Johnson & Starley ECONOMAIRE 32 User guide

RELIABILITY YOU CAN TRUST
Johnson & Starley
www.johnsonandstarley.co.uk
Publication No. ZZ 1088-12
April 2010
ECONOMAIRE 32
WARM AIR HEATER
with Intejan Water Circulator
INSTALLATION, COMMISSIONING &
SERVICING INSTRUCTIONS
G.C. NUMBERS: Air Heater 42-416-14
Water Circulator 53-416-31
These instructions are to be left with the User or
adjacent to the Gas Meter

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CONTENTS
The Benchmark Scheme 2
1 Features 3
2 Brief Description 3
3 Important Information 3
4 Technical Data 4
5 Heater Compartment & Clearances 4
6 Ventilation Air 5
7 Duct System 5
8 Flue Instructions 6
9 Electrical 9
10 Gas 9
11 Air Heater Commissioning 9
12 Intejan Circulator 12
13 Intejan Circulator Commissioning 13
14 Users Instructions 14
15 Maintenance 14
16 Defect Diagnosis 18
17 Diagnosis Flow Charts 19
18 Logic Diagram 22
19 Schematic Diagram 23
20 Circuit Diagram 24
21 Dimensions 25
22 List of Spares 26
23 Exploded Diagram 27
24 Economaire Ancillaries 28
25 Benchmark Checklist 29
THE BENCHMARK SCHEME
In order to comply with Building Regulations Part L (Part J in Scotland) the boiler MUST be fitted in accordance with the
manufacturer’s instructions.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with
the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code
of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING
THE INSTALLATION. ON COMPLETION LEAVE THESE INSTRUCTION WITH
THE USER OR AT THE GAS METER.
In the interest of continuous development Johnson and Starley reserve the right to change specification without prior notice. Johnson and Starley
prides itself on it’s ability to supply spare parts quickly and efficiently.
If your service engineer indicates a problem in obtaining a spare part, advise him to contact Johnson and Starley Spares Department.

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1. FEATURES
These appliances have been tested and certified by Advantica for use with natural gas G20.
Note: These instructions have been written to service both the ECONOMAIRE 32 and the ECONOMAIRE 32/INTEJAN. If
your heater does not have the intejan circulator fitted, simply ignore the relevant section/s.
2. BRIEF DESCRIPTION
2.1 ECONOMAIRE 32/INTEJAN is a fan assisted downflow ducted warm air heater, which is fan flued and room sealed. The
heater is supplied with digital temperature control (for maximum comfort) and a water circulator as standard. In addition,
a rear rising duct kit is available for both models as well as an INTEJAN circulator kit for retro-fit to the ECONOMAIRE 32.
2.2 The air heater output can be adjusted between 7.3kW (26.4MJ/h, 25,000 Btu/h) and 9.4kW (33.8MJ/h, 32,000 Btu/h) “summer
air circulation” of unheated air is available by manual selection (see the user’s instructions). INTEJAN output is 3.5kW (12.6MJ/h;
11,900Btu/h).
THIS APPLIANCE CONFORMS TO BS EN 55014
FEATURES
1. Thermista-stat
2. Time Control
3. Air Circulator Fan
4. Circuit Diagram Label
5. Gas Connection
6. Circulator thermostat
7. Gas Cock
8. Ignition Burner
9. Main Burner Assembly
10. Intejan circulator
11. Water Return Connection
12. Water Flow Connection
13 Air heater Multifunction Control
14. Intejan Multifunction Control
(ECONOMAIRE 32 INTEJAN)
15 Flue Gas Test Point
16. LED Diagnostics Indicator
17. Control Module
18. Combustion Air Fan
19. Filter
20. Flue Adapter
FIGURE 1
ECONOMAIRE 32 FEATURES
18
7
4
16
8
5
10
9
6
3
1
2
20
17
15
14
12
11
19

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3. IMPORTANT INFORMATION
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)
BS 7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations
BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).
BS 5440 Pt.1 (Flues for Gas Appliances)
BS 5440 Pt.2 (Air Supply for Gas Appliances)
BS 5864 Installation of Gas Fired Ducted Air Heaters
British System Design Manual “Gas Fired Warm Air Heating”
Model and Local Authority Bye-laws
BS 5546 Installation of Domestic Hot Water Supplies.
IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS,
(i.e. GAS SAFE REGISTERED INSTALLERS. GAS SAFE MEMBERSHIP ENQUIRIES - TEL: [phone]) IN
ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE
TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
4. TECHNICAL DATA
ECONOMAIRE 32 ECONOMAIRE 32 INTEJAN
WATER CIRCULATOR
WEIGHT 54kg 61kg
GAS G20
GAS SUPPLY PRESSURE 20mbar
GA CATEGORY I 2H
COUNTRIES OF INSTALLATION GB & IE
ELECTRICAL SUPPLY 230V ~ 50Hz fused 5A 250W
NOX CLASS 1
MAXIMUM WATER SIDE OPERATING PRESSURE
(PMS) N/A 3 bar
OPEN VENTED SYSTEM N/A YES
SEALED SYSTEM N/A YES
5. HEATER COMPARTMENT AND CLEARANCES (See BS 5864)
5.1 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.
5.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 3mm (1/8”) at the
sides and rear and 75mm (3”) 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, water and electrical supplies. If gas and /or water
connections are made from a side entry, a minimum clearance of 75mm (3”) is required at that side.
5.3 For service access, a minimum of 450mm (18”) 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”). However, if clearances are less than 75mm, the internal surface of the compartment
must be lined with non-combustible material and the compartment must be of a fixed rigid structure.
5.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant section of
BS 5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the
perforations not exceeding 13mm (½”). The secondary flue must be a tight fit where it passes through the partition and
must be suitably protected (see BS 5440: Part 1).

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5.5 In under-stairs installations, the compartment must comply with the relevant section of BS 5864, 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.
5.6 In free-standing installations, (see instructions packed with TC32 or TC32R top closure kit), only one or two walls
will be in close proximity to the air heater; these must be non-combustible.
5.7 Where the air heater is to be installed onto a combustible surface and under-floor ducting used, a suitable
base tray (BT32) MUST be used in order to provide insulation. NB where a base plenum is used no base tray is
required!
6. VENTILATION AIR
6.1 When installed in a compartment two permanent ventilation openings into the compartment are required, one at high level
and one at low level. The minimum effective areas specified in Table 1 are related to the rated heat input of the air heater
and assume that an INTEJAN circulator is fitted.
7. DUCT SYSTEM
(See British Design Manual - Gas fired Warm Air Heating)
7.1 RETURN AIR
7.1.1 Room-sealed appliances may be installed without return air ducting, provided that the path between the return air
grille and the appliance return air inlet is protected in such a manner that the required air-flow will be maintained
at all times. The return air grille MUST have a free area of not less than 860cm² (137in²). It is recommended that
the return air duct not be routed directly from the main living area, but from a convenient central area serving the
remainder of the dwelling.
7.1.2 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 plenum. 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 250mm x
200mm (10” x 8”). If flexible duct is used the duct diameter should not be less than 300mm (12”) diameter. The
return air grille should have a free area of not less than 860cm² (137in²).
7.1.3 An adequate and unobstructed return air path is essential from areas not served by a directly ducted return and to
which warm air is delivered. All such rooms should be fitted with relief grilles which have a free area of 0.0088m²/
kW (1in²/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms and WC.’s.
7.1.4 The return air duct should allow for ease of removal for access to the flue.
7.1.5 All duct work in the room or internal space in which the heater is installed shall be mechanically secured and
sealed with ducting tape.
7.2 WARM DELIVERED AIR
7.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (2”) fibreglass or similar. If short extended
duct runs are taken below floor level these should be similarly insulated and in addition wrapped with a sound
vapour proof barrier. They must also be protected from crushing.
7.2.2 The duct system should be carefully designed (as given in the guidelines in the British System Design Manual) to
suit the needs of specific heating requirements and building layout. The type of duct system (e.g. 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, must be constructed to support the weight of the heater,
which must be sealed using self-adhesive foam strip, ducting tape or sealing compound. All ducting and blanking
plates must be mechanically secured and sealed.
VENTILATED FROM INSIDE BUILDING
Low level grille 162cm² (25in²)
High level grille 162cm² (25in²)
VENTILATED FROM OUTSIDE BUILDING
Low level grille 81cm² (13in²)
High level grille 81cm² (13in²)
TABLE 1
MINIMUM EFFECTIVE AREAS

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8. FLUE INSTRUCTIONS
NOTE: THIS APPLIANCE MUST ONLY BE INSTALLED WITH THE SUPPLIED ACCESSORIES AND TERMINAL.
8.1 FLUES
NOTE: The ECONOMAIRE 32/INTEJAN can be used with horizontal or vertical flue types C12 and C32. You
should also consult (or be familiar with) British Standards BS 5440 Pt. 1 Flues
8.1.1 All joints must be soundly sealed.
8.1.2 Sufficient support brackets must be used in order to support the total weight of the flue system.
8.1.3 The flue must conform with Building Regulations and British Gas Materials and Installations specification (3rd
edition) regarding clearance and shielding from combustible materials.
8.1.4 ThehorizontalfluelengthMUSTNOTbelessthan300mmplus90˚bendandMUSTNOTexceed12m
excluding terminal.
8.1.5 The total vertical flue length MUST NOT be less than 1m and MUST NOT exceed 12m excluding terminal.
8.1.6 Total length refers to the equivalent worked flue length and therefore includes bends and NOT the distance from
the heater to the flue terminal.
8.1.7 When calculating total flue length, reference MUST be made to the following ‘equivalent lengths’:
 a)90˚bend =2m
 b)45˚bend =1m
8.1.8 Themaximumnumberof90˚bendsthatcanbeusedis:
 a)Horizontal=4
 b)Vertical =4
8.1.9 If a ‘short flue’ is used, the factory fitted flue orifice MUST be left
in place (see figure 4).
8.1.10 ‘Short flue’ refers to a total flue length not exceeding:
 a)Horizontal(plus90˚bend) = 0.8m
 b)Vertical(includingterminal)=5m
8.1.11 Where the total flue length exceeds these lengths, the flue
orifice MUST be removed.
8.1.12 The heater is supplied with either a horizontal or vertical flue,
dependant upon your specification when ordering. Reference
should be made to Table 3 for extra flue/terminal components.
8.2 HORIZONTAL TERMINAL LOCATION
8.2.1 The terminal must be positioned on the outside of the building
and allow for the free passage of air across it at ALL times.
8.2.2 Avoid positions where the terminal is adjacent to
projections, particularly under a balcony or immediately
adjacent to a drain pipe.
8.2.3 The terminal position must ensure that combustion
products cannot enter the building in which the heater is
installed (or any adjacent building) through windows, doors
or by any others means.
8.2.4 Figure 3 shows recommended terminal positions
8.2.5 It is recommended that the flue is fitted so that the outer part is flush with the wall. However, where this is not the
case, the maximum protrusion of the outer part of the flue through the wall MUST NOT exceed 22mm (see figure 3)
8.2.5 If the heater is to be installed in a timber framed building you MUST consult British Gas publication “Guide for Gas
Installations in Timber Framed Housing DM2” or your local gas region.
8.2.6 Where the lowest part of the flue terminal is located less than 2 metres above the ground, a balcony, or above a flat
roof across which there is access, the terminal MUST be fitted with a Tower Flue Components type K3 guard (or
similar) such that the distance between the guard and the nearest part of the terminal is no less than 50mm.
8.2.7 Reference should be made to Table 3 for required terminal components and guard.
8.2.8 NOTE: TO ENSURE THAT RAINWATER CANNOT ENTER THE HEATER UNIT, THE FLUE MUST BE
INSTALLED WITH A SLIGHT FALL AWAY FROM THE HEATER.
8.3 VERTICAL TERMINAL LOCATION
8.3.1 The ECONOMAIRE 32/INTEJAN is designed to be used with a vertical flue where the installation of a horizontal
flue is either not possible or not desired.
8.3.2 Installationofaverticalfluecanbeoneitheraflatorpitchedroofwithapitchangleofbetween25˚and50˚.
8.3.3 The terminal MUST be positioned on the outside of the building and allow for the free passage of air across it at
ALL times.
8.3.4 Avoid positions where the terminal is adjacent to projections; particularly under a balcony.
8.3.5 The terminal position must ensure that combustion products cannot enter the building in which the heater is
installed (or any adjacent building) through windows, doors or by any other means.
8.3.6 Figure 3 shows recommended terminal positions.
8.3.7 Reference should be made to Table 3 for the required terminal components.
FIGURE 2
FLUE ADAPTOR & ORIFICE

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TABLE 7 TERMINAL POSITION MINIMUM DISTANCE
A Directly below an opening, air brick, opening window etc 300mm
B Above an opening, air brick, opening window, etc. 300mm
C Horizontally to an opening, air brick, opening window etc. 300mm
D Below gutters, soil pipes or drain pipes. 75mm
E Below eaves. 200mm
F Below balconies. 200mm
G From a vertical drain pipe or soil pipe. 150mm
H From an internal or external corner. Greater than 450mm protrusion. 300mm
I Above ground, roof or balcony level. 300mm
J From a surface facing the terminal. 600mm
K From a terminal facing the terminal. 1,200mm
M Vertically from a terminal on the same wall. 1,500mm
N Horizontally from a terminal on the same wall. 300mm
Q Above intersection with roof. 530mm
P From a vertical structure on the roof 300mm
R From the terminal to the boundary 300mm
FIGURE 3
TERMINAL POSITIONS
TABLE 2
TERMINAL POSITIONS

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FIGURE 5
PLUME TERMINAL OUTLET DIMENSIONS
FIGURE 4
HORIZONTAL FLUE OUTLET PROTRUSION
TABLE 3
FLUE & TERMINAL COMPONENTS
ITEM DESCRIPTION QTY PART No. COLOUR
190˚ Standard Flue Elbow 1 1000-0014840 White
245˚ Flue Elbow 1 1000-0014850 White
3500mm Extension 1 1000-0014870 White
41000mm Extension 1 1000-0014860 White
5Vertical Terminal & Support Bracket 1 1000-0014880 Anthracite
6Vertical Terminal & Support Bracket 1 1000-0014980 Terrcotta
7Lead Pitched Roof Flashing & Collar 1 1000-0014890 Anthracite
8Lead Pitched Roof Flashing & Collar 1 1000-0014990 Terracotta
9Aluminium Flat Roof Flashing 1 1000-0014900 Aluminium
10 Horizontal Wall Terminal 1 1000-0014910 White
11 Wall Plates (for above) 2 1000-0014920 n/a
12 Horizontal Wall Terminal & 2 x Wall Plates 1 1000-0014940 n/a
13 Condensate Drain 1 1000-0014940 White
14 Syphon Kit (for above) 1 1000-0014950 n/a
15 Condensate drain & 1 x Syphon Kit 1 1000-0014960 n/a
16 Wall Bracket (100mm diameter) 1 1000-0014970 n/a
17 Terminal Guard 1 1000-0015430 n/a

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9. ELECTRICAL
WARNING: THIS APPLIANCE MUST BE EARTHED!
9.1 MAINS
 9.1.1 Theheaterissuppliedwithmainscable(PVCsheathed,heatresistingto85˚C),3core:Brown;Blue;Green/Yellow,
6A, 0.75mm²), 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 requires connection to the fixed wiring using a double pole switched, fused
spur with a contact separation of at least 3mm in ALL poles. The fuse fitted must be rated 5A to BS 1362.
Connections must also be in accordance with the current edition of I.E.E Regulations BS 7671.
NOTE: If, for any reason, the heater is re-wired, then 3 core cable that meets the above specification MUST be used. Under
NO circumstances, should 5 core cable be used for the combined purpose of supplying power to the heater and
connecting the thermista-stat!
 9.1.2 Fandelayandoverheat(limitcontrols)arenotadjustableandarefactorysetsothatthelimitswitchopensat80˚C
 andclosesat40˚C.
9.1.3. An electronic controller (thermista-stat) is supplied which acts like a room thermostat.
9.2 THERMISTA-STAT AND ITS LOCATION.
9.2.1 The thermista-stat should be located where there is free air circulation and positioned approx. 1.5m (5ft) from the
floor.
9.2.2 Avoid the following locations:
a. 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.
b. Near an outside door or windows, or on an outside wall.
c. Where it will be affected by warm air ducts, diffusers, waste pipes or the heater itself.
d. Where it will be subjected to vibration.
9.2.3 Connect the thermista-stat wires to terminals ‘8’ and ‘9’ on the terminal block (see Figures 13 & 14).
10. GAS (See BS 5864 and BS 6891)
10.1 The local gas supply conditions MUST be adequate for the specified burner pressures as stated in the technical data
(paragraph 1.3)
10.2 An independent gas supply pipe from the meter is to be preferred wherever possible. Where 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 the same pipe.
This supply should be suitably sized to conform to British Standards requirements of no more than 1.0 mbar (0.4” wg)
pressure drop (See table of discharge in BS 6891).
10.3 The ½” union gas cock (supplied) MUST be fitted to the gas inlet of the heater for easy isolation during servicing. The gas
pipe should be fitted and installed so 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 or the base, to a Rc½ (½”
BSP. external [taper] thread).
11. AIR HEATER COMMISSIONING
11.1 PREPARATION
After installation of the appliance, you MUST do the following:
11.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found.
11.1.2 Carry out preliminary electrical system checks.
11.1.3 Ensure that:
a. filter, fan and fan compartments are free from obstructions.
b. all registers or grilles are open and conform to design specifications.
c. return, relief and ventilation air installations are adequate.
11.2 SYSTEM BALANCING
11.2.1 Set the air heater electrical supply ON.
11.2.2 Set the thermista-stat to the “SUMMER AIRFLOW” position.
11.2.3 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.
11.3 LIGHTING IGNITION AND MAIN BURNER
11.3.1 Turn on the gas supply to the heater.
11.3.2 Set both the “AIR HEATER” and “WATER HEATER” switches on the time control unit to the “OFF” position.
11.3.3 Set the thermista-stat to “9”.

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FIGURE 7
IGNITION CONTROLLERS
FEATURES
1 Inlet Pressure Test Point
2 Outlet Pressure Test Point
3 Burner Pressure Adjuster
4 Ignition Control
5 Manual Reset
C) FRONT VIEW
with ignition controller removed
1
3
2
A) SIDE VIEW
with ignition controller in place
1
24 3
B) FRONT VIEW
with ignition controller in place
5
11.3.4 Locate the status LED indicator which can be
observed through the inspection hole in the bottom
right hand corner of the control module.
11.3.5 Turn on the mains power supply to the heater
11.3.6 Set the “AIR HEATER” switch on the time control to
“CONT.” and observe the LED status indicator.
11.3.7 Whilst the control module runs through its
diagnostic cycle the decimal point (DP) in the
bottom right hand corner of the LED display will
flash continuously.
11.3.8 The ignitor will spark for a maximum period of 60
seconds during which time the ignition and main
burners SHOULD ignite and the igniter will stop.
11.3.9 When the control module reaches stage 5,
(indicated by “5” on the LED) power is fed to the
gas valve and the green LED “ON” light on the
indicator panel will illuminate. After a period of
approx. 5 seconds, the module will move on to
stage 6 (indicated by “6” on the LED).
NOTE: Regardless of when the burner ignites during
the 60 second period, the LED will continue to
display stage 6.
11.3.10 If, after the 60 second period, the main burner has
ignited the LED indicator will show “0” and the
green LED “ON” light on the indicator panel will
remain steady.
11.3.11 If the main burner fails to ignite, the red LED
marked “LOCKOUT” will illuminate on the display
panel and the LED status indicator will display
an alphanumeric character relevant to the fault
detected.
11.3.12 In the event of a lockout and the ignition and main
burners failing to ignite, reference should be made
to Table 6 in the fault finding section of these
instructions in order to establish the fault condition.
11.3.13 Allow the air heater to operate for a minimum of 15
minutes to ensure stability.
11.3.14 Reset the thermista-stat to the desired comfort level
11.3.15 Set the time control to the desired “on and “off”
periods.
11.3.16 Set the “AIR HEATER” switch on the time control to
“TIMED”.
FIGURE 6
ELECTRICAL DOOR ASSEMBLY
COVER
PLATE
SCREW
TERMINAL
BLOCK
TIME CONTROL
COVER
PLATE
SCREW
LED
STATUS
INDICATOR
INDICATOR PANEL