penetrations are waterproof (in ceiling units). WiringDiagram

WIRING DIAGRAM See page 46 External Forced Draught Combustion units Commission ing

COMMISSIONING See page 47 External Forced Draught Combustion units


Page 39

HE EXTERNAL – NG & LPG

High Efficiency HighEfficiencyHeater –Externa l/ ForcedDraft NG&LPG

HIGH EFFICIENCY External NG & LPG Forced Draft Combustion


Page 40

HE EXTERNAL - NG & LPG


MODEL

A

B

C

D

E

F

G

H

I

J

K

L

M

N

15kW

70

757

197

395

710

1000

795

75

1115

300

210

55

245

563

21kW

70

757

197

395

710

1000

795

75

1115

300

210

55

245

563

30kW

70

757

197

395

710

1000

795

75

1115

350

235

55

220

615


Page 41


Unit Location and Installation UnitLocationandInstallatio n

S AFETY & ACCESSIBILITY RESPONSIBILITY The manufacturer and its agents reserve the right to refuse service unless the safety and accessibility to the unit can be guaranteed. The cost of any extra equipment required to provide access to the unit for servicing is the responsibility of the owner.

EXTERNAL UNIT L OCATION The external model is designed for installation outside the house and for connection to an under floor duct system. The return air grille must be centrally located inside the house (e.g. central hallway), using suitable return air grille fitted with a filter and correctly sized ductwork. Do not install the unit in a location where noise from its operation will disturb occupants or neighbors. Check local council regulations to ensure compliance.


Page 42


Unit Location and Installation

EXTERNAL UNIT INSTALLATION The heater may be installed close to an outside wall, subject to the local gas fitting regulations. 1. A weatherproof l0Amp GPO isolating switch must be located with 600mm of the heater cable entry. 2. External Flue Cowl. Check location of flue relative to windows, doors or other household vents. Refer to position of heater relative to building - refer AS5601 (AG601) Sections 5, 13.6.5 Fig 5.3. The flue cowl has been provided with the product. IT IS IMPORTANT THE FLUE GASSES DO NOT ENTER THE BUILDING OR PRESENT A THREAT TO LIFE.

3. 600mm minimum clearance must be provided to the heater for service and maintenance. 4. 100mm minimum clearance must be provided for air intake.


Page 43


Unit Location and Installation

EXTERNAL BASE AND WALL PREPARATION

1. The heater must be located on a level concrete or bonded brick base underlying the entire heater base. Provision must be made to drain any seepage or ground water so that water cannot enter the heater. 2. Cut a hole in the wall (as shown) for brick or masonry walls. Model

Model Dimension X

Dimension Y

15kW – 60MJ

360mm (4 courses)

920-1050mm

21kW – 85MJ

360mm (4 courses)

920-1050mm

30kW – 120MJ

440mm (5 courses)

1000-1050mm

3. Support the wall above the opening with a steel lintel beam. 4. Locate the steel lintel at least 75mm onto the supporting wall section.


Page 44


Unit Location and Installation If it’s necessary for the base of the heater to be below ground level, make sure that there’s 600mm access for service at the front of the heater. The area must prevent accumulation of water.

DUCT CONNECTION TO HEATER The heater is supplied with the room air fan (return air duct connection) on the right hand side of the heater. If the layout of ducting is such that the return air connection must be on the left-hand side (as below), the fan and air scoop assembly may be interchanged. To inter change the fan and scoop assembly 1. Remove the side lower cover on the flue side of the unit. 2. Remove the air discharge scoop by sliding out. 3. Remove the fan by sliding out. Rotate the fan assembly 180° and slide into the once discharge scoop side of the product. 4. Insert the discharge on the once fan side of the unit 5. Replace side panel. There should be no reason to disconnect fan connection cables.

FLUE TERMINAL Insert supplied flue terminal fully into the rubber outlet moulding and clamp with spring clip provided.


Page 45


Wiring Diagram WiringDiagram


Page 46


Commissioning Commissioning

COMMISSIONING PROCEDURE The heater may be temporarily operated from commissioning without the electrical access panel in place. NOTE: Do NOT attempt to operate heater with any other panels removed. 1. Press and release the ON/OFF button the thermostat control until the control is in the OFF mode. 2. Remove the electrical service access panel 3. Turn on the gas cock on the supply line. Check all joints for leaks 4. Switch on the power at the power point 5. Press the ON/OFF button to switch the thermostat control on. 6. Select heat in thermostatic mode. 7. Using the up / down arrows, make the set temperature greater than the room temperature. 8. The combustion fan will start and after about 22 seconds the igniter will operate and the burning flame will be visible. The room air fan will commence operation after a timed delay. NOTE: At first start up the ignition module can be in lockout and the unit will not st art. If unit does not fir e up.

9. Press the RESET button(s) or turn the thermostat OFF then ON or turn the 240V power to the unit OFF the ON. 10. Ensuring the set temperature is greater than the room temperature the unit will restart the lighting sequence. 11. The burner pressure is factory set and should not require adjustment. It is mandatory to check the dynamic (unit operating) supply pressure when the units is running to ensure the correct gas supply. The test point is located on the inlet side of the valve as indicated below. 12. To check the dynamic gas pressure, refer to next section “Setting the Gas Pressures”. 13. Using the thermostat control, switch the unit OFF. Wait for the room air fan to complete its run down cycle (approximately 80 seconds), and then switch the unit ON again to check its running sequence. 14. Before leaving, make sure the customer understands how to operate the heating system and the thermostat control.


Page 47


Commissioning

B URNER PRESSURE SETTING Dynamic Pressure To check dynamic gas pressure:-

1. Remove the test point screw. 2. Fit the manometer tube and check the reading against the stated supply pressure on the customer’s supply regulator. 3. If the correct supply pressure is not available, contact the local gas authority to obtain the correct pressure. 4. Remove the manometer tube, replace test point screw and check for leaks.

Burner Pressures Model

Gas Type

Burner Pressure High

Burner Pressure Low

NG

0.75Kpa

0.25Kpa

LPG

1.90Kpa

0.55Kpa

NG

0.85Kpa

0.25Kpa

LPG

1.90Kpa

0.55Kpa

NG

0.75Kpa

0.25Kpa

LPG

1.70Kpa

0.55Kpa

15KW – 60Mj

21KW – 85Mj

30KW – 120Mj


Page 48


Commissioning Burner Pressure Setting the burner pressure is done in 2 parts. The high pressure must always be set before the low pressure can be correctly established. High Burner Pressure To set the high burner pressure correctly, the combustion fan must be set to run on maximum RPM so that modulation can not take effect.

1. Remove the pressure test point screw. 2. Place the manometer tube on the gas inlet pressure test point 3. To set the combustion fan to high speed shift the wire on CFAN on the Series3 modulating control board to a spare neutral terminal 4. To adjust the burner pressure, remove the plastic cover from the adjustment screw on top of the gas valve diaphragm. A small blade screw driver is required to adjust the pressure. Do not make large adjustments 5. Set the burner pressure as per the specifications laid out on the unit rating label 6. Return the combustion fan wire back to CFAN 7. Leave the manometer in place to check low pressure.


Page 49


Commissioning Setting the Low Burner Pressure Setting the low burner pressure must only be set after the high burner pressure has been verified. The low burner pressure is set by adjusting the low speed modulation of the combustion fan.

To set the low burner pressure: 1. Ensure the combustion fan wire has been returned from neutral to CFAN. 2. Unplug the thermistor wire from the modulating control board. 3. Using a Phillips head screwdriver, adjust the low gas rate pot on the modulating control board. This will require movements in very small increments 4. Adjust the low burner pressure as set out on the gas rating label. 5. Replace the thermistor wire to the modulating control board 6. Remove the manometer, replace pressure test point screw and check for leaks.

CHECKING THE SYSTEM PERFORMANCE Once the gas pressure has been set, check the air discharge temperature in the duct to confirm the correct operation of the central heater. To test the correct operation of the heater: 1. Set room air fan speed best suited to the system. Replace electrical cover. 2. Check the temperature rise through the heater. The air temperature 300mm from the heater discharge should be between 60 to 65 0C at normal room temperature. Failure to comply will result in unsatisfactory performance of the heater. If this temperature is exceeded, check the ducting system for airflow restrictions and correct if necessary. If the temperature is still too high, increase the high fan speed setting. 3. Using the thermostat, switch the heater OFF. Wait for the room air fan to cease operation (approximately 80 seconds), then switch ON again to recheck the starting sequence. 4. Using the thermostat, switch the heater OFF unless the customer requires that it be left running. 5. Before leaving, make sure that the customer understands how to operate the heating system.


Page 50


Commissioning

STARTUP SEQUENCE 1.

Turn gas supply on

2.

Turn on power supply to unit.

3.

A 2-second self-diagnosis is performed and, if successful, the green “DIAG” Led will be continuously illuminated. RF ONLY - code thermostat. To code the thermostat •

Turn the power at the unit OFF then ON. This will provide a 4-minute coding period.

•

Turn the thermostat to the OFF position.

•

Press the UP button and the ON/OFF button till the word code flashes.

•

Release buttons and wait 15 seconds until the word CODE disappears to start unit.

4.

To start unit set the thermostat temperature above the room temperature.

5.

Combustion air fan will commence operation for approximately 22 seconds before activating the gas valve.

6.

A further 10 seconds elapses as purge time.

7.

Igniter function commences.

8.

Gas valve is energised allowing 5 seconds for the gas to ignite.

9.

Flame detected by sensor. The gas valve remains energised.

10.

Room air fan will commence 15 seconds after the gas valve is energised.

11.

When the discharge thermistor reaches 50 0C, the fan will be at high speed.

12.

The gas valve will modulate to maintain a constant discharge temperature of 60 – 650C,

13.

The person commissioning the unit can adjust the discharge temperature. This will alter the duty cycle of the system.

14.

At the end of the heating cycle, the room air fan will have a run down period of 80 seconds.

15.

Should the flame not ignite after the 3rd attempt, the unit will go to lockout. Reset unit to restart.

16.

To reset the unit, turn power OFF then ON or turn the thermostat OFF then ON or press the RESET buttons on the thermostat.


Page 51


Trouble Shoot ing Trouble-sh ooting

IF THE HEATER WILL NOT OPERATE •

Check that there is power and gas supplied to the heater.

•

Check that thermostat set temperature is above room temperature.

•

Check supply gas pressure at the test point.

•

Check that the power LED is lit on the DSI controller. If it isn’t, check that power is available at the GPO, check the circuit breaker and check the fuses on the controller.

•

If the heater will still not operate, the safety shut down device within the heater may have locked the control. Press RESET on electronics board.

•

If the heater still fails to operate correctly, contact the nearest service agent.

•

For service Australia wide see the contact details on the rear cover.

Blocked inlet or outl et flue •

The unit will go to lockout. When the restriction is removed the unit can then be reset.

Electric p ower loss •

The unit will restart automatically (if the Controller/thermostat is calling for heat) once power is resumed.

Gas int erruption •

If the unit has been working and a momentary (approximately less than 20 seconds) gas interruption occurs, the unit will restart automatically.

•

A gas interruption longer that about 20 seconds will cause the unit to lockout. The controller / thermostat must be reset after gas supply is re-established.

DSI diagnostic light sequences The DSI controller will display a coded message if an operation fault occurs. Refer to the table next page for on-board diagnostic light sequences relating to fault description. Normal operation Green LED will be continuously.


Page 52


Fault Codes Faultcodes

If a fault occurs, the green diagnostic LED will flash a number of times on the main board to indicate the fault. The LED is off for 4 seconds and then will flash the fault code. The fault code is repeated until reset or repaired. Match the number of times the LED flashes to the table below to indicate the fault. Green Fault Code Flashes

Diagnosis

1

Block Flue

Check flue cowl installed correctly, pressure tube split or not connected.

2

Pressure Switch fused closed

Flue installed with excess draft in terminal location, Service Call

3

Combustion air pressure system failure

Check: - combustion fan OK, silicone tubes OK.

4

Room air over temperature (auto reset)

Check Minimum Fan Speed, Duct design

Blocked condensate drain. Red indication light on control board.

Check for blockage in the condensate tube or poor installation.

5

Controller electronic malfunction Reset, Service Call (Sensing flame with gas valve closed)

6

Slow closing gas valve

Reset, Service Call

7

Ignition failure

Check: - igniter working, flame sensor, gas supply, burners secure for cross-lighting, electrical polarity, ignition gas rate.

8

Gas Interruption

Check: - gas supply, other appliance gas usage. Press reset button, Service Call

9

EEPROM failure

Reset, Service Call

11

Lost Transmission

Check: Thermostat location, Antenna Location, RF interference eg RF Door Bells, Steel roof structures etc

12

Touchpad Communication Error

Check: Location of the low voltage cable relative to mains cables, damage to the loom. Reset, Service Call

15

No Faults Reported

Tubular High Effic iency – Modul ating Bo ard ONLY Red Fault Code Flashes

Diagnosis

1

Condensate Detected

Check for blockage in condensate drain

2

Over Temperature – Duct temperature greater than 85ºC

Flue installed with excess draft in terminal location, Service Call

3

Thermistor temperature rise > 1ºC in the first 3 minutes of operation.

Check: - thermistor is correctly located in the discharge air duct.

4

Duct thermistor open circuit.

Check: thermistor is plugged into the control board or check for thermistor cable damage


Page 53


Commissioning Check Li st Commission ingChecklist

You must comp lete, date and sig n the ‘tick box’ checklist in the owner’s manual. Use this copy to check installation prior t o completing th e owner’s documentation. Unit





 





Polarity of the power outlet is correct. Heater is installed away from sources of dust and fumes (i.e. pool chlorine/petrol etc).



Gas leaks checked for, none present.



Flue outlet pipe complies with limits given and is sealed waterproof. Combustion air meets requirements (internal), under floor. Fan speed set is correct.



Burner pressure is correct.





The unit is level and secure.









Outlets are fitted and are neat and clean. Zone dampers (optional) are adjusted and working correctly. Air distribution is balanced correctly. Service lighting installed with switch next to access opening (internal & under floor installations). All roof penetrations are fully sealed and watertight.

Site



Rubbish has been removed.



Inside the house is clean.



Mounting pad/platform complies with requirements.



Comfort Controller/thermostat operates correctly.



Controls and all internal fittings are clean. Roof tiles/sheets have been replaced (if applicable) Manhole cover has been replaced.

Ductworkandgenera l



  



Duct diameter/airflow complies with unit and installation recommendations. No sharp bends in ductwork

Customer handover

You have explained the following to the customer: 

All ductwork is correctly insulated The thermistor is correctly located and secured in the duct work. Ductwork is correctly supported






Operation of Comfort Controller / Thermostat Operation of zones and air outlets Maintenance & service requirements

Page 54


Service SERVICE

A qualified service technician should conduct any service work carried out on the ducted gas central heating product. If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or similarly qualified person in order to avoid a hazard. An authorized Climate Technologies service provider must carry out warranty service. For Metro Service only ring the numbers below. South Australia /

(08) 8307 5230

Northern Territo ry New South Wales /

(03) 8795 2457

Au st ral ian Capital Terr it or y Western Australia

(08) 9454 1000

Victoria/Tasmania

(03) 8795 2456

Queensland

(07) 4634 1803

Outside Metro areas please contact the nearest Climate Technologies Service Provider. New Zealand (ABERGAS LTD)


0800 161 161

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Vulcan Installation Manual

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