Johnson & starley Economaire 32/intejan User guide

Publication No. ZZ 1088/11

February 2008

128

ECONOMAIRE32/INTEJANhasbeentestedandcertifiedbyAdvanticaforusewithNATURALgasG20.

ECONOMAIRE 32/INTEJAN

WARM AIR HEATER

INSTALLATION, COMMISSIONING & SERVICINGINSTRUCTIONS

G.C. Numbers:

Air Heater 42-416-14

WaterCirculator53-416-31

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

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.

1. BRIEFDESCRIPTION

1.1 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.

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 our Spares Department at the

address below.

JOHNSON & STARLEY LTD.

Telephone: (01604) 762881 Rhosili Road,

Brackmills,

Fax: (01604) 767408 Northampton NN4 7LZ

Fig.1

HeaterwithSealingPanel removed Fig.2

Sealing Panel

1. Thermista-stat

2. Time control

3. Air circulator fan

4. Circuitdiagramlabel

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 multifuntion control

14. Intejan multifunction control

(ECONOMAIRE32INTEJAN)

15 Flue gas test point

16. LED diagonstics indicator

17. Control module

18. Combustion air fan

19. Filter

20. Flue adapter

max

off

min

227

1.2 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).).

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 Instituteof ElectricalEngineers (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 GasAppliances)

BS5440 Pt. 2 (Air Supply for GasAppliances)

BS 5864 Installation of Gas Fired DuctedAir Heaters

British System Design Manual “Gas Fired WarmAir Heating”

Model and LocalAuthority Bye-laws

BS 5546 Installation of Domestic Hot Water Supplies.

IMPORTANT:ITISASTATUTORYREQUIREMENTTHATALLGASAPPLIANCESAREINSTALLEDBYCOMPETENT

PERSONS,(i.e.CORGIREGISTEREDINSTALLERS)INACCORDANCEWITHTHEGASSAFETY(INSTALLATIONANDUSE)

REGULATIONS(CURRENTEDITION).FAILURETOCOMPLYWITHTHESEREGULATIONSMAYLEADTOPROSECUTION.

1.3 TECHNICALDATA

AIR HEATER WATER CIRCULATOR

LOW RATE HIGH RATE

KW MJ/h Btu/h KW MJ/h Btu/h KW MJ/h Btu/h

INPUT (Gross) 9.8 35.3 33,500 12.25 44.1 41,800 4.86 17.5 16,600

OUTPUT 7.3 26.4 25,000 9.4 33.8 32,000 3.5 12.6 11,900

Gas rate cv

1037Btu/ft30.93 m3/h (32.9ft3/h) 1.15 m3/h (40.5ft3/h) 0.458 m3/h (16.2ft3/h)

Burner setting

pressure (hot) 10.0 mbar (3.9 in wg) 14.6 mbar (5.8in wg) 15.0 mbar (6.0 in wg)

Main Injector Polidoro AL 270 Amal 187/001/400

Air Heater Water Circulator

Gas G20

Gas Supply Pressure 20mbar

Gas Category I 2H

Countries of Installation GB & IE

Electrical Supply 230V ~ 50Hz fused 5A 250W

Nox Class 1

Max WaterSide Operating

pressure (PMS) N/A 3bar

Open VentedSystem N/A Yes

Sealed System N/A Yes

ECONOMAIRE 32 ECONOMAIRE 32 INTEJAN

We ight: 54kg 61kg

SERVICEINTERVALRECORD

It is recommended that your heating system is serviced regularly and that your service engineer completes the

appropriate service interval record below.

SERVICEPROVIDER

Before completing the appropriate service interval record below, please ensure that you have carried out the service

as described in the heater manufacturer’s instructions and in compliance with the Gas Safety Regulations

SERVICE1 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE2 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE3 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE4 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE5 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE6 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE7 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE8 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE9 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE10 Date . . . . . . . . . . . . . . . . . .

Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CompanyName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGIIDSerialNo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When all of the above services have been completed, please contact your service engineer for an additional

servicerecordsheet.

2. HEATERCOMPARTMENTANDCLEARANCES(SEEBS5864)

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 3mm (1/8 in) at the sides

and rear and 75mm (3 in) 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 in) is required at that side.

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 and 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 BS

5864 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 BS 5440: Part 1).

2.5 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.

2.6 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.

2.7 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. NBwhere abase plenumisused nobase tray isrequired!

3. VENTILATION AIR

3.1 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.

4. DUCTSYSTEM

(See British Design Manual - Gas fired WarmAir Heating)

4.1 RETURNAIR

4.1.1 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.

4.1.2 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") dia. The return air grille should

have a free area of not less than 860cm2(137in2).

4.1.3 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.

4.1.4 The return air duct should allow for

ease of removal for access to the

flue. Table1:

MinimumEffectiveAreas

EDISNIMORFDETALITNEV

GNIDLIUB

velwoLellirglemc261

52 ni

)

mc261ellirglevelhgiH

ni52

)

EDISTUOMORFDETALITNEV

GNIDLIUB

mc18ellirglevelwoL

ni31

)

mc18ellirglevelhgiH

ni31

)

WARM AIR HEATER AND CIRCULATOR

COMMISSIONING CHECKLIST

WARM AIR UNIT

BENCHMARKNumber

HOTWATERGENERATOR

CONTROLS to comply with the Building Regulations, each section must have a tick on one or other of the boxes

APPLIANCE SERIAL NUMBER: ........... . . . . . . . . . . . .......... . . . . . . . . . . . . ........ . . .... NOTIFICATION No: ...... . . . . ..... . . . . ..... . . . .

REQUIREMENT

1. Time & temp control to heating

2. Time & temp control to hot water

3. Heating zone valves

4. Thermostatic Radiator Valves

5. Boiler interlock

MEASURES PROVIDED

Room stat & integral timer

Cylinder stat & Integral timer

Fitted Not Required

Provided Not Required

FORWARMAIRHEATERS ONLY

Has the system been balanced in accordance with the heater manufacturer’s instructions? YES NO

Was an anemometer used? YES NO

Have balancing dampers been fitted? YES NO

FORWARMAIR HEATING:MEASUREAND RECORD

Burner operating pressure Mbar

Heat input KW

Temperature differential between return air inlet and nearest outlet oC

FORHOTWATERGENERATORS:MEASUREANDRECORD

Burner operating pressure Mbar

Heat input KW

Water flow temperature oC

Does the heating & hot water system comply with the appropriate building regulations? YES NO

Has the appliance and associated controls been installed & commissioned in accordance with manufacturer’s instructions? YES NO

Have you demonstrated the operation of the appliance & system controls to the customer? YES NO

Have you left all the manufacturer’s literature with the customer YES NO

Competent person’s signature . . . .. . . . ... . . ... . . .. .. . . . .. . .. .. .. .. .. .. .. . . Customer’s Signature . .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .

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

COMMISSIONING ENGINEER’S DETAILS

Name .............................................................. . . . . . . .. . . . . .. . . . . Commissioning Date .. . . . . . . . . . .. . . . . .. . . . .. . . . .

Address . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CORGI REGISTRATION No .. . . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . CORGI ID SERIAL No . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOR ALL PRODUCTS

425

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

with ducting tape.

4.2 WARMDELIVEREDAIR

4.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (2in) 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.

4.2.2 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.

5. INSTALLATIONREQUIREMENTS

NOTE: THISAPPLIANCEMUSTONLYBEINSTALLEDWITHTHESUPPLIEDACCESSORIESANDTERMINAL.

5.1 FLUES

NOTE:TheECONOMAIRE32/INTEJANcan beusedwithhorizontalorverticalfluetypesC12 andC32.Youshouldalsoconsult

(orbefamiliarwith) BritishStandards BS5440Pt. 1Flues

5.1.1 All joints must be soundly sealed.

5.1.2 Sufficient support brackets must be used in order to support the total weight of the flue system.

5.1.3 The flue must conform with Building Regulations and British Gas Materials and Installations specification (3rd

edition) regarding clearance and shielding from combustible materials.

5.1.4 The horizontal flue length MUST NOT be less than 300mm plus 90o bend and MUST NOT exceed 12m excluding

terminal.

5.1.5 The total vertical flue length MUST NOT be less than 1m and MUST NOT exceed 12m excluding terminal.

5.1.6 Total length refers to the equivalent worked flue length and therefore includes bends and NOT the distance from the

heater to the flue terminal.

5.1.7 When calculating total flue length, reference MUST be made to the following ‘equivalent lengths’:

A) 900bend= 2m B)450bend = 1m

5.1.8 The maximum number of 90o bends that can be used is:

A)Horizontal =4 B)Vertical =4

5.1.9 If a ‘short flue’ is used, the factory fitted flue orifice MUST be

left in place (see Fig.3).

5.1.10 ‘short flue’ refers to a total flue length not exceeding:

A)Horizontal(plus 90obend) =0.8m B)Vertical

(includingterminal) = 5m

5.1.11 Where the total flue length exceeds these lengths, the flue

orificeMUST be removed.

5.1.11 The heater is supplied with either a horizontal or vertical flue,

dependant upon your specification when ordering. Reference

should be made to Table 2 for extra flue/terminal components.

5.2 HORIZONTALTERMINAL LOCATION:

5.2.1 The terminal must be positioned on the outside of the building

and allow for the free passage of air across it atALL times.

5.2.2 Avoid positions where the terminal is adjacent to projections,

particularly under a balcony or immediately adjacent to a drain

pipe.

5.2.3 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.

5.2.4 Fig. 4 shows recommended terminal positions

5.2.5 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 exeed 22mm (see Fig. 5)

Fig.3

FlueAdaptorandOrifice

Flue Adaptor

Orifice

Fig. 17

ExplodedDiagram

TerminalPosition Min Distance

A Directly above or below a window or other opening 300mm

B Below gutters, soil pipes or drain pipes 75mm

C Below eaves 200mm

D Below balcony 200mm

E From vertical drain/soil pipes 150mm

F From internal or external corners 300mm

G Above ground or balcony level 300mm

H From a surface facing terminal 600mm

I Froma terminalfacing a terminal 1200mm

J Vertically from aterminal onthe samewall 1500mm

K Horizontallyfrom aterminal onthe samewall 300mm

5.2.5 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.

5.2.6 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.

5.2.7 Reference should be made to Table 2 for required terminal components and guard.

5.2.8 NOTE:TOENSURETHATRAINWATERCANNOTENTERTHEHEATERUNIT,THEFLUEMUSTBE

INSTALLEDWITHASLIGHTFALLAWAYFROMTHEHEATER.

Item G.C.No PartNo Description Qty

1 E69625 1000-0521020 Wiring harness 1

2 E80119 1000-0521860 Wiring harness (air heater) 1

3 N320-0350005 Heat exchanger 1

N322-0350005 HeatExchanger (fromserialnumber 54000501) 1

4 E69627 1000-0520990 FDC& limitswitch 1

1000-0522340 FDC& Limit switch(fromserial number54000501) 1

5 E69628 N320-0145000 Filter assembly 1

N322-0145000 Filterassembly (fromserial number54000501) 1

6 E69629 A700-0702000 Complete burner assembly 1

N322-0702000 Completeburner assembly(from serialnumber 54000501) 1

7 E69630 1000-0708260 Main burner injector (Polidoro ref:AL270) 1

8 173096 1000-0704810 Ignition burner assembly 1

9 E69631 1000-0520860 Air pressure switch 1

10 E69632 1000-0520830 Clock mechanism 1

11 E69635 1000-0708370 Ignition burner feed pipe 1

1000-0708970 Ignition burner feed pip (from serial number 54000501) 1

12 E69638 N320-0505000 Electric flamecontrol device(S.I.T.) 1

13 1000-0708990 Igniter lead 1

14 E69640 1000-0708190 Multifunction control 1

15 245514 1000-0515620 Thermista-stat 1

16 E69642 N320-0504000 Combustion air fan (SIFAN) 1

N310-0504005 Combustionair fan(SIFAN)(from serial number 54000501) 1

17 E69644 N320-0500000 Complete electrical panel 1

N322-0500000 Complete electrical panel (from serial number 54000501) 1

18 E80146 1000-0520850 Control module 1

19 245509 1000-0513820 Fuse T3.15A (anti surge) 1

20 245542 1000-0515970 Capacitor15μf1

21 E69650 N320-0167000 Cabinet door assembly 1

N322-0167000 Cabinet door assembly (from serial number 54000501) 1

22 E76429 1000-0500375 Air circulation fan 1

23 381712 1000-0705140 Ignition burner injector (No 36) 1

392935 1000-0701260 Ignitionburner injector(No 27)(from serialnumber 54000501) 1

24 E69653 1000-1507310 Gasket 1

25 E95-494 SO1159 Air Pressure Tube Kit 1

26 E80151 1000-2501050 Grommet 1

27 1000-0708410 12mm flaredconnector 1

28 E69656 1000-0505540 Electronics box (cleanflow) 1

29 E69658 AO186x0309 Cleanflow filter medium(pad) 2

30 E69662 1000-0708210 Gas feed pipe 1

1000-0708950 Gasfeed pipe(from serialnumber 54000501) 1

31 E69666 1000-0708360 Gas feed pipe 1

32 View portwindow (NOTAVAILABLEASASPARE)

33 E69648 1000-0520880 Reset panel (Daughter board) 1

WaterCirculator:

34 244-876 SOO284 Main body assembly (inc. baffle & spring clip) 1

36 E80155 1000-0521870 Wiring harness 1

37 E69670 1000-0520920 Overheat cut-off switch 1

38 E01686 A700-0700000 Complete burner assembly 1

N322-0700000 Completeburner assembly(from serialnumber 54000501) 1

39 E69640 1000-0708190 Multifunction control 1

40 384615 BOS00562 Burnerarm 1

41 244880 BOS02397/1 Ignition burner assembly 1

42 398003 1000-0702040 Thermostat 1

1000-0708930 Thermostat(from serialnumber 54000501) 1

43 E80158 1000-0702090 Maininjector nozzle(Amal187/001/400) 1

44 392935 1000-0701260 Ignition burner injector (No 27) 1

45 E80159 1000-0708990 Igniter lead 1

46 E69693 1000-0708240 Main burner gas feed pipe 1

1000-0708940 Main burner gas feed pipe (from serial number 54000501) 1

47 230328 1000-2500070 Phial retaining plug 1

48 E69638 N320-0505000 Electronic flame control device (S.I.T) 1

49 E69695 1000-0708400 Ignition burner feed pipe 1

1000-0708960 Ignition burner feed pipe (from serial number 54000501) 1

50 E69707 1000-0708200 Gas feed pipe 1

51 E80151 1000-2501050 Grommet 1

12. LISTOFSPARES(SEEFIG.17)

Fig.5

HorizontalFlueTerminal(ShowingMaximum Protrusion)

Outer Tube Flue Tube

Max.Protrusion(22mm)

Fig.4

Recommended(Horizontal)TerminalPositions

5.3 VERTICALTERMINALLOCATION:

5.3.1 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.

5.3.2 Installation of a vertical flue can be on either a flat or pitched

roof with a pitch angle of between 25oand 50o.

5.3.3 The terminal MUST be positioned on the outside of

the building and allow for the free passage of air

accross it atALLtimes.

5.3.4 Avoid positions where the terminal is adjacent to

projections; particularly under a balcony.

5.3.5 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.

5.3.6 Fig. 6 shows recommended terminal positions.

5.3.7 Reference should be made to Table 2

for the required terminal components.

TerminalPosition Min Distance

A Directly below a window or other opening 300mm

B Above roof level (to base of terminal) 300mm

C From adjacent wall to flue 300mm

D From internal corner to flue 400mm

E Fromfacing terminal 1200mm

F Betweenterminals 300mm

G Below eaves or balcony NOT

RECOMMENDED

Fig.6

Recommended(Vertical)TerminalPositions

Table2.

FlueandTerminal Components

SIDE VIEW

PLAN VIEW

FRONT VIEW

BASE VIEW

1220

615 NOM

465

505

808

1307

540

300

19 228

220

362

562

430

467

500

127 25

305

ELECTRICAL ENTRY

WATER ENTRY/EXIT (RETURN)

WATER ENTRY/EXIT (FLOW)

KNOCKOUTS FOR

WATER CONNECTION

(BOTH SIDES)

KNOCKOUTS FOR

WATER CONNECTION

(BOTH SIDES)

KNOCKOUTS FOR

GAS CONNECTION

Fig. 16

Economaire32-PrincipalDimensions

PART No CONTENTS COLOUR

1000-0014840 1 X 90° Standard Flue Elbow White

1000-0014850 1 X 45° Flue Elbows White

1000-0014870 1 X 500mm Extension White

1000-0014860 1 X 1000mm Extension White

1000-0014880 1 X Vertical Terminal and 1 X Support Bracket Anthracite

1000-0014980 1 X Vertical Terminal and 1X Support Bracket Terracotta

1000-0014890 1 X Lead Pitched Roof Flashing and 1X Collar Anthracite

1000-0014990 1 X Lead Pitched Roof Flashing and 1X Collar Terracotta

1000-0014900 1 X Aluminium Flat Roof Flashing Aluminium

1000-0014910 1 X Horizontal Wall Terminal White

1000-0014920 2 X Wall Plates (for above) N/A

1000-0014930 1 X Horizontal Wall Terminal and 2 X Wall Plates N/A

1000-0014940 1 X Condensation Drain White

1000-0014950 1 X Syphon Kit (for above) N/A

1000-0014960 1 X Condensation Drain and 1 X Syphon Kit N/A

1000-0014970 1 X Wall Bracket (100mm dia) N/A

1000-0015430 1 X Terminal Guard N/A

5.4 ELECTRICAL

WARNING:THISAPPLIANCEMUSTBEEARTHED!

5.4.1 MAINS.

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

b. Fan delay and overheat (limit controls) are not adjustable and are factory set so that the limit switch opens at

80OC and closes at 40OC.

c. An electronic controller (thermista-stat) is supplied which acts like a room thermostat.

5.4.2 THERMISTA-STATANDITSLOCATION.

a. The thermista-stat should be located where there is free air circulation and positioned 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.

ii. Near an outside door or windows, or on an outside wall.

iii. Where it will be affected by warm air ducts, diffusers, waste pipes or the heater itself.

iv. Where it will be subjected to vibration.

c. Connect the thermista-stat wires to terminals ‘8’ and ‘9’ on the terminal block (see Figs. 13 & 14).

5.5 GAS(SEEBS 5864AND BS6891)

5.5.1 The local gas supply conditions MUST be adequate for the specified burner pressures as stated in the technical

specification(para. 1.3)

5.5.2 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 (0.4in wg) pressure drop (See table of discharge in BS 6891).

5.5.3 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 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 Rc1/2 (1/2in BSP. external [taper] thread).

6. AIRHEATERCOMMISSIONING

6.1 PREPARATION:

After installation of the appliance, you MUST do the following:

6.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found.

6.1.2 Carry out preliminary electrical system checks.

6.1.3 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.

6.2 SYSTEMBALANCING:

6.2.1 Set the air heater electrical supply ON.

6.2.2 Set the thermista-stat to the “SUMMERAIRFLOW” position.

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

A/H

COM

W/H

Thermista-

stat

Thermista-stat

(Supplied)

Polarity

not

important

ExternalProgrammer

(Notsupplied)

Economaire

Heater

havevoltagefree

switchingcontacts

Must

Test

Supply

Fuse

T3.15A

230V~50Hz

27K0

ONCOMOFFONCOMOFF

NL123456

A/HTIMED

O/P

W/HTIMED

O/P

Fig. 15

SchematicDiagram(showingconnectionofanexternalcontroller)

821

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 LIGHTINGIGNITION ANDMAINBURNER:

6.3.1 Turn on the gas supply to the heater.

6.3.2 Set both the “AIR HEATER” and “WATER HEATER”

switches on the time control unit to the “OFF” position.

6.2.3 Set the thermista-stat to “9”.

6.3.4 Locate the status LED indicator which can be observed

through the inspection hole in the bottom right hand

corner of the control module.

6.3.5 Turn on the mains power supply to the heater

6.3.6 Set the “AIR HEATER” switch on the time control to

“CONT.” and observe the LED status indicator.

6.3.7 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.

6.3.8 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.

6.3.9 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:regardlessofwhenthe burnerignitesduring the60secondperiod,the LEDwillcontinue todisplaystage6.

6.3.10 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.

6.3.11 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.

6.3.12 In the event of a lockout and the ignition and main burners failing to ignite, reference should be made to table 4 in the

fault finding section of these instructions in order to establish the fault condition.

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

6.3.14 Reset the thermista-stat to the desired comfort level

6.3.15 Set the time control to the desired “on and “off” periods.

6.3.16 Set the “AIR HEATER” switch on the time control to “TIMED”.

6.4 MAINBURNERPRESSURETEST:

NOTE:AIRHEATERBURNERSAREFACTORYSETTOPROVIDEANOMINALHIGHRATEOUTPUTASDETAILEDINSUB

PARA1.2

6.4.1 Loosen the screw on the outlet pressure test point and fit a pressure test gauge (see Fig. 8)

6.4.2 Check the gauge reading against the information at paragraph 1.3.

6.4.3 If necessary, use the burner pressure adjuster to obtain required gauge reading in accordance with paragraph 1.3.

6.4.4 Remove the pressure gauge and re-tighten screw on the outlet pressure test point.

6.5 AUTOMATICCONTROLSCHECK

6.5.1 Light the ignition and main burners as detailed in 6.3 above.

6.5.2 Allow the heater to operate for 15 minutes to ensure stability.

6.5.3 After a short period, ensure that the fan increases to full speed.

6.5.4 When the temperature reaches the control setting, check that the main burner cycles ON and OFF at intervals of

approx. 75 to 120 seconds.

Fig.7

ElectricalDoorAssembly

(showingtimecontrol,indicatorpanelandstatus

indicator)

IMPORTANT

LED status

indicator

Timecontrol

Indicator panel

Terminal block

Cover Plate Screws

Fig.14

Economaire32LogicDiagram

20 9

6.6 SAFETYCHECK:

In order to check the correct operation of the control module, run the heater for a short period and introduce a fault condition by

carrying out the following sequence:

6.6.1 Check for gas soundness within the appliance.

6.6.3 Turn on both the gas and electrical supplies to the heater.

6.6.4 Set the “AIR HEATER” switch on the time control unit to “CONT”.

6.6.5 Light the ignition and main burners as described in section 6.3

6.6.6 Allow the heater to run for a

period of 5 minutes to stabalise.

6.6.7 Turn off gas supply to heater at

the heater Gas Cock. DO NOT

TURNOFFATGASMETER!

6.6.8 Having detected the fault

condition, the module should

cause the red LED on the

indicator panel to flash and the

module will go through the

ignition sequence. Having

detected the fault condition a

second time, the control module

should cause the heater to go

into lockout, indicated by a

constant red LED and the LED

status indicator will show “6”

6.6.9 Reinstate gas supply and wait

fora minimumperiodof 10

seconds.

6.6.10 Depress the “RESET” button on the Indicator Panel.

6.6.11 The heater will go through its ignition procedure and the ignition and main burners SHOULD ignite.

6.6.12 Set the “AIR HEATER” switch on the time control unit to “TIMED”

Fig.8

MultifunctionControl

1. Inlet Pressure Test Point.

2. Outlet Pressure Test Point.

3. Burner PressureAdjuster.

4.Ignition Controller.

A)Side-view(photograph)

With Ignition Controller in place. B)Rear-view(drawing)

With Ignition Controller removed.

FanPerformanceCurve

200

0.09

mbar

0.50

0.375

ResistanceExternaltoHeater

0.25 0.10

0.125

Air Volume

0.05

0.20

0.15

in.wg.

250

0.12 300

0.14 350

0.17 400 ft /min

0.19m /sec

Fig.13

Economaire32FlowDiagram

1910

7 INTEJANCIRCULATOR

7.1 WATERCIRCULATIONSYSTEM.

Detailed recommendations for the water circulation system are given in BS6798, BS5449 (for small bore and microbore central

heating systems), and BS5446. The maximum water side operating pressure (PMS) is 1bar.

7.1.1 To ensure good circulation in gravity circuits, flow pipes should be designed to run vertically from the water heater

before running laterally.Any lateral run should be less than 2 x the previous vertical run. Pipework should be

installed with a rise towards the vent point. In systems

with poor circulation, a pump kit is also available.

7.1.2 Drain cocks must be located in accessible positions

that permit the draining of the whole system, including

the appliance and hot water storage vessel. A drain

cock should be fitted at the lowest point of the water

heating circuit and, in the case of an indirect system,

another must be fitted at the lowest point of the cold

feed. Drain cocks should be at least 1/2in nominal size

and be in accordance with BS2879.

7.1.3 Economy valves can only be used in a DIRECT

installation.

NOTE: The circulator thermostat is factory set to provide a

temperature range of 50oC to 82oC. The temperature is

increased by rotating the thermostat knob clockwise

and temperature stop 2 MUST be left in position (see

fig. 9a) if the circulator is used in a direct application,

ensuringa maximumtemperature of60oC. For indirect

applications, remove temperature stop 2.

In order to ensure that soundness of the heater is

maintained, you MUST ensure that flow and return

pipes into the sealed compartment are sealed with the

supplied grommets!

7.2 WATERCONNECTIONS:

Note: Bothflow andreturnconnectionsareRp3/4(3/4inBSP

female)connections.

IMPORTANT:Usecompressionfittingsat theapplianceflow andreturnconnectionsandat theairheatercasing exit,tofacilitate

easyaccess tothecirculatorbody.

7.2.1 Remove the fixing screws holding the sealing panel in place.

7.2.2 Carefully remove the sealing panel, such that access can be gained to the

circulator compartment.

7.2.3 Side Exit: Knockouts/holes are provided in both sides of the heater

cabinet for external pipe routing. Horizontal pipe runs are to be kept to an

absoluteminimum.

7.2.4 TopExit:

A) Remove the plastic plugs from the air heater top panel and the fan

chamber floor.

B) Pass the flow and return pipes (flow pipe to the rear) from below and then

locate the pipes with the circulator body connections. Fully tighten the

connections to the main body before completing the connections to the

top ends of the Flow and Return pipes, ensuring that the pipework does

not restrict access to the circulator thermostat phial pocket or the air heater

heat exchanger access panel.

NOTE:Inorder tomaintainanairtightseal,thesuppliedgrommets MUSTbeused

wheretheflowand returnpipespassthroughtheupper sealingplateanddiaphragm.

IMPORTANT:Ensurethatthefittingsonthecirculatorbody arewellsupportedwhen

makingflowand returnconnections.

7.2.5 Using good quality duct tape, seal around the Flow and Return pipes

where they pass through the air heater top panel and fan chamber floor.

Isigniter

operating?

LEDdisplay

Doesignition

burnerlight?

Isgas

supplyon?

Cleanignition

burner

Replaceignition

lead

Restoregas

supply

Isignition

burner

blocked?

Circulator

operating

normally.

Iscirculator

switchset

toon?

Does

fluefan

start?

Doesair

pressure

switch

operate?

Isthere

230Vtothe

heater?

IsLED

Displaying

Hasfuse

blown?

Isthere230V

acrosspins11&

12atstartup?

Isthere230V

acrosspins14&

Natstart up?

Are

electrical

connections

good?

NNN

Doesmain

BurnerLight?

Changeignition

controllerand

multifunctioncontrol

Replace

ignition

controller

Doesburner

pressure

increase?

Hasigniter

stopped

sparking?

Are

igniterlead

terminalends

crackedor

broken?

Are

electrical

connections

sound?

Areair

pressure

pipes

sound?

Replacefuse

Replacecontrol

module

Re-sealpipesor

replaceif

necessary

Replace

fluefan

Press“RESET”

Replacecontrol

module

Replacecontrol

module

Isthere

230Vacross

pins

8& 9?

IsLED

Displaying

Isigniter

leadcondition

good?

Isigniter

condition

good?

Changeignition

controller

Replace

multifunction

control

Replace

igniterlead

Replaceigniter

Istheflue

thecorrect

length?

Hasorifice

beenused

correctly?

Changepressure

switch

Re-configure

flue

Referto

paragraph. 5

Set

thermostat

Water Circulator

Diagnostics Flowchart

Feed

Tank

Direct storage

cylinder

Hot water

Circulator

Draincock

Fig.9

TypicalINTEJANdirectsystemapplication.

Fig.9a

Positionoftemperature stops

Snap rivet

Temp.

stop 1

Temp. stop 2 for

direct system.

Removefor indirect

system application.

Spindle

Fixing

screw

8. INTEJANCIRCULATORCOMMISSIONING

8.1 PREPARATION:

8.1.1 Ensure that the gas and electrical supplies are OFF.

8.1.2 Fill the water circulation system, clear any air locks and check for water soundness, sealing any leaks detected.

8.1.3 Refit the sealing panel and secure using the 15 x fixing screws.

NOTE: Whilst the sealing panel needs to be fixed in such a manner so as to ensure an air tight seal, care MUST be taken not

to over tighten the fixing screws.

8.2 LIGHTING IGNITIONANDMAIN

BURNERS:

8.2.1 Turn on the gas supply to

the heater.

8.2.2 Set both the “AIR HEATER”

and“WATER HEATER”

switches on the time control

unit to the “OFF” position.

8.2.3 Set the thermostat so that it

reaches the maximum stop.

8.2.4 Locate the LED status

indicator which can be

observed through the

inspection hole located in

the bottom right hand corner

of the control module.

8.2.5 Turn on the mains power

supply to the heater

8.2.6 Set the “WATER HEATER”

switch on the time control to

“CONT.” and observe the

LED status indicator.

8.2.7 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.

8.2.8 The ignitor will spark for a maximum period of 60 seconds during which time the ignition burner and main burner

SHOULD ignite and the igniter will stop.

8.2.9 When the control module reaches stage 8, (indicated by “8” 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 9 (indicated by “9” on the LED). NOTE:regardless ofwhen theburnerignitesduringthe60secondperiod,

theLEDwill continuetodisplay stage9.

8.2.10 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.

8.2.11 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 the the fault detected.

8.2.12 In the event of a lockout and the ignition and main burners failing to ignite, reference should be made to table 4 in the

fault finding section of these instructions in order to establish the fault condition.

8.2.13 Test for gas leakage at the supply, multifunctional control, ignition burner and main burner using proprietary

detection fluid, sealing any leaks found.

8.2.14 Allow the circulator to operate for a minimum of 15 minutes to ensure stability.

8.2.15 Reset the thermostat to the desired water temperature.

8.2.16 Set the time control to the desired “on” and “off” periods.

8.2.17 Set the “WATER HEATER” switch on the time control to “TIMED”.

Min400mm

Fig. 10

TypicalINTEJANindirectsystemapplication.

Feed

tank Coldwater

storage

Hot water

Circulator

Indirect storage

cylinder

Drain

cock

Drain

cock

Circulation

Head

Working Head= 20m (65ft)maximum

Isigniter

operating?

Isthere

230Vacross

pins5 &6?

Isthere

230Vacross

pins1 &2?

Replacemodule

IsLED

Displaying

LEDdisplay

Isigniter

leadcondition

good?

Isigniter

condition

good?

Changeignition

controller

Doesignition

burnerlight?

Isgas

supplyon?

Cleanignition

burner

Replaceignition

lead

Restoregas

supply

Replace

control

module

Isignition

burner

blocked?

Heater

operating

normally.

Isair

circulator

fan

operating?

Arefan

connections

good?

Ispower

reaching

thefan?Replacefan

Isheater

switchset

to on?

Does

combustion

air fan

start?

Doesair

pressure

switch

operate?

Isthere

230Vto the

heater?

IsLED

Displaying

Hasfuse

blown?

Isthere230V

acrosspins11&

12atstartup?

Isthere230V

acrosspins14&

Natstartup?

Are

electrical

connections

good?

Doesmain

BurnerLight?

Changeigniter

controllerand

multifunction

control

Replace

ignition

controller

Doesburner

pressure

increase?

Hasigniter

stopped

sparking?

Are

igniterlead

terminalends

crackedor

broken?

Are

electrical

connections

sound?

Areair

pressure

pipes

sound?

Replacefuse

Replacecontrol

module

Re-sealpipesor

replaceif

necessary

Replace

combustion

airfan

Press“RESET”

Replacecontrol

module

Replace

multifunction

control

Replace

igniterlead

Replaceigniter

Istheflue

thecorrect

length?

Hasorifice

beenused

correctly?

Changepressure

switch

Re-configure

flue

Referto

paragraph. 5

Set

thermista-stat

to position“9”

Air Heater

Diagnostics Flowchart

8.3 WATERBURNERPRESSURETEST:

NOTE:THEWATERCIRCULATORBURNERSAREPRE-SETANDSHOULDNOTREQUIREADJUSTING.

8.3.1 Loosen the screw on the outlet pressure test point and fit a pressure test gauge (see Fig. 8)

8.3.2 Check the gauge reading against the information at paragraph 1.3.

8.3.3 If necessary, use the burner pressure adjuster to obtain the required gauge reading as shown at paragraph 1.3

8.3.4 Remove the pressure gauge and re-tighten the screw on the outlet pressure test point.

8.4 SAFETYCHECKS:

8.4.1 Check for gas soundness within the appliance.

8.4.2 Check for water soudness around circulator andALL joints.

8.4.3 Turn on both the gas and electrical supplies to the heater.

8.4.4 Set the “WATER HEATER” switch on the time control unit to “CONT”.

8.4.5 Light the ignition and main burners as described in section 8.2

8.4.6 Allow the circulator to operate for a period of 5 minutes to stabilise.

8.4.7 Turn off gas supply to heater at the heater gas cock. DO NOTTURN OFF AT GAS METER!

8.4.8 The circulator SHOULD automatically go into “LOCKOUT” indicated by the red LED on the indicator panel and the

LED status indicator will show “H”

8.4.9 Reinstate gas supply and wait for a minimum period of 10 seconds.

8.4.10 Depress the “RESET” button on the indicator panel.

8.4.11 The heater will go through its ignition procedure and the ignition and main burners SHOULD ignite.

8.4.12 Set the “WATER HEATER” switch on the time control unit to “TIMED”

9. INSTRUCTIONSFORUSERS

9.1 If the building is unoccupied, ensure that the user instructions are left taped to the air heater for the the user’s reference and

that the installation instructions are left at or near the air heater for use on future service calls.

9.2 If the building is occupied, hand the user instructions over and ensure that the user understands:

9.2.1 How to light both the air heater and water circulator.

9.2.2 How to re-set the air heater or water circulator if “LOCKOUT” occurs.

9.2.3 How to operate the time control, thermista-stat and the SUMMERAIRFLOW switch.

9.2.4 That the time control must be reset following a power failure.

9.2.5 How to use the circulator thermostat to set the water temperature.

9.2.6 How to turn off the heater and switch off the electrical supply to the heater.

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

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

9.2.9 How to obtain summer air circulation.

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

buildingMUSTNOTBEOBSTRUCTED.

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

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

9.2.13 That expert help must be obtained if persistent “LOCKOUT” occurs.

10. MAINTENANCE

NOTE: It is recommended that this appliance be serviced at intervals of no less than 12 months.

IMPORTANT: Ensure that the gas and electricity supplies are isolated before commencing any maintenance or replacement of

components. Because the appliance is room sealed, it is also imperative that if at any stage of repairs the gasket on the sealing plate

is damaged it MUST be replaced!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 paragraphs 6.1 to 6.9 inclusive.

10.1 ROUTINEMAINTENANCE:

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

Burner on

Demand satisfied

Burner on

Demand satisfied

Burner extinguishes

No further demand

Burner extinguishes

Fan slows/stops

Is time

eriod up?

START

END

Timed or continuous operation

No No

Yes Yes

Module powers up

LOCKOUT

RESET

Demand

for water

heat

Demand

for water

heat

Demand

for air

heat

Demand

for air

heat

Is no-flow

provided?

Fan starts

Yes

Pressure switch operates

Is flow

provided?

Thermostat Thermista-stat

Water circulator Air heater

Fig. 12

ControlFlowchart

1316

10.11.9 Reassembly is in reverse order.

NOTE: Whenreassembling ensurethatgasketsaresoundly sealedand replacedwhere necessary(See cautionarynote at

paragraph10) Priortouse, you MUSTfullycommissiontheheater inaccordancewiththeseinstructions.

10.12. FLUEFAN,REMOVALANDCLEANING

10.12.1 Remove the air circulation fan as detailed at 10.6

10.12.2 Disconnect the power supply to the pressure swich.

10.12.3 Carefullyremove the feed pipes to the pressure switchTAKINGCARETONOTETHEIR POSITION.

10.12.4 Unscrew the 2 x fixing screws holding the pressure switch in place and remove the switch.

10.12.5 Carefully open the plastic insulators on the fan fly-lead and break the electrical connections such that the spade

connectors can be fed through the grommet on the sealing plate.

10.12.6 Remove the 11 x fixing screws holding the flue fan sealing plate in place and remove the plate.

NOTE: WHENREMOVINGTHESEALINGPLATE,CAREFULLYFEEDTHEPRESSUREPIPESTHROUGHTHE

GROMMETSINTHEPLATE,TAKINGCARENOTTOPULLTHEPIPESOFFTHEFANPRESSURETAPPINGS!

10.12.7 Release the 4 x fixing screws holding the flue fan in place

10.12.8 Carefully withdraw the fan and its gasket from the collecter box, taking care not to damage the fan blades.

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

10.12.10Refitting/replacement isin reverseorder.

11. DEFECTDIAGNOSIS

The following table shows the LED status indicator display and the corresponding fault condition, along with the lockout type. It

should be noted that under certain conditions the red LED relating to the air heater may flash. This is part of the control sequence

and the module should reset automatically. It is ONLY necessary to press the “RESET” button if the red LED is continually

illuminated!

NOTE: Whenthe airheaterandwatercirculator areusedin combination,thestatusindicationsfor thewater circulator

willoverride thosefortheairheater; thereforeLED displays“8” and“9”willoverride“5” and“6”. Forthis

reason,itis stronglyrecommendedthattheairheaterand watercirculatorbe commissionedindependentlyofeach

other.

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

10.1.3 Remove the air heater front panel.

10.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the air circulation fan as detailed in

para10.6.

10.1.5 Remove the burner and controls assembly as detailed in para 10.2, inspect and clean the main burner and injector as

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

10.1.6 Inspect and clear the ignition burner orifice.

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

10.1.8 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.

10.1.9 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.

10.1.10Refit the air circulation fan, burner and controls assembly, and air filter/air cleaner.

10.1.11Allow the air heater to operate for approximately 15 minutes to ensure stability and, with the main burner lit, ensure

that the operation of the air circulation fan does not affect the main burner flame profile.

10.1.12Locate the flue gas test point (see fig.1) and attach a flue gas analyser to the test point in accordance with the

manufacturer’s instructions. NOTE:the CO/CO2ratio should be no greater than 0.008

10.1.13Fully commission the appliance in accordance with paragraphs 6 and 8.

NOTE:The flue gas test MUST NOT be used as an alternative to servicing the heater!

10.2 MULTIFUNCTION CONTROLANDAIR HEATER/WATERCIRCULATORBURNERASSEMBLYREMOVAL:

NOTE: Both the air heater and water circulator burner assemblies, as well as their respective ignition burner assemblies, MUST be

removed as a complete unit together with their respective multifunction control.

PROCEDURE:

10.2.1 Ensure that the gas and electrical supplies are switched OFF.

10.2.2 Remove the front door from the heater.

10.2.3 Remove the fixing screws that hold the sealing panel in place and carefully remove the panel.

10.2.4 Disconnect the electronic module from the relevant multifunction control by removing the securing bolt and sliding it

towards the left of the heater unit, taking care not to cause damage.

10.2.5 Disconnect the gas supply to the water circulator multifunction control at the flared connection on the top of the gas

supply feed.

10.2.6 For removal of the air heater multifunction control, remove the relevant burner assembly fixing screws.

10.2.7 Break the gas supply at the gas union and remove the gas feed pipe fixing screw.

10.2.8 Whilst supporting the assembly, carefully remove the fixing screws securing the multifunction control.

10.2.9 Carefully remove the complete assembly, by sliding the sealing grommet out of the bulkhead, taking care not to cause

damage to the grommet!

10.2.10Refitting the burner assembly is a reverse procedure of the above instructions.

10.3 BURNERASSEMBLYCLEANING:

10.3.1 Remove the burner assembly as detailed above.

10.3.2 Disconnect the ignition burner gas feed pipe from the ignition burner

10.3.3 Release the single screw, nut and washer securing the ignition burner to the main burner and remove the ignition

burner.

10.3.4 Release the 2 screws, nuts and washers securing the main burner to the mounting bracket and remove the main

burner.

10.3.5 Cleanthe burner thoroughly both inside and out with a soft brush.DONOT ENLARGE,DISTORTORDAMAGE

BURNERHOLES.

10.3.6 Reassemble in reverse order.

10.4. IGNITIONBURNERANDELECTRODE REMOVALANDREPLACEMENT:

10.4.1 Remove the burner as detailed in 10.2 above.

Table. 4

Controlmodulefaultindications

LED Cycle Fault Condition Lockout Type

0 Running None: all is well None

1 Air Proving Air switch closed Absolute

2 Air Proving Gas valve relay ON (either) Absolute

3 Air Proving Air switch closure failed Absolute

4 Prove Heater Relay Gas valve current, relay should be open Air Heater

5 Prove Heater Valve None (wait for Ignition Burner) Air Heater

6 Prove Heater Valve Flame failure Air Heater

7 Prove Circulator Relay Gas valve current, relay should be open Circulator

8 Prove Circulator Valve None (wait for Ignition Burner) Circulator

9 Prove Circulator Valve Flame failure Circulator

A Running Excessive cabinet teperature Absolute

C Running Air flow sensor out of range Air Heater

E Running Problem with air circulator fan Air Heater

F Running Air heater limit stat Air Heater

H Running Circulator limit stat Circulator

L Running Open air flow sensor Air Heater

14 15

10.4.2 Disconnect the igniter lead from electrode.

10.4.3 Break the gas feed at the burner end of the gas feed pipe.

10.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and carefully

remove the ignition burner assembly.

10.4.5 Release the electrode securing nut from the ignition burner assembly and withdraw the electrode.

10.4.6 Release the ignition burner feed pipe securing nut from the ignition burner assembly and withdraw the feed pipe and

injector from the ignition burner assembly. Disconnect the ignition burner injector from the ignition burner feed pipe

hook.

10.4.7 Release the 2 x 5mm screws securing the ignition burner bracket to the ignition burner mounting bracket and remove

the ignition burner bracket.

10.4.8 Refitting or replacement is in reverse order.

NOTE:If, at any time, the gas supply feed pipe is removed from the multifunction control, the ‘O’ ring MUST be replaced.

10.6 AIRCIRCULATINGFAN: REMOVALANDCLEANING:

10.6.1 Ensure that the electrical supply is isolated.

10.6..2 Remove the front door from the heater and remove the 3 x fixing screws on the electrical door assembly.

10.6.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.

10.6.4 Disconnect the fan flying leads from the fan assembly.

10.6.5 Release the fan assembly securing screw and withdraw the fan assembly from the heater cabinet, avoiding damage to

the fan blades.

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

10.6.7 Refitting or replacement is in reverse order.

10.7 CONTROLMODULEREMOVAL:

10.7.1 Ensure that the electrical supply is isolated.

10.7.2 Remove the front door from the heater.

10.7.3 Loosen the top and bottom screws holding the electrical cover plate in place on the electrical door assembly. (see fig.

7) DONOTCOMPLETELYREMOVETHESCREWS ATTHISSTAGE.

10.7.4 Remove the cover plate by sliding it upwards, such that it exposes the control module.

10.7.5 Carefully disconnect the module by lifting the connecting blocks off the circuit board (see fig. 11)

NOTE:There isnoneed toloosenanyofthe connectionscrewsontheconnector blocks!

10.7.6 Completely remove the top and bottom cover plate screws and pull the control module free of the electrical door

assembly.

10.7.7 Fit the new control module in place and partially fit the cover plate fixing screws. DO NOTTIGHTEN SCREWSAT

THISSTAGE!

10.7.8 Re-connect the module by carefully pushing the connector blocks onto the circuit board.

10.7.9 Re-fit the electrical cover plate and tighten the cover plate screws.

10.7.10Re-establish electrical supply.

10.7.11Commission air heater and water circulator as decribed in the relevant sections above.

10.8 TIMECONTROL,SWITCHANDLEDINDICATOR(DAUGHTERBOARD)REMOVAL:

Preparation:

10.8.1 Ensure that the electrical supply is isolated.

10.8.2 Remove the appliance front door and release the 3 x securing screws on the electrical door assembly.

10.8.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.

TimeControl removal:

10.8.3 Disconnect spade terminal connectors “C1”, “C2”, “C3” and “C5” from the time control.

10.8.4 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly

from the door.

10.8.5 Remove the 3 X M3 bolts that secure the time clock mechanism and remove from the mounting plate.

10.8.6 Refitting or replacement is in reverse order.

LEDIndicator(DaughterBoard)

10.8.7 Disconnect the daughter board by unplugging the flylead from the control module board.

10.8.8 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly

from the door.

10.8.9 Remove the 2 X M3 nuts holding the board onto the bolts and remove.

10.8.10Replacement is in reverse order, ensuring to refit the spacers.

Switch/sremoval:

10.8.11Disconnect the spade terminal connectors “S1”, “S2” and “S3” or

“S4”, “S5” and “S6” from the switch terminals.

10.8.12Release the switch/s by pressing out from the back of the electrical

door assembly.

10.8.13Fit new switch/s and lock into position by pressing home until the

locking tabs locate on the top and bottom of the switch.

10.8.14Re-connect the spade connectors.

10.8.15Re-fitting of the electrical door assembly is in reverse order.

10.8.16Close the electrical door assembly and secure using the 3 x fixing

screws.

10.8.17Set the time control to correct time.

10.8.18Set the time control to the required “ON” and “OFF” periods.

10.9 FANDELAYCONTROL/LIMITSWITCHREMOVAL:

10.9.1 Ensure that the electrical supply is isolated.

10.9.2 Remove the appliance front door.

10.9.3 Remove the 15 x screws holding the sealing panel in place and

carefully remove the panel.

10.9.4 Unscrew the four connection screws in the terminal block and

remove the red, brown and two black feed wires from the terminal

block.

10.9.5 Remove the 2 x fixing screws holding the FDC/limit switch assembly in place and withdraw from the appliance.

10.9.6 Refitting or replacement is in reverse order.

10.10 WATERCIRCULATORTHERMOSTATREMOVAL:

10.10.1Remove the appliance front door.

10.10.2Remove the 15 x screws holding the sealing panel in place and carefully remove the panel.

10.10.3Disconnect the two spade terminals from the back of the thermostat, located underneath the bulkhead.

10.10.4Carefully loosen the control knob from the shaft of the thermostat using a large flat head screwdriver and remove.

10.10.5Loosen and remove the 2 x screws securing the thermostat and remove the thermostat from the bulkhead.

10.10.6Refitting or replacement is in reverse order.

10.11 HEATEXCHANGER ACCESS:

10.11.1Ensure that the gas and elctrical supplies are isolated.

10.11.2Remove the appliance front door.

10.11.3Remove the 15 x screws holding the sealing panel in place and carefully remove the panel.

10.11.4Remove the burner assembly as detailed at 10.2

10.11.5Remove the multifunctional control for the water circulator (IF FITTED)

10.11.6Release the 4 x screws securing the combustion chamber heat shield and withdraw the heat shield.

10.11.7Release the 4 x screws securing the top access cover plate and withdraw the cover plate and gasket.

10.11.8Release the 4 x screws securing the heat exchanger top sealing plate and withdraw the sealing plate and gasket.

Fig.11

Controlmodule,showingconnectorblocks.

NOTE:

Todisconnectthemodule,LIFTthe

connectorblocksoff thecircuitboard. DO

NOTremovethewiresfrom theconnector

blocks!

Connector

blocks

14 15

10.4.2 Disconnect the igniter lead from electrode.

10.4.3 Break the gas feed at the burner end of the gas feed pipe.

10.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and carefully

remove the ignition burner assembly.

10.4.5 Release the electrode securing nut from the ignition burner assembly and withdraw the electrode.

10.4.6 Release the ignition burner feed pipe securing nut from the ignition burner assembly and withdraw the feed pipe and

injector from the ignition burner assembly. Disconnect the ignition burner injector from the ignition burner feed pipe

hook.

10.4.7 Release the 2 x 5mm screws securing the ignition burner bracket to the ignition burner mounting bracket and remove

the ignition burner bracket.

10.4.8 Refitting or replacement is in reverse order.

NOTE:If, at any time, the gas supply feed pipe is removed from the multifunction control, the ‘O’ ring MUST be replaced.

10.6 AIRCIRCULATINGFAN: REMOVALANDCLEANING:

10.6.1 Ensure that the electrical supply is isolated.

10.6..2 Remove the front door from the heater and remove the 3 x fixing screws on the electrical door assembly.

10.6.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.

10.6.4 Disconnect the fan flying leads from the fan assembly.

10.6.5 Release the fan assembly securing screw and withdraw the fan assembly from the heater cabinet, avoiding damage to

the fan blades.

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

10.6.7 Refitting or replacement is in reverse order.

10.7 CONTROLMODULEREMOVAL:

10.7.1 Ensure that the electrical supply is isolated.

10.7.2 Remove the front door from the heater.

10.7.3 Loosen the top and bottom screws holding the electrical cover plate in place on the electrical door assembly. (see fig.

7) DONOTCOMPLETELYREMOVETHESCREWS ATTHISSTAGE.

10.7.4 Remove the cover plate by sliding it upwards, such that it exposes the control module.

10.7.5 Carefully disconnect the module by lifting the connecting blocks off the circuit board (see fig. 11)

NOTE:There isnoneed toloosenanyofthe connectionscrewsontheconnector blocks!

10.7.6 Completely remove the top and bottom cover plate screws and pull the control module free of the electrical door

assembly.

10.7.7 Fit the new control module in place and partially fit the cover plate fixing screws. DO NOTTIGHTEN SCREWSAT

THISSTAGE!

10.7.8 Re-connect the module by carefully pushing the connector blocks onto the circuit board.

10.7.9 Re-fit the electrical cover plate and tighten the cover plate screws.

10.7.10Re-establish electrical supply.

10.7.11Commission air heater and water circulator as decribed in the relevant sections above.

10.8 TIMECONTROL,SWITCHANDLEDINDICATOR(DAUGHTERBOARD)REMOVAL:

Preparation:

10.8.1 Ensure that the electrical supply is isolated.

10.8.2 Remove the appliance front door and release the 3 x securing screws on the electrical door assembly.

10.8.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.

TimeControl removal:

10.8.3 Disconnect spade terminal connectors “C1”, “C2”, “C3” and “C5” from the time control.

10.8.4 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly

from the door.

10.8.5 Remove the 3 X M3 bolts that secure the time clock mechanism and remove from the mounting plate.

10.8.6 Refitting or replacement is in reverse order.

LEDIndicator(DaughterBoard)

10.8.7 Disconnect the daughter board by unplugging the flylead from the control module board.

10.8.8 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly

from the door.

10.8.9 Remove the 2 X M3 nuts holding the board onto the bolts and remove.

10.8.10Replacement is in reverse order, ensuring to refit the spacers.

Switch/sremoval:

10.8.11Disconnect the spade terminal connectors “S1”, “S2” and “S3” or

“S4”, “S5” and “S6” from the switch terminals.

10.8.12Release the switch/s by pressing out from the back of the electrical

door assembly.

10.8.13Fit new switch/s and lock into position by pressing home until the

locking tabs locate on the top and bottom of the switch.

10.8.14Re-connect the spade connectors.

10.8.15Re-fitting of the electrical door assembly is in reverse order.

10.8.16Close the electrical door assembly and secure using the 3 x fixing

screws.

10.8.17Set the time control to correct time.

10.8.18Set the time control to the required “ON” and “OFF” periods.

10.9 FANDELAYCONTROL/LIMITSWITCHREMOVAL:

10.9.1 Ensure that the electrical supply is isolated.

10.9.2 Remove the appliance front door.

10.9.3 Remove the 15 x screws holding the sealing panel in place and

carefully remove the panel.

10.9.4 Unscrew the four connection screws in the terminal block and

remove the red, brown and two black feed wires from the terminal

block.

10.9.5 Remove the 2 x fixing screws holding the FDC/limit switch assembly in place and withdraw from the appliance.

10.9.6 Refitting or replacement is in reverse order.

10.10 WATERCIRCULATORTHERMOSTATREMOVAL:

10.10.1Remove the appliance front door.

10.10.2Remove the 15 x screws holding the sealing panel in place and carefully remove the panel.

10.10.3Disconnect the two spade terminals from the back of the thermostat, located underneath the bulkhead.

10.10.4Carefully loosen the control knob from the shaft of the thermostat using a large flat head screwdriver and remove.

10.10.5Loosen and remove the 2 x screws securing the thermostat and remove the thermostat from the bulkhead.

10.10.6Refitting or replacement is in reverse order.

10.11 HEATEXCHANGER ACCESS:

10.11.1Ensure that the gas and elctrical supplies are isolated.

10.11.2Remove the appliance front door.

10.11.3Remove the 15 x screws holding the sealing panel in place and carefully remove the panel.

10.11.4Remove the burner assembly as detailed at 10.2

10.11.5Remove the multifunctional control for the water circulator (IF FITTED)

10.11.6Release the 4 x screws securing the combustion chamber heat shield and withdraw the heat shield.

10.11.7Release the 4 x screws securing the top access cover plate and withdraw the cover plate and gasket.

10.11.8Release the 4 x screws securing the heat exchanger top sealing plate and withdraw the sealing plate and gasket.

Fig.11

Controlmodule,showingconnectorblocks.

NOTE:

Todisconnectthemodule,LIFTthe

connectorblocksoff thecircuitboard. DO

NOTremovethewiresfrom theconnector

blocks!

Connector

blocks