wf2000 gas wall furnace - mckinnon heating & cooling€¦ ·  · 2013-05-23installation...

15
INSTALLATION MANUAL INSTALLATION MANUAL WF2000 GAS WALL FURNACE Console Inbuilt

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Page 1: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

INSTALLATION MANUALINSTALLATION MANUAL

WF2000 GAS WALL FURNACE

Console

Inbuilt

Page 2: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Employers and Employees ResponsibilityThe installation and maintenance of gas wall furnaces and flue systems, particularly at height, has the potential to create Occupational Health and Safety issues for those involved. Installers are advised to ensure they are familiar with relevant State and Federal legislation, such as Acts, Regulations, approved Codes of Practice and Australian Standards, which offer practical guidance on these health and safety issues. Compliance with these regulations will require appropriate work practices, equipment, training and qualification of workers. Seeley International provides the following information as a guide to contractors and employees to assist in minimising risk.Risk Assessment:A risk assessment of all hazardous tasks is required under legislation. A risk assessment is an essential element that should be conducted before the commencement of work, to identify and eliminate the risk of falls and other risks, or to minimise these risks by implementing control measures. This does not need to be a complicated process - it is a matter of assessing the job to be done and considering what actions are necessary so the person doing the job does not injure themselves.This should be considered in terms of:��What are the chances of an incident occurring?��What could the possible consequences be?��What can be done to reduce, or better still, eliminate the risk?Some points to consider when working on or in a roof:��What is the best and safest access to the roof and working areas?��What condition is the roof in? Should the roof structure and surface be checked?��Does the worker have appropriate footwear?��Are all power cables/extension leads safe and appropriately rated?��Are all ladders, tools and equipment suitable and in good condition?��Where ladders are to be used, is there a firm, stable base for them to stand on? Can they be tied or secured in some way at the top.��Is there a roof anchor to attach a harness and lanyard to? If so, instruction should be issued for the use of an approved harness or only suitably trained people used.��Are all tools and materials being used, prevented from slipping and falling onto a person at ground level? Is the area below the work area suitably protected to prevent people entering this area. ��Does the work schedule take into account weather conditions, allowing for work to be suspended in high winds, thunder storms/lightning or other types of weather giving wet, slippery surfaces? ��Is there an on-going safety check system of harnesses, ropes, ladders and access/lifting equipment, and where they exist on roofs, anchor points before the commencement of work? ��Is there a system which prevents employees from working on or in roofs if they are unwell or under the influence of drugs or alcohol? ��Are there any special conditions to consider i.e. excessive roof pitch, limited ground area, fragile roof, electrical power lines?Other Important Requirements:��THIS HEATER TO BE INSTALLED BY AN AUTHORISED PERSON ONLY��DO NOT Operate this appliance before reading the instruction booklet.��DO NOT Place articles on or against this appliance.��DO NOT Use or store flammable materials near this appliance.��DO NOT Operate this appliance with the front cover removed.

Safety FirstSafety First 1

Page 3: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Introduction and Spec'sIntroduction and Spec's 2INTRODUCTION

��These installation instructions cover the installation of Braemar WF2000 series gas wall furnaces. They apply to 30 and 40 MJ/hr, natural gas and propane, and inbuilt and console models.��For console installations, one of the following "Console & Flue Cover Kits" is required: - Up to 3m ceiling height P/No 087818 - 3 to 3.6m ceiling height P/No 087825��An optional "Rear Register Kit" (P/No 085142) is available to direct up to 60% of the heated air flow to the rear.

WALL FURNACE SPECIFICATIONS

Main 2.55 30 0.90 1.50 30 2.70

Pilot 0.32 0.50 - 0.20 0.50 -

40 MJ/hr

Main 2.95 40 0.90 1.75 40 2.70

Pilot 0.32 0.50 - 0.20 0.50 -

30 MJ/hr WF2000-30N

Injector diameter

(mm)

Gas rate

(MJ/hr)

Test point pressure

(kPa)

Injector diameter

(mm)

Gas rate

(MJ/hr)

Test point pressure

(kPa)

WF2000-30P

WF2000-40N WF2000-40P

Natural gas Propane

IMPORTANT

��The 30 MJ/hr wall furnace is intended for domestic applications and replacement of older wall furnaces. Due to its higher thermal efficiency and improved air distribution, it is suitable for replacement of older 40 MJ/hr models.��The 40 MJ/hr wall furnace is suitable for heating very large areas and is not generally recommended for normal domestic applications due to the higher air flow rates.

1800

496

1630

45

167232247

385385

INBUILTCONSOLE

Page 4: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Installation InstructionsInstallation Instructions 3GENERAL

��The heater must be installed in accordance with these instructions, local gas fitting regulations, municipal building codes, electrical wiring regulations, Australian Standard AS5601 'Gas Installations', and any other relevant statutory requirements. Failure to comply with these requirements may void the warranty.��A data plate fixed to the heater details both the model number and gas type.

HEATER PREPARATION

��Check markings on carton to confirm that heater supplied is as required.��With the unit laying on its back remove the top carton and liner.��Remove the protective plastic film and discard.��Remove the front cover by removing the 2 cover retaining screws above the top louvre inside the air outlet, and the 2 cover transit screws from the back of the cover top panel.��If the heater is to be installed as a console fit the console side panels to the front cover at this point - instructions are included in the 'Console & flue cover kit'.��If a rear register is to be installed with the heater, fit the required components to the back of the heater at this point - instructions are included in the 'Rear register kit'.

HEATER LOCATION

When selecting a location for the wall furnace, the following points must be considered:��Avoid corners, as this can lead to poor heated air distribution.��Locate wall studs - for an inbuilt installation the stud spacing (measured from inside to inside) must be 405 and 430mm - a false stud must be fitted if the spacing is greater than 430mm - an alternative location must be selected if the spacing is less than 405mm.��Ensure that roof timbers will not obstruct the flue and that clearances of 10mm from twin wall metal flue and 25mm from single wall metal flue can be maintained form combustible materials.��Ensure that concealed piping or wiring within the wall cavity will not obstruct the installation.��If a rear register is to be fitted, select a location to ensure that wall studs do not obstruct the rear register.��Do not obstruct the air outlet, or the rear register, with furniture as this can lead to poor heated air distribution.��Do not face the heater across a room - along the room is better.��Maintain a clearance of at least 300mm from both sides of the heater, at least 400mm above the heater, and 100-200mm from the floor.

GAS SUPPLY

��The gas connection point is on the lower right hand side of the heater.��The gas supply pipe should be terminated to suit a 1/2" male compression fitting.��Gas supply piping should be sized in accordance with pipe sizing guidelines given in AS5601 'Gas Installations'.��The gas supply can be routed from below, above or behind the heater.

280

17050

ELECTRICITY SUPPLY

��The electricity supply must be a 240Vac 50Hz earthed power outlet with switch. It must be located within 900mm from the left of the heater or within 400mm from the right of the heater.

FLUE SYSTEM

��The flue system must be installed in accordance with AS5601 'Gas Installations' and local building regulations. The flue must be an approved twin wall metal flue within a wall cavity. Single wall metal flue may be used within a ceiling space provided AS5601-specified clearances from combustible materials are maintained and access is possible for inspection and servicing.��The Braemar flue kit (P/No 077956) is recommended for installation of this heater.��If the heater is replacing an existing unit it must be confirmed that the flue system complies with current requirements of AS5601.��The flue must be terminated outside - it must not be terminated in a roof space.

GOOD

POOR

ILL2002

300300Wall, Cupboard,Bookcase etc....

300mm minimum distance between objects

Wall, Cupboard,Bookcase etc....

minimum minimum

CEILING

FLOOR

400mmminimum

100 - 200mm

GOOD

Page 5: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Inbuilt Heater InstallationInbuilt Heater Installation 4CHECK

��Select a suitable location between wall studs complying with requirements set out on page 3 of this manual.��WALL CAVITY DEPTH: 80mm MINIMUM��STUD SPACING: 405 to 430mm - FIT A FALSE STUD IF > 430mm

WALL OPENING

��HEIGHT: 1650mm - BOTTOM EDGE 100 - 200mm FROM FLOOR��WIDTH: 405 to 415mm

��Remove the section of wall frame top plate from between the studs and fit the HEADER PLATE supplied with the flue kit. ��Fit top and bottom mounting brackets as shown - brackets and mounting screws are included with the heater.

405 - 430

405 - 415

400

1650

100

100

- 200

Floor

Braemar bottommounting brackets

Wall stud

Wall opening

Braemar topmounting bracket

Twin-wall metal flue

Header plate

Wall top plate(cut between studs)

��Install the flue system in accordance with instructions contained in the flue kit.��If a rear register is required, fit the components in accordance with instructions contained in the rear register kit before fitting the heater into the wall - ENSURE THAT A SUITABLE VENTILATION OPENING IS PROVIDED AS SPECIFIED IN THE REAR REGISTER KIT.��Fit the heater onto the mounting brackets by sliding the flue spigot at the top of the heater up through the top mounting bracket, push into wall cavity at bottom and lower onto bottom mounting brackets - ENSURE THAT THE HEATER IS RESTING ON BOTH BOTTOM MOUNTING BRACKETS. Screw side flange of heater to bottom mounting bracket at each side to secure heater.

1

2

Top and bottom mounting brackets installed into wall cavity Fitting heater onto mounting brackets

Page 6: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Console Heater InstallationConsole Heater Installation 5CHECK

��The heater may be installed onto a plasterboard/timber stud wall, or a masonry wall.

��Select a suitable location between wall studs complying with requirements set out on page 3 of this manual.

��Fit top and bottom mounting brackets as shown - brackets and mounting screws are included with the heater.

��Install the flue system in accordance with instructions contained in the flue kit.��If a rear register is required, fit the components in accordance with instructions contained in the rear register kit before fitting the heater into the wall - ENSURE THAT A SUITABLE VENTILATION OPENING IS PROVIDED AS SPECIFIED IN THE REAR REGISTER KIT.��Fit the heater onto the mounting brackets by sliding the flue spigot at the top of the heater up through the top mounting bracket, push into wall at bottom and lower onto bottom mounting brackets - ENSURE THAT THE HEATER IS RESTING ON BOTH BOTTOM MOUNTING BRACKETS. Screw side flange of heater to bottom mounting bracket at each side to secure heater.��Fit the flue cover components in accordance with instructions contained in the console & flue cover kit. The console sides can also be fitted to the front cover at this stage.

Top and bottom mounting brackets installed onto face of wall Fitting heater onto mounting brackets

100

100

- 200

1650

400

Floor

Twin-wall metal flue

Braemar topmounting bracket

Braemar bottommounting brackets

Bend tabs on bottommounting bracketsas shown

FOR TIMBER STUD WALLS, THE TOP MOUNTING BRACKET MUST BE ATTACHED TO A

WALL STUD ON AT LEAST ONE SIDE OR IN THE CENTRE, AND

AT LEAST ONE BOTTOM MOUNTING BRACKET MUST BE

ATTACHED TO A WALL STUD

1

2

Page 7: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Replacing an existing W/FReplacing an existing W/F 6GENERAL

��The Braemar WF2000 wall furnace is suitable for replacement of a wide range of common existing wall furnaces without modification of the wall opening, and with minimal or no modification to the existing flue system (provided the flue system is satisfactory as specified under "Flue System" on page 3 of this manual).��The Braemar WF2000 wall furnace is NOT suitable for replacement of fully-recessed wall furnaces that are installed into a double-brick wall.

IMPORTANT��The 30 MJ/hr wall furnace is intended for domestic applications and replacement of older wall furnaces. Due to its higher thermal efficiency and improved air distribution, it is suitable for replacement of older 40 MJ/hr models.��The 40 MJ/hr wall furnace is suitable for heating very large areas and is not generally recommended for normal domestic applications due to the higher air flow rates.

INSTALLATION

��Remove the existing wall furnace.��Remove the existing mounting brackets.��Fit the Braemar mounting brackets supplied with the heater as per the dimensions given on page 4 or 5 of this manual.��Complete the heater installation as per a new installation.��Note that if the existing flue system is to be used it must comply with the current requirements of AS5601 "Gas installations".��The following table details kits that are available to assist in replacing an existing wall furnace and identifies kit requirements for MOST common replacements.

INSTALLATION KITS FOR COMMON REPLACEMENTS

Kit ApplicationModel being

replaced Flue adaptor kit(079981)

Flue extension kit(079943)

In-fill panel kit(085135)

Braemar D11/D12 Kit not required Kit not required Kit not required

Braemar D45/D55 Kit not required Kit not required Yes*

Vulcan Series 20/22 Yes Kit not required Kit not required

Vulcan Quasar Yes Yes Yes*

IXL 10862 Yes Yes Kit not required

Convair Finnesse Yes Yes Kit not required

* Required for inbuilt installations only

��Pages 7, 8 and 9 of this manual describe the installation of the above kits.

Page 8: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Flue Adaptor Kit InstallationFlue Adaptor Kit Installation 7FLUE ADAPTOR KIT (P/No 079981)

��The flue adaptor is used to connect between the flue spigot on the top of the Braemar WF2000 and the bottom of the existing flue system to allow the WF2000 to be installed at the correct height for some replacement installations, and to enable the use of the existing flue system (note that if the existing flue system is to be used it must comply with the current requirements of AS5601 "Gas installations").

��Fit the flue adaptor into the bottom of the existing flue before fitting the Braemar top mounting bracket. The location of the top and bottom mounting brackets must comply with details given on page 4 or 5 of this manual.

Braemar topmounting bracket

system and existing heaterBottom of existing flue

top mounting bracket

top mounting bracketFit over spigot on Braemar

Flue adaptor (P/No 079981)

Page 9: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Flue Extension Kit InstallationFlue Extension Kit Installation 8FLUE EXTENSION KIT (P/No 079943)

��The twin-skin flue extension is used in conjunction with the flue adaptor to connect between the flue spigot on the top of the Braemar WF2000 and the bottom of the existing flue system to allow the WF2000 to be installed at the correct height for some replacement installations, and to enable the use of the existing flue system (note that if the existing flue system is to be used it must comply with the current requirements of AS5601 "Gas installations").

��Remove and discard the liner from the flue adaptor.

��Fit the flue adaptor onto the flue extension.

��Fit the flue adaptor and flue extension into the bottom of the existing flue before fitting the Braemar top mounting bracket. The location of the top and bottom mounting brackets must comply with details given on page 4 or 5 of this manual. Trim the flue extension to length if required.

Braemar topmounting bracket

system and existing heaterBottom of existing flue

top mounting bracket

extension and screw togetherDiscard liner, fit over flue

Flue adaptor (P/No 079981)

Trim to length to give requiredFlue extension (P/No 079943)

distance between top andbottom mounting brackets.

Must be fitted over spigot onBraemar top mounting bracket.

Page 10: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

In-fill Panel Kit InstallationIn-fill Panel Kit Installation 9IN-FILL PANEL KIT (P/No 085135)

��The in-fill panel kit is used to cover the existing wall opening of wall markings when replacing some older and taller heaters.

��Fit the in-fill panel after the heater is fitted onto the mounting brackets as shown below.

��Attach the in-fill panel to the wall using screws to suit the wall type - screws to suit plaster board, timber or masonry walls are supplied in the in-fill panel kit).

��Fit the screws through the snap-cap base. Clip the snap-cap cover to the base after fitting the screws to cover the screw heads.

Top of heater - frontcover removed

In-fill panel

Wall openingoutline

10

Page 11: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Wiring diagramWiring diagram 10

FA

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Page 12: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

11

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Page 13: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

Installation Checklist Installation Checklist 12SELECT SUITABLE LOCATION��Room layout��Wall stud location/clearance��Gas and electricity available��Flue clearances OK, no obstructions

UNPACK HEATER��Remove plastic film��Remove 2 transit screws from top rear of cover��Remove cover retaining screws from bottom (above top louvre inside air outlet)

FIT MOUNTING BRACKETS��Remove existing mounting brackets��Fit bottom mounting brackets (right hand bracket 100mm higher than left)��Fit top mounting bracket (fit flue extension/flue adaptor if required for connection to existing flue system)

FIT FLUE SYSTEM��Must comply with current requirements of AS5601

FIT FLUE COVER COMPONENTS (console installation only)��Refer instructions in Console & Flue Cover Kit

FIT REAR REGISTER COMPONENTS��Refer instructions in Rear Register Kit

FIT HEATER ONTO MOUNTING BRACKETS��Slide heater flue spigot up through top mounting bracket��Lower bottom of heater onto BOTH bottom mounting brackets��Fit thermostat bracket to wall or skirting board 50mm below heater

CONNECT GAS AND ELECTRICITY��Gas inlet fitting - 1/2" compression fitting on gas valve��Power point within 900mm from left or 400mm from right��DO NOT COIL EXCESS POWER LEAD INSIDE APPLIANCE

COMMISSIONING��Check for gas leaks��Check gas pressure��Check ignition and pilot flame��Check room fan operation

FIT FRONT COVER��Fit console sides and top bracket (console installations only)��Hook on at top, push in at bottom - CONNECT EARTH LEAD��Fit cover retaining screws (above top louvre inside air outlet)

INSTRUCT USER ON HEATER OPERATION

Page 14: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

13FAULT REMEDY

Pilot will not light Purge gas line.

POSSIBLE CAUSES

Air in gas line.

Check and clear gas supply line.Blockage in gas line.

Check supply pressure at gas valve inlet pressure test point - increase supply pressure to specified value with main burner running: - Natural Gas: 1.13 kPa - Propane: 2.75 kPa

Insufficient gas supply pressure.

Check ignition lead is connected and not damaged. Check ignition electrode position.

No spark.

Pilot goes out when main burner is turned on.

See above.Insufficient gas supply pressure.

Main burner will not ignite.

Check and adjust pilot flame (see 'Commissioning').

Low pilot flame.

Cannot achieve specified test point pressure.

See above.Insufficient gas supply pressure.

Room fan does not start.

Check/connnect electricity supply.No electricity supply.

Check/re-connnect wiring.Wiring dislodged.

Check room fan is free to rotate. Gently pull motor forwards to clear fan wheel from internal rear panels if necessary.

Room fan pushed in and jammed during transport.

Fan will not switch from low to normal.

Check test point pressure - adjust if necessary (see 'Specifications').

Test point pressure too low.

Fan noisy. Select 'Auto' at manual fan switch.Boost selected at manual fan switch.

Heater turns off before room warms up.

Increase setting on control.Control set too low.

Re-locate thermostat bulb bracket (see 'Commissioning).

Thermostat bulb too close to bottom of heater.

Check/re-locate furniture to ensure clear path for heated air jet.

Hot air recirculation.

Check for air leakage from rear register components if fitted.

Objectionable odour when heater is running (see note below).

Check flue cowl installation - re-fit correctly if necessary.

Flue cowl pushed on too far.

Check flue cowl location - must be at least 500mm from roof.

Flue cowl too close to roof.

Note: Some odour from a new heater is normal - this will generally disappear after a few hours of operation at maximum gas rate.

Page 15: WF2000 GAS WALL FURNACE - McKinnon Heating & Cooling€¦ ·  · 2013-05-23Installation Instructions 3 GENERAL The heater must be installed in accordance with these instructions,

614281/h

SERVICE1300 650 644

TECHNICAL SUPPORT1300 650 399

Manufacturers and Designers of Technically Advanced Quality Heating and Cooling Products

Seeley International Pty Ltd has a policy of continuous product development and therefore reserves the right to make changes to these specifications without notice. Whilst every care has been taken to assure

accuracy of the data compiled in the document, Seeley International Pty Ltd ACN 23 054 687 035 does not assume any liability for errors and/or omissions.

Braemar is a registered trademark of Braemar Industries Pty Ltd.www.seeleyinternational.com