Johnson & Starley ECONOMAIRE 90 User guide

Publication No. ZZ 1110/6
February 2008
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ECONOMAIRE90HASBEENTESTEDANDCERTIFIEDBYADVANTICAFORUSEWITHNATURALGASG20.
ECONOMAIRE 90
WARM AIR HEATER
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
G.C. 42-416-19
These instructions are to be left with the User or adjacent to the Gas Meter
1. BRIEFDESCRIPTION
1.1 ECONOMAIRE 90 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!
1.2 The air heater output can be adjusted between 20.5kW (73.8MJ/h, 70,000 Btu/h) and 26.4kW (94.9MJ/h, 90,000 Btu/h)
“summer air circulation” of unheated air is available by manual selection (see the user’s instructions).
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 & STARLEYLTD.
Telephone: [phone] Rhosili Road,
Brackmills,
Fax: [phone] Northampton NN4 7LZ
10. LIST OFSPARES (SEE FIG.17)
ECONOMAIRE 90
Item G.C.No PartNo Description Qty
1 1000-0522180 Wiring harness 1
2 E80119 1000-0521860 Wiring harness (air heater) 1
3 N900-0101000 Heat exchanger (cabinet sub assembly) 1
4 1000-0521820 FDC&limitswitch 1
5 E80123 N650-0182000 Filter assembly 1
6 N900-0702000 Complete burner assembly 1
7 398360 BOS 01204/4 Main burner injector (Bray Cat 23/700) 3
7a 1000-0705350 Cross-light injector (Bray Cat 10/110) 1
8 E39538 BOS 02397/1 Ignition burner assembly 1
9 1000-0522250 Air pressure switch 1
10 E69632 1000-0520830 Clock mechanism 1
11 1000-0708860 Ignition burner feed pipe 1
12 E69638 N320-0505000 Electricflame control device (S.I.T.) 1
13 E08159 1000-0708990 Igniter lead 1
14 E69640 1000-0708190 Multifunction control 1
15 245514 1000-0515620 Thermista-stat 1
16 E84230 N650-0504005 Combustion air fan (SIFAN) 1
17 N900-0500000 Complete electrical panel 1
18 E80146 1000-0520850 Control module 1
18a E69648 1000-0520880 Reset panel (daughter board) 1
19 245509 1000-0513820 Fuse T3.15A (anti surge) 1
20 245542 1000-0515970 Capacitor15µf 1
21 N900-0160000 Cabinet door assembly 1
22 J903-0525000 Air circulation fan 1
23 381712 1000-0701260 Ignition burner injector (No 27) 1
24 E69653 1000-1507310 Gasket 1
25 E69709 1000-0000390 Air Pressure Tube (0.7m) 1
26 E80151 1000-2501050 Grommet 1
27 1000-0708570 12mm Bulkhead Fitting 1
28 E69656 1000-0505540 Electronics box (cleanflow) 1
29 E05248 AO354x0357 Cleanflowfiltermedium(pad) 1
30 1000-0708850 Gas feed pipe 1
31 BOS00570 Union Elbow 1
Fig. 1
HeaterwithSealingPanelremoved Fig.2 Sealing Panel
1. Thermista-stat
2. Time control
3. Air circulator fan
4. Flue gas test point
5. Gas connection
6. Union
7. Gas cock
8. Ignition burner
9. Main burner assembly
10. FDC& limit switch
11 Multifunction control
12. Combustion air fan
13. Control module
14. LED diagonstics indicator
15. Filter
16. Flue adapter
17. 4” to 5” flue enlarger
WARNING!
This appliance requires a 5” flue.
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5
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11
12
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6
15
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Installation shall be in accordance with the current editions of:-
Building Standards (Scotland) (Consolidation) Regulations
Building Regulations
Gas Safety (Installation and Use) Regulations (as amended)
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 GasAppliances)
BS 5440 Pt. 2 (Air Supply for GasAppliances)
BS 5864 Installation of Gas Fired DuctedAir Heaters
British System Design Manual “Gas Fired Warm Air Heating”
Model and Local Authority Bye-laws
IMPORTANT:IT ISASTATUTORYREQUIREMENTTHATALLGASAPPLIANCESAREINSTALLEDBYCOMPETENT
PERSONS,(i.e.CORGIREGISTEREDINSTALLERS)INACCORDANCEWITHTHEGASSAFETY(INSTALLATIONANDUSE)
REGULATIONS(CURRENTEDITION).FAILURETOCOMPLYWITHTHESEREGULATIONSMAYLEADTOPROSECUTION.
1.3 TECHNICALDATA
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 38mm (11/2in) at the rear,
75mm (3in) total at the sides (with a minimum of 25mm (1in) at any one side), and 63mm (21/2in) at the front must be left.
Consideration should also be given to the space required for the removal and replacement of the filter tray and the entry of
the gas and electrical supplies.
2.3 For service access, a minimum of 450mm (18ins) is required at the front of the heater. Space must also be allowed, in a
compartment installation, to permit the removal of the heater. The clearance between the appliance and the compartment
should be not less than 75mm (3 in). However, if clearances are less than 75mm, the internal surface of the compartment
must be lined with non-combustible material and the compartment must be of a fixed rigid structure.
Weight 90Kg
Gas G20
Gas Supply Pressure 20mbar
Gas Category I2H
Countries of Installation GB & IE
Electrical Supply 230 ~ 50Hz fused 5A 570W
Nox Class 1
LOW RATE HIGH RATE
KW MJ/h Btu/h KW MJ/h Btu/h
INPUT (Gross) 27.1 97.6 92,500 33.0 118.70 112,500
OUTPUT 20.5 73.8 70,000 26.4 94.9 90,000
Gas rate cv
1037Btu/ft32.60m3/h (91.8ft3/h) 3.10m3/h (109.4ft3/h)
Burner setting
pressure (hot) 11.8mbar (4.7 in wg) 17.2mbar (6.9 in wg)
Main Injector Bray Cat 23/700
Cross-light injector Bray Cat 10/110
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly and that your service engineer completes the
appropriate service interval record below.
SERVICE PROVIDER
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE2 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE3 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE4 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE5 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE6 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE7 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE8 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE9 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE10 Date . . . . . . . . . . . . . . . . . . .
Engineer’sName . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tel No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORGI ID Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When all of the above services have been completed, please contact your service engineer for an additional
service record sheet.

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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, only one or two walls will be in close proximity to the air heater and 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 (BT65/
90) MUST be used in order to provide insulation. NB where a base plenum is used no base tray is required!
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.
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 2118cm2 (328in2). 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 400mm x 300mm
(16" x 12"). If flexible duct is used the duct diameter should not be less than 406mm (16") dia. The return air grille
should have a free area of not less than 2118cm2(328in2).
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.
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 WARM DELIVEREDAIR
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.
VENTILATED FROM INSIDE
BUILDING
Low level grille 297cm2 (48in2)
High level grille 297cm2 (48in2)
VENTILATED FROM OUTSIDE
BUILDING
Low level grille 149cm2 (24in2)
High level grille 149cm2 (24in2)
Table1:
MinimumEffectiveAreas
WARM AIR HEATER AND CIRCULATOR
COMMISSIONING CHECKLIST
WARM AIR UNIT
BENCHMARK Number
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: . ... .. . .. . .. . .. . .. . .. ... ... .
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
Fitted Not Required
Provided Not Required
FOR WARM AIR HEATERS 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
FOR WARM AIR HEATING: MEASURE AND RECORD
Burner operating pressure Mbar
Heat input KW
Temperature differential between return air inlet and nearest outlet oC
FOR HOT WATER GENERATORS: MEASURE AND RECORD
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

421
5. INSTALLATIONREQUIREMENTS
NOTE: THISAPPLIANCEMUSTONLYBEINSTALLEDWITHTHESUPPLIEDACCESSORIESANDTERMINAL.
5.1 FLUES
TheECONOMAIRE90isdesignedtobeusedwitha125mmflueand the suppliedflue enlargerMUST befitted directlyontopof
theflueadaptor!The heater canbeusedwithhorizontal orverticalfluetypesC12 and C32andyoushouldalso consult(orbe
familiar with) British Standards BS 5440 Pt. 1 Flues
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 18m excluding
terminal.
5.1.5 The total vertical flue length MUST NOT be less than 1m and MUST NOT exceed 18m 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 = 3m B) 450bend = 1.5m
5.1.8 The maximum number of 90o bends that can be used is:
A) Horizontal=6 B) Vertical = 6
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(including terminal)= 7m
5.1.11 Where the total flue length exceeds these lengths, the flue orifice MUST be removed.
5.1.12 The heater is supplied with either a horizontal or vertical flue,
dependant upon your specification when ordering. Reference
should be made to Table 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
atALLtimes.
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 The flue MUST be fitted with the protrusion as shown
inFig. 5
5.2.5 If the heater is to be installed in a timber framed
building you MUST consult the Institute of Gas Engineers document UP/7, 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 guard,
part number: TGD1111105 (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.
Fig. 3
FlueAdaptorandOrifice
Flue Adaptor
Orifice
Fig. 17
ExplodedDiagram
24
31
28
9
20
18
18a
19
17
15
16
5
29
25
1
22
10
6
13
12
7
7a
8
23
27
14
30
2
26
11
4
3
21

520
5.3 VERTICALTERMINALLOCATION:
5.3.1 The ECONOMAIRE 90 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
achieved 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 across it at ALL
times.
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.
Fig. 16
ECONOMAIRE90 -PrincipalDimensions
SIDE VIEW
PLAN VIEW
FRONT VIEW
BASE VIEW
KNOCKOUT FOR
GAS ENTRY
(BOTH SIDES)
UNUSED
KNOCKOUT
(BOTH SIDES)
ELECTRICAL
ENTRY
UNUSED
KNOCKOUT
(BOTH SIDES)
42.5 42.5
400
485
242.5
1318
1
4
0
5
832
716
290
525
528
615
448 25
4
0
1
8
0
1
5
2
5
TerminalPosition MinDistance
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 terminal facinga terminal 1200mm
J Vertically from a terminal on the same wall 1500mm
K Horizontally from a terminal on the same wall 300mm
Fig.4
Recommended(Horizontal)
Terminal Positions
220mm
Outer Tube Flue Tube
Wall
Plate Plate
Fig. 5
HorizontalFlueTerminal

619
TerminalPosition MinDistance
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 Fromfacingterminal 1200mm
F Between terminals 300mm
G Below eaves or balcony NOT RECOMMENDED
Fig. 6
Recommended(Vertical)
Terminal Positions
1
2
3
4
5
6
7
8
9
1
0
L
N
L
N
A
/
H
C
O
M
W
/
H
T
h
e
r
m
i
s
t
a
-
s
t
a
t
Thermista-stat
(Supplied)
Polarity not important
E
x
t
e
r
n
a
l
P
r
o
g
r
a
m
m
e
r
(Not supplied)
E
c
o
n
o
m
a
i
r
e
Heater
have voltage free
switching contacts
Must
Test
Supply
Fuse
T3.15A
230V~50Hz
R
1
2
7
K
0
ON COM OFF
NL123456
A/H TIMED
O/P
Fig. 15
SchematicDiagram(showingconnection ofanexternalcontroller)
PART No CONTENTS COLOUR
1000-0016520 1 X 90° Standard Flue Elbow White
1000-0016530 1 X 45° Flue Elbows White
1000-0016550 1 X 500mm Extension White
1000-0016540 1 X 1000mm Extension White
1000-0016560 1 X Vertical Terminal
1 X Support Bracket Anthracite
1000-0016630 1 X Vertical Terminal
1 X Support Bracket Terracotta
1000-0014890 1 X Lead Pitched Roof Flashing
1 X Collar Anthracite
1000-0014990 1 X Lead Pitched Roof Flashing
1 X Collar Terracotta
1000-0014900 1 X Aluminium Flat Roof Flashing Aluminium
1000-0016570 1 X Horizontal Wall Terminal White
1000-0016580 1 X Wall Plates (for above) White
1000-0016590 1 X Horizontal Wall Terminal
2 X Wall Plates White
1000-0016600 1 X Condensation Drain White
1000-0014950 1 X Syphon Kit (for above) N/A
1000-0016610 1 X Condensation Drain
1 X Syphon Kit N/A
1000-0016620 1 X Wall Bracket (125mm dia) N/A
1000-0017130 1 X Terminal Guard N/A
Table 2.
Flueand TerminalComponents

7
18
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 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!
b. Fan delay and overheat (limit controls) are not adjustable and are factory set so that the limit switch opens at
93OC and closes at 76OC.
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 (SEE BS 5864AND BS 6891)
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 Rp1/2 (1/2in BSP. internal [parallel] thread). NB Sealing grommets are supplied for sealing around the gas
feed pipe.
6. AIR HEATER COMMISSIONING
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.
Fig.14
ECONOMAIRE90LogicDiagram
1r
b
b
g/y
br
br
r
r
r
r
br
N
L
br
bbk
w
gy
pk
w
b
bk
br
b
b
r
r
bk
w
bk
or
or
r
bk
bk
bk
bk
bk
br
gy
pk
g/y
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
CONTROL MODULE
AIR
CIRCULATION
FAN
CLEANFLOW
FILTER
(OPTIONAL)
COMBUSTION
AIR FAN
AIR PROVING
SWITCH
FAN POWER
CAPACITOR
RESISTOR
TERMINAL
BLOCK
CLOCK
AIR
HEATER
SWITCH
THERMISTA-STAT AIR HEATER
GAS CONTROL
COVER
LIMIT SWITCH
FDC ASSEMBLY
AIR HEATER
IGNITION
ELECTRODE
WIRE COLOUR
CODE
black ------bk
blue -------b
brown -----br
grey -------gy
violet ------v
white ------w
red ---------r
pink --------pk
yellow------y
WIRE COLOUR
CODE
black ------bk
blue -------b
brown -----br
grey -------gy
violet ------v
white ------w
red ---------r
pink --------pk
yellow------y
bbr
wgy

817
6.2 SYSTEMBALANCING:
6.2.1 Set the air heater electrical supply ON.
6.2.2 Set the thermista-stat to the “SUMMER AIRFLOW” position.
6.2.3 Balance the system to provide the required volume proportions at the warm air outlets.
Note: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/min), except for very
small rooms, (i.e. bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.
6.3 LIGHTINGIGNITION ANDMAINBURNER:
6.3.1 Turn on the gas supply to the heater.
6.3.2 Set the “AIR HEATER” switch on the time control unit to the “OFF” position.
6.3.3 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 igniter will spark for a maximum period of 60 seconds during which time the ignition and main burners SHOULD
ignite and the igniter will stop sparking.
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: regardless of when the burner ignites during the 60 second period,
theLEDwillcontinue to displaystage6.
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 the the fault detected.
Fig.13
ECONOMAIRE90FlowDiagram
ON
ON
12
93
Fig. 7
ElectricalDoorAssembly
(showingtimecontrol,indicatorpanelandstatusindicator)
LED status
indicator
Cover plate screws
Time control
Indicator panel

9
16
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.
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 TURN OFF AT GAS METER!
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 for a minimum period of 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”
7. INSTRUCTIONSFORUSERS
7.1 If the building is unoccupied, ensure that the user instructions are left taped to the air heater for the user’s reference and that
the installation instructions are left at or near the air heater for use on future service calls.
7.2 If the building is occupied, hand the user instructions over and ensure that the user understands:
7.2.1 How to light the air heater.
7.2.2 How to re-set the air heater if “LOCKOUT” occurs.
7.2.3 How to operate the time control, thermista-stat and the SUMMER AIRFLOW switch.
7.2.4 That the time control must be reset following a power failure.
7.2.5 How to turn off the heater and switch off the electrical supply to the heater.
7.2.6 How to remove, clean and refit the air filter and at what intervals, (i.e. fortnightly, or weekly for new houses).
Isigniter
operating?
Isthere
230Vacross
pins5 &6?
I
s
t
h
e
r
e
2
3
0
V
a
c
r
o
s
s
p
i
n
s
1
&
2
?
R
e
p
l
a
c
e
m
o
d
u
l
e
IsLED
Displaying
4?
LEDdisplay
Isigniter
leadcondition
good?
Isigniter
condition
good?
Y
N
Y
Y
Changeignition
controller
Doesignition
burnerlight?
Y
Isgas
supplyon?
Cleanignition
burner
Replaceignition
lead
Restoregas
supply
Replace
control
module
Y
Y
Isignition
burner
blocked?
N
N
6
H
e
a
t
e
r
o
p
e
r
a
t
i
n
g
n
o
r
m
a
l
l
y
.
I
s
a
i
r
c
i
r
c
u
l
a
t
o
r
f
a
n
o
p
e
r
a
t
i
n
g
?
Y
A
r
e
f
a
n
c
o
n
n
e
c
t
i
o
n
s
g
o
o
d
?
N
Y
I
s
p
o
w
e
r
r
e
a
c
h
i
n
g
t
h
e
f
a
n
?
R
e
p
l
a
c
e
f
a
n
0
5
Y
23
Isheater
switchset
to on?
Does
combustion
airfan
start?
Y
Doesair
pressure
switch
operate?
Y
Isthere
230Vto the
heater?
IsLED
Displaying
F?
Hasfuse
blown?
Isthere230V
acrosspins11&
12atstartup?
Isthere230V
acrosspins14&
Natstartup?
Are
electrical
connections
good?
NN
N
N
NN
Y
Does
m
a
i
n
Burner
L
i
g
h
t
?
Y
Y
Change
i
g
n
i
t
e
r
controll
e
r
a
n
d
multifun
c
t
i
o
n
control
Replace
ignition
controller
Does
b
u
r
n
e
r
pres
s
u
r
e
incre
a
s
e
?
Hasi
g
n
i
t
e
r
stop
p
e
d
spark
i
n
g
?
Are
igniterlead
terminalends
crackedor
broken?
N
N
N
N
Y
Y
N
N
N
N
Y
Y
Y
Are
electrical
connections
sound?
Areair
pressure
pipes
sound?
Y
Y
NN
Replacefuse
Replacecontrol
module
Re-sealpipesor
replaceif
necessary
Replace
combustion
airfan
Press“RESET”
Replacecontrol
module
Replace
multifunction
control
Replace
igniterlead
Replaceigniter
N
N
Istheflue
thecorrect
length?
Hasorifice
beenused
correctly?
Y
Y
Changepressure
switch
Re-configure
flue
Referto
paragraph. 5
Y
Y
Y
Y
N
Set
thermista-stat
to position“9”
Diagnostics Flowchart

10 15
7.2.7 How to control the heating system by opening and closing warm air outlets.
7.2.8 How to obtain summer air circulation.
7.2.9 That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of the
building MUSTNOT BEOBSTRUCTED.
7.2.10 That the heater must be serviced at least once a year by a competent person to ensure efficient and safe operation.
7.2.11 That the red instructions for safe use have been pointed out and understood.
7.2.12 That expert help must be obtained if persistent “LOCKOUT” occurs.
Fig. 8
MultifunctionControl
1. Inlet Pressure Test Point.
2. Outlet Pressure Test Point.
3. Burner Pressure Adjuster.
4.Ignition Controller.
A)Side-view(photograph)
With Ignition Controller in place. B)Rear-view(drawing) With Ignition Controller removed.
1
2
3
4
1
3
2
1
4
3
2
500
0.23
mbar
0.625
0.50
Resistance External to Heater
0.375 0.15
0.25
0.125 0.05
Air Volume
0.10
0.25
0.20
in.wg.
600
0.28 700 0.33 800 0.38 900 0.43
1000 ft /min
0.47m /sec
3
3
FanPerformanceCurve
Fig. 12
ControlFlowchart
Burner on
Demand Satisfied
No Further Demand
Igniter burner extinguishes
Fan slows/stops
Burner extinguishes
Is time
period up?
START
END
Timed or manual operation
No
No
No
No
No
Yes
Pressure switches operate
LOCKOUT
RESET
Demand
for air
heat
Demand
for air
heat
Is no-flow
provided?
Fan start
Yes
Yes
Yes
Yes
Yes
Pressure switches operate
Spark/detect for pilot burner
Is flow
provided?
Is ignition
burner lit?
Thermista-stat
Thermista-stat
No

11
14
8. MAINTENANCE
NOTE:Itisrecommendedthat this appliancebeservicedatintervals of nolessthan12months.
IMPORTANT:Ensure thatthegasandelectricity supplies areisolated beforecommencing any maintenanceorreplacement of
components. Because the appliance is room sealed, it is also imperative that if at any stage of repairs the gasket on the sealing
plateisdamageditMUSTbereplaced!Aftercompletionof any maintenance,alwaystestforgas soundnessandcarryouta
completefunctionaltest of theappliancein accordance withtheCommissioning Instructions atparagraphs 6.1to6.6 inclusive.
8.1 ROUTINEMAINTENANCE:
8.1.1 Operate the appliance and check for the correct function of the burner and controls.
8.1.2 Turn OFF the gas and electrical supplies to the appliance.
8.1.3 Remove the air heater front panel.
8.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the air circulation fan as detailed in
para10.6.
8.1.5 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.
8.1.6 Inspect and clear the ignition burner orifice.
8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below.
8.1.8 By viewing through the fan aperture, and using a torch or similar, examine the heat exchanger externally for signs of
cracks or holes, particularly around welded joints.
8.1.9 Using a torch or similar, introduce a light source into the heat exchanger burner aperture and upper access port, and
again examine the heat exchanger for signs of cracks or holes, particularly around welded joints, whilst again viewing
through the fan aperture.
8.1.10 Refit the air circulation fan, burner and controls assembly, and air filter/air cleaner.
8.1.11 Allow 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.
8.1.12 Locate 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
8.1.13 Fully 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!
8.2 MULTIFUNCTIONCONTROLANDBURNERASSEMBLYREMOVAL:
NOTE: Both the burner and ignition burner assemblies MUST be removed as a complete unit together with the multifunction
control.
PROCEDURE:
8.2.1 Ensure that the gas and electrical supplies are switched OFF.
8.2.2 Remove the front door from the heater.
8.2.3 Remove the fixing screws that hold the sealing panel in place and carefully remove the panel.
8.2.4 Disconnect the electronic module from the multifunction control by removing the securing bolt and sliding it towards
the left of the heater unit, taking care not to cause damage.
8.2.5 Remove the burner assembly fixing screws.
8.2.6 Break the gas supply at the gas union and remove the gas feed pipe fixing screw.
8.2.7 Whilst supporting the assembly, carefully remove the fixing screws securing the multifunction control.
8.2.8 Carefully remove the complete assembly, by sliding the sealing grommet out of the bulkhead, taking care not to cause
damage to the grommet!
8.2.9 Refitting the burner assembly is a reverse procedure of the above instructions.
8.3 BURNERASSEMBLYCLEANING:
8.3.1 Remove the burner assembly as detailed above.
8.3.2 Disconnect the ignition burner gas feed pipe from the ignition burner
8.3.3 Release the single screw, nut and washer securing the ignition burner to the main burner and remove the ignition
burner.
Table.4
Controlmodulefaultindications
NOTE:
Todisconnectthemodule,
LIFTtheconnectorblocks
offthecircuitboard.DO
NOTremovethewires
fromtheconnectorblocks!
8.10.6 Carefully withdraw the fan and its gasket from the collecter box, taking care not to damage the fan blades.
8.10.7 Remove all dust from both the impeller and motor, taking care not to disturb the balance of the fan.
8.10.8 Refitting/replacement is in reverse order.
9. DEFECT DIAGNOSIS
The following table shows the LED status indicator display and the corresponding fault condition. 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 ONLYnecessary to press the “RESET” button if the red LED is continually illuminated !
Fig. 11
Controlmodule,showingconnectorblocks.
Connector blocks
LED
Display Cycle Fault Condition
0 Running None: all is well
1 Air Proving Air switch closed
2 Air Proving Gas valve relay ON
3 Air Proving Air switch closure failed
4 Prove Heater Relay Gas valve current, relay should be open
5 Prove Heater Valve None (wait for Ignition Burner)
6 Prove Heater Valve Flame failure
7 Prove Circulator Relay Gas valve current, relay should be open
8 Prove Circulator Valve None (wait for Ignition Burner)
9 Prove Circulator Valve Flame failure
A Running Excessive cabinet temperature
C Running Air flow sensor out of range
E Running Problem with air circulator fan
F Running Air heater limit stat
L Running Open air flow sensor

12 13
8.3.4 Release the 2 screws, nuts and washers securing the main burner to the mounting bracket and remove the main
burner.
8.3.5 Clean the burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR DAMAGE
BURNERHOLES.
8.3.6 Reassemble in reverse order.
8.4 IGNITIONBURNERANDELECTRODEREMOVALANDREPLACEMENT:
8.4.1 Remove the burner as detailed in 8.2 above.
8.4.2 Disconnect the igniter lead from electrode.
8.4.3 Break the gas feed at the burner end of the gas feed pipe.
8.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and carefully
remove the ignition burner assembly.
8.4.5 Release the electrode securing nut from the ignition burner assembly and withdraw the electrode.
8.4.6 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.
8.4.7 Release the 2 x 5mm screws securing the ignition burner bracket to the ignition burner mounting bracket and remove
the ignition burner bracket.
8.4.8 Refitting or replacement is in reverse order.
8.5 AIRCIRCULATINGFAN,REMOVALANDCLEANING:
8.5.1 Ensure that the electrical supply is isolated.
8.5.2 Remove the front door from the heater and remove the 3 x fixing screws on the electrical door assembly.
8.5.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.
8.5.4 Disconnect the fan flying leads from the fan assembly.
8.5.5 Release the fan assembly securing screws and withdraw the fan assembly from the heater cabinet, avoiding damage
to the fan blades.
8.5.6 Remove all dust from both the impeller and motor, taking care to not disturb the balance of the fan.
8.5.7 Refitting or replacement is in reverse order.
8.6 CONTROLMODULEREMOVAL:
8.6.1 Ensure that the electrical supply is isolated.
8.6.2 Remove the front door from the heater.
8.6.3 Loosen the top and bottom screws holding the electrical cover plate in place on the electrical door assembly. (see fig.
7) DONOTCOMPLETELYREMOVETHESCREWS ATTHISSTAGE.
8.6.4 Remove the cover plate by sliding it upwards, such that it exposes the control module.
8.6.5 Carefully disconnect the module by lifting the connecting blocks off the circuit board (see fig. 11)
NOTE:Thereis noneedtoloosen anyofthe connection screwsonthe connectorblocks!
8.6.6 Completely remove the top and bottom cover plate screws and pull the control module free of the electrical door
assembly.
8.6.7 Fit the new control module in place and partially fit the cover plate fixing screws. DO NOT TIGHTEN SCREWS AT
THISSTAGE!
8.6.8 Re-connect the module by carefully pushing the connector blocks onto the circuit board.
8.6.9 Re-fit the electrical cover plate and tighten the cover plate screws.
8.6.10 Re-establish electrical supply.
8.6.11 Commission the heater as decribed in the relevant sections above.
8.7 TIMECONTROL,SWITCHANDLEDINDICATOR(DAUGHTERBOARD)REMOVAL:
Preparation:
8.7.1 Ensure that the electrical supply is isolated.
8.7.2 Remove the appliance front door and release the 3 x securing screws on the electrical door assembly.
8.7.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.
TimeControl removal:
8.7.4 Disconnect spade terminal connectors “C1”, “C2”, “C3” and “C5” from the time control.
8.7.5 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly
from the door.
8.7.6 Remove the 3 x M3 bolts that secure the time clock mechanism and remove from the mounting plate.
8.7.7 Refitting or replacement is in reverse order.
LEDIndicator(DaughterBoard)
8.7.8 Disconnect the daughter board by unplugging the flylead from the control module board.
8.7.9 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly
from the door.
8.7.10 Remove the 2 x M3 nuts holding the board onto the bolts and remove.
8.7.11 Replacement is in reverse order, ensuring to refit the spacers.
Switchremoval:
8.7.11 Disconnect the spade terminal connectors “S1”, “S2” and “S3” from the switch terminals.
8.7.12 Release the switch by pressing out from the back of the electrical door assembly.
8.7.13 Fit new switch and lock into position by pressing home until the locking tabs locate on the top and bottom of the
switch.
8.7.14 Re-connect the spade connectors.
8.7.15 Re-fitting of the electrical door assembly is in reverse order.
8.7.16 Close the electrical door assembly and secure using the 3 x fixing screws.
8.7.17 Set the time control to correct time.
8.7.18 Set the time control to the required “ON” and “OFF” periods.
8.8 FANDELAYCONTROL/LIMITSWITCHREMOVAL:
8.8.1 Ensure that the electrical supply is isolated.
8.8.2 Remove the appliance front door.
8.8.3 Remove the 2 x fixing screws holding the FDC/limit switch assembly in place and withdraw from the appliance.
8.8.4 Refitting or replacement is in reverse order.
8.9 HEATEXCHANGER ACCESS:
8.9.1 Ensure that the gas and electrical supplies are isolated.
8.9.2 Remove the appliance front door.
8.9.3 Remove the fixing screws holding the sealing panel in place and carefully remove the panel.
8.9.4 Remove the burner assembly as detailed at 8.2
8.9.5 Release the screws securing the combustion chamber heat shield and withdraw the heat shield.
8.9.6 Release the screws securing the top access cover plate and withdraw the cover plate and gasket.
8.9.7 Release the screws securing the heat exchanger top sealing plate and withdraw the sealing plate and gasket.
8.9.8 Reassembly is in reverse order.
NOTE: When reassembling ensure that gaskets are soundly sealed and replaced where necessary (See cautionary note at
paragraph10)Prior touse, youMUSTfully commissiontheheater inaccordancewith these instructions.
8.10 FLUEFAN,REMOVALANDCLEANING
8.10.1 Remove the air circulation fan as detailed at 8.5
8.10.2 Carefully open the plastic insulators on the fan fly-lead and break the electrical connections.
8.10.3 Remove the fixing screws holding the flue fan sealing plate in place and remove the plate.
8.10.4 Carefully remove the feed pipes to the pressure switch TAKING CARE TO NOTE THEIR POSITION.
8.10.5 Release the 4 x fixing screws holding the flue fan in place

12 13
8.3.4 Release the 2 screws, nuts and washers securing the main burner to the mounting bracket and remove the main
burner.
8.3.5 Clean the burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR DAMAGE
BURNERHOLES.
8.3.6 Reassemble in reverse order.
8.4 IGNITIONBURNERANDELECTRODEREMOVALANDREPLACEMENT:
8.4.1 Remove the burner as detailed in 8.2 above.
8.4.2 Disconnect the igniter lead from electrode.
8.4.3 Break the gas feed at the burner end of the gas feed pipe.
8.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and carefully
remove the ignition burner assembly.
8.4.5 Release the electrode securing nut from the ignition burner assembly and withdraw the electrode.
8.4.6 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.
8.4.7 Release the 2 x 5mm screws securing the ignition burner bracket to the ignition burner mounting bracket and remove
the ignition burner bracket.
8.4.8 Refitting or replacement is in reverse order.
8.5 AIRCIRCULATINGFAN,REMOVALANDCLEANING:
8.5.1 Ensure that the electrical supply is isolated.
8.5.2 Remove the front door from the heater and remove the 3 x fixing screws on the electrical door assembly.
8.5.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.
8.5.4 Disconnect the fan flying leads from the fan assembly.
8.5.5 Release the fan assembly securing screws and withdraw the fan assembly from the heater cabinet, avoiding damage
to the fan blades.
8.5.6 Remove all dust from both the impeller and motor, taking care to not disturb the balance of the fan.
8.5.7 Refitting or replacement is in reverse order.
8.6 CONTROLMODULEREMOVAL:
8.6.1 Ensure that the electrical supply is isolated.
8.6.2 Remove the front door from the heater.
8.6.3 Loosen the top and bottom screws holding the electrical cover plate in place on the electrical door assembly. (see fig.
7) DONOTCOMPLETELYREMOVETHESCREWS ATTHISSTAGE.
8.6.4 Remove the cover plate by sliding it upwards, such that it exposes the control module.
8.6.5 Carefully disconnect the module by lifting the connecting blocks off the circuit board (see fig. 11)
NOTE:Thereis noneedtoloosen anyofthe connection screwsonthe connectorblocks!
8.6.6 Completely remove the top and bottom cover plate screws and pull the control module free of the electrical door
assembly.
8.6.7 Fit the new control module in place and partially fit the cover plate fixing screws. DO NOT TIGHTEN SCREWS AT
THISSTAGE!
8.6.8 Re-connect the module by carefully pushing the connector blocks onto the circuit board.
8.6.9 Re-fit the electrical cover plate and tighten the cover plate screws.
8.6.10 Re-establish electrical supply.
8.6.11 Commission the heater as decribed in the relevant sections above.
8.7 TIMECONTROL,SWITCHANDLEDINDICATOR(DAUGHTERBOARD)REMOVAL:
Preparation:
8.7.1 Ensure that the electrical supply is isolated.
8.7.2 Remove the appliance front door and release the 3 x securing screws on the electrical door assembly.
8.7.3 Open the door assembly outwards on its hinges (see fig. 7) such that access is gained to the rear of the assembly.
TimeControl removal:
8.7.4 Disconnect spade terminal connectors “C1”, “C2”, “C3” and “C5” from the time control.
8.7.5 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly
from the door.
8.7.6 Remove the 3 x M3 bolts that secure the time clock mechanism and remove from the mounting plate.
8.7.7 Refitting or replacement is in reverse order.
LEDIndicator(DaughterBoard)
8.7.8 Disconnect the daughter board by unplugging the flylead from the control module board.
8.7.9 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly
from the door.
8.7.10 Remove the 2 x M3 nuts holding the board onto the bolts and remove.
8.7.11 Replacement is in reverse order, ensuring to refit the spacers.
Switchremoval:
8.7.11 Disconnect the spade terminal connectors “S1”, “S2” and “S3” from the switch terminals.
8.7.12 Release the switch by pressing out from the back of the electrical door assembly.
8.7.13 Fit new switch and lock into position by pressing home until the locking tabs locate on the top and bottom of the
switch.
8.7.14 Re-connect the spade connectors.
8.7.15 Re-fitting of the electrical door assembly is in reverse order.
8.7.16 Close the electrical door assembly and secure using the 3 x fixing screws.
8.7.17 Set the time control to correct time.
8.7.18 Set the time control to the required “ON” and “OFF” periods.
8.8 FANDELAYCONTROL/LIMITSWITCHREMOVAL:
8.8.1 Ensure that the electrical supply is isolated.
8.8.2 Remove the appliance front door.
8.8.3 Remove the 2 x fixing screws holding the FDC/limit switch assembly in place and withdraw from the appliance.
8.8.4 Refitting or replacement is in reverse order.
8.9 HEATEXCHANGER ACCESS:
8.9.1 Ensure that the gas and electrical supplies are isolated.
8.9.2 Remove the appliance front door.
8.9.3 Remove the fixing screws holding the sealing panel in place and carefully remove the panel.
8.9.4 Remove the burner assembly as detailed at 8.2
8.9.5 Release the screws securing the combustion chamber heat shield and withdraw the heat shield.
8.9.6 Release the screws securing the top access cover plate and withdraw the cover plate and gasket.
8.9.7 Release the screws securing the heat exchanger top sealing plate and withdraw the sealing plate and gasket.
8.9.8 Reassembly is in reverse order.
NOTE: When reassembling ensure that gaskets are soundly sealed and replaced where necessary (See cautionary note at
paragraph10)Prior touse, youMUSTfully commissiontheheater inaccordancewith these instructions.
8.10 FLUEFAN,REMOVALANDCLEANING
8.10.1 Remove the air circulation fan as detailed at 8.5
8.10.2 Carefully open the plastic insulators on the fan fly-lead and break the electrical connections.
8.10.3 Remove the fixing screws holding the flue fan sealing plate in place and remove the plate.
8.10.4 Carefully remove the feed pipes to the pressure switch TAKING CARE TO NOTE THEIR POSITION.
8.10.5 Release the 4 x fixing screws holding the flue fan in place

11
14
8. MAINTENANCE
NOTE:Itisrecommendedthat this appliancebeservicedatintervals of nolessthan12months.
IMPORTANT:Ensure thatthegasandelectricity supplies areisolated beforecommencing any maintenanceorreplacement of
components. Because the appliance is room sealed, it is also imperative that if at any stage of repairs the gasket on the sealing
plateisdamageditMUSTbereplaced!Aftercompletionof any maintenance,alwaystestforgas soundnessandcarryouta
completefunctionaltest of theappliancein accordance withtheCommissioning Instructions atparagraphs 6.1to6.6 inclusive.
8.1 ROUTINEMAINTENANCE:
8.1.1 Operate the appliance and check for the correct function of the burner and controls.
8.1.2 Turn OFF the gas and electrical supplies to the appliance.
8.1.3 Remove the air heater front panel.
8.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the air circulation fan as detailed in
para10.6.
8.1.5 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.
8.1.6 Inspect and clear the ignition burner orifice.
8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below.
8.1.8 By viewing through the fan aperture, and using a torch or similar, examine the heat exchanger externally for signs of
cracks or holes, particularly around welded joints.
8.1.9 Using a torch or similar, introduce a light source into the heat exchanger burner aperture and upper access port, and
again examine the heat exchanger for signs of cracks or holes, particularly around welded joints, whilst again viewing
through the fan aperture.
8.1.10 Refit the air circulation fan, burner and controls assembly, and air filter/air cleaner.
8.1.11 Allow 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.
8.1.12 Locate 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
8.1.13 Fully 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!
8.2 MULTIFUNCTIONCONTROLANDBURNERASSEMBLYREMOVAL:
NOTE: Both the burner and ignition burner assemblies MUST be removed as a complete unit together with the multifunction
control.
PROCEDURE:
8.2.1 Ensure that the gas and electrical supplies are switched OFF.
8.2.2 Remove the front door from the heater.
8.2.3 Remove the fixing screws that hold the sealing panel in place and carefully remove the panel.
8.2.4 Disconnect the electronic module from the multifunction control by removing the securing bolt and sliding it towards
the left of the heater unit, taking care not to cause damage.
8.2.5 Remove the burner assembly fixing screws.
8.2.6 Break the gas supply at the gas union and remove the gas feed pipe fixing screw.
8.2.7 Whilst supporting the assembly, carefully remove the fixing screws securing the multifunction control.
8.2.8 Carefully remove the complete assembly, by sliding the sealing grommet out of the bulkhead, taking care not to cause
damage to the grommet!
8.2.9 Refitting the burner assembly is a reverse procedure of the above instructions.
8.3 BURNERASSEMBLYCLEANING:
8.3.1 Remove the burner assembly as detailed above.
8.3.2 Disconnect the ignition burner gas feed pipe from the ignition burner
8.3.3 Release the single screw, nut and washer securing the ignition burner to the main burner and remove the ignition
burner.
Table.4
Controlmodulefaultindications
NOTE:
Todisconnectthemodule,
LIFTtheconnectorblocks
offthecircuitboard.DO
NOTremovethewires
fromtheconnectorblocks!
8.10.6 Carefully withdraw the fan and its gasket from the collecter box, taking care not to damage the fan blades.
8.10.7 Remove all dust from both the impeller and motor, taking care not to disturb the balance of the fan.
8.10.8 Refitting/replacement is in reverse order.
9. DEFECT DIAGNOSIS
The following table shows the LED status indicator display and the corresponding fault condition. 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 ONLYnecessary to press the “RESET” button if the red LED is continually illuminated !
Fig. 11
Controlmodule,showingconnectorblocks.
Connector blocks
LED
Display Cycle Fault Condition
0 Running None: all is well
1 Air Proving Air switch closed
2 Air Proving Gas valve relay ON
3 Air Proving Air switch closure failed
4 Prove Heater Relay Gas valve current, relay should be open
5 Prove Heater Valve None (wait for Ignition Burner)
6 Prove Heater Valve Flame failure
7 Prove Circulator Relay Gas valve current, relay should be open
8 Prove Circulator Valve None (wait for Ignition Burner)
9 Prove Circulator Valve Flame failure
A Running Excessive cabinet temperature
C Running Air flow sensor out of range
E Running Problem with air circulator fan
F Running Air heater limit stat
L Running Open air flow sensor

10 15
7.2.7 How to control the heating system by opening and closing warm air outlets.
7.2.8 How to obtain summer air circulation.
7.2.9 That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of the
building MUSTNOT BEOBSTRUCTED.
7.2.10 That the heater must be serviced at least once a year by a competent person to ensure efficient and safe operation.
7.2.11 That the red instructions for safe use have been pointed out and understood.
7.2.12 That expert help must be obtained if persistent “LOCKOUT” occurs.
Fig. 8
MultifunctionControl
1. Inlet Pressure Test Point.
2. Outlet Pressure Test Point.
3. Burner Pressure Adjuster.
4.Ignition Controller.
A)Side-view(photograph)
With Ignition Controller in place. B)Rear-view(drawing) With Ignition Controller removed.
1
2
3
4
1
3
2
1
4
3
2
500
0.23
mbar
0.625
0.50
Resistance External to Heater
0.375 0.15
0.25
0.125 0.05
Air Volume
0.10
0.25
0.20
in.wg.
600
0.28 700 0.33 800 0.38 900 0.43
1000 ft /min
0.47m /sec
3
3
FanPerformanceCurve
Fig. 12
ControlFlowchart
Burner on
Demand Satisfied
No Further Demand
Igniter burner extinguishes
Fan slows/stops
Burner extinguishes
Is time
period up?
START
END
Timed or manual operation
No
No
No
No
No
Yes
Pressure switches operate
LOCKOUT
RESET
Demand
for air
heat
Demand
for air
heat
Is no-flow
provided?
Fan start
Yes
Yes
Yes
Yes
Yes
Pressure switches operate
Spark/detect for pilot burner
Is flow
provided?
Is ignition
burner lit?
Thermista-stat
Thermista-stat
No

9
16
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.
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 TURN OFF AT GAS METER!
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 for a minimum period of 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”
7. INSTRUCTIONSFORUSERS
7.1 If the building is unoccupied, ensure that the user instructions are left taped to the air heater for the user’s reference and that
the installation instructions are left at or near the air heater for use on future service calls.
7.2 If the building is occupied, hand the user instructions over and ensure that the user understands:
7.2.1 How to light the air heater.
7.2.2 How to re-set the air heater if “LOCKOUT” occurs.
7.2.3 How to operate the time control, thermista-stat and the SUMMER AIRFLOW switch.
7.2.4 That the time control must be reset following a power failure.
7.2.5 How to turn off the heater and switch off the electrical supply to the heater.
7.2.6 How to remove, clean and refit the air filter and at what intervals, (i.e. fortnightly, or weekly for new houses).
Isigniter
operating?
Isthere
230Vacross
pins5 &6?
I
s
t
h
e
r
e
2
3
0
V
a
c
r
o
s
s
p
i
n
s
1
&
2
?
R
e
p
l
a
c
e
m
o
d
u
l
e
IsLED
Displaying
4?
LEDdisplay
Isigniter
leadcondition
good?
Isigniter
condition
good?
Y
N
Y
Y
Changeignition
controller
Doesignition
burnerlight?
Y
Isgas
supplyon?
Cleanignition
burner
Replaceignition
lead
Restoregas
supply
Replace
control
module
Y
Y
Isignition
burner
blocked?
N
N
6
H
e
a
t
e
r
o
p
e
r
a
t
i
n
g
n
o
r
m
a
l
l
y
.
I
s
a
i
r
c
i
r
c
u
l
a
t
o
r
f
a
n
o
p
e
r
a
t
i
n
g
?
Y
A
r
e
f
a
n
c
o
n
n
e
c
t
i
o
n
s
g
o
o
d
?
N
Y
I
s
p
o
w
e
r
r
e
a
c
h
i
n
g
t
h
e
f
a
n
?
R
e
p
l
a
c
e
f
a
n
0
5
Y
23
Isheater
switchset
to on?
Does
combustion
airfan
start?
Y
Doesair
pressure
switch
operate?
Y
Isthere
230Vto the
heater?
IsLED
Displaying
F?
Hasfuse
blown?
Isthere230V
acrosspins11&
12atstartup?
Isthere230V
acrosspins14&
Natstartup?
Are
electrical
connections
good?
NN
N
N
NN
Y
Does
m
a
i
n
Burner
L
i
g
h
t
?
Y
Y
Change
i
g
n
i
t
e
r
controll
e
r
a
n
d
multifun
c
t
i
o
n
control
Replace
ignition
controller
Does
b
u
r
n
e
r
pres
s
u
r
e
incre
a
s
e
?
Hasi
g
n
i
t
e
r
stop
p
e
d
spark
i
n
g
?
Are
igniterlead
terminalends
crackedor
broken?
N
N
N
N
Y
Y
N
N
N
N
Y
Y
Y
Are
electrical
connections
sound?
Areair
pressure
pipes
sound?
Y
Y
NN
Replacefuse
Replacecontrol
module
Re-sealpipesor
replaceif
necessary
Replace
combustion
airfan
Press“RESET”
Replacecontrol
module
Replace
multifunction
control
Replace
igniterlead
Replaceigniter
N
N
Istheflue
thecorrect
length?
Hasorifice
beenused
correctly?
Y
Y
Changepressure
switch
Re-configure
flue
Referto
paragraph. 5
Y
Y
Y
Y
N
Set
thermista-stat
to position“9”
Diagnostics Flowchart

817
6.2 SYSTEMBALANCING:
6.2.1 Set the air heater electrical supply ON.
6.2.2 Set the thermista-stat to the “SUMMER AIRFLOW” position.
6.2.3 Balance the system to provide the required volume proportions at the warm air outlets.
Note: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/min), except for very
small rooms, (i.e. bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.
6.3 LIGHTINGIGNITION ANDMAINBURNER:
6.3.1 Turn on the gas supply to the heater.
6.3.2 Set the “AIR HEATER” switch on the time control unit to the “OFF” position.
6.3.3 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 igniter will spark for a maximum period of 60 seconds during which time the ignition and main burners SHOULD
ignite and the igniter will stop sparking.
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: regardless of when the burner ignites during the 60 second period,
theLEDwillcontinue to displaystage6.
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 the the fault detected.
Fig.13
ECONOMAIRE90FlowDiagram
ON
ON
12
93
Fig. 7
ElectricalDoorAssembly
(showingtimecontrol,indicatorpanelandstatusindicator)
LED status
indicator
Cover plate screws
Time control
Indicator panel

7
18
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 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!
b. Fan delay and overheat (limit controls) are not adjustable and are factory set so that the limit switch opens at
93OC and closes at 76OC.
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 (SEE BS 5864AND BS 6891)
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 Rp1/2 (1/2in BSP. internal [parallel] thread). NB Sealing grommets are supplied for sealing around the gas
feed pipe.
6. AIR HEATER COMMISSIONING
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.
Fig.14
ECONOMAIRE90LogicDiagram
1r
b
b
g/y
br
br
r
r
r
r
br
N
L
br
bbk
w
gy
pk
w
b
bk
br
b
b
r
r
bk
w
bk
or
or
r
bk
bk
bk
bk
bk
br
gy
pk
g/y
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
CONTROL MODULE
AIR
CIRCULATION
FAN
CLEANFLOW
FILTER
(OPTIONAL)
COMBUSTION
AIR FAN
AIR PROVING
SWITCH
FAN POWER
CAPACITOR
RESISTOR
TERMINAL
BLOCK
CLOCK
AIR
HEATER
SWITCH
THERMISTA-STAT AIR HEATER
GAS CONTROL
COVER
LIMIT SWITCH
FDC ASSEMBLY
AIR HEATER
IGNITION
ELECTRODE
WIRE COLOUR
CODE
black ------bk
blue -------b
brown -----br
grey -------gy
violet ------v
white ------w
red ---------r
pink --------pk
yellow------y
WIRE COLOUR
CODE
black ------bk
blue -------b
brown -----br
grey -------gy
violet ------v
white ------w
red ---------r
pink --------pk
yellow------y
bbr
wgy

619
TerminalPosition MinDistance
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 Fromfacingterminal 1200mm
F Between terminals 300mm
G Below eaves or balcony NOT RECOMMENDED
Fig. 6
Recommended(Vertical)
Terminal Positions
1
2
3
4
5
6
7
8
9
1
0
L
N
L
N
A
/
H
C
O
M
W
/
H
T
h
e
r
m
i
s
t
a
-
s
t
a
t
Thermista-stat
(Supplied)
Polarity not important
E
x
t
e
r
n
a
l
P
r
o
g
r
a
m
m
e
r
(Not supplied)
E
c
o
n
o
m
a
i
r
e
Heater
have voltage free
switching contacts
Must
Test
Supply
Fuse
T3.15A
230V~50Hz
R
1
2
7
K
0
ON COM OFF
NL123456
A/H TIMED
O/P
Fig. 15
SchematicDiagram(showingconnection ofanexternalcontroller)
PART No CONTENTS COLOUR
1000-0016520 1 X 90° Standard Flue Elbow White
1000-0016530 1 X 45° Flue Elbows White
1000-0016550 1 X 500mm Extension White
1000-0016540 1 X 1000mm Extension White
1000-0016560 1 X Vertical Terminal
1 X Support Bracket Anthracite
1000-0016630 1 X Vertical Terminal
1 X Support Bracket Terracotta
1000-0014890 1 X Lead Pitched Roof Flashing
1 X Collar Anthracite
1000-0014990 1 X Lead Pitched Roof Flashing
1 X Collar Terracotta
1000-0014900 1 X Aluminium Flat Roof Flashing Aluminium
1000-0016570 1 X Horizontal Wall Terminal White
1000-0016580 1 X Wall Plates (for above) White
1000-0016590 1 X Horizontal Wall Terminal
2 X Wall Plates White
1000-0016600 1 X Condensation Drain White
1000-0014950 1 X Syphon Kit (for above) N/A
1000-0016610 1 X Condensation Drain
1 X Syphon Kit N/A
1000-0016620 1 X Wall Bracket (125mm dia) N/A
1000-0017130 1 X Terminal Guard N/A
Table 2.
Flueand TerminalComponents

520
5.3 VERTICALTERMINALLOCATION:
5.3.1 The ECONOMAIRE 90 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
achieved 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 across it at ALL
times.
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.
Fig. 16
ECONOMAIRE90 -PrincipalDimensions
SIDE VIEW
PLAN VIEW
FRONT VIEW
BASE VIEW
KNOCKOUT FOR
GAS ENTRY
(BOTH SIDES)
UNUSED
KNOCKOUT
(BOTH SIDES)
ELECTRICAL
ENTRY
UNUSED
KNOCKOUT
(BOTH SIDES)
42.5 42.5
400
485
242.5
1318
1
4
0
5
832
716
290
525
528
615
448 25
4
0
1
8
0
1
5
2
5
TerminalPosition MinDistance
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 terminal facinga terminal 1200mm
J Vertically from a terminal on the same wall 1500mm
K Horizontally from a terminal on the same wall 300mm
Fig.4
Recommended(Horizontal)
Terminal Positions
220mm
Outer Tube Flue Tube
Wall
Plate Plate
Fig. 5
HorizontalFlueTerminal