Johnson & Starley HI-SPEC J25 Installation, Commissioning & Servicing Instructions

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Page 1

These instructions are to be left with the User or adjacent to the Gas Meter

Johnson

& Starley

HI-SPEC J25 WARM AIR HEATERS

SYSTEM E-T and Basic Control

INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS

G.C. No 42 451 04

Publication No. ZZ 753/12

January 2010 This appliance ha been tested and certified by G . L. Industrial Services UK Ltd. for use with natural gas G20. Note: If a HIJAN 6 or SUPERJAN 6 circulator is fitted, the relevant Installation, Commissioning and Servicing instructions

provided with that appliance must also be observed.

1. BRIEF DESCRIPTION

Fig. 1

1 Air filter 2 Air circulating fan 3 Heat exchanger access cover 4 Multifunctional control 5 Data Plate 6 Heat shield 7 Burner assembly 8 Pilot burner 9 Lighting port 10 Fan delay control/limit switch 11 Gas supply pipe 1 2 Piezo igniter unit 1 3 Time control

1.1 HI-SPEC J25 is an open-flued, fan assisted downflow, ducted warm air heater , which may be supplied with SYSTEM E-T or

1.2 The Air heater output can be adjusted between 5.6kW (20.0MJ/h, 19,000Btu/h) and 7.3kW (26.4MJ/h, 25,000Btu/h). “Summer

Basic control. A HIJAN 6 or SUPERJAN 6 circulator is available as an option. A pilot burner incorporating an Atmospheric Sensing Device (ASD) is fitted which responds to the presence of flue gases and shuts down the appliance.

air circulation” of unheated air is available by manual selection (see User’s Instructions). HIJAN 6 output is 3.81kW (13.7MJ/ h, 13,000Btu/h), whilst SUPERJAN 6 output is 6.0kW (21.6MJ/h, 20,470Btu/h).

THIS APPLIANCE CONFORMS TO BS EN 45014

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Installation shall be in accordance with the current editions of:

Building Standards (Scotland) (Consolidation) Regulations Building Regulations Gas Safety (Installation and Use) Regulations (as amended) BS7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations BS6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases). BS5440 Pt.1 (Flues for Gas Appliances) BS5440 Pt.2 (Air Supply for Gas Appliances) BS5864 Installation of Gas Fired Ducted Air Heaters British System Design Manual “Gas Fired Warm Air Heating” Model and Local Authority Bye-laws BS5546 Installation of Domestic Hot Water Supplies.

IMPORT ANT: ST ATUTE LA W DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS, (i.e. GAS SAFE REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLA TION AND USE) REGULA TIONS (CURRENT EDITION). FAILURE T O COMPLY WITH THESE REGULATIONS MA Y LEAD TO PROSECUTION.

2. HEATER COMPARTMENT AND CLEARANCES (SEE BS5864)

2.1 IMPORTANT: If the heater is to be fitted to an existing base duct (warm air plenum), always ensure that installation is

carried out such that the rear left hand corner of the heater is aligned with the rear left hand corner of the base duct, so that any overhang or blanking off will be at the front and/or right hand side. In any event, blanking plates must be mechanically secured and all joints sealed.

2.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 15mm at the sides and rear, and 25mm at the front must be left. Consideration should also be given to the space required for the removal and replacement of the filter tray and the entry of the gas and electrical supplies.

2.3 For service access, a minimum of 450mm (18ins) is required at the front of the heater. Space must also be allowed, in a compartment installation, to permit the removal of the heater. The clearance between the appliance and the compartment should be not less than 75mm (3 in). However, if clearances are less than 75mm, the internal surface of the compartment must be lined with non-combustible material. The compartment must be of a fixed rigid structure.

2.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant section of BS5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the perforations not exceeding 13mm (1/2in). The secondary flue must be a tight fit where it passes through the partition and must be suitably protected (see BS5440: Part 1).

2.5 In under-stairs installations, the compartment must comply with the relevant section of BS5864, provided that in addition, all internal surfaces, including the base, are non-combustible or lined with non-combustible material. This requirement is applicable only to dwellings of more than two storeys.

2.6 If the Air Heater is to be installed onto a combustible surface, a suitable base tray (BT25) is required. However, when a base duct is used, this provides sufficient protection for combustible material and no further insulation is required.

3. VENTILA TION AND COMBUSTION AIR

3.1 The room or internal space in which the heater is installed requires a permanent air vent of minimum effective area 36cm

(5in2). The air vent should be either direct to outside air or to an adjacent room or internal space (other than a toilet or bathroom) that itself has an equivalent air vent direct to outside.

3.2 Combustion air may be introduced, via a 100mm (4in) nominal bore pipe, connected to a return air duct or plenum from a ventilated area and fitted with a lockable damper. The damper should be adjusted to control combustion airflow to 0.0083m

s (17.6cfm), (i.e. 1.06m/s [210ft/min] velocity in a 100mm [4in] bore pipe). If this arrangement is used, a non-closeable warm air register MUST be provided in the same area as the front of the air heater or heater compartment if a return air grille is not located in that area.

3.3 When installed in a compartment, two permanent ventilation openings into the compartment are required, one at high level and one at low level, both communicating either directly with outside air or with a ventilated room or space. The minimum effective areas specified in Table 1 are related to the rated heat input of the Air Heater, and assuming that a HIJAN 6 circulator is fitted. If a SUPERJAN 6 circulator is fitted, the minimum area is greater, and reference made to the relevant installation instructions for the circulator.

3.4 If any room or area from which air is drawn for ventilation or combustion contains an extract fan, the permanent vents must be sized to ensure that the operation of the appliance(s) at full rate is/are not adversely affected. A spillage test as specified in sub-para 6.8 (Safety Checks) is carried out and any remedial work undertaken.

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Ven ti la t e d fro m i ns id e building.

Low leve l g r ille 2 84c m

(44in2)

Hig h leve l g r ille 142 cm

(22in2)

Ven t i la t e d fro m o utside bu ild in g .

Low leve l g r ille 142c m

(22in2)

Hig h leve l g r ille 7 1cm

(112)

T able 1: Minimum Efective A reas

4 DUCT SYSTEM

(See British Design Manual- Gas Fired W arm Air Heating)

4.1 RETURN AIR

4.1.1 It is NOT recommended that the return air duct be routed directly from the main living area, but from a convenient central area serving the remainder of the dwelling.

4.1.2 All return air shall be POSITIVELY ducted from outside the compartment to the top of the unit via a return air duct. Where required, return air can be ducted to the side of the heater by transferring the return air spigot. Refering to fig. 9 (page25), remove the 4 x knockouts and use the return air spigot as a template in order to mark out where to cut the heater casing. Using a 2.9 mm bit, drill the fixing holes and secure using the previously removed screws. Fit the supplied blanking plate to the top of the heater and secure using the screws supplied with the blanking plate. NB

remove swarfe from the air heater compartment prior to installation and commissioning!

4.1.3 The return air system should be constructed of fire-resistant material. The flue shall not be run through an area serving as a return air path. It is extremely important that the correct size of return air grilles and ducting is used. For heaters on maximum output the return air duct size should not be less than the equivalent of 200mm x 200mm ( 8" x 8"). If flexible duct is used the duct diameter should not be less than 250mm (10") dia. The return air grille should have a free area of not less than 645cm

(100in2).

4.1.4 An adequate and unobstructed return air path is essential from areas not served by a directly ducted return and to

4.1.5 The return air duct should allow for ease of removal for access to the flue.

4.1.6 All duct work in the room or internal space in which the heater is installed shall be mechanically secured, and sealed

4.2 W ARM DELIVERED AIR

4.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (2in) fibreglass or similar. If short extended

4.2.2 The duct system should be carefully designed (as given in the guidelines in the British System Design Manual) to

5. INSTALLATION REQUIREMENTS

Note: For circulator Installation Instructions, refer to the relevant instructions provided with the circulator.

5.1 FLUES (SEE BRITISH ST ANDARDS BS5440 PT.1 FLUES)

5.1.1 All joints shall be soundly sealed.

5.1.2 The flue should be kept as short and warm as possible.

5.1.3 Sufficient support brackets shall be installed to bear the weight of the total flue system.

5.1.4 The spigot connection of the heater draught diverter will accept internally the spigot end of a non-asbestos flue to

which warm air is delivered. All such rooms should be fitted with relief grilles which have a free area of 0.0088m

/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms and WC.’ s.

(1in

/kW

with ducting tape.

duct runs are taken below floor level these should be similarly insulated, and in addition wrapped with a sound vapour proof barrier, and protected from crushing.

suit the needs of its specific heating requirements and building layout. The type of duct system, (i.e. radial/extended plenum/stepped) should be installed using the least number of fittings to minimise airflow resistance. The base duct, which equalises the air pressure to supply ducts, shall be constructed to support the weight of the heater, which shall be secured to the plenum with screws on at least two sides, and sealed using self-adhesive foam strip, ducting tape or sealing compound. All ducting and blanking plates shall be mechanically secured and sealed.

BS567 or twin wall metal flue to BS715 of nominal 100mm (4in) diameter.

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SIDE VIEW

BASE V IEW

FRONT VIEW

TOP VIEW

326088

300

2065010

254

376

120 dia.

440

695

253

393

115

593

60067

5.1.5 A split collar should be fitted to provide for flue maintenance or inspection.

5.1.6 The flue shall be in accordance with the Building Regulations and British Gas Materials and Installations specification 3rd edition) with regard to clearance and shielding from combustible materials.

5.1.7 All materials shall be in accordance with Building Regulations requirements.

5.1.8 The flue should run as vertically as possible. Horizontal runs should be avoided if at all possible and any directional change should be as gentle as possible. If there is any doubt about the flue configuration, the equivalent flue height should be determined (see 5.1.10).

5.1.9 I f th e appliance to be fitted is a replacement, the old appliance should be checked for signs of spillage prior to commencement of the installation and appropriate action taken, (i.e. check flue system and renew as necessary).

5.1.10 It is recommended that at least 600mm of vertical flue should be provided from the top of the draught diverter (for new installations this shall be incorporated into the flue design). However, when carrying out replacement installations, an existing flue system may be encountered, where the vertical flue above the appliance to the first bend is less than 600mm. In the first instance, the installer must judge whether this distance can be achieved practicably by some means. Where this is not practicable, the existing flue system may be used, providing there is no evidence of spillage from the old appliance (see 5.1.9 above). Every effort must be made, however, to ensure that the existing flue complies in every other way to BS 5440 Part 1, including the visual inspection, flue flow and spillage test described in 4.3.2 of the above standard. Flue configurations may be assessed in terms of equivalent vertical height details are given below. For air heaters, the minimum equivalent vertical height is 1 metre. The installer must make a judgement based on his knowledge and experience and the examination and testing described above as to whether an existing flue system can be used.

Note: Ventilation of the compartment, room or internal space in which the appliance is to be installed must be checked for

compliance with the requirements of BS 5440 Part 2, ( Ref. Section 3 of these instructions) and upgraded as necessary.

5.1.11 Calculation method for flue sizing: (BS 5440: Part 1, Appendix A)

a. This appendix provides a procedure for estimating whether a given flue design is likely to ensure full

clearance of combustion products.

b. The procedure is based on calculating the ‘equivalent height’ of the flue under consideration, i.e. that height

of the straight vertical circular flue pipe of specific size which will produce the same flow rate as the flue under consideration. The equivalent height is calculated from the formula:

(K He = Ha x (Ki + Ko)a - KeHa + Sum K

+ Ko )

where:

is the height of the equivalent flue;

is the vertical height of the actual or proposed flue;

Ki is the inlet resistance of the flue;

is the outlet resistance from the flue;

subscript e refers to the equivalent flue diameter; subscript a refers to the actual or proposed flue diameter;

is the resistance per unit length of the equivalent flue;

Sum K is the resistance (other than the inlet and outlet resistance) of the actual or proposed flue. Note: K and Sum K are obtained from T able 2. K

and Ki are obtained from T able 3.

c. Table 2 gives resistance factors for common flue components for use in the formula. Table 3 contains the

appropriate inlet and outlet flue resistances. The flue is likely to be satisfactory if its equivalent height exceeds 1m.

d. W orked Calculation Example:

A warm air unit with a 100 mm diameter flue spigot, fitted with a pre-fabricated flue system leading to a ridge tile in the loft (refer Fig. 2):

From table 3:

Inlet resistance of actual flue . . . . . . . . 2.5

Outlet resistance of actual flue . . . . . . 2.5

Inlet resistance of equivalent flue . . . . 2.5

Outlet resistance of the actual flue . . . 2.5

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Component Internal Size (mm) Re s istance Components Internal Size (mm) Re s is tance

Flue Blocks

197 x 67 0.85 per metre

bend

100mm pipe 0.61 per fitting 231 x 65 0.65 run 125mm pipe 0.25 per fitting 317 x 63 0.35 150mm pipe 0.12 per fitting

140 x 102 0.60 197 x 67 0.30 per fitting

200 x 75 0.60 231 x 65 0.22 per fitting 183 x 90 0.45 317 x 63 0.13 per fitting

Pipe

100 0.78 Raking Block Any 0.30 per block 125 0.25 150 0.12 Adaptor Block Any 0.50 per block

C himney 2 1 3 x 21 3 0.0 2

Terminal

100mm ridge 2.5 125mm ridge 1.0

Bend

100mm pipe 1.22 per fitting 150mm ridge 0.48 125mm pipe 0.50 per fitting 100mm GCI 0.6 150mm pipe 0.24 per fitting 125mm GCI 0.25

150mm GCI 0.12

Appliance Inlet Resistance ( Ki) Flue Out let res is t ance (Ko)

100mm Dia Spigot 2.5 100mm 2.5

125mm Dia Spigot 1.0 125mm 1.0

150mm Dia Spigot 0.48 150mm 0.48

T able 2

Resistance factors for use in calculating equivelent lengths

T able 3

Inlet and outlet resistance

From table 2:

Other resistances of actual flue:

Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Pipe bend ( 2 x 0.61) . . . . . . . . . . . . . . . . . . . . 1.22

Pipe (4 x 1m @ 0.78) . . . . . . . . . . . . . . . . . . . 3.12

(5 x 0.3m @ 0.78) . . . . . . . . . . . . . . . . . . 1.17

Sum K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01

Equivalent height :

From the formula (2.5 + 2.5)

= 6.2 x

(2.5 + 2.5) - (0.78 x 6.2) + 8.01

= 3.793 This flue exceeds 1.0m equivalent height and is therefore satisfactory.

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= 6.2m

Ridge T erminal

2 x 300 mm lengths

100 mm dia flue pipe

(Example only)

4.6m

4 x 1000 mm lengths

bend

300 mm length

1.6m

bend

2 x 300 mm lengths

Fig. 2

Flue spigot

W orked example of equivalent flue hight

Note: Ventilation of the compartment, room or internal space in which the appliance is to be installed must be checked for compli-

ance with the requirements of BS 5440 Part 2 ( Ref. Section 3 of these instructions) and upgraded as necessary

5.1.12 Consideration must be given to external flues with a view to prevention of condensation and weathering problems.

5.1.13 An approved terminal should always be used; a ridge terminal or “GC1” terminal is specifically recommended. The latter should be positioned in a free air space where it is not shielded by any structure. A minimum of 1m (3ft.) from any vertical or inclined roof structure must be allowed for.

5.1.14 Where flue blocks are used, builders should ensure that no obstruction is created during erection. The installer should ensure that the connection flue does not project beyond the internal wall of the flue blocks and that there is provision for examination and servicing.

5.1.15 Important: Before installing the appliance, carry out a visual check of the flue system as directed in the relevant section of BS5440 Pt.1, then check the flue performance as follows:

a. close all doors and windows in the room in which the appliance is to be installed; b. introduce some heat into the flue, using a blow torch or other means; c. carry out a flow visualisation check with a smoke pellet at the intended position for the appliance. Ensure that

there is discharge of smoke from the correct terminal only, and no spillage into the room. Smoke coming out of other than the correct terminal only, or a down draught or ‘no flow’ condition, indicates that the flue has failed the test, and the appliance shall not be connected until the defect has been found and rectified, and the test satisfactorily completed.

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5.2 ELECTRICAL

5.2.1 Mains.

a. The heater is supplied with mains cable (PVC sheathed, heat resisting to 85

Yellow, 6A, 0.75mm

), connected to a terminal block and exiting through the heater at the right hand top. The cable is suitable for a 230V 50Hz supply and shall be connected to the fixed wiring using a double pole switched, fused spur, incorporating a protective earth link. The fuse fitted shall be rated 5A to BS1362. Connections shall be in accordance with the current edition of I.E.E Regulations BS 7671.

b. The Fan Delay Control and Limit Switch are not adjustable and are set as follows:

Basic Models: Fan Delay Control closes at 54OC± 4.5OC; opens at 40OC±3OC.

All Models: Limit Switch opens at 80OC; closes at 60OC.

ii.

c. SYSTEM E-T MODELS: An electronic controller (Thermista-stat) is supplied which acts as a room thermostat. d. BASIC CONTROL MODELS: A 24V room thermostat (not supplied), that complies with BS800, BS3955 and

BS4201 is essential to ensure close control of comfort conditions. An anticipator is located within the thermostat and is graded in amps. The anticipator should be checked and adjusted to 0.2A.

5.2.2 Thermista-stat/Room Thermostat and its location.

a. The Thermista-stat/Room Thermostat should be located where there is free air circulation approx. 1.5m (5ft)

from the floor.

b. Avoid the following locations:

i. In a room where temperature is greatly affected by the sun or any other heat source, e.g. radiant fire,

wall light fittings or TV set.

C), 3-core Brown-Blue-Green/

ii. Near an outside door or windows, or on an outside wall. iii. Where affected by warm air ducts, diffusers, waste pipes or the heater itself. iv. Where subject to vibration.

c. Connect Thermista-stat/Room thermostat wires to control panel terminals ‘7’ and ‘8’ (see Fig. 7a/b or 8a/b).

5.2.3 IMPOR TANT: SUPERJAN 6 circulator .

a. If the air heater is fitted with a SUPERJAN 6 circulator, this will contain a pump overrun switch (CK6), which

is connected via the air heater terminal block terminals ‘6’, ‘10’ and ‘12’. Ensure that the red wire link connecting terminals ‘10’ and ‘ 12’ has been removed, as this would cause the effective short circuit of the pump overrun switch.

5.3 GAS (SEE BS5864 AND BS6891)

5.3.1 An independent gas supply pipe from the meter is to be preferred wherever possible. When this is not possible, the pipe must be capable of taking the complete input of the heater and all other gas appliances being served by this same pipe. This supply should be suitably sized to conform to British Standards requirements of no more than 1.0 mbar (0.4in wg) pressure drop (See table of discharge in BS6891).

5.4.2 The 1/2in union gas cock (supplied) must be fitted to the gas inlet of the heater for easy isolation during servicing. The gas pipe should be so fitted and installed as to be durable, substantial and gas tight. To assist in determining where a gas connection may not be tight, a leak detection fluid should be applied around the connection. Under no circumstances should a flame be used to locate a gas leak. Gas entry to the air heater is through either side to a Rc1/2 (1/2in BSP . external [taper] thread).

5.4 DRAUGHT DIVER TER & DEFELCTOR PLATE:

5.4.1 The HI-SPEC J25 heater is supplied with a draught diverter that requires fitting to the rear of the heater prior to installation, using 3 x 4mm screws and lock washers (provided).

5.4.2 The deflector plate prevents spillage from the draught diverter in the event of a leak between the air heater and the base plemum and MUST be fitted as shown in fig 3 using the pre-drilled holes and the 2 x No8 screws provided.

5.5 DEFLECTOR PLA TE SAFETY CHECK:

In order to ensure that the deflector plate is preventing warm air from entering the draught diverter and therefore causing spillage, the following test MUST be carried out BEFORE commissioning:

5.5.1 Turn on the power supply to the heater.

5.5.2 Set the summer airflow switch to “on”.

5.5.3 Using a smoke match, introduce smoke into the heat exchanger at the burner opening.

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130mm

Heater

Deflector

Plate

EXTERNAL PROG.

OPTIONAL

NOCLOCK

OPTIONAL

Park S8 when no

water htr. or for ext. prog.

230V

Timed

230V Cont.

AH(S5)

Timed

Park conns when no

clock fitted or for

external prog.

Spill

Switch

(TTB)

PCB

Wire colour code where indicated

*FELV FunctionalExtra-LowVoltage

NOTE:-

pink-----------pk red------------r blue----------b black---------bk brown--------br white---------w grey----------gy orange-------or

violet---------v yellow--------y

black/white------bk/w green/yellow----g/y

CLOCK

230V

Continuous

230V

Timed

PCB

If Superjan fitted removeredwire link

between terminals. 10 &12

AIR

HTR.

230V PUMP

WATE R

HTR.

230V

(Optional)

(See note)

Water

Htr.

Multi-functional

Control

Limit

Switch

Fan Delay

Control

N.BMay be

fittedwith start/run

capacitor.

Air Fan

Fan power

cap.

230V

PCB

ON S3

N.BBreaking conn

starts fan

Summer Air

Flow

OFF S1

Room

Thermista-stat

FELV *

Connections

2117

System E-T

PCB

Suppressed

230V Supply

Fan

Gas

Cleanflow

24V

Thermista-stat

FDC

N.C

PCB

Power

Link

Timed

230V

Cont.

230V 50Hz

Supply

T3.15A

FUSE

MAINS FILTER

24V

Room Thermista-stat

Water Heater

(Optional)

Water Pump

(Optional)

Limit Switch

Multi-functional Control 230v

Fan Delay

Control

Cleanflow (Optional)

TEST

27K0

25 19

PCB

24V

(Optional)

Cleanflow

Air

Cleaner

(TTB)

Spill

Switch

5.5.4 Ensure that the smoke is drawn into the heat exchanger and not blown back from the burner opening.

5.5.5 If smoke is blown back from the burner opening, check for air leaks between the heater and the base plenum, paying particular attention to the rear of the heater directly beneath the draught diverter.

6. COMMISSIONING

6.1 PREP ARA TION:

6.1.1 Ensure that:

a. Gas and Electrical supplies are OFF.

6.2 SYSTEM BALANCING:

6.2.1 Set the Air Heater electrical supply ON.

6.2.2 Set the SUMMER AIRFLOW switch to ‘1’.

6.2.3 Balance the system to provide the required volume proportions at the warm air outlets.

Note: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/min), except for very small rooms, (i.e., bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.

6.3 IGNITION OF PILOT AND MAIN BURNERS: W ARNING: If the Pilot Bight is extinguished either intentionally or unintentionally, no attempt should be made to relight the gas

for a minimum of 3 minutes. Ensure that the Electrical supply, time contr ol and Selector switches are set to ‘OFF’.

6.3.1 Set the Thermista-stat/room thermostat to its lowest or OFF setting.

6.3.2 On the Multifunctional Control, remove the Outlet Pressure test point cover, and fit a pressure test gauge (refer fig.

6.3.3 Turn the heater Gas supply ON, test for gas soundness and purge the whole gas pipe as described in BS6891.

6.3.4 Referring to Fig. 5, partially depress the OPERA TING CONTROL and set the control

b. Filter, fan and fan compartments are free

from obstructions.

c. All registers or grilles are open and conform

to design specifications.

d. Return, relief and ventilation air

installations are adequate.

5).

‘SP ARK’ symbol. Press and hold the OPERATING CONTROL, and whilst observing the Pilot Burner, repeatedly

Note: If the Piezo unit should fail to spark, the Pilot Burner may be lit by applying a lighted taper to the Pilot Burner whilst the OPERA TING CONTROL is pressed and held.

press the Piezo igniter button until the Pilot Burner ignites.

6.3.5 After 20 seconds release the OPERA TING CONTROL and let it spring out; ensure that the Pilot Burner remains alight. If the Pilot Burner extinguishes, rotate the OPERATING CONTROL clockwise to the ‘l’ position and ensure that the OPERATING CONTROL is fully reset. Wait three minutes and repeat steps 6.3.4 and 6.3.5, holding the OPERA TING CONTROL depressed for a longer period, until the Pilot Burner remains alight.

6.3.6 With the Pilot Burner lit, depress the OPERATING CONTROL and turn it to the position indicated by the flame symbol.

6.3.7 Ensure that the pilot flame envelops the thermocouple tip, if not, check that the pilot orifices and aeration port are free from obstruction. The pilot is factory set and is non-adjustable.

6.3.8 Set the air heater Electricity supply ON.

6.3.9 Set the Time Control to the required Heating On periods.

6.3.10 Set the Selector switch to ‘TIMED’.

6.3.11 Set the Thermista-stat or room thermostat to MAXIMUM.

6.3.12 Ensure that the Main Burner has now ignited.

8 21

Deflector Plate

Fig. 3

/4 turn anti-clockwise to the

Page 9

6.3.13 T est for gas leakage at the supply, Multifunctional Control, Pilot and Main Burners using a proprietary detection fluid, sealing any leaks found.

Electrode

Pilot Burner

6.3.14 Allow the heater to operate for a minimum of 15 minutes to ensure stability.

6.4 MAIN BURNER PRESSURE TEST:

NOTE: AIR HEA TER BURNERS ARE FACTO RY SET TO PROVIDE A NOMINAL HIGH RA TE OUTPUT AS DET AILED IN SUB P ARA 1.2

6.4.1 Referring to Table 4 and Fig. 5 below, ensure that the pressure test gauge indicates the correct burner pressure, resetting if required as follows:

At the Multifunctional Control:

i Remove the Burner Pressure

Adjuster cover.

ii. Set the Burner Pressure Adjuster

to provide a pressure test gauge indication for the correct burner pressure as detailed in Table 4.

iii. Refit the Burner Pressure Adjuster cover.

6.4.2 Apply the pressure set arrow to indicate the appropriate burner pressure on the data badge.

6.5 EXTINGUISHING OF PILOT AND MAIN BURNERS:

6.5.1 On the Multifunctional Control, rotate the OPERATING CONTROL clockwise to the ‘l’ position and ensure that the OPERA TING CONTROL fully resets and both Pilot and Main Burners are extinguished.

Thermocouple

Aeration Port

Fig. 4

Pilot Burner Assembly

6.5.2 On the Multifunctional control, remove the pressure test gauge and refit the Outlet Pressure test point cover.

6.6 TEMPERATURE RISE CHECK:

6.6.1 Ignite the Pilot and Main Burners and allow 15 minutes for stability before continuing.

6.6.2 Check that the temperature rise across the heater is

between 45

C - 55oC, setting the fan speed as follows:

i . SYSTEM E-T heaters: System E-T provides a fan

speed corresponding to the above temperature rise, if the appliance is to be set to operate at the minimum rate and the ducting has been sized accordingly, set the ‘RATE SWITCH’ to ‘MIN’, thus reducing the fan speed.

ii BASIC Control heaters, the fan speed is adjusted

by selecting the fan speed at control panel (decrease voltage selection to decrease fan speed).

Note: T apping 1 = 230V, T apping 2 = 220V , Tapping 3 = 210V ,

T apping 4 = 200V , T apping 5 = 190V , Tapping 6 = 170V .

6.7 AUTOMA TIC CONTROLS CHECK

6.7.1 Set the TIME CONTROL to ‘ON’.

6.7.2 Turn the Thermista-stat or room thermostat slowly clockwise until the Main Burner ignites.

6.7.3 Ensure that the fan starts to operate after a short period (approx. 1-2 minutes).

Sit

EV2

1. Operating control

2. Burner pressure adjuster

3. Outlet pressure test pont

Fig. 5

Multifunctional Control

920

Page 10

SYSTEM E-T models:

0.50

mbar

0.20

170V

190V

200V

210V

220V

In wg.

0.15

0.10

0.05

0.375

0.25

0.125 150

0.07

200

0.09

250

0.12

300 ft /min

0.14 m /sec

Air Volume

6.7.4 Ensure that the fan speed increases to full speed.

6.7.5 When the temperature reaches the control setting, check that the Main Burner cycles ON and OFF, at approximately

75 to 120 seconds.

BASIC CONTROL models:

6.7.6 When the temperature reaches the control setting, ensure that the Main Burner extinguishes followed by the fan

switching off after a short period.

6.7.7 When the temperature falls below the control setting, ensure that the Main Burner re-ignites followed by fan

operation.

6.8 SAFETY CHECKS:

6.8.1 Check for gas soundness within the appliance.

6.8.2 Spillage test: Carry out a full spillage test as follows, and ensure that the flue operates effectively with all doors

closed and any extractor fans in operation.

NOTE: If an extractor fan is situated in an adjoining or adjacent room, carry out the spillage test with the interconnecting doors open.

If the draught diverter is accessible:

a. Introduce smoke into the draught diverter adjacent to an exit from the heat exchanger, by means a smoke

match or puffer.

b. Ensure that there is no spillage present (indicated by displacement of smoke downwards and out of the

draught diverter).

If the Draught Diverter is not accessible:

a. Introduce smoke, by means of part of a smoke pellet on a non-combustible support, into the heat exchanger. b. Extinguish the Main and Pilot burners. c. Ensure that there is no spillage evident by visually observing the draught diverter location on the air heater. d. If spillage is evident, further investigation and rectification is required before re-testing the appliance.

W ARNING: The appliance shall not be left connected to the gas supply unless it has successfully passed the above spillage test.

6.8.3 Turn OFF the gas supply at the service cock and ensure that the Multifunctional Control fail-safe operates within 60

secs (indicated by loud click from Multifunctional Control).

6.8.4 Turn gas supply ON at service cock.

6.8.5 Switch the appliance electrical supply OFF.

6.8.6 Disconnect the Air Circulation Fan at the flying lead socket.

6.8.7 Switch the appliance electrical supply ON.

6.8.8 Ignite the Pilot and Main Burners as detailed in 6.3.1 to 6.3.5.

6.8.9 Ensure that the Limit Switch operates, indicated by the Main Burner extinguishing, within 120 and 180 seconds.

6.8.10 Switch the appliance electrical supply OFF.

6.8.11 Reconnect the Air Circulation Fan.

6.8.12 Switch the appliance electrical supply ON.

6.8.13 Ensure that the Main Burner re-ignites when the

appliance temperature reduces, (note: with the Air Circulation Fan disconnected, there may be some delay before the Main Burner re-ignites).

T able 5

Fan Performance Curve

Page 11

Low Rate Me dium Rate High Rate

kW MJ/h Btu/h kW MJ/h Btu/h kW MJ/h Btu/h

Inpu t

7.6 27.1 25,780 8.7 31.2 29,560 9.7 35.1 33,250

Output

5.6 20.0 19,000 6.5 23.2 22,00 7.3 26.4 25,000

Gas ra te C V 1037Btu/ft

0.70 m3/h (24.9ft3/h 0.80m3/h (28. 5ft3/h 0.91m3/h (32.1ft3/h

Burner s et ting pressure (hot)

10.0 mbar (4.0 in wg) 14.0 mbar (5.6 in wg) 17.0 mbar (6.8 in wg)

Main injector BRAY CAT 33/700

T able 4

Main Burner Pressure Settings

7. INSTRUCTIONS FOR USERS

7.1 If the building is unoccupied, ensure that the Instructions for User are left taped to the air heater for the User, and the Installation Instructions are left at or near the air heater for use on future service calls.

7.2 If the building is occupied, hand the User Instructions over and ensure the User understands:

7.2.1 How to ignite the pilot and burner.

7.2.2 How to operate the Thermista-stat/room thermostat, time and heater ON/OFF switch and summer air circulation

switch, and that the time control must be reset following a power failure.

7.2.3 How to extinguish the pilot and main burner at the Multifunctional control, and switch off electrical supply to the

heater.

7.2.4 How to remove, clean and refit the air filter and at what intervals (i.e. fortnightly, or for new houses, weekly).

7.2.5 How to control the heating system by opening and closing warm air outlets.

7.2.6 How to obtain summer air circulation.

7.2.7 That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of the

building must not be obstructed.

7.2.8 That the heater must be serviced at least once a year by a competent person to ensure efficient and safe operation.

7.2.9 That the red instructions for safe use have been pointed out and understood.

8. MAINTENANCE

IMPORT ANT: Ensure that the gas and electricity supplies are isolated before commencing any maintenance or replacement of components. After completion of any maintenance, always test for gas soundness and carry out a complete functional test of the appliance in accordance with the Commissioning Instructions at Sect 6.1 to 6.8 inclusive.

8.1 ROUTINE MAINTENANCE:

Note: During annual servicing, ASD pilots must be inspected for damage to any component part, the aeration port and lint arrestor

must be cleaned to remove lint or debris. No attempt should to be made to clean ASD pilots with any hard tool that could result in swarfe or foreign bodies, since this can block the pilot injector, thereby affecting the safety performance. Upon ignition, both pilot flames should appear stable and ‘clean’, and the pilot assembly replaced if this is not so. If any damage is found, then the complete pilot assembly will require replacement.

7.2.10 That expert help must be obtained if persistent failure of the pilot burner occurs.

8.1.1 Operate the appliance and check for the correct function of the burner and controls.

8.1.2 Turn OFF the gas and electrical supplies to the appliance.

8.1.3 Remove the air heater front panel.

8.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the Air Circulation fan as detailed in

para 8.7.

8.1.5 Remove the Burner and Controls Assembly as detailed in para 8.2. Inspect and clean the main burner and injector as

necessary. Examine the main burner for cracks, including hairline cracks, exchanging the burner as necessary.

8.1.6 Inspect and clear the Pilot Burner orifice.

1118

Page 12

8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below.

8.1.8 By viewing through the Fan Aperture, and using a torch or similar, examine the heat exchanger externally for signs of cracks or holes, particularly around welded joints.

8.1.9 Using a torch or similar, introduce a light source into the heat exchanger burner aperture and upper access port, and again examine the heat exchanger for signs of cracks or holes, particularly around welded joints, whilst again viewing through the Fan Aperture.

8.1.10 Refit the Air Circulation fan, Burner and Controls Assembly, and air filter/air cleaner.

8.1.11 Light the appliance and note the main burner flame profile. If the flame profile is af fected when the Air Circulation fan switches on, check for any air leaks between the air heater and the base plenum, paying particular attention to heaters with rear draught diverters. Rectify any air leaks before continuing with this procedure.

8.1.12 Allow the air heater to operate for approximately 15 minutes to ensure stability, and with the main burner lit, ensure that the operation of Air Circulation fan does not affect the main burner flame profile.

8.2 BURNER AND CONTROL ASSEMBL Y REMOVAL:

8.2.1 E ns ur e t ha t t he Ga s a nd Electrical supplies are switched OFF

8.2.2 Remove the appliance door.

8.2.3 Disconnect the igniter at the Piezo unit.

8.2.4 Disconnect the Multifunctional Control electrical connections.

8.2.5 Disconnect the gas supply by breaking the union at the input side of the Multifunctional Control.

8.2.6 Slacken the 2 lower Burner Assembly securing screws.

8.2.7 Whilst supporting the Burner and Control Assembly , release the 2 upper Burner assembly fixing screws and withdraw the Burner and Control Assembly

8.2.8 Refit the Burner and Control Assembly in reverse order.

8.3 BURNER AND CONTROL ASSEMBLY CLEANING:

8.3.1 Remove the Burner and Controls Assembly as detailed in 8.2.

8.3.2 Disconnect the Pilot Feed Pipe and Thermocouple from the Multifunctional Control.

8.3.3 Remove the lint arrestor from the Pilot Assembly, which is secured by a ‘Terry clip’.

8.3.4 Release the single screw securing the Pilot Assembly to the Burner and Controls Assembly, and remove the Pilot Assembly.

8.3.5 Release the 3 nuts and lock washers securing the Main Burner to the mounting bracket, and remove the Main Burner.

8.3.6 Release the 2 nuts securing the burner back plate and gasket, and withdraw back plate and gasket from the burner.

8.3.7 Clean the burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR DAMAGE BURNER HOLES.

8.3.8 Reassemble in reverse order, replacing the burner gasket if damaged. The Pilot Assembly is located by a tag on the burner bracket. DO NOT over tighten the Thermocouple connection at the Multifunctional Control, (finger tight plus 1 flat).

8.4 PILOT BURNER ASSEMBL Y REMOV AL AND REPLACEMENT: Note: The relationship between the Pilot and Thermocouple is critical and must not be disturbed. Do not attempt to

dismantle the Pilot Assembly. If any part of the Pilot Assembly is considered defective, the complete assembly must be replaced.

8.4.1 Remove the Burner and Controls Assembly as detailed in 8.2.

8.4.2 Disconnect the Pilot Feed Pipe and Thermocouple from the Multifunctional Control.

8.4.3 Remove the lint arrestor from the Pilot Assembly, which is secured by a ‘Terry clip’.

8.4.4 Release the single screw securing the Pilot Assembly to the Burner and Controls Assembly, and remove the Pilot

Assembly.

8.4.5 Disconnect the Pilot Feed Pipe from the Pilot Injector.

8.4.6 Refitting or replacement is in reverse order. The Pilot Assembly is located by a tag on the burner bracket. DO NOT

over tighten the Thermocouple connection at the Multifunctional Control, (finger tight plus 1 flat).

12 17

Page 13

8.5 MUL TIFUNCTIONAL CONTROL REMOV AL:

8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2

8.5.2 Disconnect the Thermocouple at the Multifunctional Control, avoiding damage to the capillary.

8.5.3 Disconnect the Pilot Feed Pipe from the Multifunctional Control.

8.5.4 Disconnect Multifunctional Control input and output supply feeds.

8.5.5 Refitting or replacement is in reverse order. NOTE: When refitting or replacing the Multifunctional Control, the ‘O’ ring seal is to be replaced.

8.6 PIEZO UNIT REMOV AL:

8.6.1 Disconnect the 2 conductors from Piezo unit.

8.6.2 Release the retaining nut and remove the Piezo unit from its mounting bracket.

8.6.3 Refitting or replacement is in reverse order.

8.7 AIR CIRCULATING FAN, REMOV AL AND CLEANING:

8.7.1 Ensure that the electrical supply is isolated.

8.7.2 Remove the appliance front door, release the 3 x securing screws and hinge down the fan chamber door.

8.7.3 Disconnect the fan flying leads from the Fan Assembly .

8.7.4 Release the Fan Assembly securing screw and withdraw the Fan Assembly from the Heater cabinet, avoiding damage to the fan blades.

8.7.5 Remove all dust from both the impeller and motor, taking care to not disturb the balance of the fan.

8.7.6 Refitting or replacement is in reverse order.

8.8 ELECTRICAL ASSEMBL Y REMOVAL:

8.8.1 Ensure that the electrical supply is isolated.

8.8.2 Remove the appliance front door, release the 3 x securing screws and hinge down the fan chamber door.

SYSTEM E-T models:

8.8.3 Disconnect the following a. Air circulation fan flying leads from the capacitor, b. 230V mains ‘L’, ‘N’ and ‘E’ from connection block terminals ‘1’ and ‘2’, and Earth stud respectively , c. Thermista-stat connections from connection block terminals ‘7’ and ‘8’, d. Limit switch from connection block terminals ‘13’ and ‘14’, e. Fan Delay Control from connection block terminals ‘18’ and ‘17’, f. Multifunctional Control from connection block terminals ‘16 (N) and ‘15’ (L), g. W ater heater from connection block terminals ‘10’ (L) and ‘9’ (N), h. W ater Pump from connection block terminals ‘12’ (L) and ‘11’ (N), i. Cleanflow from connection block terminals ‘19’ (24V) and ‘20’ (0V),

. Earth lead from the fan chamber floor,

BASIC Control models:

8.8.4 Disconnect the following: a. Air circulation fan flying leads from the Fan assembly,

b. 230V mains ‘L’, ‘N’ and ‘E’ from connection block terminals ‘1’ and ‘2’, and Earth stud respectively , c. Room thermostat connections from connection block terminals ‘7’ and ‘8’, d. Limit Switch from connection block terminals ‘13’ and ‘14’, e. Fan Delay Control from connection block terminals ‘18’ and ‘17’, f. Multifunctional Control from connection block terminals ‘16 (N) ,‘15’ (L) and Earth stud. g. W ater heater from connection block terminals ‘10’ (L) and ‘9’ (N), h. W ater Pump from connection block terminals ‘12’ (L) and ‘11’ (N), i. Cleanflow from connection block terminals ‘19’ (24V) and ‘20’ (0V), j . Earth lead from the fan chamber floor,

Both model types:

8.8.5 Release the 2 x hinge pins and withdraw the Electrical Assembly , releasing wiring from cable clamps and grommets as required.

8.8.6 Refitting or replacement is in reverse order.

Page 14

8.9 ELECTRONIC MODULE REMOV AL (SYSTEM E-T models only):

8.9.1 Ensure that the electrical is isolated.

8.9.2 R emov e the appl ianc e front door, release the 3 x securing screws and hinge down the fan chamber door.

8.9.3 Disconnect terminals ‘21’ to ‘33’ from the Electronic Module.

8.9.4 Release the 2 x screws and nuts securing the Electronic Module to the Electrical assembly and remove the module.

8.9.5 Refitting or replacement is in reverse order.

8.10 TRANSFORMER REMOV A L (BASIC Control models only):

8.10.1 Ensure that the electrical is isolated.

8.10.2 Remove t he ap plia nce f ront door, release the 3 x securing screws and hinge down the fan chamber door.

8.10.3 Disconnect the conductors from the large Transformer.

8.10.4 Relea s e t he 2 x screws and nuts securing the Transformer to the Electrical Assembly, and remove the Transformer.

8.10.5 Refitting or replacement is in reverse order.

8.11 TIME CONTROL and SWITCH REMOV AL:

8.11.1 Ensure that the electrical is isolated.

8.11.2 Remove t he ap plia nce f ront door, release the 3 x securing screws and hinge down the fan chamber door.

Time Control removal:

8.11.3 Disconnect conductors ‘C1’, ‘C2’, ‘C3’ and ‘C5’ from the Time control.

8.11.4 Release the 3 x fixing screws, and withdraw the Time control.

8.11.5 Refitting or replacement is in reverse order.

8.11.6 Set the Time Control to the required ON and OFF times.

8.11.7 Set the Time Control to the correct time.

Switch removal:

8.11.8 Disconnect the conductors from the switch terminals.

8.11.9 Depress the retaining clips and press the switch out of the fascia panel.

8.11.10 Refitting or replacement is in reverse order.

W ARNING: The fascia panel is held in place by push fit retainers which must be removed with caution to avoid causing damage to the support pins. Removal of the fascia is not advised unless it is intended to be replaced.

8.12 F AN DELA Y CONTROL/LIMIT SWITCH REMOV AL:

8.12.1 Ensure that the electrical supply is isolated.

8.12.2 Remove appliance front door, release the 3 x securing screws and hinge down the fan chamber door.

8.12.3 Disconnect the following at the Electrical Panel:

a. Limit Switch from connection block terminals ‘13’ and ‘14’, b. Fan Delay Control from connection block terminals ‘18’ and ‘17’, c. Earth connection from common earth stud.

8.12.4 Release 2 x 4mm screws securing Limit switch mounting plate, and withdraw the control from the appliance by drawing the conductors through the grommet in the fan chamber floor.

8.12.6 Refitting or replacement is in reverse order.

8.13 HE AT EXCHANGER ACCESS:

8.13.1 Ensure that the electrical supply is isolated.

8.13.2 Remove the appliance front door

8.13.3 Remove the Burner and Controls Assembly as detailed in sect 8.2.

8.13.4 Release the 6 screws securing the access plate to the bulkhead, and withdraw the access plate and gasket.

8.13.5 Release the 8 screws securing the top access cover plate, and withdraw the cover plate and gasket.

8.13.6 Reassembly is in reverse order.

NOTE: When reassembling, ensure that the baffles are pushed fully home, the gaskets are soundly sealed, and fully recommission the heater .

14 15

Page 15

9. DEFECT DIAGNOSIS

9.1 IMPORTANT: If an electrical defect occurs after installation of the appliance; preliminary earth continuity, polarity, and resistance to earth checks should be carried out with a multimeter. On completion of any maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then checks of continuity, polarity, and resistance to earth must be repeated.

9.2 WARNINGS:

9.2.1 When purging or checking gas supplies, ensure that the ventilation to the room or cupboard is adequate, and that all

naked lights are extinguished.

9.2.2 I f a defect occurs concerning the Pilot Burner, Thermocouple or Igniter Electrode, then the complete Pilot Assembly

MUST be replaced.

9.2.3 SYSTEM E-T models: a. When carrying out any electrical testing, a test meter MUST be used, since low resistance test devices can cause

damage to the Electronics module.

b. Before commencing defect diagnosis, ensure that the Thermista-stat is set to maximum, mains supply is ‘ON’ and

that the time control is at an ‘ON’ position.

c. Care is to be taken during the replacement and handling of electronic assemblies (i.e. electronic panel, airflow sensor

or Thermista-stat). It is not practical to rectify defects on these assemblies, except at the manufacturer, and any attempt to do so may render the guarantee or factory replacement arrangement invalid.

SYMPTOM POSSIBLE CAUSE REMEDY

a. Pilot will not light. i. No gas supply to heater. Check for gas at inlet pressure test

point on Multifunctional Control.

ii. Gas supply pipe not purged. Purge gas supply pipe in accordance

with BS 6891. i ii Pilot orifice restricted. Clear pilot orifice or replace pilot assembly. iv Pilot aeration port obstructed. Clear obstruction or replace pilot assembly. v. Piezo system faulty. Check igniter, lead, and electrode. vi. Excessive gas supply pressure. Check that mains gas pressure is 20mbar,

and reduce if necessary.

b. Pilot lights but goes i. Connection between thermo- Check connection is secure.

out on releasing START couple and Multifunctional button during initial Control not secure. light-up, or after normal operation. ii. Faulty Multifunctional Replace Multifunctional Control.

Control. iii. Faulty thermocouple. Replace Pilot Assembly. iv. Pilot flame affected by draught. Eliminate draught. v. Combustion air contaminated. Carry out spillage test and rectify.

c. Main burner opera- i. Gas rate or burner pressure Check gas rate and burner pressure

ting intermittently setting high. setting. with fan running.

ii. Temperature rise excessive. Adjust fan speed or gas rate accordingly. iii. Air filter or return air path Check filter is clean and air path is clear.

restricted. iv. Excessive number of outlets Open additional outlets.

closed.

SYSTEM E-T models:

d. Incorrect operation Fault related to SYSTEM E-T Consult diagnostic chart and follow

of fan or main burner. Control system (refer to pages 18-21) recommended procedure.

Basic control models:

e. Pilot alight but main i. Mains electrical supply not Check mains supply.

burner not igniting. connected to heater.

Page 16

ii. Controls not demanding heat Check that time control and

room thermostat are operating correctly.

iii. T3.15A fuse failed. Replace. If failure occurs again, check

wiring for short circuits.

iv. Loose connection to room thermo- Check connections.

stat, limit switch, gas control lead, time control, or transformer.

v. 230V/24V transformer failure. Check 24V side with test meter, if voltage

missing, replace transformer. vi. Faulty relay module Check 230V at white wire from switch S5 vii. Multifunctional Control faulty. Replace Multifunctional Control. viii.Limit Switch faulty. Short circuit control and replace if necessary. ix. Room thermostat or external Fit temporary loop in heater thermostat

wiring faulty. socket. If heater ignites, external circuit

or room thermostat is faulty.

f. Main burner lights i. Loose electrical connection Check connections.

but fan fails to run at fan control. after approx. 3 min.

ii. Fan Delay Control faulty. Replace. iii. Faulty fan assembly. Replace, taking care not to damage

impeller

iv. Burner pressure setting incorrect. Adjust pressure as necessary.

g. Main burner opera- i. Gas rate or burner pressure Check gas rate and burner pressure

ting with intermittent setting too low. setting. fan operation.

ii. Fan Delay Control faulty Replace.

h. Noisy operation. i. Gas pressure too high. Check burner pressure setting.

ii. Noisy fan motor. Replace fan assembly. iii. Fan speed setting too high. Adjust fan speed.

i. Fan runs for excessive i. Fan delay control faulty. Replace.

period or operates intermittently after main burner shuts down.

9.3 The SYSTEM E-T module is fitted with a diagnostic light emitting diode (LED) which is visible through a hole in the module cover, as shown in Fig. 5 below. If the LED is flashing, this means that :

9.3.1 The fan is not connected, or

9.3.2 The capacitor is not connected, or

9.3.3 There is a short circuit in the fan supply.

Diagnostic LED

Fig. 6

SYSTEM E-T Electronic Module

Page 17

SYSTEM E-T DEFECT DIAGNOSTIC FLOW CHART

MAIN BURNER NOT CYCLING

(ROOM TEMPERA TURE TOO HIGH)

DISCONNECT

THERMISTA-ST A T

DOES BURNER GO OUT?

DISCONNECT

MUL TIFUNCTIONAL

CONTROL A T

TERMINAL 15

DOES BURNER GO OUT?

REPLACE

MUL TIFUNCTIONAL

CONTROL

REPLACE

THERMISTA-ST A T

REPLACE

ELECTRONICS

MODULE

F AN CONTINUES T O RUN, OR CYCLES AFTER HEA TING IS TURNED OFF

DISCONNECT

TERMINALS ‘17’ &’18’

DOES

FAN

RUN?

REPLACE FAN DELA Y/

LIMIT CONTROL

REPLACE

ELECTRONIC

MODULE

Page 18

MAIN BURNER NOT OPERATING

Low Rate Me dium Rate High Rate

kW MJ/h Btu/h kW MJ/h Btu/h kW MJ/h Btu/h

Inpu t

7.6 27.1 25,780 8.7 31.2 29,560 9.7 35.1 33,250

Output

5.6 20.0 19,000 6.5 23.2 22,00 7.3 26.4 25,000

Gas ra te C V 1037Btu/ft

0.70 m3/h (24.9ft3/h 0.80m3/h (28. 5ft3/h 0.91m3/h (32.1ft3/h

Burner s et ting pressure (hot)

10.0 mbar (4.0 in wg) 14.0 mbar (5.6 in wg) 17.0 mbar (6.8 in wg)

Main injector BRAY CAT 33/700

SWITCH ON

REPLACE

MUL TIFUNCTIONAL

CONTROL

CHECK WIRING TO

MUL TIFUNCTIONAL

CONTROL

LINK TERMINALS ‘13’

& ‘14’, IF BURNER LIGHTS REPLACE

FAN/LIMIT CONTROL

CHECK WIRING

CONNECTIONS

PILOT

LIT?

IS 230V

230 V

SUPPLY

ON ?

IS TIME

CONTROL &

THERMISTA-STAT

CORRECTL Y

SET?

DISCONNECT THERMISTA-ST AT AT

TERMINALS ‘7’ & ‘8’, LINK

TERMINALS ‘7’ & ‘TEST’

DOES FAN

RUN?

CHECK FOR 230V A T

MUL TIFUNCTIONAL

CONTROL

CHECK FOR 230V A T

TERMINAL 15

CHECK FOR 230V A T

TERMINAL 13

CHECK FOR 230V A T

TERMINAL 29

IS GAS ON ?

TURN GAS

LIGHT PILOT

SET CONTROLS

CORRECTL Y

RECONNECT THERMISTA-ST AT AT

TERMINALS ‘7’ & ‘8’,

DISCONNECT ON CONNECTION A T

THERMISTA-ST A T

DOES

FAN

RUN?

EXTERNAL WIRING TO

THERMISTA-STA T

FAUL TY

REPLACE

THERMISTA-STAT

CHECK FOR 230V A T

TERMINAL 27

CHECK FOR 230V A T

CENTRE TERMINAL OF

SWITCH ‘S5’

CHECK FOR 230V AT TIME

CONTROL

TERMINAL ‘C5’

CHECK WIRING

CONNECTIONS

REPLACE AIR HEATER

SWITCH

REPLACE TIME

CONTROL MECHANISM

REPLACE

ELECTRONIC

MODULE

Page 19

FAN OPERA TES BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS REACHED

DISCONNECT THERMISTA-ST AT AT

TERMINALS ‘7’ & ‘8’, LINK

TERMINALS ‘7’ & ‘TEST’

DO NOT LINK ‘7’ &’8’

DOES

REPLACE

THERMISTA-STAT

THE BURNER

CONTINUE TO

CYCLE?

CHECK RETURN AIR P ATH

FOR RESTRICTIONS

DOES

THE BURNER

CONTINUE TO

CYCLE?

CHECK TEMPERATURE RISE. IF

LESS THAN 60

C, LINK

TERMINALS ‘13’ & ‘14’

DOES

THE BURNER

CONTINUE TO

REPLACE FAN DELA Y/

LIMIT CONTROL

CYCLE?

REPLACE

ELECTRONIC MODULE

MAIN BURNER ON BUT FAN NOT RUNNING

CHECK FOR

VOL TAGE A T

TERMINALS 30 & 31

BRIDGE OUT

F AN DELAY A T

TERMINALS 21 & 22

REPLACE

CAPACITOR

DOES

FAN

START?

REPLACE FA N

DELA Y/LIMIT

CONTROL

REPLACE

ELECTRONICS

DOES

FAN

START?

MODULE

REPLACE

FAN

1910

Page 20

FAN RUNS BUT MAIN BURNER NOT OPERATING

‘SUMMER

AIRFLOW’

SWITCH

SET TO

‘0’

THERMISTA

-STAT

CONNECTED

THERMISTA

-STAT SET

TO SUMMER

AIRFLOW

SET ‘SUMMER

AIRFLOW SWITCH TO

‘0’

CONNECT

THERMISTA-ST A T

SET THERMISTA-ST AT TO

REQUIRED

TEMPERATURE SETTING

DOES

FAN STILL

RUN ?

DISCONNECT THERMISTA-ST AT AT

TERMINALS ‘7’ & ‘8’, LINK

TERMINALS ‘7’ & ‘TEST’

DO NOT LINK ‘7’ &’8’

DOES FAN STILL RUN WITH

BURNER

LIT?

CHECK THERMISTA-ST AT WIRING . IF

OK, REPLACE THERMISTA-ST AT . IF

NOT , RECONNECT TERMINALS ‘7’ &

FAULT

CLEARED

‘8’, AND SET THERMISTA-STA T TO

DEMAND HEAT

REPLACE ELECTRONIC

MODULE. RECONNECT

THERMISTA-ST A T

HAS

FAN STOPPED

AND BURNER

LIT?

HAS

BURNER

LIT?

F AN OPERA TES AFTER BURNER HAS

RAISED THE INTERNAL

TEMPERA TURE TO CAUSE THE F AN

DELA Y CONTROL TO OPERA TE

Page 21

EXTERNAL PROG.

OPTIONAL

NOCLOCK

OPTIONAL

Park S8 when no

water htr. or for ext. prog.

230V

Timed

230V Cont.

AH(S5)

Timed

Park conns when no

clock fitted or for

external prog.

Spill

Switch

(TTB)

PCB

Wire colour code where indicated

*FELV FunctionalExtra-LowVoltage

NOTE:-

pink-----------pk red------------r blue----------b black---------bk brown--------br white---------w grey----------gy orange-------or

violet---------v yellow--------y

black/white------bk/w green/yellow----g/y

CLOCK

230V

Continuous

230V

Timed

PCB

If Superjan fitted removeredwire link

between terminals. 10 &12

AIR

HTR.

230V PUMP

WATE R

HTR.

230V

(Optional)

(See note)

Water

Htr.

Multi-functional

Control

Limit

Switch

Fan Delay

Control

N.BMay be

fittedwith start/run

capacitor.

Air Fan

Fan power

cap.

230V

PCB

ON S3

N.BBreaking conn

starts fan

Summer Air

Flow

OFF S1

Room

Thermista-stat

FELV *

Connections

2117

System E-T

PCB

Suppressed

230V Supply

Fan

Gas

Cleanflow

24V

Thermista-stat

FDC

N.C

PCB

Power

Link

Timed

230V

Cont.

230V 50Hz

Supply

T3.15A

FUSE

MAINS FILTER

24V

Room Thermista-stat

Water Heater

(Optional)

Water Pump

(Optional)

Limit Switch

Multi-functional Control 230v

Fan Delay

Control

Cleanflow (Optional)

TEST

27K0

25 19

PCB

24V

(Optional)

Cleanflow

Air

Cleaner

(TTB)

Spill

Switch

Fig. 7a System ET

Functional Diagram

Page 22

EXTERNAL PROG.

OPTIONAL

NO CLOCK

OPTIONAL

Park S8 when no

water htr. or

for ext. prog.

230V

Timed

230V Cont.

AH(S5)

Timed

Park conns when no

clock fitted or for

external prog.

230V

Multi-functional Control

Wire colour code where indicated

*FELV Functional Extra-LowVoltage

pink----------pk red-----------r blue---------b black-------bk brown------br white-------w grey-------gy orange---or violet------v yellow-----y black/white------bk/w purple/red-------p/r green/yellow----g/y

N N

CLOCK

230V

Continuous

Link

p/r

T3.15A

FUSE

AIR

HTR.

WATER

HTR.

Voltage

Selector

TX2

TX1

Summer Air Flow

S3 ON

S1 OFF

Limit

Switch

Fan Delay

Control

Fan

24V

(Optional)

Comm.

n/o

24V

Cleanflow

Air

Cleaner

T500mA

Relay Module

230V 50Hz

Supply

TIMED

230V

Cont.

24V

Room Thermostat

Water Heater

(Optional)

Water Pump

(Optional)

Limit Switch

Multi-functional Control 230v

Fan Delay

control

Cleanflow

(Optional)

24V Thermostat

(Not Fitted)

FELV * Connection

230V PUMP

230V

(Optional)

Water

Htr

(Optional)

Fig. 7b Basic Control

Functional Diagram

Page 23

Fig. 8a

System ET Circuit Diagram

Page 24

20 19 18 17 16 15 14 13 12 11 10 9

87 654 32

bk bk bbrr

br brb b

0V NL LNLNGE T

24V

Cleanflow

Fan

Delay

Control

230v

Multi-

functional

control

230v

Limit

control

230v

Water

pump

230v

Water

Heater

230v

50Hz

Mains

Supply

Th/Stat.

230v

Timed

Test

Earth

ANCILLARIES

Link Cont. 230v

to A

N. L.

Continuous.

Fuse

T3.15A

g/y

p/r

bkbkbk

p/r

OFF

bbr

b b

p/r

Sleeve

FROST

ANTI-HYPO.

Issue 02

Wire Colour Code

blue ----b black -----bk red ----r

brown ---br violet ---v black/white ---bk/w

grey ----gy white ----w purple/red ---p/r

orange ---or yellow ----y

Butt

Conn.

Butt

Conn.

TTB

Cont.

Off

When

fitted

Timed

SAC

When

fitted

Voltage Selector

Fuse

T500mA

24v

Relay

Module

N/C

N/O

Comm.

TX1

TX2

24V

230v

6VA Double Bobbin

Auto Transformer

g/y

FAN

Component Internal Size (mm) Re s istance Components Internal Size (mm) Re s is tance

Flue Blocks

197 x 67 0.85 per metre

bend

100mm pipe 0.61 per fitting 231 x 65 0.65 run 125mm pipe 0.25 per fitting 317 x 63 0.35 150mm pipe 0.12 per fitting

140 x 102 0.60 197 x 67 0.30 per fitting

200 x 75 0.60 231 x 65 0.22 per fitting 183 x 90 0.45 317 x 63 0.13 per fitting

Pipe

100 0.78 Raking Block Any 0.30 per block 125 0.25 150 0.12 Adaptor Block Any 0.50 per block

C himney 2 1 3 x 21 3 0.0 2

Terminal

100mm ridge 2.5 125mm ridge 1.0

Bend

100mm pipe 1.22 per fitting 150mm ridge 0.48 125mm pipe 0.50 per fitting 100mm GCI 0.6 150mm pipe 0.24 per fitting 125mm GCI 0.25

150mm GCI 0.12

Appliance Inlet Resistance ( Ki) Flue Out let res is t ance (Ko)

100mm Dia Spigot 2.5 100mm 2.5

125mm Dia Spigot 1.0 125mm 1.0

150mm Dia Spigot 0.48 150mm 0.48

Fig. 8b

Basic Control Circuit Diagram

24 5

Page 25

SIDE VIEW

BASE V IEW

FRONT VIEW

TOP VIEW

326088

300

2065010

254

376

120 dia.

440

695

253

393

115

593

60067

Fig. 9

Principal Dimensions

254

Page 26

WARM AIR HEATER AND CIRCULATOR COMMISSIONING CHECKLIST

Ven ti la t e d fro m i ns id e building.

Low leve l g r ille 2 84c m

(44in2)

Hig h leve l g r ille 142 cm

(22in2)

Ven t i la t e d fro m o utside bu ild in g .

Low leve l g r ille 142c m

(22in2)

Hig h leve l g r ille 7 1cm

(112)

This Commissioning Checklist is to be completed in full by the competent person who commissioned the warm air unit and associated equipment as a means of

demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name

Address

Telephone Number

Warm Air Unit Make and Model

Warm Air Unit Serial Number

Commissioned by (print name) Gas Safe Reg. No.

Company Name Telephone No.

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate*:

Building Regulations Notiﬁcation Number

CONTROLS Tick the appropriate boxes if applicable

Time & Temperature Room Thermostat & Programmable Load/Weather Optimum Start Control to Heating Programmer/Timer Roomstat Compensation Control

Time & Temperature Cylinder Thermostat & Warm Air Control to Hot Water Programmer/Timer Unit

Heating Zone Valves Fitted Not Required

Hot Water Zone Valves Fitted Not Required

Thermostatic Radiator Valves Fitted Not Required

Automatic Bypass System Fitted Not Required

Warm Air Unit Interlock Yes No If YES, Volume Litres

(if applicable)

FOR WARM AIR HEATERS ONLY

Has the system been balanced in accordance with the heater manufacture’s instructions? Yes No

Was an anemometer used? Yes No

Have balancing dampers been ﬁtted? Yes No

FOR WARM AIR HEATING: MEASURE AND RECORD

Burner operating pressure mbar

Heat input kW

Temperature difference between return air inlet and nearest outlet °C

FOR HOT WATER GENERATORS: MEASURE AND RECORD

Burner operating pressure mbar

Heat input kW

Water ﬂow temperature °C

ALL INSTALLATIONS

The heating and hot water system complies with the appropriate Building Regulations Yes

The system and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes

The efﬁcient operation of system and its controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm demonstration of equipment and receipt of appliance instructions)

* All installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

www.centralheating.co.uk

Page 27

Page 28

Johnson

& Starley

10. SHORT LIST OF SPARES

HI-SPEC J25

KEY G.C No MFR’S No DESCRIPTION QTY

1 232 878 BOS 02064 Fan Assembly 1 2 381 627 1000-0701140 Multifunctional Control (S.I.T. Nova) 1 3 379 837 1000-0704250 Pilot Assembly (S.I.T .) 1 4 378 466 BOS 02031 Time Control 1 5 245 503 T193-0751000 Burner Assembly 1 6 398 388 BOS 02060 Main Injector (Bray 33/700) 1 7 395 945 1000-0701160 Piezo Unit (High Energy) 1 8 245 509 1000-0513820 Fuse T3.15A anti-surge 1

9 T193-0145000 Filter Tray 1 10 364 835 S00832 Solenoid Valve 1 11 242 228 S00174 Heat Exchanger 1 12 245 542 1000-0515970 Capacitor 15 uF 1

System E-T Models only

13 245 510 ET 001 Electronic Panel Assembly with daughter board 1 14 245 514 1000-0515620 Thermista-stat 1 15 245 515 1000-0515455 Fan Delay/Overheat (limit) switch 1 16 1000-0515090 Mains Filter 1 18 T193 0531000 Complete Electrical panel 1

T193 0131000 Cabinet Door Assembly 1

Basic Control Models only

19 T193 0530000 Electrical Panel 1 20 245 520 1000-0516125 Fan delay/Overheat (limit) switch 1 21 245 522 1000-0515200 Transformer Fan Speed 1 22 245 525 1000-0515730 Transformer 24 volt 1 23 245 413 1000-0511760 Relay Module 1

Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently . If you have a problem in obtaining a spare part, please contact Johnson and Starley Spares Department at the address below .

Telephone: (01604) 762881 Rhosili Road,

F a x : (01604) 767408 Northampton NN4 7LZ

JOHNSON & STARLEY LTD.

Brackmills,