Johnson & starley Janstar mk 2 User guide

Summer Airflow

Air Heating

BURNER

JANSTAR Mk 2

WARMAIR HEATER

INSTALLATION,COMMISSIONING&SERVICINGINSTRUCTIONS

G.C. No 42 *** **

Publication No. ZZ 1019/1E

September 1999

Fig. 1

JANSTAR Mk2 Principal Components

1.1 The Johnson & Starley JANSTAR Mk 2 is a wall mounted, room sealed, fan assisted, down flow warm air heater. It is

designed for use with a concentric air inlet/flue, which enables combustion air to be admitted to the burner, whilst

combustion products are discharged to the outside, via a concentric terminal.

1.2 The air heater output is 8.0 kW (27,300Btu/h) for horizontal flued installations, and 8.5 kW (96000Btu/h) for vertical

flued installations.

1.3 The appliance is supplied assembled for left hand return air entry. For conversion to right hand return entry, refer to

Section 4. If return air is via the top of the fan chamber, a side blanking plate (Pt No ****-*******) is required. The

appliance may be base duct mounted. JANSTAR Mk 2 is also provided with the facility for connection to a remote time

control (not supplied), with volt-free contacts (i.e. The switching supply is provided by JANSTAR Mk 2), to enable

selection of operating times.

1.4 A mesh filter, for air return duct mounting, is supplied as standard. However, a Cleanflow electronic filter is offered as an

alternative option.

THIS APPLIANCE CONFORMS TO BS EN 55014

Key Description Key Description

1 Air circulating fan 7 Air filter (L H shown)

2 Burner assembly 8 Flue outlet/combustion air inlet

3 Ignition/detection electrode 9 Fan to flue connection

4 Gas connection 10 Flue gas test point

5 Multifunctional control 11 Combustion air fan

6 Fan delay/ Overheat limit control 12 Pressure switch

This appliance has been tested and certified for use with natural gas.

1. GENERALDESCRIPTION

ZZ 1019/1E

11. SHORTLISTOFSPARES

G.C. MAKER’S DESCRIPTION QTY

No No

E00 124 W800-0701000 Burner assembly 1

E00 125 W800-0774000 Burner metal fibre assembly 1

245 549 1000-1500840 Gasket - burner top plate 1

*** *** 1000-0705480 Injector Bray Cat 15.3400 1

245 530 W800-0300000 Heat exchanger assembly 1

*** *** 1000-0708060 Multifunctional control valve 1

245 534 1000-0704490 Ignition/detection electrode 1

*** *** 1000-0520105 Fan delay/limit control 1

*** *** 1000-0519440 Electronics module 1

*** *** ****-******* Transformer 1

245 525 1000-0515730 Transformer (Cleanflow filter) 1

*** *** ****-******* Ignition module 1

*** *** ****-******* Combustion air fan assembly 1

*** *** 1000-0500130 Air circulation fan 1

245 509 1000-0513820 Fuse T3.15A 1

*** *** ****-******* Thermostat 1

*** *** 1000-0520110 Ignition Control Module 1

*** *** 1000-0519430 Air Proving Switch 1

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 & STARLEY LTD.

Telephone: (01604) 762881 Rhosili Road,

Brackmills,

Telefax: (01604) 767408 Northampton NN4 7LZ

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 (IEE.) 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

British System Design Manual “Gas Fired Warm Air Heating”

Model and Local Authority Bye-laws

IMPORTANT:STATUTELAWDEFINESTHATALLGASAPPLIANCES MUSTBEINSTALLED BYCOMPETENT

PERSONS,(i.e. CORGIREGISTERED INSTALLERS)INACCORDANCEWITHTHEGAS SAFETY(INSTALLATION

ANDUSE) REGULATIONS(CURRENTEDITION). FAILURETOCOMPLYWITHTHESEREGULATIONS MAY

LEADTO PROSECUTION.

2. HEATER COMPARTMENTAND CLEARANCES (See BS5864)

2.1 A minimum clearance of 15mm (5/8in) at either side of the heater, and 150mm (6in) above the heater, should be allowed.

For service access, a minimum of 450mm (18in) is required at the front of the heater, and 75mm at the left hand side.

Space must also be allowed, in a compartment installation, to permit the removal of the heater. If a Cleanflow electronic

air filter is to be fitted in the compartment, allowance must be made for this in the width of the compartment. The

compartment must be of a fixed rigid structure and the internal construction must be of half-hour fire resistance to

internal fire; the inside lining or finishing of the enclosure must be noncombustible or a class 1 finish (see also BS 476).

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

BS 5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the

perforations not exceeding 13mm (0.5in).

2.3 In under-stair installations, the compartment must comply with the relevant section of BS5864, provided that, in addition,

all internal surfaces, including the base, are of, or lined with non-combustible material.

3. VENTILATIONANDCOMBUSTIONAIR

3.1 A room sealed 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 below, (in reference to BS5440 Pt 2, Table 1).

ZZ 1019/1E

Position of Air from room Air direct

air vents or internal space from outside

High level 89cm2(14 in2)45cm

2(7 in2)

Low level 89cm2(14 in2)45cm

2(7 in2)

TABLE 1

MINIMUMEFFECTIVE AREAS

4. ADAPTINGTORIGHTHANDAIRENTRY

4.1 Remove the return air spigot and the short side cover from the left hand side of the appliance, and lay to one side.

4.2 Remove the long side cover from the right hand side of the appliance, and reassemble it on the left hand side, ensuring

that the slots are towards the front of the appliance.

4.3 Reassemble the short side cover and the return air spigot ton the right side of the appliance, ensuring that the slots in the

side cover are towards the front of the appliance.

5. DUCTSYSTEM

(See British Design Manual - Gas Fired Warm Air Heating).

IMPORTANT: All duct work MUST be mechanically secured, and sealed with ducting tape.

5.1 RETURNAIR

5.1.1 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. Where no ducting is fitted, a finger guard (Ref. ***, available from Johnson and Starley Ltd.), MUST be

fitted.

Fig. 9 Principal dimensions (mm)

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Fig. 8 JANSTAR Mk2 functional flow diagram

ZZ 1019/1E

5.1.2 The return air system should be constructed of fire-resistant material. It is extremely important that the correct

size of return air grilles and ducting is used. The return air duct size should be NOT LESS THAN ***mm x

***mm (*in x *in). If flexible duct is used, the duct diameter should be NOT LESS THAN 250mm (10in) dia. The

return air grille should have a free area of not less than 645cm2(100in2).

5.1.3 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.

5.1.4 For top return, a ‘starter’ knockout is provided to assist in creating the required aperture in the fan chamber top.

5.2 WARMDELIVEREDAIR

5.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (2in) glass fibre or similar. If extended

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

proof barrier, and protected from crushing.

5.2.2 The duct system should be carefully designed (as detailed in the guidelines in the British Design Manual) to suit

the needs of its specific heating requirements and building layout. The type of duct system, i.e. radial/extended/

stepped plenum should be installed using the least number of fittings to minimise air flow resistance.

6. INSTALLATIONREQUIREMENTS

6.1 AIRHEATER

6.1.1 Heater mounting is by means of five screws (provided) into a wall or structure sufficiently rigid to support the

appliance without deflection (for mounting hole positions see Fig. 8. The weight of the appliance is **kg.

Recommendedscrew size is No 10 x 2 in with suitable wall plugs. Attach the plenum to the underside of the

appliance using the four M4 x 10 screws and gasket provided. NOTE: Ensure that the aperture in the gasket is

correctly aligned with the warm air outlet on the underside of the appliance. Position the return air and warm air

outlet spigots to suit the application before mounting the assembly on the wall. For replacement, the appliance

may be fitted to an existing base plenum, with any blanking plates being mechanically secured and sealed.

6.2 FLUES (See BS 5440 Pt. 1 Flues)

6.2.1 The maximum allowable flue length is 5.0m plus one 90obend for horizontally flued appliances, and 11.0m plus

terminal for vertically flued appliances.

6.2.2 The minimum allowable flue length is 350mm plus one 90obend for horizontally flued appliances, and the length

of the terminal (1240mm) for vertically flued appliances. For applications where the flue exits directly through a

wall, the telescopic flue supplied with the heater may be used, as shown in Fig. 2.

6.2.3 The horizontal flue shall be installed with horizontal runs having a continuous fall to the terminal of at least 1:50.

(20mm per 1m run).

6.2.4 The overall flue shall be kept as short as possible, with the minimum number of bends. The flue should terminate

in its direction, with the terminal section meeting the outer side of the wall, or roofing at the point where it begins

to flare out, (refer to Fig. 2). One 90ohorizontal bend is equivalent to 1m of straight flue, a 45ohorizontal bend is

equivalent to 0.5m of straight flue. One 90overtical bend, where the bend radius is equal to the flue diameter, is

equivalent to 1.3m of flue; one 90overtical bend, where the bend radius is equal to 0.5 flue diameter, is equivalent

to 2.9m of flue; and a 45obend, where the bend radius is equal to the flue diameter, is equivalent to 0.85m of flue.

6.2.5 Sufficient support brackets (not supplied) shall be fitted to bear the weight of the total flue system.

6.2.6 The annular space between the flue assembly and surrounding structure must be sealed. If a cement sealant is

used, then the flue pipe must be coated with a suitable varnish a that point, to prevent corrosive attack of the

aluminium pipe.

6.2.7 For a vertical flue, a 60/100mm dia. concentric flue available from Johnson & Starley must to be used.

6.2.8 For a horizontal flue, the terminal supplied must be used. It shall be positioned in accordance with the

recommendations of BS 5440 Pt. 1, Clause 8 and Appendix B, and be guarded against damage and for

protection of passers-by, by using a terminal guard (Tower Flue Components Type K4), obtainable from builders’

merchants and Johnson & Starley (Pt No 1000-0002870).

6.2.9 The flue/air duct spigot on the appliance is female. For horizontal flued appliances, the flue/air duct should be

constructed that such that condensate cannot leak from the joints. Therefore, on vertical runs, all female ends

should face away from the appliance, and on horizontal runs should face towards the appliance, as depicted in

Fig. 3. To reverse the lay of joints, it is recommended to use male/male adaptors, available from Johnson &

Starley (Pt Nos. 1000-0002840 [inner], and 1000-0002850 [outer]). The flue should be constructed working

from the appliance towards the telescopic flue.

TX1

CONTROL MODULE

Fuse

T3.15A

230V 50Hz

Supply

230V

Continuous

Thermostat

(24V)

Link

C10

IGNITIONCONTROLUNIT

br b

br br

g/y

bk bk r

0V 14V

Air

GAS ON

Indicator

Light

Limit Switch

Pressure

Switch

nition/flame

Control

Fan Delay

Control

Fan Plug

Summer

Air Flow

Air Heating

CAF

17 16 15

AUTO

120

ACF N

MFC

Summer Airflow

Air Heating

BURNER

76512 4 3

10 2

19 18 17

24 16

23 1522 1421 1320

ZZ 1019/1E

6.2.10 Construction of flue joints.

a. Coat the end of the inner tube with silicone sealant capable of withstanding temperatures of up to 200OC

(not provided), and insert it fully into the female end of the next tube.

b. Using 3.3mm dia. drill, drill one hole through the assembly and secure with 1 x blind pop rivet (provided).

c. Fit 1 x centring clip (provided) over the tube, immediately down flow of the joint.

d. Slide the outer tube over the centring clip; assembly, secure and seal the outer joint in the same manner as

the inner joint.

NOTE: Only use the BLIND POP RIVETS PROVIDED.

Fig. 2

Telescopic flue applications

300mm

minimum

Fig. 3

Vertical flue application

Fig. 4

Flue jointing

Fig. 6, Electrical panel

ZZ 1019/1E

Ignition Control Unit

Control Module Fuse

Fan speed

selector

Air Heating/

Summer Airflow

switch

Burner ON

indicator

Fig. 7 JANSTAR Mk2 circuit diagram

ACF

TX1

CONTROL MODULE

FUSE

T3.15A

AUTO

CAF

C4C8

CAF

IGNITIONCONTROLUNIT

br br b

g/y

brryy

yyr b

24V 0V

bbb

bbbor

br br

bbbr

br br

0V 14V

bpk

C3C7

Air

C1C5

Thermo-

stat

GAS ON

Indicator

Light

Summer

Air Flow

Off

Continuous

Link cont. 230V

Voltage

Selector

230V~

Multi-

functional

Control

Pressure Switch

Ignition/flame

Control

Fan Plug

Time

Control Earth

Post

230V~50Hz

Supply

7654

24 19

23 18

12 2

22 17

11 10 98 1

21 16

20 15 14 13

COLOUR CODE

g/y

brown

blue

black

red

orange

yellow

green/yellow

pink

white

green

ZZ 1019/1E

6.3 CONDENSATE

6.3.1 When firing , the unit may produce condensate which must be drained away. A JDT1 kit, which externally drains

the condensate away from the flue terminal is available for horizontal flued applications. Vertical flued

applications require the fitment of an in-line condensate trap within 0.5 m of the unit, in the first vertical flue run,

and before any bends in the flue run. Such a trap, with a 32 mm male drainage connection, is available for this

purpose.

6.3.2 Condensate from vertical flued applications must be drained away using 32 mm or 20 mm internal diameter, rigid

plastic pipe, connected to the condensate drain using KUTERLITE 700 or similar straight coupling. The pipe

should be installed in such a manner, that it forms a continuous downward slope away from the unit at a minimum

3oangle (6 mm per 100 mm, or, 0.75 in per foot run), and that the risk of mechanical damage and interior

interference is minimised. The pipe is to be protected against frost damage.

6.4 ELECTRICAL

6.4.1 Mains: The heater is supplied with mains cable (PVC sheathed, high temperature resistant, 3 core [Brown-

Blue-Green/Yellow], 6A, 0.75mm2), connected to a terminal block and exiting from the heater at the bottom right

hand rear. The cable is suitable for a 230V 50Hz single phase supply and must be protected by a 5A fuse, and an

earth wire must be connected. This cable must only be replaced by either the maunfacturer or a recognised and

qalified service engineer.A double pole switch or fused spur box should also be used. All wiring conform to I.E.E.

regulations, (current edition).

6.4.2 Thermostat: A Thermostat is provided with the appliance. The Thermostat wiring is to be connected to

terminals 6 and 7 on the air heater control panel, (marked ‘THERMOSTAT’), polarity being unimportant. It should

be located where there is free air circulation, and approximately 1.5m (5ft) from the floor. The following

locations should be avoided.

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

light fitting or TV set).

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

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

d. Where it can be subject to vibration.

6.4.3 Time Control: If an external time control (not supplied) is to be fitted, connect the live supply to terminal 3,

the neutral to terminal 4, and the time-switch output to terminal 5. If no time control is fitted, link terminal 3

and 5.

6.5 GAS (see BS 5864 and BS 6891)

6.5.1 An independent gas supply pipe from the gas meter is to be preferred wherever possible. However, 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 (0.4 in. wg.) pressure drop (see table of discharge in BS 6891).

6.5.2 The 1/2in union gas cock (supplied) must be fitted externally in the gas inlet of the heater for easy isolation during

servicing. The gas pipe should be fitted and installed as to be durable, substantial and gas tight. Gas entry to the air

heater may be through the left hand side, right hand side front, or rear, to an Rc1/2(1/2in B.S.P. internal (taper)

thread).

7. COMMISSIONING

7.1 Ensure the following:

7.1.1 Gas and Electrical supplies are OFF.

7.1.2 Filter, fan and fan compartments are free from obstructions.

7.1.3 All registers or grilles are open and conform to design specifications.

7.1.4 Return, relief and ventilation air installations are adequate.

7.1.5 Adhesive label is removed from the centre of the combustion air fan to expose the motor cooling slots.

7.2 Turn ON the gas supply to the heater.

7.3 Test for gas soundness at supply, Multifunctional control and the Main burner using proprietary detection fluid, sealing

any leaks found, and purge the whole gas pipe as described in BS 6891.

7.4 Set the Thermostat to its maximum setting.

7.5 Ensure that the time control (if fitted) is in an ON position.

7.6 Switch on the electrical supply to the heater. The combustion air fan will start up immediately; after a minimum of 30

seconds, the burner will automatically ignite and the green ‘BURNER ON’ indicator will illuminate.

ZZ 1019/1E

BURNERNOTOPERATING

Check that the time control is on and Thermostat is calling for heat.

Check mains electrical supply.

Link terminals 3 & 5 (shorts out clock).

Disconnect Thermostat at terminals 6 & 7.

Noresponse Burner lights

Linkterminals 15&16. Reinstate connections at 6 & 7.

Check wiring to, or replace

Thermostat.

Noresponse Burner lights

Checkterminal 14for 230volts. Replace fandelay/limit

control.

No230 volts 230volts detected

CheckICU terminal5 for230 volts. Check wiring to, or replace

multifunctionalcontrol.

No230 volts 230volts detected

CheckICU terminal8 for230 volts. Checkwiring.

No230 volts 230volts detected

Check terminal C4 for230volts. Replace Ignition Control

Unit.

No230 volts 230volts detected

Check terminal C3 for 230 volts. Check wiring.

No230 volts 230volts detected

Checkterminal 5for 230volts Replace Control Module.

No230 volts 230volts detected

Check 3.15 A fuse, if OK check 230 volt Check wiring and Air Heating

input at terminal 1 Switch.

AirHeatingSwitchand

WiringOK

Replace Ignition Control unit

or Pressure switch

BURNERON,BUTAIRCIRCULATIONFANNOTRUNNING

Check for 230 volts at fan terminals 11 & 12

No230 voltsdetected 230voltsdetected

Switchto ‘SummerAirflow’. Switchto ‘SummerAirflow’.

230volts detected

Replace air circulation fan.

Aircirculation fanruns Aircirculationfandoes

Replacefan delay/limit control. notrun

Replace Fan Speed Transformer

BURNERONCONTINUOUSLY

(ROOMTEMPERATURETOOHIGH)

Setthe Air HeatingSwitch to‘Summer Airflow’

Burnerremainsalight Burner goesout

Disconnect solenoid plug at Replace Thermostat.

multifunctionalcontrol.

Burnerremainsalight

Replace multifunctional control.

AIRCIRCULATIONFANCONTINUESTORUNORCYCLES

WHENBURNERISNOTON

Check that Air Heating switch is not set to ‘Summer Airflow’.

Disconnect Thermostat and link terminals 6 & 7.

Disconnect the fan delay/limit control.

Aircirculation fanstops Air circulationfan continuesto run

Replacefan delay/limit ReplaceControl module

control

AIRCIRCULATIONFANON,BUTBURNERCYCLESBEFORE

REQUIREDCOMFORTLEVELISREACHED

Disconnect Thermostat at terminals 6 & 7.

Burnercontinuestocycle Burnerremains on

Check air filter, return air path Thermostat defective.

and outlets for restrictions.

Burnercontinuestocycle

Link terminals 15 & 16 to bypass limit control.

Burnercontinuestocycle Burnerrunsand room

Replace Thermostat. temperaturerises

Check temperature rise.

Less than 60 degrees C Morethan 60degreesC

Replace fan delay/overheat (limit) Replace Thermostat

control.

PRESSURESWITCHDEFECTIVE

ZZ 1019/1E

9.16 HEATEXCHANGERREMOVAL:

9.16.1 Referring to 9.3, remove the burner assembly.

9.16.2 Referring to 9.9, remove the Ignition/detection electrode.

9.16.3 Referring to 9.12, remove the combustion air fan, including complete removal of the two upper securing screws.

9.16.4 Referring to 9.13, remove the fan delay/overheat (limit) control.

9.16.6 Disconnect the base plenum from its associated duct work, and remove it form the appliance by releasing the two

screws from inside the plenum, and one hexagonal screw from the appliance floor.

9.16.7 Release the two hexagonal screws securing the heat exchanger at the burner aperture, and withdraw the heat

exchanger from the appliance through the base aperture.

9.16.8 Refitting or replacement is in reverse order, ensuring that the two upper combustion fan securing screws are fitted

before fully tightening the heat exchanger securing screws at the burner aperture.

10. DEFECTDIAGNOSIS

10.1 IMPORTANT: If an electrical fault 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 service/

defect rectification tasks which have required the breaking and remaking of electrical connections, then

continuity, polarity and resistance to earth checks should be repeated.

10.2 Note: When purging or checking gas supplies, ensure that there is adequate ventilation to the room or cupboard, and all

naked lights are extinguished.

10.3 Care must be taken during replacement and handling of electronic assemblies, i.e. printed circuit board module

or fan delay/limit control switch. It is not practical to rectify defects in these assemblies except in the factory,

and any attempt to do so may render any guarantee or factory replacement arrangement invalid.

10.4 GENERALINFORMATION:

10.4.1 This appliance is fitted with an automatic sequence control which also provides a spark ignition and flame

detection facility. If the ignition/detection electrode fails to detect the presence of a flame during normal

operating conditions, it will cause the multifunctional control to close. The control will then make one attempt at

re-ignition by repeating the pre-purge/ignition cycle and then lock out. The combustion air fan will continue to

run, provided there is a demand for heat. Operation of the time control (if fitted) or if the room temperature

exceeds plenum the set comfort level will simply cause the appliance to switch off (green light goes out). In this

case, recycling the electrical supply will initiate the ignition sequence.

10.4.2 If the combustion air fan will not start when the electrical supply to the appliance is on, and there is a demand for

heat, the defect lies in the control module or the combustion air fan. Check that the connections to the fan are

sound, and then, if necessary, change the control module followed by the combustion air fan.

10.4.3 If lockout occurs and it is known that gas is being supplied to the appliance, attempt to restart the appliance by

recycling the electrical supply to the appliance. If this attempt to restart the appliance is unsuccessful, check the

electrode lead and the electrode for damage and replace as necessary. Note: It is possible to obtain a spark, even

when the electrode lead is damaged, but the lead may not be able to conduct the very small detection current to

the ignition/detection control. If there is no evidence of damage to the electrode or lead, replace the ignition

control unit.

ZZ 1019/1E

7.6.1 If the burner fails to light, re-initiate the ignition sequence setting the switching the electrical to supply to the

appliance OFF and then ON again.

7.6.2 If the burner ignites but then extinguishes: An automatic purging sequence will take place, which lasts for

approximately 30 seconds. Following this, a second ignition will take place.

7.7 Set the time control (if fitted) to the required ‘Heating On’ periods and adjust the Thermostat to the desired comfort

setting. The burner will then initially operate at maximum output until it reaches the set comfort level with the air

circulation fan operating, followed by the burner extinguishing and the air circulation fan switching off after a delay

governed by the Fan Delay Control.

7.8 BURNER PRESSURE CHECK:

Note: The Burner pressure is factory set and MUST NOT BE ADJUSTED.

7.8.1 Turn the gas and electrical supplies to OFF.

7.8.2 Referring to Fig. 5, remove and retain the Burner Pressure Test Point blanking screw, and fit pressure test gauge

to the test point,

7.8.3 Turn ON the gas and electrical supplies.

7.8.4 Reinstate the ignition sequence as detailed in sub-para 7.6.1

7.8.5 Ensure that the burner ignites, and allow 15 minutes of operation to elapse to ensure stability.

7.8.6 Referring to Table 2, ensure that the gas rate is NOT GREATER THAN 0.92m3/h (32.3ft3/h) for horizontal flued

installations, or 0.98m3/h (34.6ft3/h) for vertical flued installations.

7.8.7 If the gas rate is not within the limits stated, run the appliance for a further 10 minutes and then re-check the

gas rate. If the rate is still not within the stated limits, contact Johnson and Starley Ltd. Service Department, since

rectification requires the use of special equipment.

7.8.8 Turn the gas and electrical supplies to OFF.

7.8.9 Remove the pressure test gauge, and refit the pressure test point blanking screw.

7.8.12 Turn ON the gas and electrical supplies.

7.9 WARMAIR SYSTEMBALANCING:

7.9.1 Set the SUMMER AIRFLOW switch to ‘I’.

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

Note: If the system includes ceiling diffusers, it is important that the velocities of air through these (except in

very small rooms such as bathrooms) are at least 1.5m/s (300ft/min). In order to achieve this, it may be necessary

to blank off part of the outlet face.

7.9.3 Set the SUMMER AIRFLOW switch to ‘O’.

7.10 AUTOMATIC CONTROLS CHECK: Lighting the heater and allowing it to operate for a short time will effectively

check these controls.

7.11 SAFETYCHECK:

7.11.1 Turn OFF the gas supply at service cock and ensure that the Multifunctional control fail-safe operates (indicated

by loud click from the Multifunctional control ).

7.11.2 Turn the gas supply ON at the service cock, and ensure that the burner ignites.

HORIZONTALFLUE VERTICALFLUE

APPLICATIONS APPLICATIONS

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

INPUT 9.80 35.3 33,500 10.5 37.8 35,800

OUTPUT 8.0 29.0 27,300 8.57 30.86 29,200

Gas rate cv 0.92 m3/h (32.3ft3/h) 0.98 m3/h (34.6ft3/h)

1037 Btu/h

Burner setting Not available Not available

pressure (hot)

Main Injector BRAY CAT 15.3400

TABLE 2

MAINBURNER PRESSURE SETTINGS

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7.12 TEMPERATURERISECHECK:

7.12.1 Ignite the Main burner and allow 15 minutes for stability before continuing.

7.12.2 Check that the temperature rise across the heater is between 45oC - 55oC, setting the fan speed accordingly,

(decrease fan speed to increase temperature rise). The fan speed is adjusted by the selecting fan speed at the

control panel (decrease voltage selection to decrease fan speed).

Note: Tapping 1 = 175V, Tapping 2 = 210V and Tapping 3 = 230V.

Fig. 5

Multifunctional control

8. INSTRUCTIONSFOR USERS

8.1 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.

8.2 If the building is occupied, hand the User Instructions over and ensure the User understands:

8.2.1 How to operate the Thermostat, time and heater ON/OFF switch and summer air circulationswitch, and that the

time control (if fitted) must be reset following a power failure.

8.2.2 How to turn off the appliance, and switch off electrical supply to the heater.

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

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

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

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

8.2.7 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.

8.2.8 That expert help must be obtained if malfunction of the appliance occurs.

8.2.9 How to obtain summer air circulation.

8.2.10 How to reset the appliance in the event of lockout.

Inlet pressure test point

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9.12 CONTROLMODULE REPLACEMENT:

9.12.1 Ensure that the electrical supply is switched off.

9.12.2 Remove the heater front cover.

9.12.3 Disconnect the Control Module as follows, and with reference to Fig. 7:

a. PINK lead from the terminal marked ‘C1’,

b. BLUE lead from the terminal marked ‘C2’,

c. RED lead from the terminal marked ‘C3’,

d. BROWN lead from the terminal marked ‘C4’,

e. YELLOW lead from the terminal marked ‘C5’,

f. YELLOW lead from the terminal marked ‘C6’,

g. RED lead from the terminal marked ‘C7’,

h. BLACK lead from the terminal marked ‘C8’,

i. WHITE lead from the terminal marked ‘C9’,

j. YELLOW lead from the terminal marked ‘C10’.

9.12.4 Disconnect the 2 x ORANGE leads (from the Control Module Transformer) from the Control Module.

9.12.5 Remove the 2 x securing screws and nuts, and remove the control module.

9.12.6 Refitting or replacement is in reverse order.

9.13 COMBUSTIONAIR FAN REMOVAL:

9.13.1 Ensure that the electrical supply is switched off.

9.13.2 Remove the heater front cover.

9.13.3 Disconnect the combustion air fan from the Control Module as follows:

a. RED lead from the terminal marked ‘C7’,

b. BLACK lead from the terminal marked ‘C8’,

cWHITE lead from the terminal marked ‘C9’,

dYELLOW lead from the terminal marked ‘C10’.

9.13.4 Remove the upper and lower screws securing combustion air fan, and withdraw the fan complete with gasket.

9.13.5 Refitting or replacement is in reverse order.

Important: Ensure that the gasket is undamaged, and that the flue connection is sound. Only use the securing

screws supplied, as longer screws will cause damage to the heat exchanger.

9.14 FANDELAY/LIMITCONTROL(FDC)REMOVAL:

9.14.1 Ensure that the electrical supply is switched off.

9.14.2 Remove the heater front cover.

9.14.3 Disconnect the five conductors in the FDC lead from the control panel terminal strip, having first noted their

positions.

9.14.4 Release 2 x screws securing FDC to the bulkhead, and withdraw the FDC from the heater.

9.14.5 Refitting or replacement is in reverse order.

9.15 PRESSURESWITCH REMOVAL:

9.15.1 Ensure that the electrical supply is switched off.

9.15.2 Remove the heater front cover.

9.15.3 Disconnect the Pressure Switch electrical connections as follows:

a. BLACK lead from the terminal marked ‘1’,

b. WHITE lead from the terminal marked ‘2’,

c2xPINK leads from the terminal marked ‘3’.

9.15.4 Disconnect the single flexible silicon tube from the pressure terminal marked ‘P2’ (forward most connection).

9.15.5 Disconnect the flexible silicon tube with the Tee-connector from the pressure terminal marked ‘P1’ (rearmost

connection).

9.15.6 Release the 2 x screws securing the Pressure Switch to the bulkhead, and withdraw the switch from the heater.

9.15.7 Refitting or replacement is in reverse order.

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9. SERVICING

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 for gas

soundness and carry out a complete functional test of the appliance in accordance with the

CommissioningInstructions.

9.1 ROUTINEMAINTENANCE:

9.1.1 Operate the appliance and check for correct function.

9.1.2 Clean the air circulation fan and the air filter.

Note: The air/fuel ratio is controlled automatically and therefore combustion is and will remain extremely clean. In the

unlikely event of this ratio deviating from the norm, the system will lock out. It is, therefore, not necessary to remove the

burner assembly for internal inspection during an annual service.

9.1.3 Reassemble all items in reverse order and carry out the commissioning procedure as detailed in Sect 6.

9.2 MULTIFUNCTIONALCONTROLREMOVAL:

9.2.1 Ensure that the gas and electrical supplies are switched off.

9.2.2 Remove the single screw securing the heater front cover, and remove the front cover.

9.2.3 Remove the central securing screws and disconnect 2 x electrical plugs from Multifunctional control.

9.2.4 Disconnect the flexible silicon tube from the rear and the 8mm pipe from the top of the multifunctional control.

9.2.5 Disconnect the gas supply union from beneath the multifunctional control.

9.2.6 Remove 2 x screws securing multifunctional control mounting bracket to heater body, and withdraw the

multifunctional control.

9.2.7 Refitting or replacement is in reverse order. Note: If the multifunctional control is to be replaced, transfer the

pipe fittings and mounting bracket to the new unit.

9.3 BURNERASSEMBLYREMOVAL:

9.3.1 Referring to 9.2, remove the multifunctional control.

9.3.2 Disconnect the igniter lead from the ignition/detection electrode.

9.3.3 Disconnect the gas feed pipe from the burner assembly.

9.3.4 Remove the four hexagonal burner manifold fixing screws from the manifold front flange, and slacken the three

hexagonal screws at the rear of the manifold.

9.3.5 Slide the manifold down to disengage the air connection, and then forward to disengage the rear screws. Withdraw

the burner manifold and burner face plate.

9.3.6 Refitting or replacement is in reverse order, ensuring that the metal fibre on the burner face plate is TOWARDS

the manifold.

9.4 BURNER ASSEMBLY CLEANING:

9.4.1 Referring to 9.3, remove the burner assembly.

9.4.2 Using a soft brush, lightly brush the burner manifold inside and out, taking care to avoid damaging the injector.

9.4.3 Using a vacuum cleaner with nozzle attachment, carefully clean the burner face plate element if necessary. DO

NOT USE a wire brush or sharp implement, since the element is fragile and easily damaged.

9.5 AIR CIRCULATION FAN REMOVALAND CLEANING:

9.5.1 Ensure that the electrical supply is switched off.

9.5.2 Remove the heater front cover.

9.5.3 Disconnect the air circulation fan flying lead from the electrical panel.

9.5.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.5.5 Remove the air circulation fan securing screw, and slide the fan from its locating channel.

9.5.6 Remove all dust from both the impeller and motor, taking care to avoid disturbance of the fan balancing.

9.5.7 Refitting or replacement is in reverse order, referring to Fig. 7 for correct wiring.

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9.6 REMOVAL OF INJECTOR:

9.6.1 Referring to 9.3, remove the burner assembly.

9.6.2 Using 14mm A/F ring spanner, undo the nut and washer, and remove injector from burner manifold.

9.6.3 Refitting or replacement is in reverse order.

9.7 FUSE REPLACEMENT:

9.7.1 Ensure that the electrical supply is switched off.

9.7.2 Remove the heater front cover.

9.7.3 Replace the appliance fuse, situated on the electrical panel. The only fuse to be fitted is 20mm, T3.15 (slow

blow).

9.8 FAN SPEEDTRANSFORMER REMOVAL:

9.8.1 Ensure that the electrical supply is switched off.

9.8.2 Remove the heater front cover.

9.8.3 Disconnect the leads from the transformer as follows:

a. YELLOW lead from terminal marked ‘T1’,

b. WHITE lead from terminal marked ‘T2’,

c. BROWN lead (terminal block ‘8’) from terminal marked ‘L’,

d. BROWN lead (fan speed terminal block ‘230V) from terminal marked ‘L2’,

e. BLUE lead from terminal marked ‘N’.

9.8.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.8.5 Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.

9.8.6 Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.

9.9 CONTROLMODULETRANSFORMER REMOVAL:

9.9.1 Ensure that the electrical supply is switched off.

9.9.2 Remove the heater front cover.

9.9.3 Disconnect the transformer leads as follows:

a. 2 x ORANGE leads from the Control Module terminals,

b. BROWN lead from the terminal block terminal marked ‘8’,

c. BLUE lead from the terminal block terminal marked ‘9’.

9.9.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.9.5 Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.

9.9.6 Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.

9.10 IGNITION/DETECTIONELECTRODE REMOVAL:

9.10.1 Referring to 9.3, remove the burner assembly.

9.10.2 Remove the securing nut and washer, and carefully remove the electrode from the burner.

9.10.3 Refitting or replacement is in reverse order, taking care to avoid bending the electrode since its profile is critical.

9.11 IGNITIONMODULE REMOVAL:

9.11.1 Ensure the electrical supply is switched off.

9.11.2 Remove the heater front cover.

9.11.3 Disconnect the ignition lead from the ignition module.

9.11.4 Disconnect the ignition module edge connector plug.

9.11.5 Remove the 2 x securing screws and withdraw the ignition module.

9.11.6 Refitting or replacement is in reverse order.

ZZ 1019/1E

9. SERVICING

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 for gas

soundness and carry out a complete functional test of the appliance in accordance with the

CommissioningInstructions.

9.1 ROUTINEMAINTENANCE:

9.1.1 Operate the appliance and check for correct function.

9.1.2 Clean the air circulation fan and the air filter.

Note: The air/fuel ratio is controlled automatically and therefore combustion is and will remain extremely clean. In the

unlikely event of this ratio deviating from the norm, the system will lock out. It is, therefore, not necessary to remove the

burner assembly for internal inspection during an annual service.

9.1.3 Reassemble all items in reverse order and carry out the commissioning procedure as detailed in Sect 6.

9.2 MULTIFUNCTIONALCONTROLREMOVAL:

9.2.1 Ensure that the gas and electrical supplies are switched off.

9.2.2 Remove the single screw securing the heater front cover, and remove the front cover.

9.2.3 Remove the central securing screws and disconnect 2 x electrical plugs from Multifunctional control.

9.2.4 Disconnect the flexible silicon tube from the rear and the 8mm pipe from the top of the multifunctional control.

9.2.5 Disconnect the gas supply union from beneath the multifunctional control.

9.2.6 Remove 2 x screws securing multifunctional control mounting bracket to heater body, and withdraw the

multifunctional control.

9.2.7 Refitting or replacement is in reverse order. Note: If the multifunctional control is to be replaced, transfer the

pipe fittings and mounting bracket to the new unit.

9.3 BURNERASSEMBLYREMOVAL:

9.3.1 Referring to 9.2, remove the multifunctional control.

9.3.2 Disconnect the igniter lead from the ignition/detection electrode.

9.3.3 Disconnect the gas feed pipe from the burner assembly.

9.3.4 Remove the four hexagonal burner manifold fixing screws from the manifold front flange, and slacken the three

hexagonal screws at the rear of the manifold.

9.3.5 Slide the manifold down to disengage the air connection, and then forward to disengage the rear screws. Withdraw

the burner manifold and burner face plate.

9.3.6 Refitting or replacement is in reverse order, ensuring that the metal fibre on the burner face plate is TOWARDS

the manifold.

9.4 BURNER ASSEMBLY CLEANING:

9.4.1 Referring to 9.3, remove the burner assembly.

9.4.2 Using a soft brush, lightly brush the burner manifold inside and out, taking care to avoid damaging the injector.

9.4.3 Using a vacuum cleaner with nozzle attachment, carefully clean the burner face plate element if necessary. DO

NOT USE a wire brush or sharp implement, since the element is fragile and easily damaged.

9.5 AIR CIRCULATION FAN REMOVALAND CLEANING:

9.5.1 Ensure that the electrical supply is switched off.

9.5.2 Remove the heater front cover.

9.5.3 Disconnect the air circulation fan flying lead from the electrical panel.

9.5.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.5.5 Remove the air circulation fan securing screw, and slide the fan from its locating channel.

9.5.6 Remove all dust from both the impeller and motor, taking care to avoid disturbance of the fan balancing.

9.5.7 Refitting or replacement is in reverse order, referring to Fig. 7 for correct wiring.

ZZ 1019/1E

9.6 REMOVAL OF INJECTOR:

9.6.1 Referring to 9.3, remove the burner assembly.

9.6.2 Using 14mm A/F ring spanner, undo the nut and washer, and remove injector from burner manifold.

9.6.3 Refitting or replacement is in reverse order.

9.7 FUSE REPLACEMENT:

9.7.1 Ensure that the electrical supply is switched off.

9.7.2 Remove the heater front cover.

9.7.3 Replace the appliance fuse, situated on the electrical panel. The only fuse to be fitted is 20mm, T3.15 (slow

blow).

9.8 FAN SPEEDTRANSFORMER REMOVAL:

9.8.1 Ensure that the electrical supply is switched off.

9.8.2 Remove the heater front cover.

9.8.3 Disconnect the leads from the transformer as follows:

a. YELLOW lead from terminal marked ‘T1’,

b. WHITE lead from terminal marked ‘T2’,

c. BROWN lead (terminal block ‘8’) from terminal marked ‘L’,

d. BROWN lead (fan speed terminal block ‘230V) from terminal marked ‘L2’,

e. BLUE lead from terminal marked ‘N’.

9.8.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.8.5 Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.

9.8.6 Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.

9.9 CONTROLMODULETRANSFORMER REMOVAL:

9.9.1 Ensure that the electrical supply is switched off.

9.9.2 Remove the heater front cover.

9.9.3 Disconnect the transformer leads as follows:

a. 2 x ORANGE leads from the Control Module terminals,

b. BROWN lead from the terminal block terminal marked ‘8’,

c. BLUE lead from the terminal block terminal marked ‘9’.

9.9.4 Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,

ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.

9.9.5 Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.

9.9.6 Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.

9.10 IGNITION/DETECTIONELECTRODE REMOVAL:

9.10.1 Referring to 9.3, remove the burner assembly.

9.10.2 Remove the securing nut and washer, and carefully remove the electrode from the burner.

9.10.3 Refitting or replacement is in reverse order, taking care to avoid bending the electrode since its profile is critical.

9.11 IGNITIONMODULE REMOVAL:

9.11.1 Ensure the electrical supply is switched off.

9.11.2 Remove the heater front cover.

9.11.3 Disconnect the ignition lead from the ignition module.

9.11.4 Disconnect the ignition module edge connector plug.

9.11.5 Remove the 2 x securing screws and withdraw the ignition module.

9.11.6 Refitting or replacement is in reverse order.