Johnson & starley Hi-spec j40 User guide

1 AirFilter

2 Air circulating fan

3 Heat exchanger access cover

4 Data plate

5 TimeControl

6 Multifunctional Control

7 Fan Delay Control /Limit Switch

8 PilotBurner

9 Burner Assembly

10 Gas connection

11 Heat shield

12 Piezo igniter unit

13 Spillage monitoring Device (TTB)

This appliance has been tested and certified by B GTechnology for use with natural gas G20.

Note: If an ELJAN 6 circulator is fitted, the relevant Installation, Commissioning and Servicing instructions provided with that

appliance must also be observed.

1. BRIEFDESCRIPTION

HI-SPEC J40 WARM AIR HEATER

SYSTEM E-T and Conventional Control

INSTALLATION, COMMISSIONING& SERVICING INSTRUCTIONS

G.C. No 42 451 09 Publication No. ZZ 815/9.

October 2006

Fig. 1

1.1 HI-SPEC J40 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with SYSTEM E-T

or BASIC control.An ELJAN 6 circulator is available as an option.ASpillage Monitoring Device (TTB) is fitted

which senses the temperature in the draught diverter, and shuts down the appliance when this temperature rises due to the

presence of flue gases.

1.2 The Air heater output can be adjusted between 8.8kW (31.65MJ/h, 30,000Btu/h) and 11.2kW (42.2MJ/h, 40,000Btu/h) .

“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions). ELJAN 6 output is

3.32kW (11.5MJ/h, 11,340Btu/h).

THISAPPLIANCE CONFORMS TO BS EN 45014

Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. If you have a problem in

obtaining a spare part, please contact Johnson and Starley Spares Department at the address below.

JOHNSON&STARLEYLTD.

Telephone: (01604) 762881 RhosiliRoad,

Brackmills,

Fax: (01604) 767408 NorthamptonNN47LZ

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 ofElectrical Engineers (I.E.E.) Wiring Regulations

BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).

BS 5440 Pt. 1 (Flues for Gas Appliances)

BS 5440 Pt. 2 (Air Supply for Gas Appliances)

BS 5864 Installation of Gas Fired Ducted Air Heaters

British System Design Manual “Gas Fired Warm Air Heating”

Model and Local Authority Bye-laws

BS 5546 Installation of Domestic Hot Water Supplies.

IMPORTANT: STATUTE LAWDEFINES THATALLGAS APPLIANCES MUSTBE INSTALLED BYCOMPETENT

PERSONS, (i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY

(INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE

REGULATIONSMAYLEADTOPROSECUTION.

2. HEATERCOMPARTMENTAND CLEARANCES(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 consideration should 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 500mm (20ins) is required at the front of the heater. Space must also be allowed, in a

compartment installation, to permit the removal of the heater. The clearance between the appliance and the compartment

should be not less than 75mm (3 in). However, if clearances are less than 75mm, the internal surface of the

compartment must be lined with non-combustible material. The compartment must be of a fixed rigid structure.

2.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant section of

BS5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the

perforations not exceeding 13mm (1/2in). The secondary flue must be a tight fit where it passes through the partition and

must be suitably protected (see 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. Combustible floors must be insulated from the

heater.

2.6 In free-standing installations, (see instructions packed with free standing kit), only one or two walls will be in contact

with the air heater and therefore complying with the relevant section of BS 5864.

2.7 If theAir Heater is to be installed onto a combustible surface, a suitable base tray (BT40) is required. However, when a base

duct is used, this provides sufficient insulation, and no insulation is required.

2.8 Fir Slot Fix applications (see instructions packed with the Slot Fix Kit), it is important to ensure that the draught diverter

relief is maintained on both sides of the application.

3. VENTILATIONANDCOMBUSTIONAIR

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

62cm2 (9in2). The air vent should be either direct to outside air or to an adjacent room or internal space (other than a

toilet or bathroom) that itself has an equivalent air vent direct to outside.

Note: The above minimum area assumes that an ELJAN 6 circulator is fitted.

3.2 Combustion air may be introduced, via a 127mm (5in) nominal bore pipe, connected to a return air duct or plenum from

a ventilated area and fitted with a lockable damper. The damper should be adjusted to control combustion airflow to

0.0108m3/s (22.9cfm), (i.e. 0.95m/s[165ft/min] velocity in a 127mm[5in] bore pipe). Ifthisarrangement is used, anon-

closeable warm air register MUST be provided in the same area as the front of the air heater or heater compartment if a return

air grille is not located in that area.

3.3 When installed in a compartment, two permanent ventilation openings into the compartment are required, one at high

level and one at low level, both communicating either directly with outside air or with a ventilated room or space. The

minimum effective areas specified in Table 1 are related to the rated heat input of the Air Heater, and assuming that an

ELJAN 6 circulator is fitted.

3.4 If any room or area from which air is drawn for ventilation or combustion contains an extract fan, the permanent vents

must be sized to ensure that the operation of the appliance(s) at full rate is/are not adversely affected.A spillage test as

specified in sub-para 6.8 (Safety Checks) is carried out and any remedial work undertaken.

Fig.7b,BASICCONTROLFUNCTIONALDIAGRAM

Fig.6a,SYSTEME-TCIRCUITDIAGRAM

Fig.6b,BASICCONTROLCIRCUITDIAGRAM

Fig.8,PRINCIPALDIMENSIONS(mm)

10. SHORTLISTOFSPARES

HI-SPECJ40

KEY G.CNo MFR’SNo DESCRIPTION QTY

1 245502 1000-0516580 Fan Assembly 1

2 381627 1000-0701140 Multifunctional Control (S.I.T. Nova) 1

232903 BOS02061 O RingSeal 2

3 A432-0852000 Pilot Mounting Bracket 1

173096 1000-0704810 Pilot BurnerAssembly 1

381712 1000-0705140 Pilot Injector 1

S01496 Pilot Feed Pipe Kit 1

395676 1000-0701800 HookNut4mm 1

386775 1000-0701790 HookOlive 4mm 1

386775 BOS01970 Igniter Electrode 1

387819 BOS02394 Igniter Lead 1

381626 1000-0704830 Thermocouple 1

382775 1000-0701810 ShearOff 4mm 1

244898 BOS02406 Electrode Retaining Nut 1

4 378466 BOS02031 TimeControl 1

5 245526 A432-0760000 Burner and ControlsAssembly 1

245526 A4300/0751 Main BurnerArm 1

6 E00409 1000-0700270 MainInjector(Bray 23/1050) 1

7 395945 1000-0700570 PiezoUnit (High Energy) 1

8 245509 1000-0513820 Fuse T3.15A anti-surge 1

9 A432-0182000 FilterTray 1

10 364835 S00832 SolenoidValve 1

11 A4300/0300WE HeatExchanger 1

12 245542 1000-0515970 Capacitor15 uF 1

13 245500 1000-0516010 SpillageMonitor Device (TTB) upto (& inc) serialNo: 16001719 1

E83-211 1000-0521880 SpillageMonitorDevice(TTB)fromserial No: 16001720 1

A432-0161000 LowerCabinet Door 1

SystemE-TModelsonly

14 245513 ET004 Electronic PanelAssembly with daughter board 1

15 245514 1000-0515620 Thermista-stat 1

16 245516 1000-0516370 FanDelayControl/Limit Switch 1

17 E05328 1000-0515090 Mains Filter 1

A432-0157000 FanChamber Door 1

BasicModelsonly

18 245524 1000-0501000 ElectricalPanelAssembly 1

19 245521 1000-0516360 FanDelayControl/Limit Switch 1

20 245523 1000-0516540 Transformer Fan Speed 1

21 245525 1000-0515730 Transformer24 volt 1

22 245413 1000-0511760 Relay Module 1

245423 1000-0502240 Fuse T500mA anti-surge 1

A432-0156000 FanChamber Door 1

VENTILATED Low levelgrille 352cm2(54in2)

FROMINSIDE

BUILDING High level grille 176cm2(27in2)

VENTILATED Low level grille 176cm2(27in2)

FROMOUTSIDE

BUILDING High level grille 88cm2(13in2)

Table 1

Minimum EffectiveAreas

4. DUCTSYSTEM

(See British Design Manual - Gas fired WarmAir Heating)

4.1 RETURNAIR

4.1.1 All return air shall be POSITIVELYducted from outside the compartment to the top of the unit via a return air

duct, or if appropriate, using a J & S Side Return Air Kit, and mechanically secured. It is recommended that the

return air duct be not 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 path. It is extremely important that the correct size of return air grilles and ducting is used.

For heaters on maximum output the return air duct size should not be less than the equivalent of 300mm x 250mm

(12" x 10"). If flexible duct is used the duct diameter should not be less than 350mm (14") dia. The return air

grille should have a free area of not less than 1120cm2(174in2).

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 WARMDELIVEREDAIR

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

duct runs are taken below floor level these should be similarly insulated, and in addition wrapped with a sound

vapour proof barrier, and 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 its specific heating requirements and building layout. The type of duct system, (i.e. radial/

extended plenum/stepped) should be installed using the least number of fittings to minimise airflow resistance.

The base duct, which equalises the air pressure to supply ducts, shall be constructed to support the weight of the

heater, which shall be secured to the plenum with screws on at least two sides, and sealed using self-adhesive

foam strip, ducting tape or sealing compound. All ducting and blanking plates shall be mechanically secured and

sealed.

5. INSTALLATIONREQUIREMENTS

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

5.1 FLUES(see British Standards BS5440 Pt. 1 Flues)

5.1.1 All joints shall be soundly sealed.

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

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

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

to BS 567 or twin wall metal flue to BS 715 of nominal 100mm (4in) diameter.

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

5.1.6 The flue shall be in accordance with the Building Regulations and British Gas Materials and Installations

specification 3rd edition) with regard to clearance and shielding from combustible materials.

326

Fig.7a,SYSTEME-TFUNCTIONALDIAGRAM

SIDE VIEW

PLAN VIEW

FRONT VIEW

BASE VIEW

646

400

128

120 dia.

127

480 42

1524

807

299

273 54

196

324 12

273

348

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

5.1.8 The flue should run as vertically as possible. Horizontal runs should be avoided if at all possible and any

directional change should be as gentle as possible. If there is any doubt about the flue configuration, the

equivalent flue height should be determined (see 5.1.10).

5.1.9 If the appliance to be fitted is a replacement, the old appliance should be checked for signs of spillage prior to

commencement of the installation and appropriate action taken. (i.e. check flue system and renew as necessary).

5.1.10 It is recommended that at least 600mm of vertical flue should be provided from the top of the draught diverter

(for new installations this shall be incorporated into the flue design). However, when carrying out replacement

installations, an existing flue system may be encountered, where the vertical flue above the appliance to the first

bend is less than 600mm. In the first instance, the installer must judge whether this distance can be achieved

practicably by some means. Where this is not practicable, the existing flue system may be used, providing there is

no evidence of spillage from the old appliance (see 5.1.9 above). Every effort must be made, however, to ensure

that the existing flue complies in every other way to BS 5440 Part 1, including the visual inspection, flue flow and

spillage test described in 4.3.2 of the above standard. Flue configurations may be assessed in terms of equivalent

vertical height - details are given below. For air heaters, the minimum equivalent vertical height is 1 metre. The

installer must make a judgement based on his knowledge and experience and the examination and testing

described above as to whether an existing flue system can be used.

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

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

necessary.

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

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

clearance of combustion products.

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

height of the straight vertical circular flue pipe of specific size which will produce the same flow rate as

the flue under consideration. The equivalent height is calculated from the formula:

(Ki+ Ko )e

He= Hax

(Ki+ Ko)a- KeHa+ Sum K

where:

Heis the height of the equivalent flue;

Ha is the vertical height of the actual or proposed flue;

Kiis the inlet resistance of the flue;

Ko is the outlet resistance from the flue;

subscript e refers to the equivalent flue diameter;

subscript a refers to the actual or proposed flue diameter;

Keis the resistance per unit length of the equivalent flue;

Sum K is the resistance (other than the inlet and outlet resistance) of the actual or proposed flue.

Note: K and Sum K are obtained from Table 2. Koand Kiare obtained from Table 3.

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

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

exceeds 1m.

425

Component InternalSize Resistance Component Internal Size Resistance

(mm) Factor (mm) Factor

FlueBlocks 197x67 0.85 per meter 45OBend 100mmpipe 0.61per

231 x 65 0.65 run 125 mm pipe 0.25 fitting

317 x 63 0.35 150 mm pipe 0.12

140 x 102 0.60 197 x 67 0.30

200 x 75 0.60 231 x 65 0.22

183 x 90 0.45 317 x 63 0.13

Pipe 100 0.78 Raking block Any 0.30 per block

125 0.25

150 0.12 Adaptor block Any 0.50

Chimney 213 x 213 0.02 Terminal 100 mm ridge 2.5

125 mm ridge 1.0

90OBend 100 mm pipe 1.22 per 150 mm ridge 0.48

125 mm pipe 0.50 fitting 100 mm GCI 0.6

150 mm pipe 0.24 125 mm GCI 0.25

150 mm GCI 0.12

Table 2

Resistance factors for use in calculating equivalent heights

Appliance Inlet Flue Outlet

Resistance (Ki) Resistance (Ko)

100 mm dia spigot 2.5 100 mm flue 2.5

125 mm dia spigot 1.0 125 mm flue 1.0

150 mm dia spigot 0.48 150 mm flue 0.48

Table 3

Inlet and outlet resistance

d. WorkedCalculationExample:

A warm air unit with a 100 mm diameter flue spigot, fitted with a prefabricated flue system leading to a

ridge tile in the loft (refer Fig. 2):

Fromtable3:

Kia Inlet resistance of actual flue =2.5

Koa Outlet resistance of actual flue = 2.5

Kie Inlet resistance of equivalent flue = 2.5

Koe Outlet resistance of the actual flue = 2.5

Fromtable2:

Other resistances of actual flue:

Terminal =2.5

Pipe bend ( 2 x 0.61) = 1.22

Pipe (4 x 1m @ 0.78) = 3.12

(5x 0.3m @ 0.78) =1.17

SumK = 8.01

Equivalent height :

Fromtheformula

(2.5 + 2.5)

He= 6.2 x

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

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

524

SYSTEME-TElectronic module

Fig.2

Workedexampleofequivalentflueheight

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

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

necessary.

5.1.12 Special consideration must be given to external flues with a view to prevention of condensation and weathering

problems.

5.1.13 An approved terminal should always be used; a ridge terminal or “GC1” terminal is specifically recommended.

The latter should be positioned in a free air space where it is not shielded by any structure. A minimum of 1m

(3ft.) from any vertical or inclined roof structure must be allowed for.

5.1.14 Where flue blocks are used, builders should ensure that no obstruction is created during erection. The installer

should ensure that the connection flue does not project beyond the internal wall of the flue blocks and that there

is provision for examination and servicing.

1.6m

4.6m

Ha=6.2m

RidgeTerminal

2x300mmlengths

4x1000mm lengths

45Obend

2x300mmlengths

300mmlength

Flue spigot

100mmdiafluepipe

SYSTEM E-T DEFECTDIAGNOSIS FLOW CHART

5.1.15 Important: Before installing the appliance, carry out a visual check of the flue system as directed in the relevant

section of BS5440 Pt.1, then check the flue performance as follows:-

a. Close all doors and windows in the room in which the appliance is to be installed.

b. Introduce some heat into the flue, using a blow torch or other means.

c. Carry out a flow visualisation check with a smoke pellet at the intended position for the appliance. Ensure

that there is discharge of smoke from the correct terminal only, and no spillage into the room.

Smoke coming out of other than the correct terminal only, or a down draught or ‘no flow’condition,

indicates that the flue has failed the test, and the appliance shall not be connected until the defect has been

found and rectified, and the test satisfactorily completed.

5.2 ELECTRICAL

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

i. BASIC Models: Fan delay control closes at 54OC± 4.5OC; opens at 40OC±3OC.

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

c. SYSTEM E-T MODELS:An electronic controller (Thermista-stat) is supplied which acts as a room

thermostat.

d. BASIC MODELS:A24Vroomthermostat (not supplied), thatcomplieswith BS 800, BS 3955and BS4201 is

essential to ensure close control of comfort conditions. An anticipator is located within the thermostat and is

graded in amps. The anticipator should be checked and adjusted to 0.2A.

5.2.2 Thermista-stat/Room Thermostat and its location.

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

(5ft)from the floor.

b. Avoid the following locations:-

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

fire, wall light fittings or TV set.

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 the Thermista-stat/Room thermostat wires to control panel terminals ‘7’ and ‘8’ (see Fig. 6a/b

or 7a/b).

5.3 GAS (SeeBS5864 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).

ZZ815/7

722

ZZ815/7

Fig. 3

PILOTBURNERASSEMBLY

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 SYSTEMBALANCING:

6.2.1 Set theAir Heater electrical supply ON.

6.2.2 Setthe SUMMERAIRFLOW switch to ‘I’.

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 (300 ft/min),

except for very small rooms, (i.e., bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.

6.2.4 Set the SUMMER AIRFLOW switch to ‘0’.

6.3 IGNITIONOFPILOTAND MAIN BURNERS:

WARNING: If the pilot light is extinguished either intentionally or unintentionally, no attempt should be made to

relight the gas for a minimum of 3 minutes. Ensure Electrical supply, time control and Selector switches are set to

‘OFF’.

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

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

Fig.4).

6.3.3 Turn the heater Gas supply ON, test for gas soundness and purge the whole gas pipe as described in BS 6891.

6.3.4 Referring to Fig .4, 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 Multifunctional Control OPERATING CONTROLand let it spring out; ensure that

the Pilot Burner remains alight. If the Pilot Burner extinguishes, rotate the OPERATING CONTROLclockwise to

the ‘z’position and ensure that the OPERATING CONTROLis fully reset. Wait three minutes and repeat steps

6.3.4 and 6.3.5, holding the OPERATING CONTROLdepressed for a longer period, until the Pilot burner remains

alight.

6.3.6 With the Pilot Burner lit, depress the OPERATING CONTROLand turn it to the position indicated by the flame

symbol.

6.3.7 Ensure that the pilot flame envelops the thermocouple tip (refer Fig. 3).

6.3.8 Set the Heater Electricity supplyON.

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

6.3.10 Set the Selector switch to ‘TIMED’.

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

6.3.12 Ensure that the Main Burner has now ignited.

6.3.13 Test for gas leakage at the supply, Multifunctional Control, Pilot and Main Burners using proprietary detection

fluid, sealing any leaks found.

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

MAIN BURNER NOT OPERATING

PILOT

LIT ?

IS TIME

CONTROL &

THERMISTA-

STAT

CORRECTLY

SET ?

GAS

ON?

LIGHT

PILOT

SWITCHON

230 V N

SETCONTROLS

CORRECTLY

DISCONNECTTHERMISTA-STATAT

TERMINALS‘7’&‘8’,LINKTERMI-

NALS‘7’&‘TEST’

IS 230V

SUPPLY

ON ?

YRECONNECTTHERMISTA-STATAT

TERMINALS‘7’&‘8’,

DISCONNECTONCONNECTIONAT

THERMISTA-STAT

DOES

FAN

RUN ?

DOES

FAN

RUN ?

YREPLACE

THERMISTA-STAT

EXTERNALWIRINGTO

THERMISTA-STAT

FAULTY

CHECKFOR230VAT

MULTIFUNCTIONAL

CONTROL

REPLACE

MULTIFUNCTIONAL

CONTROL

CHECKWIRINGTO

MULTIFUNCTIONAL

CONTROL

CHECKFOR230VAT

TERMINAL15

CHECKFOR230VAT

TERMINAL13

LINKTERMINALS‘13’

&‘14’, IF BURNER

LIGHTSREPLACE

FAN/LIMITCONTROL N

CHECKFOR230VAT

TERMINAL29

BRIDGEOUTTTB&

CHECKFOR230VAT

TERMINAL29

ALLOWTTB TO COOL

& CHECK FOR

CONTINUITY. IFOK

CARRYOUTSPILLAGE

TEST.

IFNOT, REPLACETTB

RECONNECTTTB

CHECKFOR230VAT

TERMINAL27

REPLACE

ELECTRONICMOD-

ULE

CHECKWIRING

CONNECTIONS Y

CHECKWIRING

CONNECTIONS Y

CHECKFOR230VAT

CENTRETERMINALOF

SWITCH‘S5’

CHECKFOR230VATTIME

CONTROL

TERMINAL‘C5’

REPLACEAIRHEATER

SWITCH Y

REPLACETIME

CONTROLMECHANISM

TURNGAS

Thermocouple

Electrode

PilotBurner

6.4 MAINBURNER PRESSURETEST:

NOTE:AIR HEATER BURNERSARE FACTORYSETTOPROVIDEANOMINALHIGHPRESSURE OUTPUTAS

DETAILED IN SUB PARA1.2

6.4.1 Referring to Table 4 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.

1. Operating control

2. Burner PressureAdjuster

3. Outlet Pressure test point

Fig. 4

MULTIFUNCTIONALCONTROL

6.5 EXTINGUISHINGOFPILOTAND MAINBURNERS:

6.5.1 On the Multifunctional Control, rotate the OPERATING CONTROLclockwise to the ‘z’ 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 the temperature rise across 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 heaters: The fan speed is adjusted by selecting the fan speed at control panel (decrease voltage

selection to decrease fan speed).

Note:Tapping 1 = 210V, tapping 2 = 200V, tapping 3 = 190V, tapping 4 = 180V, tapping 5 = 170V.

Sit

EV2

PI-

LOT

FAN RUNS BUT MAIN BURNER NOT OPERATING

‘SUMMER

AIRFLOW’

SWITCH

SETTO

‘0’

NSET‘SUMMER

AIRFLOWSWITCHTO

‘0’

THERMISTA

-STAT

CONNECTED

THERMISTA

-STATSETTO

‘SUMMER

AIRFLOW

NCONNECT

THERMISTA-STAT

SETTHERMISTA-STATTO

REQUIRED

TEMPERATURESETTING

NFAULT

CLEARED

DISCONNECTTHERMISTA-STATAT

TERMINALS‘7’&‘8’,LINKTERMI-

NALS‘7’&‘TEST’

DONOTLINK‘7’&’8’

DOES

FANSTILL

RUN?

DOES

FANSTILL

RUNWITH

BURNER

LIT?

CHECKTHERMISTA-STATWIRING.IF

OK,REPLACETHERMISTA-STAT.IF

NOT,RECONNECTTERMINALS‘7’&

‘8’,ANDSETTHERMISTA-STATTO

DEMANDHEAT

HAS

BURNER

LIT?

REPLACEELECTRONIC

MODULE.RECONNECT

THERMISTA-STAT

FANOPERATESAFTERBURNERHAS

RAISEDTHEINTERNAL

TEMPERATURETOCAUSETHEFAN

DELAYCONTROLTOOPERATE

HAS

FANSTOPPED

ANDBURNER

LIT?

6.7 AUTOMATIC CONTROLSCHECK:

6.7.1 Ignite the Pilot and Main Burners and allow to operate for 15 minutes to ensure stability.

6.7.2 SettheTIME CONTROL 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.

BASICmodels:

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 Check for gas soundness within the appliance.

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

closed and any extractor fans in operation.

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

doors open.

If the draught diverter is accessible:

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

match or puffer.

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

draught diverter.

If the Draught Diverter is not accessible:

a. Introduce smoke, by means of part of a smoke pellet on a non-combustible support, into the heat

exchanger.

b. Extinguish the Main and Pilot burners.

c. Ensure that there is no spillage evident by visually observing the draught diverter location on the air

heater.

d. If spillage is evident, further investigation and rectification is required before re-testing the appliance.

e. Repeatspillage testsbutwiththe fan running,orSummerAirflow switch settoON.

WARNING:The applianceshallnot be leftconnectedtothe gas supplyunlessit has successfullypassed

theabovespillagetest.

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

60 secs (indicated by loud click from Multifunctional control).

6.8.4 Turn gas supply ON at service cock.

6.8.5 Switch the appliance electrical supply OFF.

6.8.6 Disconnect theAir Circulation Fan at the flying lead socket.

6.8.7 Switch the appliance electrical supply ON.

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

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

6.8.10 Switch the appliance electrical supply OFF.

6.8.11 Reconnect theAir Circulation Fan.

6.8.12 Switch the appliance electrical supply ON.

6.8.13 Ensure that the Main Burner re-ignites when the appliance temperature reduces, (note: with theAir Circulation Fan

disconnected, there may be some delay before the Main Burner re-ignites).

10 19

FAN OPERATES, BUT BURNER CYCLES BEFORE REQUIREDTEMPERATURE IS REACHED

DOES

THEBURNER

CONTINUETO

CYCLE?

REPLACE

THERMISTA-STAT N

CHECKRETURNAIRPATH

FORRESTRICTIONS

CHECKTEMPERATURERISE.IF

LESSTHAN60OC,LINKTERMI-

NALS‘13’& ‘14’

DOES

THEBURNER

CONTINUETO

CYCLE?

DOES

THEBURNER

CONTINUETO

CYCLE?

REPLACE

ELECTRONIC

MODULE

DISCONNECTTHERMISTA-STATAT

TERMINALS‘7’&‘8’,LINKTERMI-

NALS‘7’&‘TEST’

DONOTLINK‘7’&’8’

REPLACEFANDELAY

CONTROL/LIMIT

SWITCH

LOWRATE MEDIUMRATE HIGHRATE

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

INPUT 11.75 42.35 40,100 13.5 48.58 46,050 15.18 54.65 51,800

OUTPUT 8.79 31.65 30,000 10.26 36.92 35,000 11.72 42.2 40,000

Gas rate cv 1.08m3/h(38.4ft3/h) 1.24m3/h(44.1ft3/h) 1.40m3/h(49.8ft3/h)

1037Btu/ft3

Burner setting 9.2mbar(3.7 in wg) 12.2mbar(4.9inwg) 16.0mbar(6.4 in wg)

pressure (hot)

Main Injector BRAY CAT 23/1050

250 300 350 400 450 ft3/min

0.12 0.14 0.17 0.19 0.21 m3/sec

AIRVOLUME

mbar in.wg.

0.625 0.25

0.50 0.20

0.375 0.15

0.25 0.10

0.125 0.05

RESISTANCEEXTERNALTOHEATER

170V

180V

190V

200V

210V

Table 4

Main Burner Pressure Settings

Table 5

FanPerformance Curve

7. INSTRUCTIONS FOR USERS

7.1 If the building is unoccupied, ensure that the Instructions for User are left taped to the air heater for the User, and

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 the 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 weekly for new houses).

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

buildingMUST 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.

DISCONNECT

TERMINALS‘17’&’18’

REPLACEFANDELAY

CONTROL/LIMIT

SWITCH

REPLACE

ELECTRONICMOD-

ULE

FAN CONTINUES TO RUN, OR CYCLESAFTER HEATING IS TURNED OFF

DOES

FAN

RUN ?

MAIN BURNER NOT CYCLING

(ROOMTEMPERATURETOOHIGH)

REPLACE

MULTIFUNCTIONAL

CONTROL

YREPLACE

ELECTRONICS

MODULE

DISCONNECT

MULTIFUNCTIONAL

CONTROLAT

TERMINAL15

DOES

BURNER

OUT?

DISCONNECT

THERMISTA-STAT

REPLACE

THERMISTA-STAT

DOES

BURNER

GO OUT?

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 that the gas and electricity supplies are isolated before commencing any maintenance or

replacement of components.After completion of any maintenance, always test forgas soundness and carry out a complete

functional test of the appliance in accordance with the Commissioning Instructions at Sect 6.1 to 6.8 inclusive.

8.1 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 theAir Circulation fan as

detailed in para 8.8.

8.1.5 Remove the Burner and ControlsAssembly 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.

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 of Air Circulation fan does not affect the main burner flame profile.

8.2 BURNERANDCONTROLASSEMBLYREMOVAL:

8.2.1 Ensure that the Gas and Electrical supplies are switched OFF

8.2.2 Remove the appliance lower door.

8.2.3 Disconnect the igniter at the Piezo unit.

8.2.4 Disconnect the Multifunctional Control electrical connections.

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

8.2.6 Release the burner assembly fixing screw at the left hand side of the burner bar and withdraw the Burner and

Controls Assembly

8.2.7 Refit the Burner and Controls Assembly in reverse order.

8.3 BURNERANDCONTROLSASSEMBLYCLEANING:

8.3.1 Remove the Burner and ControlsAssembly as detailed in 8.2.

8.3.2 Remove the 2 screws securing the gas feed pipe to the burner bar, and remove the burner bar.

8.3.3 Clean the burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR

DAMAGEBURNERHOLES.

8.3.4 Reassemble in reverse order.

8.4 MAININJECTORREMOVAL, CLEANINGANDREPLACEMENT:

8.4.1 Remove the Burner and ControlsAssembly as detailed in 8.2.

8.4.2 Unscrew the main injector from the housing.

8.4.3 Cleanasnecessary.DO NOT ENLARGE, DISTORTOR DAMAGE THE MAIN INJECTOR HOLE.

8.4.4 If the injector is to be replaced, ensure that it is correctly marked, referring to the data badge for details.

8.4.5 Refitment or replacement is in reverse order.

8.5 PILOTBURNER,THERMOCOUPLEAND ELECTRODE, REMOVALANDREPLACEMENT:

8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2

8.5.2 Disconnect the Igniter lead from the Electrode.

12 17

module cover, as shown in Fig. 4 below. If the LED is flashing, this means that :

9.3.1 The fan is not connected, or

9.3.2 The capacitor is not connected, or

9.3.3 There is a short circuit in the fan supply.

Fig. 5

MAIN BURNER ON, BUT FAN NOT

RUNNING

iii. Fan speed setting too high. Adjust fan speed.

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

period or operates

intermittently after

main burner shuts down.

9.3 The SYSTEM E-T module is fitted with a diagnostic light emitting diode (LED) which is visible through a hole in the

DiagnosticLED

CHECKFOR

VOLTAGEAT

TERMINALS

30 & 31

BRIDGEOUT

FANDELAYAT

TERMINALS21&22

REPLACEFANDELAY

CONTROL/LIMIT

SWITCH

REPLACE

ELECTRONICS

MODULE

DOES

FAN

START?

REPLACE

CAPACITOR

DOES

FAN

START?

REPLACE

FAN

8.5.3 Release the Pilot Feed Pipe from the pilot injector.

8.5.4 Release the retaining nut and withdraw theThermocouple from the Pilot BurnerAssembly, taking care to avoid

causing damage to the capillary.

8.5.5 Release the Electrode securing nut from the Pilot BurnerAssembly and withdraw the Electrode.

8.5.6 Release the two screws securing Pilot BurnerAssembly to the main burner, and remove Pilot BurnerAssembly.

8.5.7 Refitting or replacement is in reverse order.

NOTE:When refitting orreplacingThermocouple, tighten only toFINGER TIGHT+1 FLAT.

8.6 MULTIFUNCTIONALCONTROLREMOVAL:

8.6.1 Remove the Burner and ControlsAssembly 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 Feed Pipe from the Multifunctional Control.

8.6.4 Disconnect 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 seal is 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, REMOVALANDCLEANING:

8.8.1 Ensure that the electrical supply is isolated.

8.8.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

8.8.3 Disconnect the fan flying leads from the FanAssembly.

8.8.4 Release the FanAssembly securing screw and withdraw the Fan Assembly from the Heater cabinet, avoiding

damage to the fan blades.

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

8.8.6 Refitting or replacement is in reverse order.

8.9 ELECTRICALASSEMBLYREMOVAL:

8.9.1 Ensure that the electrical supply is isolated.

8.9.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

SYSTEME-Tmodels:

8.9.3 Disconnect the following

a. Air circulation fan flying leads from the capacitor,

b. 230V mains ‘L’, ‘N’ and ‘E’from connection block terminals ‘1’ and ‘2’, and Earth stud respectively,

c. Thermista-stat connections from connection block terminals ‘7’ and ‘8’,

d. Limit Switch from connection block terminals ‘13’ and ‘14’,

e. Fan Delay Control from connection block terminals ‘18’ and ‘17’,

f. Multifunctional Control from connection block terminals ‘16 (N) and ‘15’ (L),

g. Water heater from connection block terminals ‘10’ (L) and ‘9’ (N),

h. Water Pump from connection block terminals ‘12’ (L) and ‘11’ (N),

i. Cleanflow from connection block terminals ‘19’ (24V) and ‘20’ (0V),

j. Earth lead from the fan chamber floor,

BASICmodels:

8.9.4 Disconnect the following:

a. Air circulation fan flying leads from the Fan assembly,

b. 230V mains ‘L’, ‘N’ and ‘E’from connection block terminals ‘1’ and ‘2’, and Earth stud respectively,

c. Room thermostat connections from connection block terminals ‘7’ and ‘8’,

d. Limit Switch from connection block terminals ‘13’ and ‘14’,

e. Fan Delay Control from connection block terminals ‘18’ and ‘17’,

f. Multifunctional Control from connection block terminals ‘16 (N) and ‘15’ (L),

g. Water heater from connection block terminals ‘10’ (L) and ‘9’ (N),

closed.

v. Spillage of flue gases. Carry out spillage test and rectify.

vi. Spillagemonitor device (TTB) Replace Spillage device (TTB)

faulty.

SYSTEM E-T models:

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

of fan or main burner. Control system (refer to pages 17-21) recommended procedure.

BASICmodels:

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

burner not igniting. connected to heater.

ii. Controls not demanding heat Check that time control and room thermostat

are operating correctly.

iii. T3.15Afusefailed. Replace. If failure occurs again, check

wiring for short circuits.

iv. Loose connection to room thermo- Check connections.

stat, limit switch, gas control lead,

time control, or transformer.

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

missing, replace transformer.

vi. Faulty relay module Check 230V at white wire from switch S5

vii. Multifunctional Control faulty. Replace Multifunctional Control.

viii.Limitswitchfaulty. Short circuit control and replace if necessary.

ix. Room thermostat or external Fit temporary loop in heater thermostat

wiring faulty. socket. If heater ignites, external circuit

or room thermostat is faulty.

x. Spillage device faulty Check Spillage device and wiring for open

circuit.

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

but fan fails to run at fan control.

after approx. 3 min.

ii. Fan Delay Control faulty. Replace.

iii. Faulty fan assembly. Replace, taking care not to damage

impeller.

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

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

ting with intermittent setting too low. setting.

fan operation.

ii. Fan Delay Control faulty Replace.

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

ii. Noisy fan motor. Replace fan assembly.

h. Water Pump from connection block terminals ‘12’(L) and ‘11’(N),

i. Cleanflow from connection block terminals ‘19’ (24V) and ‘20’ (0V),

j. Earth lead from the fan chamber floor,

Bothmodel types:

8.9.5 Disconnect the 2 x Spillage switch connections from terminal block terminal ‘15’, and the relay module

‘COMM’terminal.

8.9.6 Release the 2 x screws from the hinged access door and withdraw the ElectricalAssembly, releasing wiring from

cable clamps and grommets as required..

8.9.7 Refitting or replacement is in reverse order.

8.10 ELECTRONICMODULEREMOVAL(SYSTEME-Tmodelsonly)

8.10.1 Ensure that the electrical supply is isolated.

8.10.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

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

8.10.4 Release the 2 x screws and nuts securing the Electronic Module to the Electrical Assembly and remove the

module.

8.10.5 Refitting or replacement is in reverse order.

8.11 TRANSFORMER REMOVAL(BASIC models only):

8.11.1 Ensure that the electrical supply is isolated.

8.11.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

8.11.3 Disconnect the conductors from the Transformer.

8.11.4 Release 2 x screws and nuts securing Transformer to ElectricalAssembly, and remove theTransformer.

8.11.5 Refitting or replacement is in reverse order.

8.12 TIMECONTROLand SWITCH REMOVAL:

8.12.1 Ensure that the electrical supply is isolated.

8.12.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

TimeControl removal:

8.12.3 Disconnect conductors ‘C1’, ‘C2’, ‘C3’ and ‘C5’ from the Time Control.

8.12.4 Release the 2 x fixing screws, and withdraw the Time Control.

8.12.5 Refitting or replacement is in reverse order.

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

8.12.7 Set the Time Control to the correct time.

Switchremoval:

8.12.8 Disconnect the conductors from the switch terminals.

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

8.12.10 Refitting or replacement is in reverse order.

WARNING: The fascia panel is held in place by push fit retainers which must be removed with caution to

avoid causing damage to the support pins. Removal of the fascia is not advised unless it is intended to be

replaced.

8.13 FAN DELAYCONTROL/LIMIT SWITCHREMOVAL:

8.13.1 Ensure that the electrical supply is isolated.

8.13.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

8.13.3 Disconnect the following at the Electrical panel:

a. Limit Switch from connection block terminals ‘13’ and ‘14’,

b. Fan Delay Control from connection block terminals ‘18’ and ‘17’,

c. Earth connection from common earth stud.

8.13.4 Release 2 x 4mm screws securing the Limit switch mounting plate, and withdraw the control from the appliance by

drawing the conductors through the grommet in the fan chamber floor.

8.13.6 Refitting or replacement is in reverse order.

8.14 SPILLAGEMONITORINGDEVICE (TTB) REMOVAL:

8.14.1 Ensure that the electrical supply is isolated.

8.14.2 Remove the appliance louvre door, release the securing screw and hinge down the fan chamber door.

8.14.3 Disconnect the TTB from its conductors.

8.14.4 Release 2 x screws securing the TTB Bracket to the fan chamber floor, and withdraw the TTB Bracket.

8.14.5 Refitting or replacement is in reverse order.

8.15 HEATEXCHANGERACCESS:

8.15.1 Ensure that the electrical supply is isolated.

8.15.2 Remove the appliance louvre door.

8.15.3 Remove the 4 screws and withdraw the Heat Exchanger access plate.

8.15.4 Remove the 4 screws and withdraw the Heat Exchanger Cover plate.

8.15.5 Removethe Heat Exchanger ‘U’baffle.

8.15.6 Refitting is in reverse order.

9. DEFECTDIAGNOSIS

9.1 IMPORTANT: If an electrical defect occurs after installation of the appliance; preliminary earth continuity, polarity,

and resistance to earth checks should be carried out with a multimeter. On completion of any

maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then checks

of continuity, polarity, and resistance to earth must be repeated.

9.2 WARNINGS:

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

naked lights are extinguished.

9.2.2 SYSTEM E-T models:

a. When carrying out any electrical testing, a test meter MUST be used, since low resistance test devices can

cause damage to the Electronics module.

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

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

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

airflow sensor or Thermista-stat). It is not practical to rectify defects on these assemblies, except at the

manufacturer, and any attempt to do so may render the guarantee or factory replacement arrangement

invalid.

SYMPTOM POSSIBLE CAUSE REMEDY

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

point on Multifunctional Control.

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

with BS 6891.

iii Pilot orifice restricted. Clear pilot orifice or replace pilot injector.

iv. Piezo system faulty. Check igniter, lead, and electrode.

v. Excessive gas supply pressure. Check that mains gas pressure is 20mbar,

and reduce if necessary.

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

out on releasing START couple and Multifunctional

button during initial Control not secure.

light-up, or after

normal operation. ii. Faulty Multifunctional Replace Multifunctional Control.

Control.

iii. Faulty thermocouple. Replace Thermocouple.

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

ting intermittently setting high. setting.

with fan running. ii. Temperature rise excessive. Adjust fan speed or gas rate accordingly.

iii. Air filter or return air path Check filter is clean and air path is clear.

restricted.

iv. Excessive number of outlets Open additional outlets.

h. Water Pump from connection block terminals ‘12’(L) and ‘11’(N),

i. Cleanflow from connection block terminals ‘19’ (24V) and ‘20’ (0V),

j. Earth lead from the fan chamber floor,

Bothmodel types:

8.9.5 Disconnect the 2 x Spillage switch connections from terminal block terminal ‘15’, and the relay module

‘COMM’terminal.

8.9.6 Release the 2 x screws from the hinged access door and withdraw the ElectricalAssembly, releasing wiring from

cable clamps and grommets as required..

8.9.7 Refitting or replacement is in reverse order.

8.10 ELECTRONICMODULEREMOVAL(SYSTEME-Tmodelsonly)

8.10.1 Ensure that the electrical supply is isolated.

8.10.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

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

8.10.4 Release the 2 x screws and nuts securing the Electronic Module to the Electrical Assembly and remove the

module.

8.10.5 Refitting or replacement is in reverse order.

8.11 TRANSFORMER REMOVAL(BASIC models only):

8.11.1 Ensure that the electrical supply is isolated.

8.11.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

8.11.3 Disconnect the conductors from the Transformer.

8.11.4 Release 2 x screws and nuts securing Transformer to ElectricalAssembly, and remove theTransformer.

8.11.5 Refitting or replacement is in reverse order.

8.12 TIMECONTROLand SWITCH REMOVAL:

8.12.1 Ensure that the electrical supply is isolated.

8.12.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

TimeControl removal:

8.12.3 Disconnect conductors ‘C1’, ‘C2’, ‘C3’ and ‘C5’ from the Time Control.

8.12.4 Release the 2 x fixing screws, and withdraw the Time Control.

8.12.5 Refitting or replacement is in reverse order.

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

8.12.7 Set the Time Control to the correct time.

Switchremoval:

8.12.8 Disconnect the conductors from the switch terminals.

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

8.12.10 Refitting or replacement is in reverse order.

WARNING: The fascia panel is held in place by push fit retainers which must be removed with caution to

avoid causing damage to the support pins. Removal of the fascia is not advised unless it is intended to be

replaced.

8.13 FAN DELAYCONTROL/LIMIT SWITCHREMOVAL:

8.13.1 Ensure that the electrical supply is isolated.

8.13.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door.

8.13.3 Disconnect the following at the Electrical panel:

a. Limit Switch from connection block terminals ‘13’ and ‘14’,

b. Fan Delay Control from connection block terminals ‘18’ and ‘17’,

c. Earth connection from common earth stud.

8.13.4 Release 2 x 4mm screws securing the Limit switch mounting plate, and withdraw the control from the appliance by

drawing the conductors through the grommet in the fan chamber floor.

8.13.6 Refitting or replacement is in reverse order.

8.14 SPILLAGEMONITORINGDEVICE (TTB) REMOVAL:

8.14.1 Ensure that the electrical supply is isolated.

8.14.2 Remove the appliance louvre door, release the securing screw and hinge down the fan chamber door.

8.14.3 Disconnect the TTB from its conductors.

8.14.4 Release 2 x screws securing the TTB Bracket to the fan chamber floor, and withdraw the TTB Bracket.

8.14.5 Refitting or replacement is in reverse order.

8.15 HEATEXCHANGERACCESS:

8.15.1 Ensure that the electrical supply is isolated.

8.15.2 Remove the appliance louvre door.

8.15.3 Remove the 4 screws and withdraw the Heat Exchanger access plate.

8.15.4 Remove the 4 screws and withdraw the Heat Exchanger Cover plate.

8.15.5 Removethe Heat Exchanger ‘U’baffle.

8.15.6 Refitting is in reverse order.

9. DEFECTDIAGNOSIS

9.1 IMPORTANT: If an electrical defect occurs after installation of the appliance; preliminary earth continuity, polarity,

and resistance to earth checks should be carried out with a multimeter. On completion of any

maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then checks

of continuity, polarity, and resistance to earth must be repeated.

9.2 WARNINGS:

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

naked lights are extinguished.

9.2.2 SYSTEM E-T models:

a. When carrying out any electrical testing, a test meter MUST be used, since low resistance test devices can

cause damage to the Electronics module.

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

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

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

airflow sensor or Thermista-stat). It is not practical to rectify defects on these assemblies, except at the

manufacturer, and any attempt to do so may render the guarantee or factory replacement arrangement

invalid.

SYMPTOM POSSIBLE CAUSE REMEDY

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

point on Multifunctional Control.

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

with BS 6891.

iii Pilot orifice restricted. Clear pilot orifice or replace pilot injector.

iv. Piezo system faulty. Check igniter, lead, and electrode.

v. Excessive gas supply pressure. Check that mains gas pressure is 20mbar,

and reduce if necessary.

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

out on releasing START couple and Multifunctional

button during initial Control not secure.

light-up, or after

normal operation. ii. Faulty Multifunctional Replace Multifunctional Control.

Control.

iii. Faulty thermocouple. Replace Thermocouple.

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

ting intermittently setting high. setting.

with fan running. ii. Temperature rise excessive. Adjust fan speed or gas rate accordingly.

iii. Air filter or return air path Check filter is clean and air path is clear.

restricted.

iv. Excessive number of outlets Open additional outlets.