BROMIC 300 Burner Tungsten Smart Heat Gas Heater Instruction Manual

BROMIC 300 Burner Tungsten Smart Heat Gas Heater

Product Information

The Tungsten Smart-HeatTM Gas Heater by Bromic is a gas radiant heater suitable for outdoor or amply ventilated area use and non-residential indoor application. The heater is available in two models: Tungsten 300 – Burner and Tungsten 500 – Burner. The appliance is designed to be connected only to reticulated gas and installed in accordance with AS/NZS 5601. The product features Honeywell control, Honeywell valve, Brahma control box, Dungs gas valve, and White Rodgers gas valve. The installation, instruction, and service manual contain detailed information about the assembly, operation, and maintenance of the Tungsten Smart-HeatTMHeaters.

Product Usage Instructions

Before using the Tungsten Smart-HeatTM Gas Heater, it is important to read the installation, operating, and maintenance instructions thoroughly. Any safety information will be accompanied by the following safety alert symbols: ! DANGER, ! WARNING, !

IMPORTANT. Here are some important usage instructions:

Gas Usage

• If you smell gas, shut off gas to the appliance immediately.
• Do not store or use petrol or other flammable vapor and liquids in the vicinity of this or any other appliance.
• Make sure to use an approved pressure limiting regulator during installation to prevent damage.

Installation Requirements

• Follow the installation requirements mentioned in the manual for proper installation of the heater.
• The appliance should be installed in outdoor or amply ventilated areas and non-residential indoor applications only.

Operating Instructions

• Follow the operating instructions mentioned in the manual to turn the appliance on and off.
• Make sure to maintain an optimum mounting distance to ensure proper functioning of the heater.

Maintenance and Servicing

• Regular servicing is required to keep the heater functioning properly.
• Exterior servicing should be done to clean and maintain the heater’s appearance.

Troubleshooting

• If you come across any issues while using the heater, refer to the troubleshooting section of the manual for assistance.

TUNGSTEN SMART-HEATTM GAS HEATER
BY BROMIC
INSTALLATION, INSTRUCTION AND SERVICE MANUAL
SUITABLE FOR GAS RADIANT HEATER MODELS: TUNGSTEN 300 – BURNER AND TUNGSTEN 500 – BURNER

!
If you smell gas:

DANGER

1. Shut off gas to the appliance

2. Extinguish any open flame

3. If odor continues, keep away from the appliance and immediately call your gas supplier or fire department.

! WARNING: For Outdoor or Amply
Ventilated area use and for NON RESIDENTIAL INDOOR APPLICATION
Version 4.4 AUS

! WARNING
Do not store or use petrol or other flamable vapor and liquids in the vicinity of this or any other appliance.
This appliance to be connected only to reticulated gas & installed in accordance with AS/NZS 5601
! WARNING: Improper installation,
adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

!
This manual contains important information about the assembly, operation, and maintenance of Tungsten Smart-HeatTM Heaters. Please pay close attention to the important safety information shown throughout this instruction manual. Any safety information will be accompanied by the
following safety alert symbols: ! DANGER, ! WARNING, ! IMPORTANT
· READ THIS MANUAL CAREFULLY before installing or servicing this product.
· Improper installation, operation, or maintenance can result in death, severe injury, or property damage.
· Installation must be carried out by Authorised person/s in accordance with AS5601 Gas Installation Code.
· This appliance is to be used ONLY for outdoor and nonresidential indoor use (minimum room volume must be 250m3)
· When installed outdoors this appliance MUST be protected

Head Office: 10 Phiney Place, Ingleburn, Sydney, NSW 2565 Australia T: 1300 276 642 (within Australia) or +61 2 9748 3900 (from overseas) F: +61 2 9748 4289
E: info@bromicheating.com W: www.bromic.com.au

Note: Bromic Heating reserves the right to make changes to specifications, parts, components and equipment without prior notification. This Installation, operation and service manual may not be reproduced in any form with prior written consent from Bromic Heating.

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CONTENTS

IMPORTANT NOTES & WARNINGS

PRODUCT OVERVIEW

PRODUCT DESCRIPTION

SPECIFICATIONS

GENERAL INFORMATION

PRODUCT FEATURES

INSTALLATION REQUIREMENTS

GAS REQUIREMENTS

INSTALLATION CLEARANCES

INSTALLATION INSTRUCTIONS

HEATER INSTALLATION INSTRUCTIONS

GAS SUPPLY INSTALLATION

POWER SUPPLY INSTALLATION

LEAKAGE TEST

HEAT DEFLECTOR INSTALLATION INSTRUCTIONS

CEILING MOUNT POLE INSTALLATION INSTRUCTIONS

OPERATING INSTRUCTIONS

TURNING THE APPLIANCE ON

TURNING THE APPLIANCE OFF

MAINTENANCE AND SERVICING

REGULAR SERVICE REQUIREMENTS

EXTERIOR SERVICING

OPTIMUM MOUNTING DISTANCE

HONEYWELL CONTROL

HONEYWELL VALVE

OPERATION DATA – BRAHMA CONTROL BOX

DUNGS GAS VALVE

WHITE RODGERS GAS VALVE

WIRING DIAGRAM

REPLACEMENT PARTS

POST-INSTALLATION REPORT

TROUBLE SHOOTING

APPENDIX A

WARRANTY

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5 5 6 6
6
6 7
8
8 12 12 12 13 13 14 14 14
14
14 14
15 15 16 17 18 18 19 22 24 25 26 28
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IMPORTANT NOTES AND WARNINGS

! WARNING

of excessive abrasion or wear, or if the hose is damaged. · The replacement hose assembly must be AGA approved.

· THIS APPLIANCE SHALL NOT BE INSTALLED OR USED · The hose assembly is not to be located in areas where

IN RESIDENTIAL DOMESTIC INDOOR AREAS

the hose may be subject to accidental damage.

· DO NOT PLACE ARTICLES ON OR AGAINST THIS · This radiant heater is NOT intended to be installed on

APPLIANCE

recreational vehicles and/or boats.

· DO NOT USE OR STORE FLAMMABLE MATERIALS · Repair to be carried out ONLY by an authorised person.

NEAR THIS APPLIANCE

· DO NOT SPRAY AEROSOLS OR FLAMMABLE · Improper installation, adjustment, or alteration can cause

MATERIALS IN THE VACINITY OF THIS APPLIANCE

personal injury, property damage, or even death.

WHILE IT IS IN OPERATION

· Do not attempt to alter the unit in any manner.

· Ensure that the heater is never used without an AGA

Failure to follow the warnings and instructions in this manual approved pressure limiting regulator could result in severe personal injury, death or property · Remove transit protection before use. damage.

· Never operate the heater in an explosive environment

· This Installation, Operation and Service manual should not be removed from the site of installation. such as areas where petrol or other flammable liquids or vapours are stored.

· This Appliance is for outdoor and non-residential indoor · Turn off the gas supply immediately if smell of gas is areas only. (see attached diagrammatical representations detected. of outdoor areas “Appendix A”).

· Do not paint any surface of the heater.

· Any guard or other protective device removed for · Do not throw objects at Glass facia. servicing (conducted by an authorised person) must be · If Glass facia breaks, discontinue use, disconnect power replaced before operating the heater. and gas and isolate area affected by breakage.

· Adults and children should stay away from high · Control compartment, burner and circulation air temperature surfaces to avoid burns or other serious passageways of the heater must be kept clean. Frequent personal injury. cleaning may be required as necessary.

· Children should be carefully supervised when they are in · Turn Gas Supply off when not in use. the area of the heater.

· Check the heater immediately if any of the following

· Clothing or other flammable materials should not be occurs:

hung from the heater or placed on or near the heater.

» The heater does not reach temperature.

· Do not perform maintenance until heater has been turned off, power disconnected, and heater temperature has cooled to room temperature.

» The burner makes popping noise during use (a slight noise is normal when the burner is ignited or extinguished).

· Do not expose the burner to water or moisture. The · Young children should be supervised to ensure that they

appliance is to be protected from rain.

don’t play with the appliance.

· Do not use the heater if any of these parts are exposed · This appliance is not intended for use by young or infirm to water until the appliance is inspected or repaired by persons unless they have been adequately supervised

an authorised service person.

by a responsible person to ensure that they can use the

· The installer is to ensure that the requirements of the local

appliance safely.

authority, local gas fitting regulations, municipal building · Check for damage to the appliance regularly. If damage codes, and any other relevant statutory regulations are to the cord, plug or appliance is suspected, discontinue carried out. use immediately and contact the supplier or qualified

· Certain materials or items, when stored under or near the person for repair.

appliance, will be subjected to radiant heat and could · If the cord, plug or appliance is damaged, unplug from be seriously damaged. Ensure combustible materials eg. the outlet, discontinue use immediately, and only an overhead structures, walls, floors, furniture, fixtures and authorised person or similar may repair the unit. plants must be kept 1100mm from the top and side.

· Avoid inhaling fumes emitted from the heater’s first

· The whole gas system, hose assembly, regulator, pipes, use. Smoke and odour from the burning of oils used in and burner should be inspected for damage and leaks manufacturing will appear. Both the smoke and odour before use and at least annually by an authorized person will dissipate after approximately 30 minutes. for the life of the heater.

· Ensure that a watertight seal is maintained on the

· All leak tests should be done with a soap solution. Never electrical control box at all times use an open flame to check for leaks.

· Regularly check for damage to the rubber seals. If

· Do not use the heater until all connections have been damage to the rubber seals is suspected, discontinue leak tested by an authorised person. use immediately, switch off power and contact the place

· Inspect the hose assembly before each use of the of purchase or authorised service technician for repair. appliance.

· The hose assembly must be replaced prior to the appliance being put into operation if there is evidence

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PRODUCT OVERVIEW

PRODUCT DESCRIPTION
The Tungsten Smart-HeatTM Gas Radiant Heaters are designed to provide effective outdoor heating to both commercial and residential premises whilst offering an appealing design. The heaters incorporate full function electronic controls, allowing them to be operated remotely from a conveniently located switch. The heaters have been designed to withstand the rigors of the outdoors.

SPECIFICATIONS

Gas type Manufactured by AGA Approval No. Gas Consumption Gas Type Gas Pressure Injector Size Weight Voltage Current

Tungsten Smart-HeatTM 3 BURNER

Tungsten Smart-HeatTM 5 BURNER

LPG

NATURAL GAS

LPG

NATURAL GAS

BROMIC HEATING PTY LTD

7289

7289

7289

7289

25 MJ/hr

25 MJ/hr

42 MJ/hr

42 MJ/hr

Propane Gas (LPG) Only

Natural Gas

Propane Gas (LPG) Only

Natural Gas

2.75 KPA

1 KPA

2.75 KPA

1 KPA

0.8mm

1.4mm

0.8mm

1.4mm

15kg

15kg

20kg

20kg

220-240V

220-240V

220-240V

220-240V

1 Amp

1 Amp

1 Amp

1 Amp

TUNGSTEN SMART-HEATTM HEATER DIMENSIONAL DETAILS TUNGSTEN SMART-HEAT HEATER DIMENSIONAL DETAILS

356

150

263

404

Without Heater Deflector With Heater Deflector

335

286

302

497 255
316

9 9

306

135 Wall Bracket / Control Housing
Mounting Hole Positions

2 8

! IMPORTANT

This appliance is NOT approved for indoor domestic use and must be installed by authorised persons only in accordance with AS5601-2010 Gas Installation Code.
This appliance is to be protected from rain. Install under a protective cover.

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PRODUCT OVERVIEW CONTINUED…

GENERAL INFORMATION
The Calortch Series Gas radiant heaters are suitable for outdoor and non- residential indoor spaces. In addition to the installation instructions provided, authorised installers must abide by the Australian installation code AS-5601-2010. Please note that these standards are subject to change.
The heater is designed to function in winds up to 15Km/h. The heater is subject to reduced performance or failure in adverse weather conditions such as high wind or extreme saturation.

INSTALLATION REQUIREMENTS

! IMPORTANT

GAS REQUIREMENTS

This appliance shall only be used in above ground open-air situations with:
· natural ventilation · without stagnant areas · where gas leakage and products of combustion are
rapidly dispersed by wind and natural convection
Any enclosure in which the appliance is used shall comply with one of the following:
1. An enclosure with walls on all sides, but at least one permanent opening at ground level (ref. Appendix A, Example 1)
2. Within a partial enclosure that includes an overhead cover and no more than two walls (ref. Appendix A, Example 2)
3. Within a partial enclosure that includes an overhead cover and more than two walls, the following shall apply:
· At least 25% of the total wall area is completely open (ref. Appendix A, Example 4), and
· At least 30% of the remaining wall area is open and unrestricted (ref. Appendix A, Example 4)

Tungsten Smart-Heat LPG Models: · Use Propane (LPG) gas only · The approved inlet pressure to the appliance is 2.75KPA
Tungsten Smart-Heat Natural Gas Models: · Use Natural Gas Only · Always use Bromic Natural Gas Governor (supplied) ­
Model: BM-WF1A (AGA No. 5149) · Ensure that Inlet pressure to the regulator does not
exceed 5KPA · The approved inlet pressure to the appliance is 1.0KPA

Note: The definition of outdoors is an above ground openair situation with natural ventilation, without stagnant areas, where gas leakage and products of combustion are rapidly dispersed by wind and natural convection.

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INSTALLATION REQUIREMENTS CONTINUED…

INSTALLATION CLEARANCES
When selecting the installation location for the Tungsten Smart-Heat Gas Heaters, the following mounting clearances should be followed.
Care should be taken to ensure that the heater is not installed: · Where heat/ignition can cause damage to gas cylinders/
lines · Near other combustible materials · In open locations subject to rain · In indoor residential locations · In areas without sufficient clearances (refer below)
Note: When Installing with No protective cover, the following installation clearances shall apply:

The stated clearance to combustible materials represents surface temperature of 65oC above room temperature. Building material with a low heat tolerance (such as plastic, vinyl siding, canvas, tri-ply etc.) may subject to degradation at lower temperature. It is the installer’s responsibility to assure that adjacent materials are protected.
Note: Heater should be installed in such a way so as to allow adequate; · Clearance around air openings to combustion chamber · Clearance from combustible material · Provisions for accessibility and clearance for combustion
and ventilating air supply.
Note: When installing with the Tungsten Smart-Heat Gas Heat Shield (Part No. 2620165 or 2620166) the following installation clearances Shall Apply:

A

” 2

·a,
C

‘E

j

E
:I
::,

§ ·o

Minimum height to combustible materials

Model 3 – Burner

A 1100mm

B 1100mm

C 2000mm
(Outdoor areas)
(N2o5n-0re0smidemntial
indoor)

5 -Burner

1100mm

1100mm

2000mm
(Outdoor areas)
(N2o5n-0re0smidemntial
indoor)

*Bromic recommended minimum installation height. Local authority regulations
I a;;; s ust be checked prior to installation
& ;; M
In the Case of appliances intended for non-residential indoor use: This appliance must not be used in a room smaller than V cubic metres. Where V = Five (5) times the rated gas consumption (MJ/h). NOTE: For example in the case of an appliance with a rated gas consumption of 20 MJ/h, V = 5 x 20, 100 cubic metres.

Minimum height to combustible materials

Model

A

B

C

3-Burner

350mm

1100mm

2000mm
(Outdoor areas)
(N2o5nin0-rde0osmiodrem)ntial

5-Burner

350mm

1100mm

2000mm
(Outdoor areas)
(N2o5n-0re0smidemntial
indoor)

*Bromic recommended minimum installation height. Local authority regulations and building codes must be checked prior to installation

&IMPORTANT
This appliance must only be used in a well ventilated area.

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INSTALLATION INSTRUCTIONS

HEATER INSTALLATION INSTRUCTIONS 2. Connect AGA approved Flexible Gas Connector (as
supplied) to the inlet fitting on the heater using 2

wrenches to tighten. Leak Test by applying compressed

! WARNING

air (1/2″ PSI) to open end of flexible hose. Spray gas

This appliance must be installed and used in accordance with AS5601-2010 Gas installation standard and must meet all the requirements stipulated in the “Installation Requirements” section of this manual.

fittings with a soapy water solution and Check for leaks. Alternatively, leak check can be done after assembly using inspection hole on bracket arm. (see. leakage test section of this manual).

!
WARNING:
Installation should be done by a qualified service person.

! CAUTION

Please see specifications for the weight of the Heater. The installer of the Tungsten Smart-Heat Series Radiant Heaters must comply with all relevant State Occupational Health & Safety Regulations.
1. Mount Wall Bracket/Control Housing To Wall:

· Remove Wall Bracket/Control Housing From Packaging

· Place the mounting bracket in position and mark

the fixing hole location on the wall. Drill holes using appropriate drill size and type.

3. Fix Mounting Arm to the back of the heater ­

· Attach the bracket to the wall using appropriate fixtures

· Slide Gas Connector and Wiring Harness inside the centre of the arm and have them exit through the shaped cut-out on top surface of the arm

· Ensure that the arm faces downwards at a 55º angle

· Position the 4 mounting holes on the arms plate over the corresponding fixtures on the heater Manipulate the gas hose as necessary to allow for correct alignment

· Insert and tighten 4 M6 bolts as provided to fit mounting arm to heater.

! IMPORTANT

The Heater shall be firmly and securely attached to the wall. For Brick and masonry, use M8 “Flush Head” “Dynabolts” (or equivalent). For Wood / Timber fixtures, use suitable screw fixings no less than 60mm in length.

! WARNING

When mounting wall bracket/ control housing, ensure the anchoring to the structure is of sufficient strength, quality and workmanship to support the weight of the heater and any other load that could be applied to the fixture.

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INSTALLATION INSTRUCTIONS CONTINUED…

4. Attach Heater to Wall Bracket/Control Housing
· Remove Front Cover from Control Housing
· Attach Heater to Wall Bracket/Control Housing by inserting Mounting Arm into lower channel of Wall Bracket. Ensure that the Gas Hose and Wiring Harness slide through the groove on top side of the control Housings lower channel and remain undamaged by the metals edges during assembly.
· It may be necessary to manipulate the gas Hose so that the arm can slide into place.
TIP: Do not install the mounting pin at this point.
· Spray soapy water on the arm to ease the sliding.

5. Connect the AGA approved flexible connector to the Gas Valve Outlet Fitting
· Position heater and hose so that the gas hose and fitting are in alignment
· NOTE: ensure that the hose nut and valve fitting are parallel to one another and threads are engaged correctly before tightening! Incorrect installation can cause gas leaks and damage components.
TIP: Sliding the mounting arm inside the control housing’s channel can help accurately Position the Gas hose in place under the gas valve’s fitting.
· Spanner Tighten using 2 wrenches, and leak test using soapy water (see section “leakage test”)

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INSTALLATION INSTRUCTIONS CONTINUED…

6. Insert Pivot Bolt
· Position Arm so that the rear hole’s on the mounting arm and Control Housing are in alignment
· Insert Bolt and washer (as supplied) through Control Housing and Mount Arm, using the hole located on the bottom surface of the Control Housing, towards the rear. Spanner tighten in place
· Select desired heater angle and insert the M6 Bolt and washer (as supplied) through the bottom surface of Control Housing into the mounting arm, using the corresponding hole. (Heaters angle will be 0º, 10º or 20º). Spanner tighten in place

· Insert Black Ignitor Cable directly into control box using 2.8mm spade connector, located on the side of the controller

· Insert White Ionisation Cable directly into control box using 4.75mm spade connector, located on the side of the controller

· Insert Earth Terminal over earth tab, attached to body of control housing and marked with Earth

! IMPORTANT
Electrical connections must be completed by trained and authorized electrical technicians only!

7. Connect the 3 wires from the heater by carefully following the instructions below

For Honeywell Control
· Disconnect Honeywell control from Honeywell gas valve by unscrewing retaining screw and pulling away from gas valve

Symbol
· Re-connect Honeywell control to the gas valve by positioning the controllers inbuilt Molex plug over the gas valve’s connector

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INSTALLATION INSTRUCTIONS CONTINUED…

and carefully slide into place. Fix in place using the retaining screw.
For White Rodger

· Insert Earth Terminal over Earth Tab, attached to side of Wall Bracket Housing and marked with the symbol:
8. Connect gas inlet fitting to mains gas supply in accordance with local gas installation code and gas supply installation section of manual. Leak test with soapy water.

White Rodger

9. Fix Front cover to control housing using the 4xM4 screws provided.
· Insert Black Ignitor Cable directly into Control Box at terminal marked:

· Insert White Ionisation Cable directly into Control Box at terminal marked:

10. Main Power supply connection is to completed in line with instructions in the “Power supply installation” section of this manual.

! IMPORTANT
Ensure that a water tight seal is maintained.

! IMPORTANT

After gas installation and electrical installation is complete, all gas lines should be tested for leaks using a soapy water solution. See Section titled “Leakage Test” for further information. Ensure gas pressure meets the requirements outlined in Gas Supply Installation above.

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INSTALLATION INSTRUCTIONS CONTINUED…

GAS SUPPLY INSTALLATION

POWER SUPPLY INSTALLATION

! IMPORTANT
· All gas supply installation work must be performed by trained and authorized person(s) and comply with the requirements of local Gas Installation Codes.
· All Piping Joints should be tested for leaks with a soapy water solution before use.
· Gas hose must be located out of pathway where people may trip over it, or in areas where the hose may be subject to accidental damage.
Verify the type of gas supply complies with the appliance rating plate, located at the back of the heater.
An approved manual isolating valve must be fitted before the heater in accordance with local Gas Installation Codes.

! WARNING
This heater is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug.
The Tungsten Smart-Heat Gas Heater comes standard with 900mm of power cord in addition to the Approved 3 pin power plug.
If an appropriate power socket is available, the heater can be plugged into this power socket and operated using the on/ off switch supplied on the power socket. Alternatively, the power installation can be tailored to suit the site requirements by an Authorized Electrician.
Keep electrical supply cord away from any heated surface and flue gasses.

The inlet connection to the heater control box is a 3/8″ SAE Male

Please Note: Tungsten Smart-Heat Gas do not have their own on/off

! WARNING

Ensure that power socket is switched off before plugging in power cord. switch. Operation should be controlled via the main power supply.

LEAKAGE TEST

Tighten all the connections and then turn on the gas supply. Check for gas leakage with a soapy water solution. (See section titled “Leakage Test”).
Do not use an open naked flame to check for leaks.
When the heater is operating, check gas pressure at the test point and ensure the manifold pressure to the heater is: NG: 1KPA LPG: 2.75KPA
Gas supply pressure must be limited to 5KPA If gas line pressure exceeds this level, a separate pressure reducing regulator must be installed.
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi.

Gas connections on the heater are leak tested at the factory prior to shipment. A complete gas tightness check must be performed at the installation site due to possible mishandling in shipment or excessive pressure being applied to the heater. Check ALL connections.

· The heater must be checked with the gas supply turned on.

· Make sure the safety control valve is in the OFF position.

· Make a soap solution of one part liquid detergent and one part water. The soap solution can be applied with a spray bottle, brush or rag. Soap bubbles will appear in case of a leak.

· Turn the gas supply ON.

· In case of a leak, turn off the gas supply. Tighten any leaking fittings, then turn the gas supply on and recheck.

· Never leak test while smoking.

· The following points MUST be leak checked before operation.

1

2

The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig.

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INSTALLATION INSTRUCTIONS CONTINUED…

3

NOTE: Tungsten Smart-Heat Heating recommends running power and gas lines, to the heater, inside the pole to reduce visibility and likelihood of damage.

HEAT-DEFLECTOR INSTALLATION

1. Assemble Heat Deflector following instructions supplied in the Heat Deflector carton.

1

2. Mount Heat Deflector to back of heater by loosening the two screws and secure brackets underneath washers.

Re-tighten screws to original position using screw driver.

2

CEILING POLE INSTALLATION

3

! WARNING

When mounting ceiling pole, ensure the anchoring to the structure is of sufficient strength, quality and workmanship to support the weight of the heater and any other load that could be applied to the fixture. Note: Ceiling pole must be perpendicular (90deg) to the ground when mounted (irrespective of pitched or flat ceiling).

1. Mount Top Bracket to ceiling or support beam using suitable fixings no less than 60mm length.

2. Assemble pole to the mounting bracket using the M8x100mm and M19x100mm bolts, and fix using nuts and washers (as supplied).

4

3. Assemble both lower paddles to the pole (back to back) and insert 3 M10x100mm bolts and fix using nuts and washers (as supplied).

4. Fix Heater to Lower paddles using suitable fixtures.

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OPERATING INSTRUCTIONS

TURNING THE APPLIANCE ON

gas supply.

1. Ensure that gas installation and power installation has NOTE: The appliance must be completly shutoff for a period been carried out in accordance with the manufacturers of 5 minutes before being relighted. instructions outlined in this document. 2. Turn on gas supply.

! IMPORTANT

3. Ensure correct gas supply pressures are set.

Check the heater immediately if any of the following occurs:

4. Switch on power to heater.

· The heater does not reach temperature.

5. If Gas heater does not light, turn power off.
6. Wait 5 seconds before turning power back on. If heater does not ignite after 5 attempts, consult the troubleshooting section of this manual, or contact Tungsten Smart-Heat Heating Pty. Ltd for service information.

· The burner makes popping noise during use (a slight noise is normal when the burner is ignited or extinguished).
Note: Avoid inhaling fumes emitted from the heater’s first use. Smoke and odour from the burning of oils used in manufacturing will appear. Both the smoke and odour will dissipate after approximately 30 minutes.

TURNING THE APPLIANCE OFF
1. For temporary shutdown, turn off power. 2. For permanent shutdown, turn off power and shut off

Installers please Note: When the installation and testing is completed, make sure that the customer knows how to operate the heater. Leave the operating instructions with the customer.

MAINTENANCE AND SERVICING

It is important that regular maintenance is carried out on the heater to maintain efficient operation. All maintenance should be carried out ONLY by authorized service personnel.
Control compartment, burner and circulation air passageways of the heater must be kept clean. Inspect and clean at least every six months or more frequently in adverse conditions.
Never obstruct the flow of combustion and ventilation air. Always keep the appliance area clear and free from combustible materials, gasoline and other flamable vapors and liquids.
Do not clean heater with cleaners that are combustible or corrosive.
REGULAR SERVICE REQUIREMENTS
1. AGA approved Gas Hose, located within the mounting arm, must be checked at least once annually. The hose must be replaced if there is any evidence of excessive wear, or if the hose is damaged. The replacement hose assembly must be AGA approved with 3/8″SAE flared ends. To Check the Gas Hose, remove control housing cover by removing 8 screws and slide cover outwards. Alternatively, disassemble heater by reversing the installation instructions as outlined in Installation section of this handbook.
2. VISUALLY CHECK BURNER FLAMES. During heaters function visually check that all burners are alight and glowing hot. This can be done by observing the red glow through the translucent face, or by peering down the product combustion passageway. Note: A slight variation in colour is to be expected.

3. Clean burners: Burners can be cleaned by directing compressed air (max20PSI) at outlet ports. Avoid directing air at gasket material between ceramic tile and burner cup.
4. Clean manifold and injectors: Undo gas hose from gas valve outlet (heater should be switched off) and inject compressed air (max20PSI) down the inlet fittings.
5. Clean dust and foreign matter from inside of heater housing: Open up rear housing and clear dust using compressed air (max20PSI) and a damp cloth.
6. Remove debris, spider and insect nests from, control compartment, burner and circulation air passageways of the heater with heavy-duty pipe cleaner or compressed air to keep appliance clean and safe for use. Never clear ports or other openings with toothpicks or other articles that will break and block the ports.
7. In a salt-air environment, such as near an ocean, corrosion occurs more quickly than normal. Check frequently for corroded areas and repair them promptly.
! IMPORTANT
More frequent cleaning may be required as necessary. It is imperative that control compartment, burners and circulating air passageways of the heater be kept clean.
EXTERIOR SERVICING
The exterior Tungsten Smart-Heat Series Heater components are constructed from stainless steel, and high temperature coated black paint. For all exterior black parts (excluding fascia trims), a brushed finish has been used. This is not a coating and under prolonged use, may slightly discolour from high temperatures emitted by the heater. This is a normal occurrence and does not affect the operation of the appliance.

1 2 34 5

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Replacement parts can be purchased to restore the heater to its original appearance from Tungsten Smart-Heat Heating Pty Ltd. (Refer to parts list in manual).

! IMPORTANT
Do not apply any additional surface coating to the heater under any circumstances. Use of additional coating other than those applied during manufacture could result in hazardous reactions such as toxic fumes or fires. Additional coatings will void the warranty.

OPTIMUM MOUNTING DISTANCE

B

A

B A

Model 3 – Burner 5 -Burner

A 1100mm 1100mm

B 2500 – 3500mm 2500 – 3500mm

Model 3 – Burner 5 -Burner

A 6000 – 7000mm 8000 – 9000mm

OPERATION DATA – HONEYWELL CONTROL BOX

The following operation sequence is valid only where the components are installed according to the manufactures assembly and installation instructions. Please do not modify the wiring configuration, gas train or any other part of the heater assembly.
Application
The Honeywell electronic gas burner control system is suitable for atmospheric gas burners for non-permanent operation. Although the Honeywell unit is available non volatile lockout, its configuration in the Tungsten Smart-Heat series heaters limits it to volatile lockout, i.e. the restart from this condition is possible by the interruption and subsequent restoration of the mains power supply.
Features:
· Compliance with AGA standard for automatic gas burner flame monitoring and control systems
· Compliance with EN 298 (European standard for automatic gas burner flame monitoring and control systems)
· Compliance with AGA (Australian standard for automatic gas burner flame monitoring and control systems)
· Flame monitoring based on rectification property of the flame (ionisation)

TECHNICAL DATA

Supply voltage

230V-50/60Hz

Operating temperature

-20°C +60°C

Ambient humidity

90%max at 40°C

Protection degree

IPX4

Timings:

Self Check time

1.5 s

Safety time (TS)

25 s

Drop out time on running flame failure 1 s

Power consumption, at start up

10VA

Power Consumption, Running

4VA

Ignition

Ignition Voltage

15kV with 40pF load

Spark repetition rate

33 Hz

Max. Cable length

1M

Recommended spark gap

0.14″

Consumption

2,5 VA

Spark energy

3 uAs

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OPERATION DATA – HONEYWELL CONTROL BOX CONTINUED…

Directions for use
· Automatic controls are safety devices and shall not be opened. The manufacturer’s responsibility and guarantee are invalid if the control is unduly opened.
· A regulation shutdown must occur every 24hours to enable the unit to check its own efficiency (systems for non permanent operation)
· Connect and disconnect the unit only after switching off the power supply
· Avoid exposing the unit to dripping water
· Ventilation and the lowest temperature ensures the longest life of the control
Electrical Installation
· Live and Neutral should be connected correctly; a mistake could cause a dangerous situation.
· Before starting the system check cables carefully for incorrect installation
· The earth terminal of the control, the metal frame of the burner and the earth on the mains supply must be well connected

Operation
At every start, the control unit proceeds to a self-checking of its own components. During the pre-purge or waiting time (TW) the internal circuit makes a test of the flame signal amplifier. Extraneous light or fault in the amplifier will result in the simulation of a flame which will prevent the control from starting.
At the end of the waiting or pre-purge time, the gas valve is energised and the ignition device is operated. In this way, the safety time (TS) begins.
If a flame is detected during the safety time, the ignition device is inhibited and the gas valve remains energised.
If the control does not detect any flame signal during the safety time, at the end of safety time (TS), the unit proceeds to lockout and the gas valve and ignition device are switched off.
If the established flame signal is lost, (during the safety time or during operation thereafter) this will cause the ignition device to be reactivated within 1 second.
If the burner does not light within 25 seconds of ignition reactivation, the heater will enter failure lockout mode and must be reset.

OPERATION DATA HONEYWELL VALVE:

The VK series gas control have been specially developed for application in domestic appliances. The Honeywell Gas Valve is a multi-functional control which incorporates an adjustable direct acting pressure regulator. It is designed for operation on 220/240V.

Adjust Regulator Pressure
· Unscrew the regulator cover.
· Unscrew the outlet plug to measure the outlet regulator pressure by using manometer.

Standard Specifications · 1/2″ G Female Pipe Thread connection · Ambient Temperature Range of 0°C to 60°C

· Adjust the pressure by turning the regulator screw clockwise or anti wise.
· Adjust the pressure according to appliance specification.

· Compact Size: 86.5mm x 63.5mm x 65.9mm · 50mb Pressure Rating · 1/2″ x 1/2″ (BSP- G) Inlet and Outlet

! IMPORTANT
Remember to place the regulator cover, outlet and inlet back on.

· Earthing terminal ­ 6mm spade tab

· Tamper resistant screws

· Top mounted coils that can be field replaced

TECHNICAL DATA Max inlet working pressure Installation group Operating Temperature Voltage Ratings

50 mbar Group 2 0°C to 60°C 220/240VAC 50/60Hz .52A

Inlet Pressure test point Outlet Pressure test point Regulator

16

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OPERATION DATA – BRAHMA CONTROL BOX

The following operation sequence is valid only where the components are installed according to the manufactures assembly and installation instructions. Please do not modify the wiring configuration, gas train or any other part of the heater assembly.
Application
The Brahma electronic gas burner control system is suitable for atmospheric gas burners for non-permanent operation. Although the Brahma unit is capable of non volatile lockout, its configuration in the Tungsten Smart-Heat series heaters limits it to volatile lockout, i.e. the restart from this condition is possible by the interruption and subsequent restoration of the mains power supply.
Features
· Compliance with EN 298 (European standard for automatic gas burner flame monitoring and control systems)
· Compliance with AGA (Australian standard for automatic gas burner flame monitoring and control systems)
· Flame monitoring based on rectification property of the flame (ionisation)
· Two independent safety contacts in series on the gas valve output
· Electrical service life at max. declared loading > 250.000 operations
· Inbuilt ignition device with completely solid state design and high efficiency

TECHNICAL DATA Supply voltage Operating temperature Ambient humidity Protection degree Timings:
Prepurge or waiting time Safety time (TS) Drop out time on running flame failure Power consumption, at start up Power Consumption, Running Ignition Ignition Voltage Spark repetition rate Max. Cable length Recommended spark gap Consumption Spark energy

23V-50/60Hz -20°C +60°C 95%max at 40°C IP00
10 s 10 s < 1 s 10VA 7VA
20kV with 30pF load 25 Hz 2 m 2-4mm 2,5 VA 15 mJ

Directions for use
· Automatic controls are safety devices and shall not be opened. The manufacturer’s responsibility and guarantee are invalid if the control is unduly opened.
· A regulation shutdown must occur every 24hours to enable the unit to check its own efficiency (systems for non permanent operation)
· Connect and disconnect the unit only after switching off the power supply
· Avoid exposing the unit to dripping water
· Ventilation and the lowest temperature ensures the longest life of the control
Electrical Installation
· The applicable state and Australian standards (eg. AS3350) regarding electrical safety must be respected.
· Live and Neutral should be connected correctly; a mistake could cause a dangerous situation.
· Before starting the system check cables carefully for incorrect installation
· The earth terminal of the control, the metal frame of the burner and the earth on the mains supply must be well connected
Operation
At every start, the control unit proceeds to a self-checking of its own components. During the pre-purge or waiting time (TW) the internal circuit makes a test of the flame signal amplifier. Extraneous light or fault in the amplifier will result in the simulation of a flame which will prevent the control from starting.
At the end of the waiting or pre-purge time, the gas valve is energised and the ignition device is operated. In this way, the safety time (TS) begins.
If a flame is detected during the safety time, the ignition device is inhibited and the gas valve remains energised.
If the control does not detect any flame signal during the safety time, at the end of safety time (TS), the unit proceeds to lockout and the gas valve and ignition device are switched off.
If the established flame signal is lost, (during the safety time or during operation thereafter) this will cause the ignition device to be reactivated within 1 second.
If the burner does not light within 10 seconds of ignition reactivation, the heater will enter failure lockout mode and must be reset.

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OPERATION DATA – WHITE RODGER VALVE:

The White Rodgers Gas Valve is a compact multi-functional control which incorporates an adjustable direct acting pressure regulator. It is designed for quiet operation with cushioned solenoid stops and operates on 220/240V.
Standard Specifications
· Inlet Screen ­ will filter to 180 microns
· Quiet operation
· Ambient Temperature Range of 0°C to 60°C
· Compact Size: 86.5mm x 63.5mm x 65.9mm
· 50mb Pressure Rating
· Class `B’ Group 2 Direct Acting Solenoid Valves with high sealing force
· 3/8″ x 3/8″ (BSP PI.) Inlet and Outlet
· Opening time < 0.25 seconds
· Closing time < 0.25 seconds
· Earthing terminal ­ 6mm spade tab
· Tamper resistant screws
· Top mounted coils and electronics that can be field replaced without entering the gas stream.

TECHNICAL DATA Max Working pressure Installation group Operating Temperature Regulator adjustment range Voltage Ratings

50 mbar Group 2 0°C to 60°C 9.2 to 13.7 mbar 220/240VAC 50/60Hz .52A

18

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WIRING DIAGRAM – HONEYWELL CONTROL, HONEYWELL GAS VALVE

ELECTRICAL DIAGRAM

SEE INSTRUCTION MANUAL FOR DETAILS ON HOW TO CONNECT THE ELECTRICAL COMPONENTS.

Ionisation Ignition +

Ionisation

L Brown 230 V N Blue E

Red 230 V Blue

Green

Purple

Purple

N/A
12 11 10 9 8 7 6 5 4 3 2 1

Yellow/Green

HONEYWELL

Yellow/Green

White

Black

Note:

Yellow/Green

If any of the original wire as supplied with the heater must be replaced, it must be replaced with 18AWG, 90ºC type UL

approved wire or its equivalent. If Transformer must be replaced, a UL approved model of similar type must be used.

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WIRING DIAGRAM

ELECTRICAL DIAGRAM
SEE INSTRUCTION MANUAL FOR DETAILS ON HOW TO CONNECT THE ELECTRICAL COMPONENTS.
Gas Valve
Blue

Orange

N Blue

L Brown

F2a

E

Purple
C1

Yellow/Green Yellow/Green

Brahma Control Box
CE11U
Yellow/Green

Ignition + Ionisation

Ionisation

Black White

20

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REPLACEMENT PARTS

White Rodger
21 18

Honeywell
19
17

7
6 16

14 15

13 22

13 20

9 12
4 8

10

5 1
24

3

11

23 2

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REPLACEMENT PARTS DISCRIPTION

No. Description
1 Front Cover 2 Flame Protector 3 Right Side Mount 4 Left Side Mount 5 Ionization Holder Assembly 6 White Rodger Spacer 7 Control Mount 8 Rear Housing 9 Rear Cover Assembly 10 Burner 11 Wiring Harness + Ignitor Assembly- Honeywell 12 Inner Skin 13 Wall Bracket Assembly 14 Honeywall Control 15 Honeywell Gas Valve 16 Brahma Control 17 White Rodger 24V Gas Valve 18 19mm ID Grommet 19 Gas Inlet Fitting (Honeywell 1/2″ Gas Valve) 20 Gas Outlet Fittings ( Honeywell 1/2″Gas Valve) 21 Gas Inlet Fitting (WhiteRodgers Gas Valve) 22 Gas Outlet Fitting (WhiteRodgers Gas Valve) 23 Manifold Assembly 24 Injector (LPG) 24 Injector (NG) 25 Wall Bracket Replacement Screw Set 26 Heater Replacement Screw Set 27 Gas Hose

Part No. 300 Series Part No. 500 Series

2620701
2620711 2620720 2620721 2620730 2620732 2620734 2620815 2620819 2620822 2620736 2620751 2626760 2120770 2120771 2620829 2620830 2620831 2620780 2620781 2620782 2620783 2620790 4440080 4440130 2620829 2620840 HG095

2620700
2620710 2620720 2620721 2620730 2620732 2620734 2620816 2620820 2620822 2620736 2620750 2626760 2120770 2120771 2620829 2620830 2620831 2620780 2620781 2620782 2620783 2620790 4440808 4440130 2620829 2620840 HG095

Note: For more information on obtaining spare parts contact the place of purchase or BROMIC HEATING
Head Office: 10 Phiney Place, Ingleburn, Sydney, NSW 2565 Australia T: 1300 276 642 (within Australia) or +61 2 9748 3900 (from overseas) F: +61 2 9748 4289
E: info@bromicheating.com W: www.bromic.com.au

22

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POST-INSTALLATION REPORT

POST-INSTALLATION REPORT
FOR TUNGSTEN SMART-HEAT GAS RADIANT HEATERS
AFTER HEATER INSTALLATION PLEASE PHOTOCOPY, COMPLETE, & SEND THIS REPORT BY:
FAX TO (02) 9748 4289 or BY MAIL TO Bromic Heating Pty Ltd, 10 Phiney Place, Inglegurn NSW 2565Australia or SCAN AND EMAIL TO info@bromicheating.com

Customer Business Name:
Date: dd / mm / yyyy
Site Address:

Suburb:

State:

Postcode:

Customer Contact Details: Name:

Position: Ph: ( ) Mobile: Installer Contact Details: Name:

Fax: ( )

Position: Ph: ( ) Mobile:

Fax: ( )

Please fill in the relevant information or circle the appropriate Yes/No responses below:

How many Tungsten Smart-Heat heaters are installed on this site?

3-Tile: 5-Tile: ____ ____

What type of gas is used?
Is/Are the heater(s) exposed to salt air or any other corrosive or chemical atmosphere?
Does the heater(s’) installation location pose a hazard to the site?

LPG

Natural Gas

Yes

No

Yes

No

Do heater clearances match the

minimum requirements outlined

in the “Installation Requirements”

Yes

No

section of the Installation,

Operation and Service Manual?

Is the gas supply line adequately sized for the number of heaters installed?

Yes

No

Have gas lines been purged of air?

Yes

No

Have gas lines been checked for leaks with a soapy water solution?
Was the heater field tested and operated without malfunction?
What is the inlet gas supply pressure?
What is the gas valve outlet pressure (at test point)?

Yes

No

Yes

No

_____ kPa

_____ kPa

Signature of authorised person:

Name: Company:
Date: dd / mm / yyyy

Position:

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TROUBLESHOOTING

SYMPTOM
Heater will not turn on

POSSIBLE CAUSE
1. No power 2. No gas

CORRECTIVE ACTION
1. Have authorized electrician check power supply
2. Have authorized gas fitter check gas supply

Heater turns on, but then cycles on and off

1. Insufficient flame on ionisation rod 2. Drafty conditions 3. Insufficient earth connection between
heater and control box

1. · Check and set gas pressure · Check and clear obstruction to burner venturi and injectors
2. Discontinue use in high winds 3. Replace wiring harness and clean
connections to ensure good earth

No gas

1. Air in gas line 2. Manual shut-off valve closed 3. Regulator sticking 4. Regulator reversed

1. Purge line 2. Open valve 3. Replace regulator 4. Remove and install properly

Low ceramic tile surface temperature

1. Low manifold gas pressure 2. Low gas inlet pressure 3. Orifice partially blocked with foreign
matter 4. Combustion by-products not
adequately ventilated 5. Manifold misaligned from excessive
torque applied on pipe at installation 6. Gas supply piping too small 7. Foreign matter in venturi tube

1. Adjust valve regulator until 1kpa for natural gas, or 2.75kpa for propane is obtained
2. Adjust main supply regulator until at least 1.25kpa for natural gas or 3kpa for propane precedes heater’s control assembly
3. Clean orifice 4. Provide adequate ventilation of
by-products 5. Replace manifold 6. Increase gas pressure or replace
piping 7. Remove with bottle brush

Gas odour
Burning of gas/air mixture inside burner casting (flashback) Control assembly is overheating

1. Loose pipe connection 2. Defective regulator 3. Defective manual shut-off valve 4. Defective gas control valve 5. Loose flexible hose
1. Separation of ceramic tiles 2. Ceramic tile(s) cracked 3. Heater mounted at incorrect angle 4. Excessive drafts
1. Heater not mounted correctly

1. Check all connections with soap solution and tighten where necessary
2. Replace regulator 3. Replace manual shut-off valve 4. Replace gas control valve 5. Tighten flexible hose
1. Replace burner assembly 2. Replace burner assembly 3. Check angle of heater. See heater
nameplate. 4. Shield or relocate heater.
1. Mount wall bracket / control housing against a vertical flat surface, following the instructions outlined in the installation section of this manual. Always use supplied parts to mount heater.

Carbon formation on ceramic tile surface of burner
24

1. Misaligned orifice 2. Obstruction in venturi tube 3. Low gas pressure 4. Wrong gas supplied to heater
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1. Consult sales agent or factory 2. Clean with bottle brush 3. Provide required pressure 4. Check label for type of gas
required

APPENDIX A

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APPENDIX A CONTINUED…

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APPENDIX A CONTINUED…

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References

• Luxury Commercial & Residential Outdoor Heaters | Bromic Heating Australia

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