Johnson & Starley HI-SPEC J25SC Series User guide

1 Air Filter
2 Air circulating fan
3 Heat exchanger access cover
4 Data plate
5 Electrical Panel Assembly
6 Multifunctional control
7 Fan delay control/limit switch
8 Viewing port
9 Pilot Burner
10 Burner Assembly
11 Gas supply pipe
12 Piezo igniter unit
13 ELJAN 4/SE Water heater (if fitted)
Fig. 1
1.1 HI-SPEC J25SC is a fanned-circulation, downflow, ducted warm air heater for SE-duct applications, which may be
supplied with SYSTEM E-T or Basic control, and in combination with an ELJAN 4/SE (electrically switched) water
heater.
1.2 The Air heater output can be adjusted between 6.44kW (23.2MJ/h, 22,000 Btu/h) and 7.3kW (26.4MJ/h, 25,000Btu/h).
“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions). ELJAN 4/SE output is
3.32kW (12.0MJ/h, 11,340Btu/h).
THIS APPLIANCE CONFORMS TO BS EN 55014
This appliance has been tested and certified by B G Technology for use with natural gas G20.
Note: If a water heater is fitted, these instructions must be read in conjunction with the Installation, Commissioning
and Servicing Instructions for that appliance.
1. BRIEF DESCRIPTION
HI-SPEC J25SC SERIES WARM AIR HEATERS
SYSTEM E-T and BASIC Control
INSTALLATION,COMMISSIONING&SERVICINGINSTRUCTIONS
G.C. No 42 417 96 PublicationNo.ZZ839/6
October2007
These instructions are to be left with the User or adjacent to the Gas Meter
124
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5
10. SHORTLISTOFSPARES
HI-SPECJ25SC
KEY G.CNo MFR’SNo DESCRIPTION QTY
1 BOS02064SP Fan Assembly 1
2 T193-0145000 FilterAssembly 1
3 378466 BOS02031 TimeControl 1
4 381627 1000-0701140 Multifunctional Control 1
5 232948 BOS02061 ‘O’Ring Seal 2
6 245482 S00556 Pilot BurnerAssembly (including gaskets) 1
S01494 Pilot Feed Pipe Kit 1
7 1000-2500580 PilotGasket 1
8 381713 1000-0702030 Thermocouple 1
9 245509 1000-0513820 Fuse T3.15A anti-surge 1
10 S252-0700000 Burner and ControlsAssembly 1
11 245480 S250-0709000 Main BurnerAssembly 1
12 397484 1000-0703450 Main Injector 1
13 392935 1000-0701260 Pilotinjector (S.I.T.No.27) 1
14 395945 1000-0700570 PiezoUnit 1
15 386775 BOS01970 Igniter Electrode 1
16 397819 BOS02394 Electrode lead 1
SystemE-TModelsOnly
17 245539 ET005 Electronic PanelAssembly and Daughter board 1
18 S252-0500000 ElectricalPanelAssembly 1
19 245514 1000-0515620 Thermista-stat 1
20 245516 1000-0516375 Fan Delay Control/Limit Switch 1
21 245542 1000-0515970 Capacitor15µf 1
Basic Modelsonly
22 245544 S252-0501000 Electrical Panel 1
23 245521 1000-0516365 Fan Dely Control/Limit Switch 1
24 245522 1000-0515200 Fan Speed Transformer 1
25 245525 1000-0515730 Transformer24V 1
26 245413 1000-0511760 Relay Module 1
JohnsonandStarleypridesitselfonitsabilitytosupplysparepartsquickly and efficiently.Ifyouhaveaprobleminobtaininga
sparepart,pleasecontactJohnsonandStarley SparesDepartmentattheaddressbelow.
JOHNSON&STARLEYLTD.
Telephone: [phone] RhosiliRoad,
Brackmills,
Fax: [phone] NorthamptonNN47LZ
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3
4
6
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9
10
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Installation shall be in accordance with the current editions of:-
Building Standards (Scotland) (Consolidation) Regulations
Building Regulations
Gas Safety (Installation and Use) Regulations (as amended)
BS7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations
BS6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).
BS5440 Pt.1 (Flues for Gas Appliances)
BS5440 Pt.2 (Air Supply for Gas Appliances)
BS5864 Installation of Gas Fired Ducted Air Heaters
Model and Local Authority Bye-laws
IMPORTANT: STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT
PERSONS, (i.e. CORGI REGISTERED INSTALLERS) INACCORDANCE WITH THE GAS SAFETY(INSTALLATION
ANDUSE)REGULATIONS (CURRENTEDITION).FAILURETOCOMPLYWITHTHESEREGULATIONS MAYLEAD
TOPROSECUTION.
2. HEATER COMPARTMENTAND CLEARANCES (See BS5864)
2.1 IMPORTANT: If the heater is to be fitted to an existing base duct (warm air plenum), always ensure that installation is
carried out such that the rear right hand corner of the heater is aligned with the rear right hand corner of the base duct, so
that any overhang or blanking off will be at the front and/or left 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 side walls of 20mm (0.75 in)
and 25mm (1.0 in) from 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 600mm (24 ins) 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
must be not less than 75mm (3 in). However, if clearances are less than 75mm, the internal surface of the compartment
must be lined with non-combustible material. The compartment must be of a fixed rigid structure.
2.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant sections 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 (0.5 in).
2.5 The base duct on which the air heater stands must be only placed on a non-combustible floor.
2.6 IMPORTANT: The red ‘SAFETY’ label supplied with the heater, MUST BE AFFIXED in a prominent position
on the inside of the compartment door.
3. VENTILATIONANDCOMBUSTIONAIR
3.1 An SE-duct appliance does not require a combustion air vent in the room or internal space in which it is installed. If
the appliance is installed in a compartment, the minimum total free area of the high and low level ventilation air vents
must be as specified in Table 1 (as per BS5440 Pt. 2 Table 1).
Note: These free areas allow for the operation of the appliance in combination with an ELJAN 4/SE water heater.
VENTILATED Low level grille 127 cm2(19.7in2)
FROM INSIDE
BUILDING High level grille 127cm2(19.7in2)
VENTILATED Low level grille 63cm2(9.8in2)
FROMOUTSIDE
BUILDING High level grille 63cm2(9.8in2)
Table 1: Minimum Effective Areas
3.2 Both vents must communicate with the same room or internal space, or must both be on the same wall to outside air. The
vertical distance between the vents shall be as large as is practicable. The compartment containing the room sealed
appliance MUST be labelled to warn against blockage of vents - referring to BS 5440 Part 2, clause 4.2.4.
223
Fig.8,PRINCIPALDIMENSIONS(mm)
SIDE VIEW REAR VIEW
BASE VIEW
FRONT VIEW
TOP VIEW
31
187
380
281
164
362
52
33
32
41
14
76
127
374 459 37
32
257
816
1022
39
376
566
111
110dia.120dia.
KNOCKOUTS
FOR WATER
CONNECTIONS
(BOTH SIDES)
KNOCKOUT FOR
GAS CONNECTION
(BOTH SIDES)

22
4. DUCTSYSTEM
All ductwork MUST be mechanically secured and sealed with good quality ducting tape.
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 airflow will be maintained at
all times. The return air grille should have a free area of not less than 0.06m2(93 in2).
4.1.2 An adequate and unobstructed return air path is essential from areas 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 (1 in2/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms and
w.c’s.
4.2 WARMDELIVEREDAIR
4.2.1 All ductwork, including riser ducts, should be fully insulated with 50m (2 in.) of 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 and protected from crushing.
4.2.2 The duct system should be carefully designed to suit the needs of its specific heating requirements and building
layout. The type of duct system, i.e., radial/extended plenum/stepped, should be installed using the least number of
fittings to minimise the resistance to air flow.
4.2.3 The base duct, which equalises the air pressure to supply ducts, shall be constructed to support the weight of the
heater, which shall be secured to the plenum with screws on at least two sides, and sealed using self-adhesive
foam strip, ducting tape or sealing compound. All ducting and blanking plates shall be mechanically secured and
sealed.
5. INSTALLATION
5.1 SIDERETURNAIR
If return air is to be introduced via the side of the appliance, it will be necessary to prepare it prior to installation. Return
air ducting may be connected to either side of the heater as follows:
5.1.1 Remove the air filter, front cover and the air circulation fan.
5.1.2 Cut a hole in the chosen side of the fan compartment. The knock outs will determine the size and position.
5.1.3 Remove and the filter frame retaining screws and remove the filter frame.
5.1.4 Position the filter frame centrally over the prepared hole so that the front of the frame is flush with the front of
the heater.
5.1.5 Using the frame as a template, mark and drill the 6 x 3.2mm dia. frame fixing holes.
5.1.6 Secure the filter frame to the side of the heater using the screws previously removed.
5.1.7 Refit the air circulation fan, front cover and air filter.
5.1.8 Using suitable material, manufacture a plate to cover the original return air opening in the top of the air heater, and
secure with self tapping screws (not provided).
5.2 SE-DUCTPREPARATION
5.2.1 Ensure that the existing air heater has first been removed.
IMPORTANT: Many SE-ducts are constructed from asbestos-based materials, and due to dimensional
variations between Johnson & Starley and other manufacturers appliances, a certain amount of rework
will be required on the SE-duct by REGISTERED CONTRACTORS.
5.2.2 In some circumstances, the SE-duct may be completely exposed and special components needed to complete the
installation. Consult Johnson & Starley Service Department if this situation is encountered.
5.2.3 Referring to Fig. 2, NOTE THE DATUM POINTS INDICATED before proceeding. A Sealing
Template Kit (ST25) is available for cutting the holes in the SE-duct.
5.2.4 Thoroughly clean and replace the sealing material from the top of the existing base duct.
5.2.5 The holes in the SE-duct MUST correspond with the positions ‘A’ and ‘B’ as shown in Fig. 2, 138mm (5.5 in.)
minimum diameter, 152mm (6.0in.) maximum diameter, and clear the duct of all resulting debris. Should the
original heater be a SUGG Type 22/WH ‘Halcyon’, the existing bottom hole is suitable for use.
5.2.6 Seal the redundant hole/s in the SE-duct using a suitable cement or blanking material, to ensure a good flat surface
on both the inner and outer faces of the duct wall.
IMPORTANT: Any debris which falls into the SE-duct MUST BE REMOVED.
3
Fig.7b,BASICCONTROLCIRCUITDIAGRAM
r

5.2.7 Referring to Fig. 2, drill 2 x 9mm diameter holes and fix the eye-bolts using the masonry plugs provided in the
installation kit.
5.4 METHOD OF FIXING
5.4.1 Due to base plan variations between the replacement and the original heaters, at some stage it may be necessary to
blank off part or parts of the base duct aperture. This can be done at the discretion of the installer, but it is
important that a suitable non-combustible material is used and that the perimeter of the remaining aperture is
bounded by suitable sealing tape to ensure a good seal between the heater and the base duct. Blanking plates
MUST be mechanically secure to the base duct, and the use of TAPE ALONE IS NOT ACCEPTABLE.
5.4.2 Measure the thickness of the SE-duct wall and, using one of the expanding spigots as the flue spigot, adjust it
such that it projects 38mm (1.5 in), and secure the spigot to length using 2 x self tapping screws provided.
Note: This dimension is critical.
5.4.3 Adjust the other spigot to a length equal to the thickness of the SE-duct wall and secure to length as above.
Note: If the SE-duct wall is 125mm or less, the inner tube of the expanding spigot should be discarded,
and the outer tube cut to length as necessary.
5.4.4 Apply a suitable mastic (not provided) to the spigot flanges and insert them into their respective apertures, and
seal them to the face of the SE-duct wall.
5.4.5 Position the larger rope ring seal over the raised flange on the heater inlet spigot, and secure with three
equally spaced beads of a suitable mastic (not provided).
5.4.6 Place the smaller rope ring (denoted by blue ident) onto the air heater flue spigot, and place the air heater onto the
base plenum to engage the spigots with the SE-duct apertures.
NBensurethat theroperingisfitted such thatitis pushed OVER thebulge the protrudesfromtheheater. Seefig2.
5.4.7 Hook the tie rods to the eye-bolt wall fixings, and secure using the brackets provided, hooked into the slots in the
front edge of the side of the air heater.
5.4.8 Fit the nuts and washers provided, then carefully tighten the tie rods so that the air heater is effectively sealed
against the SE-duct.
Note: If the air heater is installed in a compartment, the warning label must be applied in a prominent position.
5.4.9 The air heater must be mechanically secured to the base plenum on at least 2 sides.
421
Fig.7a,SYSTEME-TCIRCUITDIAGRAM
Fig.2
HI-SPECJ25RSfittedtoSE-Duct-fittingdimensions
FrontView SideView
r
ImportantDimension
1 Eyebolt
2 Expanding Spigot
3 SmallRope Ring
4 LargeRope Ring
5 Tie Rod
6 FixingBracket
7 Spacer
8 Locknut
1
2
3
4
5
6
78
Eyebolt
position

20 5
5.5 ELECTRICAL
5.5.1 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 top left
hand front. The cable is suitable for a 230V 50Hz supply and shall be connected to the fixed wiring
using a double pole switched, fused spur, incorporating a protective earth link. The fuse fitted shall be
rated 5A to BS1362. Connections shall be in accordance with the current edition of I.E.E Regulations BS
7671.
b. SYSTEM E-T MODELS: An electronic controller (Thermista-stat) is supplied which acts as a room
thermostat.
c. BASIC CONTROL MODELS: A 24V room thermostat (not supplied), that complies with BS800,
BS3955 and BS4201 is essential to ensure close control of comfort conditions. An anticipator is located
within the thermostat and is graded in amps. The anticipator should be checked and adjusted to 0.3.
d. To gain access to the control panel to make the Thermista-stat/Room Thermostat connections, remove the
air filter and the front cover from the air heater, release the 2 x securing screws and hinge down the
electrical panel.
5.5.2 Thermista-stat/Room Thermostat and its location.
a. The Thermista-stat/Room Thermostat should be located where there is free air circulation approx. 1.5m
(5ft) from the floor.
b. Avoid the following locations:-
i. In a room where temperature is greatly affected by the sun or any other heat source, e.g. radiant
fire, wall light fittings or TV set.
ii. Near an outside door or windows, or on an outside wall.
iii. Where affected by warm air ducts, diffusers, waste pipes or the heater itself.
iv. Where subject to vibration.
c. Connect Thermista-stat/Room thermostat wires to control panel terminals ‘7’ and ‘8’ (see Fig. 6a/b
or 7a/b).
5.3 GAS (See BS5864 and BS6891)
5.3.1 An independent gas supply pipe from the meter is to be preferred wherever possible. When this is not possible,
the pipe must be capable of taking the complete input of the heater and all other gas appliances being served by
this same pipe. This supply should be suitably sized to conform to British Standards requirements of no more than
1.0 mbar (0.4in wg) pressure drop (See table of discharge in BS6891).
5.3.2 The 1/2in union gas cock (supplied) must be fitted to the gas inlet of the heater for easy isolation during
servicing. The gas pipe should be so fitted and installed as to be durable, substantial and gas tight. To assist in
determining where a gas connection may not be tight, a leak detection fluid should be applied around the
connection. Under no circumstances should a flame be used to locate a gas leak. Gas entry to the air heater is
through either side to a Rc1/2 (1/2in BSP. external [taper] thread).
6. COMMISSIONING
6.1 PREPARATION:
6.1.1 Ensure that:
a. Gas and Electrical supplies are OFF.
b. Filter, fan and fan compartments are free from obstructions.
c. All registers or grilles are open and conform to design specifications.
d. Return, relief and ventilation air installations are adequate.
6.2 SETTING OF FAN SPEED:
6.2.1 Remove air filter and air heater front door.
SYSTEM E-T MODELS: On the electronic control module, set:
6.2.2 Rate Switch to ‘MAX’,
6.2.3 Cleanflow switch to ‘0’. (If not fitted)
Fig.6b,BASICCONTROLFUNCTIONALDIAGRAM
r

619
6.3 IGNITIONOFPILOTANDMAINBURNERS:
WARNING: If the pilot burner is extinguished either intentionally or unintentionally, no attempt should be made to
relight the gas for a minimum of 3 minutes. Ensure that the Electrical supply, time control and Selector switches are set
to ‘OFF’.
6.3.1 Set the Thermista-stat/room thermostat to lowest or OFF setting.
6.3.2 On the Multifunctional control, remove the Outlet Pressure test point cover, and fit a pressure test gauge (refer
Fig. 4).
6.3.3 Turn the heater Gas supply ON, test for gas soundness and purge the whole gas pipe as described in BS6891.
6.3.4 Referring to Fig. 4, partially depress the OPERATING CONTROL and set the control 1/4turn anti-clockwise to
the ‘SPARK’ symbol. Press and hold the OPERATING CONTROL, and whilst observing the Pilot Burner,
repeatedly press the Piezo igniter button until the Pilot burner ignites.
6.3.5 After 20 seconds release the OPERATING CONTROL and let it spring out; ensure that the Pilot burner remains
alight. If the Pilot burner extinguishes, rotate the OPERATING CONTROLclockwise to the ‘’position and
ensure that the OPERATING CONTROL is fully reset. Wait three minutes and repeat steps 6.3.4 and 6.3.5,
holding the OPERATING CONTROL depressed for a longer period, until the Pilot burner remains alight.
6.3.6 Ensure that the pilot flame envelops thermocouple tip, if not, check that the pilot orifices is free from
obstruction. The pilot is factory set and is non-adjustable.
6.3.7 With the Pilot burner lit, depress the OPERATING CONTROL and turn it to the position indicated by the flame
symbol.
6.3.8 Set the air heater Electricity supply ON.
6.3.9 Set the Time control to required Heating On periods.
6.3.9 Set the Selector switch to ‘TIMED’.
6.3.10 Set the Thermista-stat or room thermostat to MAXIMUM.
6.3.11 Ensure that the main burner has now ignited.
6.3.12 Test for gas leakage at the supply, Multifunctional control, Pilot and Main burners using proprietary detection
fluid and sealing any leaks found.
6.3.13 Allow the heater to operate for a minimum of 15 minutes to ensure stability.
6.4 MAIN BURNER PRESSURE TEST:
NOTE:AIR HEATER BURNERSARE FACTORYSET TO PROVIDEANOMINALHIGH PRESSURE OUTPUTAS
DETAILED IN SUB PARA1.2
6.4.1 Referring to Table 2 and Fig. 4 below, ensure that the pressure test gauge indicates the correct burner pressure,
resetting if required as follows:
a. At the Multifunctional control:
i. Remove the Burner Pressure Adjuster cover.
ii. Set the Burner Pressure Adjuster to provide a pressure test gauge indication for the correct burner
pressure as detailed in Table 2.
iii. Refit the Burner Pressure Adjuster cover.
6.4.2 Apply the pressure set arrow to indicate the appropriate burner pressure on the data badge.
6.5 EXTINGUISHING OF PILOT AND MAIN BURNERS:
6.5.1 On the Multifunctional control, rotate the OPERATING CONTROLclockwise to the ‘’ position and ensure that
the OPERATING CONTROLfully resets, and both the Pilot and Main Burners are extinguished.
6.5.2 On the Multifunctional control, remove the pressure test gauge and refit the Outlet Pressure test point cover.
6.6 TEMPERATURERISECHECKS:
6.6.1 Ignite the Pilot and Main burners and allow 15 minutes for stability before continuing.
6.6.2 Check that the temperature rise across the heater is between 45oC - 55oC, setting the fan speed as follows:
i. SYSTEM E-T heaters: System E-T provides a fan speed corresponding to the above temperature rise, if
the appliance is to be set to operate at the minimum rate and the ducting has been sized accordingly, set
the ‘RATE SWITCH’to ‘MIN’, thus reducing the fan speed.
ii BASIC Control heaters, the fan speed is adjusted by selecting the fan speed at control panel
(decrease voltage selection to decrease fan speed).
Fig.6a,SYSTEME-TFUNCTIONALDIAGRAM
r

18
6.7 AUTOMATICCONTROLSCHECK
6.7.1 Ignite the Pilot and Main burners and allow to operate for 15 minutes to ensure stability.
6.7.2 SettheTIMECONTROL(iffitted)to‘ON’.
6.7.3 Turn the Thermista-stat or room thermostat slowly clockwise until the Main burner ignites.
6.7.4 Ensure that the fan starts to operate after a short period (approx. 1-2 minutes).
SYSTEME-Tmodels:
6.7.5 Ensure that the fan speed increases to full speed.
6.7.6 When the temperature reaches the control setting, check that the main burner cycles ON and OFF, at
approximately 75 to 120 seconds.
BASIC CONTROL models:
6.7.7 When the temperature reaches the control setting, ensure that the Main burner extinguishes followed by the fan
switching off after a short period.
6.7.8 When the temperature falls below the control setting, ensure that the Main Burner re-ignites followed by fan
operation.
6.8 SAFETYCHECKS:
6.8.1 On the Multifunctional control, rotate OPERATING CONTROLclockwise to the ‘’position and ensure that the
OPERATING CONTROL fully resets, and both Pilot and Main Burners are extinguished.
6.8.2 Switch OFF the electrical supply to the air heater.
6.8.3 Release the securing screw and hinge down the fan chamber door.
6.8.4 Disconnect the air circulation fan as follows:
a. System E-T models: disconnect the 2 x red conductors at the terminal block terminals ‘30’ and ‘31’
b. Basic control models: disconnect the 2 x black conductors at the terminal block terminals ‘16’ and ‘18’
6.8.5 Switch ON the electrical supply to the air heater.
FAN CONTINUESTORUN, ORCYCLESAFTER HEATINGISTURNED OFF
DISCONNECT
TERMINALS ‘17’ &’18’
Y
N
REPLACE FAN DELAY/
LIMIT CONTROL
REPLACE
ELECTRONIC
MODULE
DOES
FAN
RUN?
N
CHECK FOR
VOLTAGEAT
TERMINALS
30 & 31
MAINBURNER ON, BUTFANNOTRUNNING
Y
N
BRIDGE OUT
FANDELAYAT
TERMINALS 21 & 22
Y
REPLACE FAN
DELAY/LIMIT
CONTROL
REPLACE
ELECTRONICS
MODULE
DISCONNECTFANLEADS
FROM CAPACITOR,AND
CONNECTDIRECTTO FAN
DOES
FAN
START?
DOES
FAN
START?
REPLACE
CAPACITOR
Y
REPLACE
FAN
N
MAINBURNERNOT CYCLING
(ROOM TEMPERATURE TOO HIGH)
REPLACE
MULTIFUNCTIONAL
CONTROL
N
YREPLACE
ELECTRONICS
MODULE
DISCONNECT
MULTIFUNCTIONAL
CONTROLAT
TERMINAL15
N
DOES
BURNER
GOOUT?
DISCONNECT
THERMISTA-STAT
REPLACE
THERMISTA-STAT
Y
DOES
BURNER
GOOUT?
1 Operating control
2. Burner Pressure Adjuster
3. Outlet Pressure test point
7
Sit
EV2
PI-
LOT
EA
1
2
3
Fig.4
MultifunctionalControl

817
100 150 200 250 300 ft3/min
0.05 0.07 0.09 0.12 0.14 m3/sec
AIR VOLUME
mbar in.wg.
0.375 0.15
0.25 0.10
0.125 0.05
RESISTANCE EXTERNALTO HEATER
170V
190V
200V
210V
220V
230V
FANRUNS BUTMAIN BURNERNOTOPERATING
Y
IS
‘SUMMER
AIRFLOW’
SWITCH
SETTO
‘0’
NSET‘SUMMER
AIRFLOWSWITCHTO
‘0’
IS
THERMISTA
-STAT
CONNECTED
IS
THERMISTA
-STATSETTO
‘SUMMER
AIRFLOW
Y
NCONNECT
THERMISTA-STAT
SETTHERMISTA-STATTO
REQUIRED
TEMPERATURE SETTING
NFAULT
CLEARED
Y
Y
DISCONNECTTHERMISTA-STAT
AT TERMINALS ‘7’& ‘8’, LINK
TERMINALS‘7’ & ‘TEST’
DO NOT LINK ‘7’ &’8’
DOES
FANSTILL
RUN ?
DOES
FANSTILL
RUNWITH
BURNER
LIT?
N
CHECKTHERMISTA-STATWIRING.
IFOK,REPLACETHERMISTA-STAT.
IFNOT, RECONNECTTERMINALS
‘7’& ‘8’,AND SET THERMISTA-STAT
TODEMAND HEAT
Y
HAS
BURNER
LIT?
REPLACEELECTRONIC
MODULE.RECONNECT
THERMISTA-STAT
FAN OPERATESAFTERBURNERHAS
RAISEDTHE INTERNAL
TEMPERATURETO CAUSE THEFAN
DELAYCONTROLTOOPERATE
HAS
FAN STOPPED
AND BURNER
LIT?
Y
Y
Table3
FanPerformanceCurve
6.9 SYSTEMWARMAIR BALANCING:
6.9.1 Set the ‘SUMMERAIRFLOW’switch to ‘I’.
6.9.2 Balance the system to provide required volume proportions at warm air outlets.
NOTE:If the system includes ceiling diffusers, air velocities 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.
6.9.3 Setthe ‘SUMMERAIRFLOW’switch to ‘O’.
6.9.4 Ignite the Pilot and Main burners as detailed in sub-paras 6.3.4 to 6.3.7.
6.9.5 Set the appliance to operate in accordance with the User’s requirements.
6.8.6 Ignite the pilot and main burners, and check that the Limit switch operates between 120 and 180 seconds
(indicated by the main burner extinguishing).
6.8.7 Switch OFF the electrical supply to the air heater.
6.8.8 Reconnect the air circulation fan at the terminal block.
6.8.9 Hinge up the fan chamber door, taking care to avoid causing damage to wiring, and secure using the 3 x screws
previously removed.
6.8.10 Switch ON the electrical supply to the air heater.
6.8.11 Ensure that the Limit switch resets, indicated by the main burner igniting, within approximately 60 seconds.
6.8.12 Check for gas soundness within the appliance.
6.8.13 Turn OFF the gas supply at the service cock and ensure that the Multifunctional control fail-safe operates within
60 seconds (indicated by loud click from Multifunctional control).
6.8.14 Turn the gas supply ON at the service cock.
LOW RATE HIGHRATE
kW MJ/h Btu/h kW MJ/h Btu/h
INPUT 8.59 30.9 29,350 9.69 34.9 33,100
OUTPUT 6.44 23.21 22,000 7.32 26.4 25,000
Gas rate cv 0.80m3/h (28.3ft3/h) 0.90m3/h (31.9ft3/h)
1037Btu/ft3
Burner setting 12.0mbar (4.8 in wg) 16.0mbar (6.4 in wg)
pressure (hot)
Main Injector AMAL187/001/800
Table2
Main Burner Pressure Settings

916
FANOPERATES,BUT BURNER CYCLESBEFOREREQUIREDTEMPERATUREIS REACHED
DOES
THE BURNER
CONTINUETO
CYCLE?
REPLACE
THERMISTA-STAT N
CHECKRETURNAIRPATH
FORRESTRICTIONS
Y
CHECKTEMPERATURERISE.
IF LESS THAN 60OC, LINK
TERMINALS ‘13’ & ‘14’
Y
DOES
THE BURNER
CONTINUETO
CYCLE?
DOES
THE BURNER
CONTINUETO
CYCLE?
Y
NREPLACE FAN DELAY/
LIMIT CONTROL
REPLACE
ELECTRONIC
MODULE
DISCONNECTTHERMISTA-STAT
AT TERMINALS ‘7’& ‘8’, LINK
TERMINALS‘7’ & ‘TEST’
DO NOT LINK ‘7’ &’8’
7. INSTRUCTIONSFORUSERS
7.1 If the building is unoccupied, ensure that the Instructions for User are left taped to the air heater for the User, and
Installation Instructions are left at or near the air heater for use on future service calls.
7.2 If the building is occupied, hand the User Instructions over and ensure the User understands:
7.2.1 How to ignite the pilot and burner.
7.2.2 How to operate the Thermista-stat/room thermostat, time and heater ON/OFF switch and summer air circulation
switch, and that the time control must be reset following a power failure.
7.2.3 How to extinguish the pilot and main burner at the Multifunctional control, and switch off electrical supply to the
heater.
7.2.4 How to remove, clean and refit the air filter and at what intervals (i.e. fortnightly, or for new houses, weekly).
7.2.5 How to control the heating system by opening and closing warm air outlets.
7.2.6 How to obtain summer air circulation.
7.2.7 That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of
the building must not be obstructed.
7.2.8 That the heater must be serviced at least once a year by a competent person to ensure efficient and safe operation.
7.2.9 That the red instructions for safe use have been pointed out and understood.
7.2.10 That expert help must be obtained if persistent failure of the pilot burner occurs.
8. MAINTENANCE
IMPORTANT: Ensure gas and electricity supplies are isolated before commencing any maintenance or
replacement of components. After completion of any maintenance, always test for gas soundness and carry
out a complete functional test of the appliance in accordance with Commissioning Instructions at Sect 6.1
to 6.8 inclusive. Replace any sealing gasket or insulation that is damaged before re-commissioning, taking
care to not disperse fibrous materials.
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 para 8.8.
8.1.5 Remove the Burner and Controls Assembly as detailed in para 8.2. Inspect and clean the main burner and injector
as necessary. Examine the main burner for cracks, including hairline cracks, exchanging the burner as necessary.
8.1.6 Inspect and clear the pilot burner orifice.
8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below, as shown in para 8.10.
8.1.8 By viewing through the FanAperture, and using a torch or similar, examine the heat exchanger externally for signs
of cracks or holes, particularly around welded joints.
8.1.9 Using a torch or similar, introduce a light source into the heat exchanger burner aperture and upper access port,
and again examine the heat exchanger for signs of cracks or holes, particularly around welded joints, whilst again
viewing through the Fan Aperture.
8.1.10 Refit the Air Circulation fan, Burner and Controls Assembly, and air filter/air cleaner.
8.1.11 Light the appliance and note the main burner flame profile. If the flame profile is affected when the Air
Circulation fan switches on, check for any air leaks between the air heater and the base plenum, paying particular
attention to heaters with rear draught diverters. Rectify any air leaks before continuing with this procedure.
8.1.12 Allow the air heater to operate for approximately 15 minutes to ensure stability, and with the main burner lit,
ensure that the operation ofAir Circulation fan does not affect the main burner flame profile.
8.1.13 If no defects are found, fully commission the air heater in accordance with the Installation, Commissioning and
Maintenance instructions applicable to the appliance.

10 15
CHECK FOR 230V AT
TERMINAL27
MAINBURNER NOTOPERATING
IS
PILOT
LIT?
ISTIME
CONTROL&
THERMISTA-STAT
CORRECTLY
SET?
IS
GAS
ON ?
NN
LIGHT
PILOT
Y
Y
SWITCHON
230 V N
Y
N
Y
SETCONTROLS
CORRECTLY
DISCONNECTTHERMISTA-STAT
ATTERMINALS ‘7’& ‘8’, LINK
TERMINALS‘7’ & ‘TEST’
IS230V
SUPPLY
ON?
YRECONNECTTHERMISTA-STAT
AT TERMINALS ‘7’ & ‘8’,
DISCONNECTONCONNECTION
ATTHERMISTA-STAT
DOES
FAN
RUN?
DOES
FAN
RUN?
YREPLACE
THERMISTA-STAT
N
EXTERNALWIRINGTO
THERMISTA-STAT
FAULTY
CHECK FOR 230VAT
MULTIFUNCTIONAL
CONTROL
N
Y
REPLACE
MULTIFUNCTIONAL
CONTROL
Y
CHECKWIRINGTO
MULTIFUNCTIONAL
CONTROL
N
CHECK FOR 230VAT
TERMINAL15
N
CHECK FOR 230VAT
TERMINAL13
Y
LINK TERMINALS ‘13’
& ‘14’, IF BURNER
LIGHTS REPLACE
FAN/LIMIT CONTROL N
CHECK FOR 230V AT
TERMINAL29
CHECKWIRING
CONNECTIONS Y
TURNGAS
ON
NREPLACE
ELECTRONIC
MODULE
Y
CHECKWIRING
CONNECTIONS Y
N
CHECK FOR 230V AT
CENTRETERMINALOF
SWITCH‘S5’
N
CHECK FOR 230V AT
TIMECONTROL
TERMINAL‘C5’
REPLACEAIRHEATER
SWITCH Y
N
REPLACETIME
CONTROLMECHANISM
8.2 BURNERANDCONTROLASSEMBLYREMOVAL:
8.2.1 Ensure that the Gas and Electrical supplies are switched OFF
8.2.2 Remove air filter and the appliance door.
8.2.3 Disconnect igniter at the piezo unit.
8.2.4 Disconnect Multifunctional control electrical connections.
8.2.5 Disconnect the gas supply by breaking the union at the input of the Multifunctional control.
8.2.6 Remove the 8 Burner assembly securing screws and withdraw the Burner and Control Assembly.
8.2.7 Refitment or replacement is in reverse order.
8.3 MAINBURNER REMOVAL:
8.3.1 Remove the Burner and Controls assembly as detailed in 8.2.
8.3.2 Release the 4 x securing screws and withdraw the Main Burner.
8.3.3 Refitment or replacement is in reverse order.
8.4 MAININJECTORREMOVAL:
8.4.1 Remove the Main Burner as detailed in 8.3.
8.4.2 Unscrew the main injector from its holder.
8.4.3 Refitment or replacement is in reverse order.
8.5 PILOTBURNERASSEMBLYDISMANTLINGAND REMOVAL:
8.5.1 Remove Burner and Controls assembly as detailed in 8.2.
8.5.2 Release the Thermocouple lock nut from the Pilot Burner Assembly and Multifunctional Control, and withdraw
the Thermocouple, taking care to avoid damage to the capillary.
8.5.3 Release the Igniter electrode lock nut from the Pilot Assembly and withdraw the electrode.
8.5.4 Disconnect the pilot gas feed pipe from the Multifunctional control and Pilot Assembly.
8.5.5 Withdraw the Pilot injector from the Pilot Assembly.
8.5.6 Release the 2 x screws, nuts and lock washers securing the Pilot Assembly to the Burner and Controls assembly,
and withdraw the Pilot Assembly.
8.5.7 Refitting or replacement is in reverse order, ensuring that the Pilot Assembly gaskets are not damaged and that the
Pilot Assembly firmly seals with the Burner and Controls assembly. DO NOT over tighten the thermocouple
connection at the Multifunctional control, (finger tight plus 1 flat).
8.6 MULTIFUNCTIONALCONTROLREMOVAL:
8.6.1 Remove the Burner and Controls Assembly as detailed in 8.2
8.6.2 Disconnect the Thermocouple at the Multifunctional control, avoiding damage to the capillary.
8.6.3 Disconnect the Pilot gas feed pipe from the Multifunctional control.
8.6.4 Disconnect the Multifunctional control input and output supply feeds.
8.6.5 Refitting or replacement is in reverse order.
NOTE: When refitting or replacing the Multifunctional control, the ‘O’ ring seals are to be replaced.
8.7 PIEZOUNITREMOVAL:
8.7.1 Disconnect the 2 conductors from Piezo unit.
8.7.2 Release the retaining nut and remove the Piezo unit from its mounting bracket.
8.7.3 Refitting or replacement is in reverse order.
8.8 AIRCIRCULATINGFAN, REMOVALAND CLEANING:
8.8.1 Ensure that the electrical supply is isolated.
8.8.2 Remove the appliance front door, release the 2 x securing screws and hinge down the electrical panel.
8.8.3 Disconnect the fan flying lead socket.
8.8.4 Withdraw the fan flying lead from the cable clamp on fan chamber floor.
8.8.5 Release the 2 x Fan Assembly securing screws and withdraw the Fan Assembly from the Heater cabinet, avoiding
damage to the fan blades.
8.8.6 Remove all dust from both the impeller and motor, taking care to not disturb the balance of the fan.
8.8.7 Refitting or replacement is in reverse order.
SYSTEME-TDEFECTDIAGNOSISFLOWCHART