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Braemar TG Series Gas Ducted Heaters Technical and Training Manual March 2007

Section 8: Service and troubleshooting

®

P/No: 631059a

Braemar TG series gas ducted heater technical & training manual

March 2007

TABLE OF CONTENTS

Section SECTION 8 - SERVICE AND TROUBLE SHOOTING 8.1 General 8.2 Heater troubleshooting 8.2.1 Heater commissioning 8.2.1.1 Heater commissioning checks 8.2.1.2 Set heater and cooler type 8.2.1.3 Set time and day 8.2.2 Start-up checklist - TG3 8.2.3 Run checklist - TG3 8.2.4 Start-up checklist - TG4 & TG5 8.2.5 Run checklist - TG4 & TG5 8.2.6 Component specifications and checks 8.2.6.1 Room fan and capacitor sizes 8.2.6.2 Room fan motor winding resistance 8.2.6.3 Room fan voltage vs fan speed setting 8.2.6.4 Gas valve coil resistances 8.2.6.5 Pressure switch ratings 8.3 Thermostat troubleshooting (Spectrolink Comfort Control, SCC) 8.3.1 Diagnostic codes 8.3.1.1 Diagnostic code definintions 8.3.1.2 DC 1 - P-100 (TG3), P-55 (TG4/5) closed at start 8.3.1.3 DC 2 - P-100 (TG3), P-55 (TG4/5) failed to close 8.3.1.4 DC 3 - P-100 (TG3), P-55 (TG4/5) open during run 8.3.1.5 DC 4 - Thermistor > 70oC during run (TG4/5 only) 8.3.1.6 DC 5 - Thermistor not connected or short circuit (TG4/5) 8.3.1.7 DC 6 - OT4 open (TG5 only) 8.3.1.8 DC 7 - Ignition failure 8.3.1.9 DC 9 - Internal memory failure 8.3.1.10 DC 10 - HX OT1 open 8.3.1.11 DC 11 - EFS shutdown 8.3.1.12 DC 12 - P-100 closed at start (TG4/5 only) 8.3.1.13 DC 13 - P-100 failed to close (TG4/5 only) 8.3.1.14 DC 14 - P-100 open > 30 sec during run (TG4/5 only) 8.3.1.15 DC 15 - Thermistor in cool location in duct (TG4/5 only) 8.3.1.16 DC 16 - Thermistor not installed in duct (TG4/5 only) 8.3.1.17 DC 17 - Condensate detected in run (TG5 only) 8.3.1.18 DC 18 - Condensate detected at start (TG5 only) 8.3.1.19 DC 19 - HX OT2 open at start 8.3.2 Lockout states and reset procedure 8.3.2.1 Lockout 1 8.3.2.2 Lockout 2 8.3.3 Retrieving and clearing recorded diagnostic codes 8.3.4 Communication check 8.3.5 Operating hours check 8.3.6 Program settings check 8.3.7 Restore factoy default program settings 8.3.8 Security Code setting - enable and disable 8.3.9 Checking duct air temperature 8.4 Ductwork checks Page

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Page (i)

Braemar TG series gas ducted heater technical & training manual

March 2007

8. 8.1

SERVICE AND TROUBLE SHOOTING General checks

The following points are provided as a guide to assist in diagnosing problems which may prevent correct heater operation.

DISCUSS THE PROBLEM WITH THE CUSTOMER

· IS THE HEATER WORKING SOMETIMES OR NOT AT ALL ? · IS THE HEATER NOT WORKING AS THE CUSTOMER EXPECTS ? CHECK DIAGNOSTIC CODE HISTORY: · See section 5.3.3 to access stored diagnostic codes · See section 5.3.1 for a description of diagnostic codes CHECK CONTROL-TO-HEATER COMMUNICATION: · Spectrolink Comfort Control displays "yes" when power is first applied - this confirms that control and loom are OK - see section 5.3.4 for how to perform a communication check from Service Mode. CHECK HIGH AND LOW OPERATING TIMES: · See section 5.3.5 to access operating times · A complaint that "the heater does not heat properly" combined with long periods on low gas rate may indicate restricted duct work CHECK PROGRAM SETTINGS: · Check that program settings are as the customer requires - see section 5.3.6 to check settings, see section 5.3.7 for restoring factory default program settings · Incorrect settings can cause the heater to appear to operate incorrectly CHECK POWER SUPPLY: · Supply voltage and polarity CHECK GAS SUPPLY PRESSURE: · If the test point pressure is low, check the supply pressure to the heater when it is running on maximum gas rate - it must be at least 1.13 kPa for natural gas, and 2.75 kPa for propane. If the supply pressure is less than this determine the reason and rectify. · All gas valves are factory set and should not require field adjustment CHECK INSTALLATION: · Supply and return air duct sizing · Duct layout, bends · Return air grille size · Return air filter · Number of outlets

Section 8 - Page 1

Braemar TG series gas ducted heater technical & training manual

March 2007

8.2 8.2.1 8.2.1.1

Heater troubleshooting Heater commissioning Heater commissioning checks CHECK DETAILS Check all gas lines - rectify any leaks found. Gas supply pressure must be checked at the appliance inlet with all other gas appliances running and the heater running on maximum gas rate. Minimum gas supply pressures must be: - Natural gas: 1.13 kPa - Propane: 2.75 kPa Check that the gas test point pressure is correct - adjust only if outside specified limits. High gas rate: - Natural gas: 0.87 +/- 0.05 kPa - Propane: 2.25 +/- 0.1 kPa Low gas rate (TG4 and TG5 only): - Natural gas: 0.4 +/- 0.02 kPa - Propane: 1.0 +/- 0.1 kPa Check that the flue system is adequately sealed, and the flue cowl is not pushed on too far and not adding excessive restriction to the flue. Check that ducting is not providing excessive restriction: - Supply and return air duct is sized appropriately, - Ducting is not squashed, - Bends are smooth and as large a radius as possible. Check that return air grille is correctly sized - minimum sizes recommended are (equivalent areas are acceptable):

Heater model 15 kW 20/22 kW 20/22 kW extra air 30/32 kW 30/32 kW extra air 35 kW Min' grille size (mm) No filter 500 x 400 500 x 400 600 x 400 750 x 400 900 x 400 900 x 400 With filter 750 x 400 750 x 400 900 x 400 1000 x 400 1200 x 400 1200 x 400 Duct dia' 300 300 350 350 400 400

No gas leaks Gas supply pressure

Gas test point pressure

Flue system

Ducting

Return air grille

Return air filter

Check that return air filter is clean.

This section continued on next page.

Section 8 - Page 2

Braemar TG series gas ducted heater technical & training manual

March 2007

8.2.1.1

Heater commissioning checks (continued) DETAILS Check that thermostat/s are installed in suitable location/s: - Out of direct sunlight, - Not on an external wall, - Away from draughts or heated air jet from outlet register, - In common area where required, - In suitable location in each zone. Check that the duct thermistor is located approximately 3m along the duct from the heater outlet and mounted correctly using the bracket supplied. CHECK THAT THE DUCT THERMISTOR IS LOCATED IN A DUCT SECTION THAT CANNOT BE TURNED OFF - RE-LOCATE IF REQUIRED. Check that zone dampers are fitted and wired correctly where appropriate. Check that the heater is level in both directions - this is improtant for TG5 heaters to enable correct condensate drainage. Check that the condensate drain is connected, and that it runs downhill away from the heater.

INSTALLATION CHECKS (continued) Thermostat location/s

Duct thermistor installed correctly (TG4 and TG5 only)

Zone dampers (TG4 and TG5 only) Heater level

Condensate drain (TG5 heaters only) 8.2.1.2

Set heater and cooler type

With the SCC in the off mode, and within 15 minutes of powering up the SCC (disconnect from loom and discharge capacitor at back of SCC if powered for longer than 15 minutes): · Simultaneously press the 'SET' AND 'AC MODE' buttons, · The display will show 'HEAT 3' - press 'SET', · The display will show 'COOL 1': · Evaporative cooling - leave as 'COOL 1' and press 'SET', · Refrigerated cooling - use up arrow to change to 'COOL 2' and press 'SET'. · Heat and cool mode options: · HEAT 1 Braemar SPI control system · HEAT 2 Braemar MPI control system · HEAT 3 Braemar BSC control system (all TG series heaters) · COOL 1 Evaportaive cooling · COOL 2 Refrigerated cooling If 'HEAT 1' or 'HEAT 2' is selected the SCC will not operate a TG series heater. SCC's supplied from March 2006 have default settings of 'HEAT 3' and 'COOL 1'. 8.2.1.3 Changing the time and day on the SCC

With the SCC in the off mode: · Press the 'SET' button and hold for 3 seconds, · The display will show 'SET' and the time flashing, · Use the up/down arrows to adjust to the correct time, · Press 'SET'. · The display will show 'SET' and the day flashing, · Use the up/down arrows to adjust to the correct day, · Press 'SET'.

Section 8 - Page 3

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.2 Start-up checklist - 3 star

If the heater fails to start check the following:

SYMPTOM POTENTIAL CAUSE REMEDY INDICATORS

1

No LED's on.

Power supply turned off or not connected. Blown fuse on BSC circuit board. Transformer failed or disconnected. BSC earth wire disconnected.

Connect/turn on power supply. Check/replace fuse (use 10A slow-blow only). Check transformer and connections. Check earth wire connection.

"PWR" LED on BSC (green) should come on. "PWR" LED on BSC (green) should come on. "PWR" LED on BSC (green) should come on. "PWR" LED on BSC (green) should come on.

2 3

Nothing displayed on t/stat. No response to t/stat call for heat.

T/stat cable damaged or not connected. T/stat not set to correct heat type (HEAT 1/2/3 refer section 5.2.1.2).

Perform t/stat comm's check (section 5.3.2). Check/connect/replace t/stat cable. Ensure t/stat is on and set temp is above room temp.

Should respond with "yes".

T/stat display should be showing. BSC "ON" LED (red) should come on when call for heat received.

4

Combustion fan does not start.

Wiring damaged or disconnected. Pressure switch closed at start-up (fault 1). HX OT1 open at start (fault 10).

Check/connect wiring refer wiring diagram. Check/replace pressure switch. Check HX OT1 is closed when cool - replace if open circuit when cool.

Combustion fan should start after call for heat. Diagnostic code 1 recorded. RESET flashing and 1 displayed. Diagnostic code 10 recorded.

5

Combustion fan starts, no ignition attempt.

Pressure switch does not close after 3 x 60 sec attempts (fault 2).

Check flue cowl is correctly installed (not blocking flue outlet). Check flue system for blockage. Check combustion fan is free to spin. Check 240 Vac to combustion fan.

Diagnostic code 2 recorded. RESET flashing and 2 displayed. Combustion fan suction pressure (must be > 110 Pa cold).

(Continued next page)

HX OT2 open at start (fault 19).

Check HX OT2 is closed when cool - replace if open circuit when cool.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8 - Page 4

Diagnostic code 19 recorded. RESET flashing and spanner and 19 displayed.

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT.

8.2.2

Start-up checklist - 3 star (continued)

SYMPTOM POTENTIAL CAUSE REMEDY INDICATORS

6

System sparks but no ignition after 3 attempts.

Gas supply turned off at heater inlet or gas meter. Gas turned off at on/off switch on gas valve.

Check gas supply.

Check gas valve on/off switch is ON.

Incorrect gas pressure.

Check gas pressure at test point on gas valve.

Diagnostic code 7 recorded. RESET flashing and 7 displayed.

Incorrect spark gap.

Check spark gap is 34mm from burner face.

OT3 (burner cover) open.

Press button on switch will click only if switch was open and is cool enough to reset. Check flame sense lead connected and not damaged.

7

Ignition occurs but gas turns off after 7 seconds.

EFS not sensing flame signal.

Check location of flame sense electrode.

8

Room fan does not start.

Wiring damaged or disconnected.

Check/connect wiring refer wiring diagram. Check capacitor wiring. Check power to room fan. Should be approx' 75Vac (105 Vac rms) at fan speed 1.

Room fan should start on speed 1 approx' 10 sec after ignition.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8 - Page 5

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.3 Run checklist - 3 star

If the heater stops while running check the following:

SYMPTOM

POTENTIAL CAUSE

REMEDY

INDICATORS

1

Heater turns off while running.

T/stat not calling for heat.

Check thermostat is set above room temperature.

'ON' LED (red) is illuminated when thermostat call for heat is received.

Check programmed operating times and set temperatures. Braemar SCC t/stat Perform t/stat comm's check (section 5.3.2). Should respond "yes". If "no" check cable is plugged in securely, or replace cable.

T/stat cable damaged.

Other t/stats Check cable and connections, repair/ relace if damaged. Check location of flue cowl. Check exposure to severe winds. Check sufficient outlets installed and open, return air grille not obstructed, return air filter clean, maximum fan speed set correctly, ducting correctly sized. Incorrect or unstable gas pressure. Check gas pressure at test point on gas valve with all other appliances on and off.

'ON' LED (red) is illuminated when thermostat call for heat is received.

Pressure switch opened.

Diagnostic code 3 recorded.

HX OT1 opened due to low air flow.

Diagnostic code 10 recorded.

EFS shut down due to loss of flame signal.

Diagnostic code 11 recorded. RESET flashing and 11 displayed.

OT3 (burner cover) open. Press button on switch - will click only if switch was open and is cool enough to reset.

Diagnostic code 11 stored. RESET flashing and 11 displayed.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8- Page 6

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.4 Start-up checklist - 4 & 5 star

If the heater fails to start check the following:

SYMPTOM POTENTIAL CAUSE REMEDY INDICATORS

1

No LED's on.

Power supply turned off or not connected. Blown fuse on BSC circuit board. Transformer failed or disconnected.

Connect/turn on power supply. Check/replace fuse (use 10A slow-blow only). Check transformer and connections. Perform t/stat comm's check (section 5.3.4). Check/connect/replace t/stat cable. Ensure t/stat is on and set temp is above room temp.

"PWR" LED on BSC (green) should come on. "PWR" LED on BSC (green) should come on. "PWR" LED on BSC (green) should come on. Should respond with "yes".

2 3

Nothing displayed on t/stat. No response to t/stat call for heat.

T/stat cable damaged or not connected. T/stat not set correctly.

T/stat display should be showing. BSC "ON" LED (red) should come on when call for heat received. Combustion fan should start after call for heat. Diagnostic code 18 recorded. RESET flashing and 18 displayed. Diagnostic code 12 recorded. RESET flashing and 12 displayed. Diagnostic code 1 recorded. RESET flashing and 1 displayed. Diagnostic code 10 recorded.

4

Combustion fan does not start.

Wiring damaged or disconnected. Condensate detected at start (fault 18) - 5 star only. High pressure switch closed at start (fault 12). Low pressure switch closed at start (fault 1). HX OT1 open at start (fault 10).

Check/connect wiring refer wiring diagram. Check condensate drain is fitted and working. Check/replace pressure switch. Check/replace pressure switch. Check HX OT1 is closed when cool - replace if open circuit when cool. Check flue cowl is correctly installed (not blocking flue outlet). Check wiring to pressure switches.

5

Combustion fan starts, no ignition attempt.

Low press' switch does not close after 3 x 60 sec attempts (fault 2). High press' switch does not close after 3 x 5 sec attempts (fault 13).

Low press' switch Diagnostic code 2 stored. RESET flashing and 2 displayed. High press' switch: Diagnostic code 13 stored. RESET flashing and 13 displayed. Combustion fan suction pressure (must be > 110 Pa cold).

Check flue system for blockage. Check combustion fan is free to spin. Check 240 Vac to combustion fan. HX OT2 open at start (fault 19). Check HX OT2 is closed when cool - replace if open circuit when cool.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Diagnostic code 19 recorded. RESET flashing and spanner and 19 displayed.

Section 8 - Page 7

(Continued next page)

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.4 Start-up checklist - 4 & 5 star (continued)

If the heater fails to start check the following:

SYMPTOM POTENTIAL CAUSE REMEDY INDICATORS

6

System sparks but no ignition after 3 attempts.

Gas supply turned off at heater inlet or gas meter. Gas turned off at on/off switch on gas valve.

Check gas supply.

Check gas valve on/off switch is ON.

Incorrect gas pressure.

Check gas pressure at test point on gas valve.

Diagnostic code 7 stored. RESET flashing and 7 displayed.

Incorrect spark gap.

Check spark gap is 34mm from burner face.

OT3 (burner cover) open.

Press button on switch will click only if switch was open and is cool enough to reset. Check flame sense lead connected and not damaged.

7

Ignition occurs but gas turns off after 7 seconds.

EFS not sensing flame signal.

Check location of flame sense electrode.

8

Room fan does not start.

Wiring damaged or disconnected.

Check/connect wiring refer wiring diagram. Check capacitor wiring. Check power to room fan. Should be approx' 75Vac (105 Vac rms) at fan speed 1.

Room fan should start on speed 1 approx' 10 sec after ignition.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8 - Page 8

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.5 Run checklist - 4 & 5 star

If the heater stops while running check the following:

SYMPTOM

POTENTIAL CAUSE

REMEDY

INDICATORS

1

Heater turns off while running.

T/stat not calling for heat.

Check thermostat is set above room temperature.

'ON' LED (red) is illuminated when thermostat call for heat is received.

Check programmed operating times and set temperatures. Should respond "yes". If "no" check cable is plugged in securely, or replace cable. Diagnostic code 14 recorded if high pressure switch is open for > 30 seconds during run.

T/stat cable damaged.

Perform t/stat comm's check (section 5.3.2).

High pressure switch open for > 30 sec.

Check location of flue cowl. Check exposure to severe wind.

Low pressure switch opened.

Check location of flue cowl. Check exposure to severe wind.

Diagnostic code 3 recorded.

Condensate detected (5 star only).

Check condensate drain is fitted and working.

Diagnostic code 17 recorded.

If condensate not cleared in < 10 minutes, diagnostic code 18 recorded. RESET flashing and 18 displayed. Check sufficient outlets installed and open, return air grille not obstructed, return air filter clean, maximum fan speed set correctly, ducting correctly sized.

HX OT1 opened due to low air flow.

Diagnostic code 10 recorded.

Thermistor reached 70 deg C.

Gas switches to low rate when thermistor reaches 60 deg C and off when thermistor reaches 70 deg C. This is normal operation when the room fan is set to a low speed.

Diagnostic code 4 recorded.

(Continued next page) NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8 - Page 9

Braemar TG series gas ducted heater technical & training manual

March 2007

DO NOT REPLACE COMPONENTS WITHOUT FIRST RUNNING THROUGH THESE CHECKS TO HELP DIAGNOSE THE FAULT. 8.2.5 Run checklist - 4 & 5 star (continued)

If the heater stops while running check the following:

SYMPTOM

POTENTIAL CAUSE

REMEDY

INDICATORS

Heater turns off while running.

EFS shut down due to loss of flame signal.

Incorrect or unstable gas pressure. Check gas pressure at test point on gas valve with all other appliances on and off. Diagnostic code 11 recorded. OT3 (burner cover) open. Press button on switch - will click only if switch was open and is cool enough to reset.

NOTES: Diagnostic codes referenced above can only be accessed and displayed using a Braemar SCC thermostat.

Section 8 - Page 10

Braemar TG series gas ducted heater technical & training manual

March 2007

8.2.6 8.2.6.1

Component specifications Room fan and capacitor sizes

Heater model TG315 TG320 TG330 TG3X20 TG3X30 TG415 TG420 TG430 TG435 TG4X20 TG4X30 TG515 TG522 TG532 TG5X22 TG5X32

Blower size 9x7 9x7 10 x 10 9x7 10 x 10 9x7 9x7 10 x 10 10 x 10 9x7 10 x 10 9x7 9x7 10 x 10 9x7 10 x 10 Motor (W) 315 315 600 600 750 315 315 600 750 600 750 315 315 600 600 750 Capacitor (uF) 15 15 15 15 20 15 15 15 20 15 20 15 15 15 15 20

8.2.6.2

Room fan motor winding resistance

Winding resistance range at 20oC (ohms)

Motor (W)

Start winding (Motor BROWN to BLACK) 24 - 26 14.5 - 15.5 8-9

Run winding (Motor BROWN to BLUE) 11 - 13 7-8 5-6

Kulthorn 315 Kulthorn 600 Kulthorn 750

DISCONNECT ELECTRICITY SUPPLY FROM HEATER BEFORE MEASURING MOTOR WINDING RESISTANCES. RESISTANCE MEASUREMENTS MUST BE MADE WITH: · MOTOR SHAFT STATIONARY · MOTOR WIRES DISCONNECTED FROM CIRCUIT BOARD Values are approximate only - resistance varies between motors, and also varies with temperature.

Section 8 - Page 11

Braemar TG series gas ducted heater technical & training manual

March 2007

8.2.6.3

Room fan voltage vs fan speed setting

APPROXIMATE room fan voltage - Vac (Vac rms) Maximum set fan speed (7/8/9/10)

Displayed fan speed 1 2 3 4 5 6 7 8 9 10

Note:

7 70 (97) 73 (101) 77 (105) 80 (109) 88 (117) 93 (122) 102 (130) 106 (134) 114 (141) 127 (152)

8 70 (97) 73 (101) 76 (105) 84 (113) 92 (121) 100 (129) 108 (137) 117 (145) 129 (156) 141 (165)

9 70 (97) 72 (100) 75 (104) 83 (112) 91 (120) 104 (132) 116 (144) 121 (148) 141 (166) 164 (186

10 70 (97) 73 (101) 80 (109) 88 (117) 96 (125) 108 (137) 121 (148) 141 (166) 164 (186) 236 (238)

Fan voltages are approximate and will vary with supply voltage, motor load and from heater to heater. Voltages above measured with 240Vac supply to heater. A true rms multi meter is recommended.

8.2.6.4

Gas valve coil resistance

· 3.5 - 4.5 ohms 3.5 - 4.5 ohms 3.5 - 4.5 ohms

TG3 heaters (White Rodgers model 36G22): TG4/5 heaters (White Rodgers model 36G54):

· HI-C · M-C

8.2.6.5

TG3 heaters: P-100 ·

Pressure switch ratings

Switch opens at 100 Pa (connected to EFS unit, red and purple wires)

TG4/5 heaters: P-55 P-100 · · Switch opens at 55 Pa (connected to EFS unit, red and purple wires) Switch opens at 100 Pa (connected to BSC and HI coil on gas valve, blue and yellow wires)

Section 8 - Page 12

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3 8.3.1 8.3.1.1

Thermostat - Spectrolink Comfort Control (SCC) Diagnostic codes Diagnostic code definitions 3 STAR HEATERS

Code No 1 2 3 7 9 Description P-100 closed at start P-100 failed to close P-100 open during run Ignition failure Internal memory failure HX OT1 opened EFS shutdown HX OT2 open at start Shut down type L1 L1 SSD L1 L2 SSD/L1 SSD/L1 L2 SCC display Reset, 1 Reset, 2 Normal Reset, 7 Reset, 9 Normal Normal Reset, 19 Detailed description 5.3.1.2 5.3.1.3 5.3.1.4 5.3.1.8 5.3.1.9 5.3.1.10 5.3.1.11 5.3.1.19

*

10 11 19

4 & 5 STAR HEATERS

Code No 1 2 3 Description P-55 closed at start P-55 failed to close P-55 open during run Thermistor > 70 C during run Thermistor not connected or short circuit OT4 opened (5 star only) Ignition failure Vacant Internal memory failure HX OT1 opened EFS shutdown P-100 closed at start P-100 failed to close P-100 open > 30 sec during run Thermistor in cool location in duct Thermistor not installed in outlet duct Condensate detected in run Condensate detected at start HX OT2 open at start

o

Shut down type L1 L1 SSD SSD L1 SSD L1 L2 SSD/L1 SSD/L1 L1 L1 SSD L1 L1 SSD L1 L2

SCC display Reset, 1 Reset, 2 Normal Normal Reset, 5 Normal Reset, 7 Reset, 9 Normal Normal Reset, 12 Reset, 13 Normal Reset, 15 Reset, 16 Normal Reset, 18 Reset, 19

Detailed description 5.3.1.2 5.3.1.3 5.3.1.4 5.3.1.5 5.3.1.6 5.3.1.7 5.3.1.8 5.3.1.9 5.3.1.10 5.3.1.11 5.3.1.12 5.3.1.13 5.3.1.14 5.3.1.15 5.3.1.16 5.3.1.17 5.3.1.18 5.3.1.19

*

#

4 5 6 7 8 9

* *

10 11 12 13 14 15 16

# #

17 18 19

#

*

SSD L1

5 star heaters only. Shut down type dependent on current operating status. Safety shut down: Lockout 1: Reset not required. User reset from SCC, or Manual t/stat off-on-off-on - wait 5 seconds at each state, or Power off - power on. Reset from SCC service mode only

Section 8 - Page 13

L2

Lockout 2:

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.2

Diagnostic code 1

3 star heaters: 4/5 star heaters:

P-100 closed at start P-55 closed at start

Description: The BSC has detected that the pressure switch connected to the EFS unit is closed at the start of an ignition sequence without the combustion fan running - '01' shown in time display. SCC Display: Diagnostic code

MAN HEAT RESET OFF HEAT RESET MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Faulty pressure switch - contacts stuck in closed position.

Potential Remedies Replace pressure switch: 3 star: P/No 630397 (open at 100 Pa) 4* & 5 star: P/No 628547 (open at 55 Pa) TG435* only: P/No 630403 (open at 55 Pa) Replace EFS unit: 3/4/5 star: P/No 628608 Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Drill 0.5mm diameter hole in centre the suction tube tee connector (pre-drilled tee available, P/No 628523).

Combustion fan on as soon as call for heat received - combustion fan relay on EFS welded closed. Condensate blocking suction hose or connnection nipple on combustion fan - 5 STAR ONLY.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 14

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.3

Diagnostic code 2

3 star heaters: 4/5 star heaters:

P-100 failed to close P-55 failed to close

Description: The BSC has detected that the pressure switch connected to the EFS unit did not close when required at the start of an ignition sequence - '02' shown in time display. SCC Display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator ('-' displays with diagnostic code if 'system setup' routine not completed - 2006 version only)

Potential Causes Flue cowl pushed too far onto flue pipe causing combustion air flow restriction. Flue system blockage causing combustion air flow restriction. Combustion fan suction pressure hose damaged or disconnected from pressure switch or combustion fan. Wiring disconnected or damaged. Combustion fan blocked. Combustion fan dislodged/jammed.

Potential Remedies Check and re-fit flue cowl correctly if required.

Check flue system - clear blockage if required. Check and re-fit/replace combustion fan suction pressure hose. Check and re-fit or replace wiring if required. Check combustion fan for blockage - clear if required. Check combustion fan motor mounts to ensure that fan is not jammed - rectify mounting if required. Replace pressure switch: 3 star: P/No 630397 (open at 100 Pa) 4 & 5 star: P/No 628547 (open at 55 Pa) TG435* only: P/No 630403 (open at 55 Pa) Check combustion fan is receiving 240 Vac at the appropriate time - if it still does not run replace combustion fan. Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Drill 0.5mm diameter hole in centre the suction tube tee connector (pre-drilled tee available, P/No 628523). Check both ends of pressure tapping are clear of swarf - remove combustion fan to check inside end. Remove swarf if necessary.

Faulty pressure switch - contacts stuck in open position.

Faulty combustion fan.

Condensate blocking suction hose or connnection nipple on combustion fan - 5 STAR ONLY.

Plastic swarf blocking or partly blocking plastic pressure tapping - 5 STAR ONLY.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 15

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.4

Diagnostic code 3

3 star heaters: 4/5 star heaters:

P-100 open during run P-55 open during run

Description: The BSC has detected that the pressure switch connected to the EFS unit has opened during run mode. This results in the EFS unit immediately shutting off the gas valve. SCC Display: This diagnostic code is not displayed - the normal SCC display remains. Potential Causes Severe wind on flue terminal or poor flue terminal location (eg, too close to roof). Potential Remedies Check location and distance from roof - extend flue pipe if required. Also check that flue cowl is not pushed too far on to flue pipe, and that flue is not partly blocked - both of these will cause some flue restriction and make pressure switch operation more susceptible to wind effects. Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Check both ends of pressure tapping are clear of swarf - remove combustion fan to check inside end. Remove swarf if necessary.

Condensate blocking suction hose or connnection nipple on combustion fan. Plastic swarf blocking or partly blocking plastic pressure tapping - 5 STAR ONLY.

Reset: The system will record the diagnostic code and reset automatically once the condition has cleared - a manual reset is not required.

Section 8 - Page 16

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.5

Diagnostic code 4

3 star heaters: 4/5 star heaters:

Not applicable Thermistor > 70oC during run

Description: The BSC has detected that the outlet duct thermistor has reached 70oC during run mode. This results in the gas being shut off, with a re-ignition sequence commencing once the thermistor has cooled to 60oC - normal display. If the thermistor does not cool to 60oC in 10 minutes the system goes to lockout 1 - 04 shown in time display. SCC display: Diagnostic code 4 is recorded but not displayed. If the thermistor does not cool to less than 60oC within 10 minutes then the thermistor is faulty and diagnostic code 5 is displayed. Potential Causes Low room air flow due to user selection of a low fan speed, or automatic selection of a low fan speed when heating only a small zone. Low room air flow due to poor ducting design or installation. Potential Remedies NORMAL OPERATION.

Check the following: · Sufficient outlets installed for heater size. · Correct duct diameter for supply and return air ducts. · Long duct runs not too small in diameter. · Return air grille sized correctly. · Return air filter clean. · Ducting installed without excessive/tight radius bends. · Ducting not squashed. Check thermistor location - should be 3m along the duct from heater outlet - re-fit if required. Check maximum room fan voltage - if not approx' 240 Vac - check/increase maximum fan speed - see section 5.2.1.

Thermistor too close to heater outlet. Maximum room fan speed set too low during 'system setup' routine.

Reset: In normal operation the system will record the diagnostic code and reset automatically once the condition has cleared - a manual reset is not required. If the thermistor fails to cool to 60oC within 10 minutes the system goes to lockout 1 and requires the following reset procedure: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 17

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.6

Diagnostic code 5

3 star heaters: 4/5 star heaters:

Not applicable Thermistor not connected or SC

Description: The BSC has detected that the outlet duct thermistor is not connected at the BSC circuit board or short circuited. This prevents the system from starting. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Thermistor inadvertently disconnected during installation. Thermistor damaged during installation, or in use.

Potential Remedies Check thermistor connection on BSC - reconnect if required. Check thermistor cable for damage - replace if damaged. 4 & 5 star: P/No 611136 - thermistor P/No 613963 - thermistor bracket Check thermistor sensor or cable for damage replace if damaged. 4 & 5 star: P/No 611136 - thermistor P/No 613963 - thermistor bracket

Thermistor failed to cool to 55oC after turning gas off at 70oC.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - wait 5 seconds - turn thermostat on, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 18

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.7

Diagnostic code 6

3/4 star heaters: 5 star heaters:

Not applicable OT4 open during run

Description: The BSC has detected that the over-temperature switch mounted on the plastic flue terminal on 5 star heaters (OT4) has opened during run mode. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Diagnostic code "06" is displayed only if the switch does not close in less than 10 minutes, otherwise the normal SCC display remains.

Potential Causes Low room air flow due to poor ducting design or installation. Faulty OT4 switch.

Potential Remedies See section 5.3.1.10. Check OT4 - should be closed when cool. Replace if faulty. 5 star only: P/No 611518 (80oC open) See section 5.3.1.10.

Thermistor too far from heater outlet.

Reset: The system will record the diagnostic code and reset automatically once the condition has cleared - the room fan will run for up to 10 minutes to attempt to cool and close the switch. If the switch closes a manual reset is not required. If the switch does not close within 10 minutes the system will proceed to lockout 1, and will require the following reset procedure: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 19

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.8

Diagnostic code 7

3/4/5 star heaters:

Ignition failure

Description: The BSC has detected that the EFS unit has failed to establish flame after 3 ignition attempts. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Gas supply turned off at heater, gas meter, or gas valve on/off switch. Ignition lead damaged or disconnected. Incorrect gas supply pressure.

Potential Remedies Check gas supply, turn on if required. Check ignition lead. Re-connect, or replace if faulty. 3/4/5 star: P/No 625430 Check gas supply pressure with ducted heater and all other gas appliances operating - must be at least 1.13 kPa for natural gas, and 2.75 kPa for propane. Check fitting line size/meter outlet pressure if unable to achieve required minimum supply pressure. Check gas pressure at test point on gas valve outlet - adjust if outside the following limits: Natural gas: 0.87 +/- 0.05 kPa Propane: 2.25 +/- 0.1 kPa Check spark gap - must be 3mm from burner face - adjust if required. Check OT3 - press button on switch - it will click only if switch was open and is below approximately 80oC. Check flame sense lead is connected at flame sense electrode and at EFS unit. Check that flame sense lead is not damaged or shorted. Check flame sense gap - should be 3-4mm to burner face.

Incorrect burner pressure.

Incorrect spark gap. OT3 open (located on burner cover).

EFS not detecting flame signal ignition occurs but gas turns off after approximately 7 seconds.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 20

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.9

Diagnostic code 9

3/4/5 star heaters:

Internal memory error

Description: The BSC has detected an internal fault. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

Spanner indicates 'lockout 2'

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Internal memory error - faulty BSC circuit board.

Potential Remedies Turn power off, wait 5 seconds, turn power on. Attempt reset from SCC service mode as detailed below - if fault cannot be cleared replace BSC.

Reset: After the fault has been rectified, reset from service mode: · Open door on SCC. · To enter service mode press and hold 'zone 3' button for 5 seconds. · Wait 5 seconds - latest recorded diagnostic code will display with 'F01', 'RESET' will flash. · Press 'RESET' button. · To clear recorded codes press and hold the 'FAN' button for 5 seconds. · To exit service mode close the door on the SCC and press the ON/OFF button.

Section 8 - Page 21

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.10

Diagnostic code 10

3/4/5 star heaters:

HX OT1 open at start or in run

Description: The BSC has detected that the heat exchanger over temperature switch 1 (HX OT1) is either open at the start of an ignition sequence, or has opened during run mode. The room fan will run for up to 10 minutes to attempt to cool and close the switch. While HX OT 1 is open the red LED on the EFS unit will flash each time the switch is checked (approximately every 15 seconds) until HX OT 1 closes. SCC display:

HEAT RESET

Diagnostic code

MAN OFF HEAT RESET MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

Diagnostic code "10" is displayed only if the switch does not close in less than 10 minutes, otherwise the normal SCC display remains.

System setup indicator ('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes 3/4/5 star: Low room air flow due to poor ducting design or installation.

Potential Remedies Check the following: · Sufficient outlets installed for heater size. · Correct duct diameter for supply and return air. · Long duct runs not too small in diameter. · Return air grille sized correctly. · Return air filter clean. · Ducting installed without tight radius bends. · Ducting not squashed. Check maximum room fan voltage - if not approx' 240 Vac - check/increase maximum fan speed - see section 5.2.1. Check HX OT1 - should be closed when cool. Replace if faulty. 4 star: P/No 611581 (80oC open) 3 & 5 star: P/No BGH-262 (60oC open) Check thermistor location - should be 3m along the duct from heater outlet - re-fit if required. In normal operation, and with low air flow, the gas will be switched to low and off based on the temperature of the thermistor. It should only switch HX OT1 if the thermistor is in a slightly cooler than average location. Check thermistor location.

3/4/5 star: Maximum room fan speed set too low during 'system setup' routine. 3/4/5 star: Faulty HX OT1 - switch open when cool. 4/5 star: Thermistor too far from heater outlet. 4/5 star: Low room air flow due to user selection of a low fan speed, or automatic selection of a low fan speed when heating only a small zone.

Reset: The system will record the diagnostic code and reset automatically once the condition has cleared - the room fan will run for up to 10 minutes to attempt to cool and close the switch. If the switch closes a manual reset is not required. If the switch does not close within 10 minutes the system will proceed to lockout 1, and will require the following reset procedure: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 22

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.11

Diagnostic code 11

3/4/5 star heaters:

EFS shutdown

Description: The BSC has detected that the EFS unit has de-energised the gas valve due to loss of flame signal when in run mode, or that the EFS unit has failed to energise the gas valve during the flame establishment period. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Diagnostic code "11" is displayed only if the EFS unit fails to energise the gas valve during the flame establishment period. If the flame signal is lost during run mode the normal SCC display remains.

Potential Causes EFS has lost flame signal.

Potential Remedies · Check gas pressure (test point on gas valve outlet) with ducted heater running on HIGH gas adjust only if outside 0.87 +/- 0.05 kPa for natural gas, or 2.25 +/- 0.10 kPa for propane. · Check gas pressure (test point on gas valve outlet) with ducted heater running on LOW gas adjust only if outside 0.40 +/- 0.02 kPa for natural gas, or 1.00 +/- 0.10 kPa for propane. · Check location of flame sense electrode - must be in flame - adjust location if required. · Check flame sense lead is connected and not damaged - re-fit of replace wiring loom if required. 3 star: P/No 628615 4 star: P/No 628622 5 star: P/No 628639

Reset: If the flame signal is lost during run mode the system will record the diagnostic code and reset automatically once the condition has cleared - a manual reset is not required. If the EFS unit fails to energise the gas valve during the flame establishment period the system will go to lockout 1 status and the following reset procedure is required: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 23

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.12

Diagnostic code 12

3 star heaters: 4/5 star heaters:

Not applicable P-100 closed at start

Description: The BSC has detected that the pressure switch connected to the high/low coil on the gas valve unit is closed at the start of an ignition sequence without the combustion fan running. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Faulty pressure switch - contacts stuck in closed position. Condensate blocking suction hose or connnection nipple on combustion fan - 5 STAR ONLY.

Potential Remedies Replace pressure switch: 4* & 5 star: P/No 630397 (open at 100 Pa) TG435* only: P/No 619453 (open at 100 Pa) Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Drill 0.5mm diameter hole in centre the suction tube tee connector (pre-drilled tee available, P/No 628523).

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 24

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.13

Diagnostic code 13

3 star heaters: 4/5 star heaters:

Not applicable P-100 failed to close

Description: The BSC has detected that the pressure switch connected to the high/low coil on the gas valve did not close when required at the start of an ignition sequence. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Flue cowl pushed too far onto flue pipe causing combustion air flow restriction. Flue system blockage causing combustion air flow restriction. Combustion fan suction pressure hose damaged or disconnected from pressure switch or combustion fan. Wiring disconnected or damaged. Combustion fan blocked. Combustion fan dislodged/jammed.

Potential Remedies Check and re-fit flue cowl correctly if required.

Check flue system - clear blockage if required. Check and re-fit/replace combustion fan suction pressure hose. Check and re-fit or replace wiring if required. Check combustion fan for blockage - clear if required. Check combustion fan motor mounts to ensure that fan is not jammed - rectify mounting if required. Replace pressure switch: 4* & 5 star: P/No 630397 (open at 100 Pa) TG435* only: P/No 619453 (open at 100 Pa) Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Drill 0.5mm diameter hole in centre the suction tube tee connector (pre-drilled tee available, P/No 628523). Check both ends of pressure tapping are clear of swarf - remove combustion fan to check inside end. Remove swarf if necessary.

Faulty pressure switch - contacts stuck in open position. Condensate blocking suction hose or connnection nipple on combustion fan - 5 STAR ONLY.

Plastic swarf blocking or partly blocking plastic pressure tapping - 5 STAR ONLY.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 25

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.14

Diagnostic code 14

3 star heaters: 4/5 star heaters:

Not applicable P-100 open during run

Description: The BSC has detected that the pressure switch connected to the high/low coil on the gas valve has opened while running on high gas. If the switch opens the high/low coil on the gas valve is de-energised causing the gas rate to switch to low (combustion fan remains on high) - if it closes again within 30 seconds the gas switches back to high rate. If it does not close within 30 seconds the BSC shuts down the EFS turning off all gas. Diagnostic code 14 is recorded only if the switch is open for more than 30 seconds. SCC display: This diagnostic code is not displayed - the normal SCC display remains. Potential Causes Severe wind on flue terminal or poor flue terminal location (eg, too close to roof). Potential Remedies Check location and distance from roof - extend flue pipe if required. Also check that flue cowl is not pushed too far on to flue pipe, and that flue is not partly blocked - both of these will cause some flue restriction and make pressure switch operation more susceptible to wind effects. Check and clear blockage. Fit flue condensate drain components (supplied with 5 star internal installation kits). Check both ends of pressure tapping are clear of swarf - remove combustion fan to check inside end. Remove swarf if necessary.

Condensate blocking suction hose or connnection nipple on combustion fan. Plastic swarf blocking or partly blocking plastic pressure tapping - 5 STAR ONLY.

Reset: The system will record the diagnostic code and reset automatically once the condition has cleared - a manual reset is not required.

Section 8 - Page 26

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.15

Diagnostic code 15

3 star heaters: 4/5 star heaters:

Not applicable Thermistor in cool location in heater outlet duct

Description: The BSC has detected that the outlet duct thermistor is installed in a cool location in the heater outlet duct. If the BSC detects that HX OT1 has opened multiple times in a one heating cycle the 'thermistor-off-temperature' (normally 70oC) is reduced in steps until it reaches a pre-set minimum limit. When it reaches the minimum limit the system is shutdown and requires a manual reset . This procedure is to prevent excessive cycling of HX OT1. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Thermistor too far from heater outlet. Thermistor in duct in which air flow can be shut off in zoned system, with one outlet duct connected to heater.

Potential Remedies Check thermistor location - should be 3m along the duct from heater outlet - re-fit if required. Check thermistor location - re-locate to duct that always has air flow if possible. If this is not possible install multiple thermistor kit and fit a thermistor into each heater outlet duct, both must be 3m from heater outlet. 4 & 5 star: P/No 077253 Check thermistor location - re-locate to duct that always has air flow if possible, or install multiple thermistor kit and fit a thermistor into each heater outlet duct, both must be 3m from heater outlet. 4 & 5 star: P/No 077253

Thermistor in duct in which air flow can be shut off in zoned system, and where more than one outlet duct is connected directly to the heater.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - on -off - on - wait 5 seconds at each state, OR · Turn power off - wait 5 seconds - turn power on

Section 8 - Page 27

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.16

Diagnostic code 16

3 star heaters: 4/5 star heaters:

Not applicable Thermistor not in outlet duct

Description: The BSC has detected that the outlet duct thermistor is not installed. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Thermistor not installed, or has been removed from duct.

Potential Remedies Fit thermistor into heater outlet duct - should be 3m along the duct from heater outlet.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - wait 5 seconds - turn thermostat on, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 28

Braemar TG series gas ducted heater technical & training manual

March 2007

5.3.1.17

Diagnostic code 17

3/4 star heaters: 5 star heaters:

Not applicable Condensate detected in run

Description: The BSC has detected condensate during run mode. SCC display: This diagnostic code is not displayed - the normal SCC display remains. Potential Causes Condensate drain transit plug left in heater at installation. Potential Remedies Check condensate drain plug - remove plug and fit condensate drain. TAKE CARE REMOVING DRAIN PLUG, HAVE SUITABLE CONTAINER READY TO COLLECT THE CONDENSATE. Check condensate drain - clear blockage if required. Check condensate drain - re-route if required. Check heater - must be level in both directions rectify if required. Check installation - rectify if required.

Condensate drain blocked. Condensate drain running up-hill away from heater. Heater not level. Flue condensate drain kit (internal heaters only) not fitted or not fitted correctly.

Reset: The system will record the diagnostic code and reset automatically once the condition has cleared - a manual reset is not required.

Section 8 - Page 29

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.18

Diagnostic code 18

3/4 star heaters: 5 star heaters:

Not applicable Condensate detected in run

Description: The BSC has detected condensate during start-up, or has detected condensate during run mode that has not cleared within 10 minutes. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Condensate drain transit plug left in heater at installation.

Potential Remedies Check condensate drain plug - remove plug and fit condensate drain. TAKE CARE REMOVING DRAIN PLUG, HAVE SUITABLE CONTAINER READY TO COLLECT THE CONDENSATE. Check condensate drain - clear blockage if required. Check condensate drain - re-route if required. Check heater - must be level in both directions rectify if required. Check installation - rectify if required.

Condensate drain blocked. Condensate drain running up-hill away from heater. Heater not level. Flue condensate drain kit (internal heaters only) not fitted or not fitted correctly.

Reset: After the fault has been rectified: · Press RESET on SCC thermostat, OR · Turn manual thermostat off - wait 5 seconds - turn thermostat on, OR · Turn power off - wait 5 seconds - turn power on.

Section 8 - Page 30

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.1.19

Diagnostic code 19

3/4/5 star heaters:

HX OT2 open at start

Description: The BSC has detected that heat exchanger over temperature switch 2 (HX OT2, 130oC) is open at start-up and heat exchanger over-temperature switch 1 (HX OT1, 60 or 80oC) is closed - the system goes to 'lockout 2' and can only be reset using a Braemar SCC from service mode. This switch is connected in the 24V supply line to the gas valve on/off coil - if it is open the heater cannot operate. This indicates that either or both HX OT1 or HX OT2 is faulty - both switches should be replaced. SCC display:

MAN HEAT RESET OFF HEAT RESET

Diagnostic code

MAN ON WAIT

WE D

MAN HEAT RESET ZONE 1 2 3 4 ON WAIT

WE D

WE D

HOME

HOME

Spanner indicates 'lockout 2'

ZONE 1 2 3 4

OFF MODE

ON MODE

System setup indicator

('-' displays with diagnostic code if 'system setup' routine not completed 2006 version only)

Potential Causes Wiring disconnected from HX OT2. Faulty HX OT1 (switch does not open when hot), and or faulty HX OT2 (switch open when cool).

Potential Remedies Check wiring - re-connect if required. REPLACE BOTH HX OT1 and HX OT2: HXOT1: 4 star: P/No 611518 (80oC open) 3 & 5 star: P/No BGH-262 (60oC open) HX OT2: 3/4/5 star: P/No 628646 (130oC open) After replacing both switches check system for normal operation and normal air flow rates.

Reset: After the fault has been rectified, reset from service mode: · Open door on SCC. · To enter service mode press and hold 'zone 3' button for 5 seconds. · Wait 5 seconds - latest recorded diagnostic code will display with 'F01', 'RESET' will flash. · Press 'RESET' button. · To clear recorded codes press and hold the 'FAN' button for 5 seconds. · To exit service mode close the door on the SCC and press the ON/OFF button.

Section 8 - Page 31

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.2 8.3.2.1

Lockout states and reset procedure Lockout 1

In 'lockout 1' state the gas valve and combustion fan are turned off and the room fan runs down normally. The relevant diagnostic code No is shown in the time display of the SCC and "RESET" flashes. To reset from 'Lockout 1' using a conventional (2-wire) thermostat do one of the following: · Turn thermostat off-on-off-on, wait 5 seconds at each state, OR · Turn power off, wait 5 seconds, turn power on. To reset from 'Lockout 1' using a Braemar SCC thermostat do one of the following: · Open SCC door, pres RESET button, close SCC door, OR · Turn power off, wait 5 seconds, turn power on. Once the RESET signal is received the system will attempt to re-start normally. If the condition that caused the 'lockout 1' state is still present, the system will go back into 'lockout 1' state. Diagnostic code

MAN HEAT RESET OFF HEAT RESET MAN ON WAIT

WE D

Lockout 1 display

WE D

HOME

ZONE 1 2 3 4

OFF MODE 8.3.2.2 Lockout 2

ON MODE

In 'lockout 2' state the gas valve and combustion fan are turned off and the room fan runs down normally. A spanner symbol will appear on the display (Braemar SCC thermostat), the relevant diagnostic code (see section 5.3.1) will be displayed in the time location and RESET flashes. To reset from 'lockout 2' a Braemar SCC thermostat is required and a reset signal must be sent from 'service mode' as follows: · Open SCC door, · To enter service mode press and hold 'zone 3' button for 5 seconds, · Wait 5 seconds - latest recorded diagnostic code will display with 'F01', 'RESET' will flash, · Press 'RESET' button, · To clear recorded codes press and hold the 'FAN' button for 5 seconds, · To exit service mode close the door on the SCC and press the ON/OFF button. Once the RESET signal is received (refer table above) the system will attempt to re-start normally. If the fault condition is still present, the system will go back into 'lockout 2' status. Diagnostic code

MAN HEAT RESET OFF HEAT RESET MAN ON WAIT

WE D

Lockout 2 display

Spanner indicates 'lockout 2'

WE D

HOME

ZONE 1 2 3 4

OFF MODE

Section 8 - Page 32

ON MODE

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.3

Retrieving and clearing recorded diagnostic codes

The 10 latest diagnostic codes are recorded on the BSC and are able to be accessed using a Braemar SCC thermostat as follows: To enter 'service mode': · Press ON/OFF button to turn SCC off, · Open SCC door, · Press 'zone 3' button and hold for 5 seconds. The display will show the latest recorded diagnostic code, 'F01', as follows: F01 Latest recorded diagnostic code

Diagnostic code

To scroll through the 10 latest recorded diagnostic codes: · Press the UP or DOWN arrow button on the SCC. F10 Earliest recorded diagnostic code

Diagnostic code

RECORDED DIAGNOSTIC CODES MUST BE CLEARED WHEN SERVICING HAS BEEN COMPLETED. To do this: · Press and hold the FAN button on the SCC for 5 seconds. Note - for systems with multiple SCC's this function is available on the 'Master' SCC only. 8.3.4 Communication check

When a Braemar SCC is connected to the BSC a communication check is performed to ensure correct communication between the SCC and the BSC. The SCC will display either 'yes' or 'no' to indicate the communication status as follows:

A communication check can also be initiated from the 'master' SCC (the one connected to the BSC) from service mode as follows: · Press ON/OFF button to turn SCC off, · Open SCC door, · Press 'zone 3' button and hold for 5 seconds (display will now show recorded diagnostic codes - see section 5.3.3) · Press 'zone 4' button - the display will show 'yes' or 'no' as above. If a 'no' is shown check the following: · Each end of the loom is plugged in correctly, · Condition of tthe loom between the SCC and BSC - replace if damaged, · Heater type must be set to 'HEAT 3' for TG series heaters (see section 5.2.1.2). Note - for systems with multiple SCC's this function is available on the 'Master' SCC only.

Section 8 - Page 33

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.5

Checking hours of operation

The number of hours that the heater has run on high and low gas can be retrieved using a Braemar SCC thermostat as follows: To enter 'service mode': · Press ON/OFF button to turn SCC off, · Open SCC door, · Press 'zone 3' button and hold for 5 seconds. The display will initially show the latest recorded diagnostic code (see section 5.3.3). To check hours of operation: HIGH GAS: LOW GAS: Press 'ZONE 1' button Press 'ZONE 2' button

The display will show hours of operation as follows: HIGH gas rate

LOW gas rate

To exit this mode close the SCC door and press the 'ON/OFF' button. To reset the hours of operation: · In the OFF mode simultaneously hold down the 'ZONE 1' and 'ZONE 2' buttons for more than 1 second. Note - for systems with multiple SCC's this function is available on the 'Master' SCC only. 8.3.6 Program settings check

Enter programming mode: · Open the SCC door and press the 'MAN/AUTO' button to place the SCC in 'AUTO' mode. · Using the down arrow button reduce the set temperature below the displayed room temperature to ensure that the SCC is in 'STANDBY' mode (ie, not calling for heat). · Press the 'SET' button. The SCC will now scroll through the following sequence with the current item flashing pressing 'SET' will accept the selection - use the up/down arrows to adjust if required then press 'SET'.

Days for program to apply: Mon - Fri Sat - Sun Mon - Sun Individual days WAKE PERIOD: Start time Set temperature Fan speed Zones open AWAY PERIOD: Start time Set temperature Fan speed Zones open HOME PERIOD: Start time Set temperature Fan speed Zones open SLEEP PERIOD: Start time Set temperature Fan speed Zones open

Check the start times for each time period, the set temperatures, fan speeds and zones on to ensure that they match the customer's requirements. Note - for systems with multiple SCC's this function is available on the 'Master' SCC only.

Section 8 - Page 34

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.7

Restore SCC factory default program settings

The factory default program settings can be restored using the following procedure: With the SCC in the OFF mode: · Open the SCC door · Press and hold the small door button (to do this you will need something around 3mm diameter · With the door button still held down, press the zone 3 buttton. Factory default times, temperatures, zones and fan speeds have now been restored. Note - for systems with multiple SCC's this function is available on the 'Master' SCC only. 8.3.8 Security Lock - activate and deactivate procedure

When the security lock is enabled the heater will only run for 1 hour then lockout - the display will show 'LOC' and the spanner symbol. To deactivate the security lock a 4-digit code must be entered. DEACTIVATE SECURITY LOCK: · Contact Seeley International Techhnical Support (1300 650 399) and supply the relevant heater information (heater serial number, owners name/address) - the unlock code for the heater will be provided. · Disconnect the SCC from the loom, discharge the capacitor at the back of the control then reconnect the loom to the control. · With the SCC in OFF mode press and hold the 'ZONE 4' button then press 'SET'. · The display will show 'SET', 'CdE' and '2' - this indicates that the security lock is active. · Using the zone 1 to 4 buttons enter the security code supplied. · The display will show 'SET', 'CdE' and '1'. · Press 'SET' - the security lock is now deactivated.

SET 2

SET 1

Security lock active. Heater has locked out.

Security lock active. Enter unlock code using zone 1 to 4 buttons.

Security lock deactivated. Press 'SET' to resume normal operation.

1 = SECURITY LOCK DEACTIVATED HEATER UNLOCKED 2 = SECURITY LOCK ACTIVATED HEATER LOCKED CAUTION

Pressing 'SET' with 'SET', 'CdE' and '2' displayed will activate the security lock.

Note - for systems with multiple SCC's this function is available on the 'Master' SCC only.

Section 8 - Page 35

Braemar TG series gas ducted heater technical & training manual

March 2007

8.3.9

Checking the duct air temperature (TG4 and TG5 heaters only)

To determine the approximate heater outlet air temperature: · Press the up and down arrow buttons simultaneously and hold for around 5 seconds · The display will show the temperature sensed by the duct thermistor in the normal temperature display for around 15 seconds then revert to the normal display

MAN HEAT ON

WE D

Thermistor temperature

HOME

ZONE 1 2 3 4

Note - for systems with multiple SCC's this function is available on the 'Master' SCC only.

Section 8 - Page 36

Braemar TG series gas ducted heater technical & training manual

March 2007

8.4

Ductwork checks

The standard of the ductwork design and installation has a significant effect on the operation of the heating system. Poor ducting can lead to a reduced total air flow rate which can decrease the overall effectiveness of the heating system. It can also contribute to poor balancing of air flows between different heated areas. The following points provide a guide to checking characteristics of the ducting system which can effect system performance. Item Duct sizing: Check · Long runs of small diameter ductwork must be avoided to prevent excessive air flow restriction · Main ducts should run to areas that require the highest air flow - eg, main living areas · Branch ducts should run to areas that require less air flow · Bends in ducting should not be less than the values listed below and must not be squashed Duct diameter (mm) 150 200 250 300 350 400 Duct supports: Duct sealing: Return air: Minimum bend radius (mm) 200 300 350 450 700 800

Duct bend radius:

· Duct should be supported at 1m intervals with suitable hanging tape to prevent excessive sagging · There should be no air leakage from ductwork or connections · The return air grille must be located at a low level for installations using ceiling outlets to help prevent poor heated air distribution. · The return air grille must be correctly sized to minimise noise and air flow restriction - see section 5.2.1.1. · The return air filter must be cleaned regularly. · Ensure that adequate relief air openings exist to allow a clear path from supply air outlets back to the return air grille. The air velocity through relief air openings should not exceed 2 m/sec to minimise noise and air flow restriction. · Check that the air flow at all outlets with all outlets open is balanced - adjust if required

Air flow balancing:

Section 8 - Page 37

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