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

Transcription

1 These instructions are to e left with the User or adjacent to the Gas Meter HI-SPEC JU55 WARM AIR HEATERS MODAIRFLOW and non-modairflow Control ISTALLATIO, COMMISSIOIG & SERVICIG ISTRUCTIOS G.C. o Pulication o. ZZ 905/4 Octoer 2006 This appliance has een tested and certified for use with natural gas. 1. BRIEF DESCRIPTIO Air Filter 2 Air circulating fan 3 Fuse 4 Time control 5 Data plate 6 Limit switch 7 Multifunctional control 8 Pilot urner 9 Burner and Control Asseml 10 Gas connection 11 Airflow sensor (Modairflow models) 12 Fan Dela Control (non- Modairflow) 13 Electrical Asseml 14 Piezo unit 15 Spillage monitoring device (TTB) (at rear) 16 Electronics module (MODAIRFLOW) 17 Summer Air Circulation switch 2 1 Fig HI-SPEC JU55 is an open-flued, fan assisted Upflow, ducted warm air heater, which ma e supplied with MODAIR- FLOW control. A non-modairflow version is availale as an option. A Spillage 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 e adjusted etween 11.72kW (42.2MJ/h, 40,000Btu/h) and 16.1kW (58.0MJ/h, 55,000Btu/h). Summer air circulation of unheated air is availale manual selection (see User s Instructions). THIS APPLIACE COFORMS TO BS E Installation shall e in accordance with the current editions of:- Building Standards (Scotland) (Consolidation) Regulations Building Regulations Gas Safet (Installation and Use) Regulations (as amended) BS 7671 Institute of Electrical Engineers (IEE.) Wiring Regulations BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd famil gases). BS 5440 Pt. 1 (Flues for Gas Appliances) BS 5440 Pt. 2 (Air Suppl for Gas Appliances) BS 5864 Installation of Gas Fired Ducted Air Heaters British Sstem Design Manual Gas Fired Warm Air Heating Model and Local Authorit Be-laws 1

2 IMPORTAT: STATUTE LAW DEFIES THAT ALL GAS APPLIACES MUST BE ISTALLED B COMPE- TET PERSOS, (i.e. CORGI REGISTERED ISTALLERS) I ACCORDACE WITH THE GAS SAFET (ISTALLATIO AD USE) REGULATIOS (CURRET EDITIO). FAILURE TO COMPL WITH THESE REGULATIOS MA LEAD TO PROSECUTIO. 2. HEATER COMPARTMET AD CLEARACES (See BS 5864) 2.1 IMPORTAT: If the heater is to e fitted to an existing ase duct (warm air plenum), alwas 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 ase duct, so that an overhang or lanking off will e at the front and/or right hand side. In an event, lanking plates must e mechanicall secured and all joints sealed. 2.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 25mm (1in) at the sides and 75mm (3in) at the front must e left. Consideration should also e given to the space required for the removal and replacement of the filter tra and the entr of the gas and electrical supplies. 2.3 For service access, a minimum of 450mm (18ins) is required at the front of the heater. Space must also e allowed, in a compartment installation, to permit the removal of the heater. The clearance etween the appliance and the compartment should not e less than 75mm ( 3in). However, where clearances are less than 75mm, the internal surface of the compartment must e lined with non-comustile material. The compartment must e of a rigid structure. 2.4 In airing cupoard installations, the part used as the air heater compartment must compl with the relevant section of BS5864 and must e completel separated either a non-comustile partition or a perforated metal partition with the perforations not exceeding 13mm ( 1 / 2 in). The secondar flue must e a tight fit where it passes through the partition and must e suital protected (see BS 5440: Part 1). 2.5 In under-stairs installations, the compartment must compl with the relevant section of BS 5864, provided that in addition, all internal surfaces, including the ase, are non-comustile or lined with non-comustile material. This requirement is applicale onl to dwellings of not more than two stores. 2.6 IMPORTAT: When the heater is installed in a compartment, the SAFET lael supplied with the heater MUST BE AFFIXED in a prominent position on the ISIDE of the COMPARTMET DOOR. 3. VETILATIO AD COMBUSTIO AIR 3.1 The room or internal space in which the heater is installed requires a permanent air vent of minimum effective area 67cm 2 (12in 2 ). The air vent should e either direct to outside air or to an adjacent room or internal space (other than a toilet or athroom) that itself has an equivalent air vent direct to outside. 3.2 Comustion air ma e introduced, via a 120mm (5in) nominal ore pipe, connected to a return air duct or plenum from a ventilated area and fitted with a lockale damper. The damper should e adjusted to control comustion airflow to m 3 /s (25.6cfm) i.e. 0.98m/s (195ft/min) velocit in a 120mm (5in) ore pipe. If this arrangement is used, a noncloseale warm air register MUST e 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, oth communicating either directl with outside air or with a ventilated room or space. The minimum effective areas specified in Tale 1 are related to the rated heat input of the Air Heater. 3.4 If an room or area from which air is drawn for ventilation or comustion contains an extract fan, the permanent vents must e sized to ensure that the operation of the appliance at full rate is/are not adversel affected. A spillage test as specified in su-para 6.8 (Safet Checks) is carried out and an remedial work undertaken. VETILATED Low level grille 392cm 2 (60in 2 ) FROM ISIDE BUILDIG High level grille 196cm 2 (30in 2 ) VETILATED Low level grille 196cm 2 (30in 2 ) FROM OUTSIDE BUILDIG High level grille 98cm 2 (15in 2 ) Tale 1 Minimum Effective Areas 2

3 4. DUCT SSTEM (See British Design Manual - Gas fired Warm Air Heating) 4.1 RETUR AIR All return air shall e POSITIVEL ducted from outside the compartment to the ottom of the unit either via a plenum, or if appropriate using Side Return Kit SR55, and mechanicall secured. The plenum must e constructed to support the weight of the heater, and the heater must e secured to the plenum with screws on at least 2 sides, and sealed using self adhesive foam strip, ducting tape or sealing compound. It is recommended that the return air duct e not routed directl from the main living area, ut from a convenient central area serving the remainder of the dwelling The return air sstem should e constructed of fire-resistant material. The flue shall not e run through an area serving as a return air path. It is extremel 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 e less than the equivalent of 300mm x 300mm (12" x 12"). If flexile duct is used the duct diameter should not e less than 400mm (16") dia. The return air grille should have a free area of not less than 1365cm 2 (212in 2 ) An adequate and unostructed return air path is essential from areas not served a directl ducted return and to which warm air is delivered. All such rooms should e fitted with relief grilles which have a free area of m 2 /kw (1in 2 /250Btu/h) of heat supplied to the room. The onl exceptions are kitchens, athrooms and WC. s The warm air duct should allow for ease of removal for access to the flue All duct work in the room or internal space in which the heater is installed shall e mechanicall secured, and sealed with ducting tape. 4.2 WARM DELIVERED AIR All duct work, including riser ducts, should e full insulated with 50mm (2in) fieglass or similar. If short extended duct runs are taken elow floor level these should e similarl insulated, and in addition wrapped with a sound vapour proof arrier, and protected from crushing The duct sstem should e carefull designed (as given in the guidelines in the British Sstem Design Manual) to suit the needs of its specific heating requirements and uilding laout. The tpe of duct sstem, i.e. radial/ extended plenum/ stepped should e installed using the least numer of fittings to minimise airflow resistance. 5. ISTALLATIO REQUIREMETS 5.1 FLUES (see British Standards BS5440 Pt.1 Flues) All joints shall e soundl sealed The flue should e kept as short and warm as possile Sufficient support ackets shall e installed to ear the weight of the total flue sstem The spigot connection of the heater draught diverter will accept internall the spigot end of a non-asestos flue to BS567 or twin wall metal flue to BS715 of nominal 100mm (4in) diameter A split collar should e fitted to provide for flue maintenance or inspection The flue shall e in accordance with the Building Regulations and British Gas Materials and Installations specification 3rd edition) with regard to clearance and shielding from comustile materials All materials shall e in accordance with Building Regulations requirements The flue should run as verticall as possile. Horizontal runs should e avoided if at all possile and an directional change should e as gentle as possile. If there is an dout aout the flue configuration, the equivalent flue height should e determined (see ) If the appliance to e fitted is a replacement, the old appliance should e checked for signs of spillage prior to commencement of the installation and appropriate action taken. i.e. check flue sstem and renew as necessar. 3

4 It is recommended that at least 600mm of vertical flue should e provided from the top of the draught diverter (for new installations this shall e incorporated into the flue design). However, when carring out replacement installations, an existing flue sstem ma e encountered, where the vertical flue aove the appliance to the first end is less than 600mm. In the first instance, the installer must judge whether this distance can e achieved practical some means. Where this is not practicale, the existing flue sstem ma e used, providing there is no evidence of spillage from the old appliance (see aove). Ever effort must e made, however, to ensure that the existing flue complies in ever other wa to BS 5440 Part 1, including the visual inspection, flue flow and spillage test descried in of the aove standard. Flue configurations ma e assessed in terms of equivalent vertical height - details are given in For air heaters, the minimum equivalent vertical height is 1 metre. The installer must make a judgement ased on his knowledge and experience and the examination and testing descried aove as to whether an existing flue sstem can e used. ote: Ventilation of the compartment, room or internal space in which the appliance is to e installed must e checked for compliance with the requirements of BS 5440 Part 2 ( Ref. Section 3 of these instructions) and upgraded as necessar Calculation method for flue sizing: ( from BS 5440: Part 1, Appendix A) a. This appendix provides a procedure for estimating whether a given flue design is likel to ensure full clearance of comustion products.. The procedure is ased 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: (K i + K o ) e H e = H a x (K i + K o ) a - K e H a + Sum K where: H e is the height of the equivalent flue; H a is the vertical height of the actual or proposed flue; K i is the inlet resistance of the flue; K o is the outlet resistance from the flue; suscript e refers to the equivalent flue diameter; suscript a refers to the actual or proposed flue diameter; K e is 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. ote: K and Sum K are otained from Tale 2. K o and K i are otained from Tale 3. c. Tale 2 gives resistance factors for common flue components for use in the formula. Tale 3 contains the appropriate inlet and outlet flue resistances. (the flue is likel to e satisfactor if its equivalent height exceeds 1m). Component Internal Size Resistance Component Internal Size Resistance (mm) Factor (mm) Factor Flue Blocks 197 x per meter 135 O Bend 100 mm pipe 0.61 per 231 x run 125 mm pipe 0.25 fitting 317 x mm pipe x x x x x x Pipe Raking lock An 0.30 per lock Adaptor lock An 0.50 Chimne 213 x Terminal 100 mm ridge mm ridge O Bend 100 mm pipe 1.22 per 150 mm ridge mm pipe 0.50 fitting 100 mm GCI mm pipe mm GCI mm GCI 0.12 Tale 2 Resistance factors for use in calculating equivalent heights 4

5 Appliance Inlet Flue Outlet Resistance (K i ) Resistance (K o ) 100 mm dia spigot mm flue mm dia spigot mm flue mm dia spigot mm flue 0.48 Tale 3 Inlet and outlet resistance d. Worked Calculation Example: A warm air unit with a 100 mm diameter flue spigot, fitted with a pre-faicated flue sstem leading to a ridge tile in the loft (refer Fig. 2): From tale 2: K ia Inlet resistance of actual flue = 2.5 K oa Outlet resistance of actual flue = 2.5 K ie Inlet resistance of equivalent flue = 2.5 K oe Outlet resistance of the actual flue = 2.5 From tale 3: Other resistances of actual flue: Terminal = 2.5 Pipe end ( 2 x 0.61) = 1.22 Pipe (4 x 0.78) = 3.12 (5 x 0.234) = 1.17 Sum K = 8.01 Equivalent height : From the formula ( ) H e = 6.2 x ( ) - (0.78 x 6.2) H e = This flue exceeds 1.0m equivalent height and is therefore satisfactor Where flue locks are used, uilders should ensure that no ostruction is created during erection. The installer should ensure that the connection flue does not project eond the internal wall of the flue locks and that there is provision for examination and servicing Important: Before installing the appliance, carr out a visual check of the flue sstem as directed in the relevant section of BS 5440 Pt.1, then check the flue performance as follows:- a. Close all doors and windows in the room in which the appliance is to e installed.. Introduce some heat into the flue, using a low torch or other means. c. Carr 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 onl, and no spillage into the room. Smoke coming out of other than the correct terminal onl, or a down draught or no flow condition, indicates that the flue has failed the test, and the appliance shall not e connected until the defect has een found and rectified, and the test satisfactoril completed. 5

6 STET Terminal 2 x 300 mm lengths 100 mm dia flue pipe H a = 6.2m 4.6m 4 x 1000 mm lengths 45 O end 300 mm length 1.6m 45 O end 2 x 300 mm lengths Fig. 2 Worked example of equivalent flue height 6 Appliance draught diverter 5.2 ELECTRICAL Mains. a. The heater is supplied with mains cale (PVC sheathed, heat resisting to 85 o C), 3-core Brown-Blue- Green/ellow, 6A, 0.75mm 2 ), connected to a terminal lock. The cale ma exit through either side of the fan compartment via a Universal ush. The cale is suitale for a 230V 50Hz suppl and shall e connected to the fixed wiring using a doule pole switched, fused spur, incorporating a protective earth link. The fuse fitted shall e rated 5A to BS Connections shall e in accordance with the current edition of I.E.E Regulations. ote: If a Side Return Kit SR55 is fitted, the mains cale should exit the heater from the OPPOSITE side.. MODAIRFLOW Models: An electronic controller (Thermista-stat) is supplied which acts as a room thermostat. c. on-modairflow models: A 24V room thermostat (not supplied), that complies with BS 800, BS 3955 and BS 4201 is essential to ensure close control of comfort conditions. An anticipator is located within the thermostat and is graded in amps. The anticipator should e checked and adjusted to 0.2A.

7 5.2.2 Thermista-stat/Room Thermostat and its location. a. The Thermista-stat/Room Thermostat should e located where there is free air circulation approx. 1.5m (5ft) from the floor.. Avoid the following locations:- i) In a room where temperature is greatl affected the sun or an other heat source, e.g. radiant fire, wall light fittings or TV set. ii) ear an outside door or windows, or on an outside wall. iii) Where affected warm air ducts, diffusers, waste pipes or the heater itself. iv) Where suject to viation. c. For MODAIRFLOW models, connect Thermista-stat wires to control panel terminals 4 and 5 (see Fig. 5a and 6a), connection polarit eing important, connect +ve side on control panel to +ve side on Thermista- stat. d. For non-modairflow models, connect room thermostat wires control panel terminals 16 and GAS (See BS 5864 and BS 6891) An independent gas suppl pipe from the meter is to e preferred wherever possile. When this is not possile, the pipe must e capale of taking the complete input of the heater and all other gas appliances eing served this same pipe. This suppl should e suital sized to conform to British Standards requirements of no more than 1.0 mar (0.4in wg) pressure drop (See tale of discharge in BS 6891) The 1/2in union gas cock (supplied) must e fitted to the gas inlet of the heater for eas isolation during servicing. The gas pipe should e so fitted and installed as to e durale, sustantial and gas tight. To assist in determining where a gas connection ma not e tight, a leak detection fluid should e applied around the connection. Under no circumstances should a flame e used to locate a gas leak. Gas entr to the air heater is through either side to a Rc1/2 (1/2in BSP. external [taper] thread). 5.4 Draught Diverter: The HI-SPEC JU55 heater is supplied with a draught diverter which requires fitting to the rear of the heater prior to installation, using 6 x 4mm screws and lock washers (provided), and the TTB connection to the terminal lock which is situated eneath the Overheat (Limit) switch cover (see para 8.15). 6. COMMISSIOIG 6.1 PREPARATIO: Ensure that: a. Gas and Electrical supplies are OFF.. Filter, fan and fan compartments are free from ostructions. c. All registers or grilles are open and conform to design specifications. d. Return, relief and ventilation air installations are adequate. 6.2 SETTIG OF FA SPEED: (on-modairflow models) Remove the air filter and fan chamer door Ensure that the Fan Control is set to OFF and 40 0 DIFF, Ensure that the Limit switch is set to F. This control is not to e set to an other setting Refit the fan chamer door and air filter. 6.3 IGITIO OF PILOT AD MAI BURERS: WARIG: If the pilot light is extinguished either intentionall or unintentionall, no attempt should e made to relight the gas for a minimum of 3 minutes. Ensure that the Electrical suppl, time control and Selector switches are set to OFF Set the Thermista-stat/room thermostat to lowest or OFF setting On the Multifunctional control, remove the Outlet Pressure test point cover, and fit a pressure test gauge (refer Fig. 4) Turn the heater Gas suppl O, test for gas soundness and purge the whole gas pipe as descried in BS Referring to Fig. 4, press and hold the OPERATIG COTROL, and whilst oserving the Pilot Burner, repeatedl press the Piezo igniter utton until Pilot urner ignites. 7

8 6.3.5 After 20 seconds release the OPERATIG COTROL and let it spring out; ensure that the Pilot urner remains alight. If Pilot urner extinguishes, rotate the OPERATIG COTROL clockwise to l position and ensure that the OPERATIG COTROL is full reset. Wait three minutes and repeat steps and until the Pilot urner remains alight, holding the OPERATIG COTROL depressed for a longer period than efore Ensure that the pilot flame envelops thermocouple tip, adjusting the Pilot Adjuster as required (refer Fig. 3) Set the Heater Electricit suppl O Set the Time control to the required Heating On periods Set the Selector switch to TIMED Set Thermista-stat or room thermostat to MAXIMUM Ensure that the main urner has now ignited Test for gas leakage at suppl, Multifunctional control, Pilot and Main urners using proprietar detection fluid, sealing an leaks found Allow heater to operate for a minimum of 15 mins. to ensure stailit. Thermocouple Pilot Burner Electrode Fig. 3 Pilot Burner Asseml 6.4 MAI BURER PRESSURE TEST: OTE: AIR HEATER BURERS ARE FACTOR SET TO PROVIDE A OMIAL HIGH PRESSURE OUTPUT AS DETAILED I SUB PARA Referring to Tale 4 and Fig. 4 elow, ensure that the pressure test gauge indicates the correct urner 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 correct urner pressure as detailed in Tale 4. iii. Refit the Burner Pressure Adjuster cover Appl the pressure set arrow to indicate the appropriate urner pressure on the data adge. 6.5 EXTIGUISHIG OF PILOT AD MAI BURERS: On the Multifunctional control, rotate the OPERATIG COTROL clockwise to the l position and ensure that the OPERATIG COTROL full resets, and oth Pilot and Main Burners are extinguished On the Multifunctional control, remove the pressure test gauge and refit the Outlet Pressure test point cover. 6.6 TEMPERATURE RISE CHECK: Ignite the Pilot and Main urners and allow 15 minutes for stailit efore continuing With the Main Burner operating continuousl, check that the temperature rise across heater is etween 45 o C - 55 o C, setting the fan speed accordingl, (decrease fan speed to increase temperature rise). For MODAIRFLOW heaters, adjusting the alancing screw sets fan speed; for non-modairflow heaters, fan speed is adjusted selecting fan speed at control panel (decrease voltage selection to decrease fan speed). ote: Tapping 1 = 130V, Tapping 2 = 140V, Tapping 3 = 150V, Tapping 4 = 170V, Tapping 5 = 230V 8

9 Operating control 2. Burner Pressure Adjuster 3. Outlet Pressure test point 4. Pilot Adjuster Fig. 4 Multifunctional Control 6.7 AUTOMATIC COTROLS CHECK Ignite the Pilot and Main urners and allow to operate for 15 minutes to ensure stailit Set the TIME COTROL (if fitted) to O Turn the Thermista-stat or room thermostat slowl clockwise until the Main urner ignites Ensure that the fan starts to operate after a short period (approx. 1-2 minutes). MODAIRFLOW models: Ensure that the fan speed increases to full speed When the temperature reaches the control setting, check that the Main urner ccles O and OFF, at approximatel 75 to 120 seconds. on-modairflow models: When the temperature reaches the control setting, ensure that the Main urner extinguishes followed the fan switching off after a short period When the temperature falls elow the control setting, ensure that the Main Burner re-ignites followed fan operation. 6.8 SAFET CHECKS: Check for gas soundness within the appliance Carr out a full spillage test as follows, and ensure that the flue operates effectivel with all doors closed and an extractor fans in operation. OTE: If an extractor fan is situated in an adjoining or adjacent room, carr out the spillage test with interconnecting doors open. If the Draught Diverter is accessile: a. Introduce smoke into the draught diverter adjacent to an exit from the heat exchanger, means a smoke match or puffer.. Ensure that there is no spillage present (indicated displacement of smoke downwards and out of the draught diverter. If the Draught Diverter is not accessile: a. Introduce smoke, means of part of a smoke pellet on a non-comustile support, into the heat exchanger ut not in contact with the heat exchanger.. Extinguish the Main and Pilot Burners as detailed in para 6.5 c. Ensure that there is no spillage present (indicated discharge of smoke from the draught diverter). d. Repeat spillage tests ut with the fan running, or Summer Airflow switch set to O Extinguish the Main and Pilot Burners as detailed in su para Switch the electrical suppl OFF. 9

10 6.8.5 MODAIRFLOW models, disconnect the Air Circulation fan at the fling socket on-modairflow models, disconnect the Air Circulation fan at the electrical control panel Switch the electrical suppl O Ignite the Main and Pilot urners as detailed in su para to Ensure that the Limit switch operates, indicated the Main Burner extinguishing, within 120 and 180 seconds Switch the electrical suppl OFF Reconnect the Air Circulation Fan Switch the electrical suppl O Ensure that the Main Burner re-ignites when the appliance temperature reduces, (note: with the fan disconnected, there ma e some dela efore the Main Burner re-ignites) Turn OFF the gas suppl at the service cock and ensure that the Multifunctional control fail-safe operates within 60 secs (indicated loud click from the Multifunctional control). 6.9 SSTEM BALACIG AD COMPLETIO: Set the SUMMER AIR CIRCULATIO switch to O Balance the sstem to provide the required volume proportions at the warm air outlets. OTE: If the sstem includes ceiling diffusers, air velocities through these should e OT LESS THA 1.5m/s (300ft/ min), except for ver small rooms (i.e. athrooms, etc.). Outlet faces ma require partial lanking in order to achieve this Turn the gas suppl O at the service cock Ignite the Pilot and Main urners as detailed in su para to Low Rate Low Medium Rate High Medium Rate HighRate kw MJ/h Btu/h kw MJ/h Btu/h kw MJ/h Btu/h kw MJ/h Btu/h IPUT , , , ,670 OUTPUT , , , ,000 Gas rate cv 1.52m 3 /h (53.65ft 3 /h) 1.71m 3 /h (60.46ft 3 /h) 1.87m 3 /h (66.02ft 3 /h) 2.03m 3 /h (71.75ft 3 /h) 1037Btu/ft 3 Burner setting 10.2mar (4.1 in wg) 12.9mar (5.2 in wg) 15.7mar (6.3 in wg) 18.0mar (7.2 in wg) pressure (hot) Main Injector BRA CAT 23/600 Tale 4 Main Burner Pressure Settings mar in.wg RESISTACE EXTERAL TO HEATER V 170V 190V ft 3 /min m 3 /sec AIR VOLUME Tale 5 Fan Performance Curve V 230V

11 7. ISTRUCTIOS FOR USERS 7.1 If the uilding 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 uilding is occupied, hand the User Instructions over and ensure the User understands: How to ignite the pilot and urner How to operate the Thermista-stat/room thermostat, time and heater O/OFF switch and summer air circulation switch, and that the time control must e reset following a power failure How to extinguish the pilot and main urner at the Multifunctional control, and switch off electrical suppl to the heater How to remove, clean and re-fit the air filter and at what intervals (i.e. fortnightl, or for new houses, weekl) How to control the heating sstem opening and closing warm air outlets How to otain summer air circulation That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of the uilding must not e ostructed That the heater must e serviced at least once a ear a competent person to ensure efficient and safe operation That the red instructions for safe use have een pointed out and understood That expert help must e otained if persistent failure of the pilot urner occurs. 8. MAITEACE IMPORTAT: Ensure gas and electricit supplies are isolated efore commencing an maintenance or replacement of components. After completion of an maintenance, alwas test for gas soundness and carr out a complete functional test of the appliance in accordance with Commissioning Instructions at Sect 6.1 to 6.8 inclusive. 8.1 ROUTIE MAITEACE: Operate the appliance and check for correct function of the urner and controls Check return air filter/air cleaner (if fitted) for cleanliness, remove and clean the air circulation fan as detailed in Sect Remove the urner and controls asseml as detailed in 8.2, inspect and clean the main urner and injectors as necessar. Examine the main urner for cracks, including hairline cracks, exchanging the urner as necessar Inspect and clear the pilot urner orifice Check the condition of thermocouple, igniter electrode and leads, cleaning as necessar Clean the heat exchanger fluewas thoroughl ushing from aove and elow, and inspect for damage Reassemle all items in reverse order and carr out the commissioning procedure as detailed in Sect BURER AD COTROLS ASSEMBL REMOVAL: Ensure that the Gas and Electrical supplies are switched OFF Remove the appliance upper front door Disconnect the igniter at the piezo unit Disconnect the Multifunctional control electrical connection Disconnect the gas suppl eaking the union at the input side of the Multifunctional control Remove the 6 x Burner asseml fixing screws and withdraw the Burner and Controls asseml Refit the Burner and Controls asseml in reverse order, ensuring that the guide plates on the end of each urner arm engage in the slots at the rear of the heat exchanger, and that the spillage affle aove the urner asseml contacts the top of each urner arm. 8.3 MAI BURER ASSEMBL CLEAIG: Remove the Burner and Controls asseml as detailed in Clean the urner thoroughl oth inside and out with a soft ush. DO OT ELARGE, DISTORT OR DAMAGE BURER HOLES Reassemle in reverse order. 11

12 8.4 MAI IJECTORS REMOVAL, CLEAIG AD MET: Remove the Burner and Control asseml as details in Remove the 2 x screws securing the Pilot urner asseml to the Burner and Control asseml and withdraw the Pilot urner asseml, taking care to avoid causing damage to the thermocouple capillar Remove the 2 x screws securing the Burner arm to the Burner and Controls asseml, and withdraw the Burner Arm Unscrew the 2 x Main injectors, and 1 x cross lighter injector from their housings Clean as necessar. DO OT ELARGE, DISTORT OR DAMAGE MAI IJECTOR HOLES If the injectors are to e replaced, ensure that the are correctl marked, referring to the Data Badge for details Refit or replace injectors in reverse order. 8.5 PILOT BURER, THERMOCOUPLE AD ELECTRODE, REMOVAL AD MET: Remove the Burner and Control asseml as detailed in Disconnect the Igniter lead from the Piezo unit Disconnect the Thermocouple from the Thermocouple adapter on the Multifunctional control, taking care to avoid causing damage to the thermocouple capillar Release the Pilot Gas Feed pipe from the Multifunctional control Remove the 2 x 4mm screws securing the Pilot Burner asseml to Burner and Control asseml, and withdraw the Pilot Burner Asseml Release the Thermocouple securing nut from the Pilot Burner asseml and withdraw the Thermocouple, taking care to avoid causing damage to the Thermocouple capillar Release the Electrode securing nut from the Pilot Burner asseml and withdraw the Electrode Release the Pilot Feed Pipe securing nut from the Pilot urner asseml and withdraw the Pilot Feed pipe and Pilot Injector from the Pilot Burner asseml, and disconnect the Pilot Injector from the Pilot Feed Pipe hook Refitting or replacement is in reverse order. OTE: When refitting or replacing Thermocouple, tighten onl to FIGER TIGHT + 1 FLAT. 8.6 MULTIFUCTIOAL COTROL REMOVAL: Remove the Burner and Control asseml as detailed in Disconnect the Thermocouple at Multifunctional control including adapter, avoiding damage to capillar Disconnect the Pilot gas suppl pipe from the Multifunctional control Disconnect the Multifunctional control input and output suppl feeds Refitting or replacement is in reverse order. 8.7 PIEZO UIT REMOVAL: Disconnect the 2 x conductors from the Piezo unit Unscrew the Piezo retaining nut and remove the unit from mounting its acket Refitting or replacement is in reverse order. 8.8 AIR CIRCULATIG FA, REMOVAL AD CLEAIG: Ensure that the electrical suppl is isolated Remove Air Filter and appliance lower and upper doors Release the 3 x screws securing the Electrical panel, and withdraw the panel, avoiding damage to wiring Disconnect the 2 x conductors from the Summer Air Circulation switch Release the Summer Air Circulation switch ezel, and remove the switch from the fan compartment diaphragm Withdraw the Fan Asseml from the Heater cainet sliding it forward, avoiding damage to fan lades Disconnect the 230V (L//E) connections from fan asseml Remove all dust from the impeller and motor, avoiding damage to the fan lades Refitting or replacement is in reverse order. 12

13 8.9 ELECTRICAL ASSEMBL REMOVAL: Ensure that the electrical suppl is isolated Remove the Air Filter and appliance lower and upper doors Release the 2 x 4mm screws securing Limit switch cover and withdraw cover. MODAIRFLOW models: Disconnect the following: a. Disconnect 230V connections (L//E) from Fan Asseml,. 230V mains L, and E from connection lock terminals 1, 3 and 2 respectivel, c. Thermista-stat connections from connection lock terminals 4 (+ve) and 5 (-ve), d. Limit switch LOAD and COMMO connections, e. 2 x Airflow sensor connections, O-MODAIRFLOW models: Disconnect the following: a. Disconnect 230V connections (L//E) from Fan Asseml,. 230V mains L, and E from connection lock terminals 1 and 3, and earth stud respectivel, c. Room thermostat connections from connection lock terminals 5 and 6, d. Limit switch LOAD and COMMO connections, e. Fan Dela Control LOAD, COMMO and EARTH connections, Both model tpes: Disconnect the 2 x TTB connections Disconnect the Multifunctional control connections Release the 3 x 4mm screws securing the Electrical asseml to the heater cainet and remove the Electrical asseml, releasing wiring from cale clamps and grommets as required Refitting or replacement is in reverse order ELECTROIC MODULE REMOVAL (MODAIRFLOW models onl) Remove the Electrical Asseml as detailed in Sect Disconnect the Electronic module from the Electrical asseml Release the 3 x screws securing the Electronic module to the Electrical asseml and remove the module Refitting or replacement is in reverse order TRASFORMER REMOVAL (MODAIRFLOW models onl): Remove Electrical asseml as detailed in sect Disconnect Transformer from Electrical asseml terminal lock, and fuse from Earth stud, Release 2 x screws and nuts securing Transformer to Electrical asseml, and remove Transformer Refitting or replacement is in reverse order TIME COTROL REMOVAL: Ensure electrical suppl is isolated Release securing screw situated on lower face of Time Control and remove partiall withdrawing ottom of Time Control and then lifting upwards Disconnect Time Control electrical connections from integral terminal strip Refitting or replacement is in reverse order Set Time Control to required O and OFF times Set Time Control to correct time. 13

14 8.13 FA DELA COTROL, LIMIT SWITCH AD AIRFLOW SESOR REMOVAL: OTE: Airflow sensor applies to MODAIRFLOW models onl, whilst Fan Dela Control applies solel to non- MODAIRFLOW models Ensure electrical suppl is isolated Remove appliance lower and upper doors Release 2 x 4mm screws securing Limit switch cover and withdraw cover Disconnect required control/switch Release 2 x securing screws and remove required control/switch Refitting or replacement is in reverse order SPILLAGE MOITORIG DEVICE (TTB) REMOVAL: Ensure electrical suppl is isolated Remove appliance lower and upper doors, and TTB Terminal cover secured to the Overheat (Limit) switch cover Disconnect the TTB from the terminal lock Remove the TTB wiring guard to upper left hand side of the heater (the rear screw need not e removed as the rear of the wiring guard has a kehole slot Withdraw the TTB wiring from the grommet situated on the upper left hand side of the Air Heater If the heater is fitted in a compartment, ascertain if access to the TTB Mounting acket is possile from the top left hand side of the heater. If access to the TTB is not possile, remove the Deliver duct from the top of the heater, and ascertain if access to the TTB mounting acket is now possile. If access to the TTB mounting acket is not possile from either the side or the top of the heater, the heater must e removed from the installation efore proceeding With access to the TTB Mounting acket gained, release the stainless steel fixing screw securing the TTB Asseml to the Draught Diverter, and withdraw the TTB Asseml Refitting or replacement is in reverse order HEAT EXCHAGER ACCESS: Release 2 x securing screws and remove heat exchanger access cap and gasket Remove heat exchanger affle Reasseml is in reverse order. OTE: When reassemling, ensure affle is pushed full home and access cap is full sealed. In the event of heat exchanger replacement eing necessar, contact Johnson and Starle Service Department. 9. DEFECT DIAGOSIS 9.1 IMPORTAT: If an electrical defect occurs after installation of the appliance; preliminar earth continuit, polarit, and resistance to earth checks should e carried out with a multimeter. On completion of an maintenance/fault-finding task that has required the eaking and remaking of electrical connections, then checks of continuit, polarit, and resistance to earth must e repeated. 9.2 WARIGS: When purging or checking gas supplies, ensure ventilation to the room or cupoard is adequate, and all naked lights are extinguished MODAIRFLOW models: Before commencing defect diagnosis, ensure Thermista-stat is set to maximum, mains suppl is O and time control (if fitted) is at an O position Care is to e taken during the replacement and handling of electronic assemlies (i.e. electronic panel, airflow sensor or Thermista-stat), it is not practical to rectif defects on these assemlies, except at the manufacturer, and an attempt to do so ma render the guarantee or factor replacement arrangement invalid. 14

15 SMPTOM POSSIBLE CAUSE REMED a. Pilot will not light. i. o gas suppl to heater. Check for gas at inlet pressure test point on multifunctional control. ii. Gas suppl pipe not purged. Purge gas suppl pipe in accordance with BS iii Pilot orifice restricted. Clear pilot orifice or replace pilot injector. iv. Piezo sstem fault. Check igniter, lead, and electrode. v. Excessive gas suppl pressure. Check that mains gas pressure is 20mar, and reduce if necessar.. Pilot lights ut goes i. Connection etween thermo- Check connection is secure. out on releasing START couple and multifunctional utton during initial control not secure. light-up, or after normal operation. ii. Fault power unit on gas Replace Multifunctional control. control. iii. Fault thermocouple. Replace Thermocouple. iv. Comustion air contaminated. Conduct spillage test and rectif. c. Main urner lights i. Loose electrical connection Check connections. ut fan fails to run fan dela control. after approx. 3 min. ii. Fan control set incorrectl. Check for correct settings. iii. Fault fan asseml. Replace, taking care not to damage impeller. iv. Fault fan control. Replace. d. Main urner opera- i. Gas rate or urner pressure Check gas rate and urner pressure ting intermittentl setting high. setting. with fan running. ii. Temperature rise excessive. Adjust fan speed or gas rate accordingl. iii. Air filter or return air path Check filter is clean and air path is clear. restricted. iv. Excessive numer of outlets Open additional outlets. closed. v. Spillage of flue gases. Carr out spillage test and rectif. vi. Spillage monitor device (TTB) Replace Spillage device (TTB) fault. e. Main urner opera- i. Gas rate or urner pressure Check gas rate and urner pressure ting with intermittent setting too low. setting. fan operation. ii. Fan control set incorrectl. Check for correct settings. f. Fan runs for excessive i. Fan control set incorrectl. Check for correct settings. period or operates intermittentl after main urner shuts down. g. ois operation. i. Gas pressure too high. Check urner pressure setting. ii. ois fan motor. Replace fan asseml. iii. Fan speed setting too high. Adjust fan speed. 15

16 MODAIRFLOW models: h. Incorrect operation Fault related to Modairflow Consult diagnostic chart and follow of fan or main urner. Control sstem (refer to pages 14-18) recommended procedure. on-modairflow models: j. Pilot alight ut main i. Mains electrical suppl not Check mains suppl. urner not igniting. connected to heater. ii. Controls not demanding heat Check that time control (if fitted) and room thermostat are operating correctl. iii. 3A fuse failed. Replace. If failure occurs again, check wiring for short circuits. iv. Loose connection to room thermo- Check connections. stat, overheat (limit) control, gas control lead, time control, or transformer. v. Transformer open circuit. Check with test meter and replace transformer (Modairflow) or electrical asseml (non- Modairflow). vi. Multifunctional control fault. Replace Multifunctional control. vii. Limit switch fault. Short circuit switch and replace if necessar. viii. Room thermostat or external Fit temporar loop in heater thermostat wiring fault. socket. If heater ignites, external circuit or room thermostat is fault. ix. TTB fault Check TTB and wiring for open circuit. MODAIRFLOW DEFECT DIAGOSIS FLOW CHART MAI BURER O, BUT FA OT RUIG CHECK FOR VOLTAGE AT FA LIVE TO EUTRAL BRIDGE OUT AIRFLOW SESOR FA DOES FA START? AIRFLOW SESOR CHECK FOR VOLTAGE AT FA LIVE TO EARTH ELECTROICS MODULE IS FUSE OK? TRASFORMER FUSE 16

17 MAI BURER OT OPERATIG IS PILOT LIT? IS GAS O? TUR GAS O SWITCH O 230 V IS 230V SUPPL O? LIGHT PILOT IS TIME COTROL & THERMISTA-STAT CORRECTL SET? SET COTROLS CORRECTL IS FUSE OK? FUSE CHECK 24V AT MULTIFUC- TIOAL COTROL BRIDGE THERMISTA-STAT TERMIALS AT HEATER MULTIFUCTIOAL COTROL CHECK, TTB LIMIT SWITCH & COECTIOS CHECK 230V I/P & TIME COTROL OPERATIO TRASFORMER IS BURER LIT? CHECK TERMIAL D9 IS 18V CHECK TERMIAL C8 IS 230V CHECK TERMIAL C10 IS 24V ELECTROIC MODULE CHECK POLARIT OF THERMISTA-STAT COECTIOS IS POLARIT CORRECT? BRIDGE THERMISTA-STAT TERMIALS AT HEATER IS BURER LIT? WIRIG DEFECT BETWEE HEATER & THERMISTA-STAT RECTIF DEFECT THERMISTA-STAT 17

18 FA OPERATES, BUT BURER CCLES BEFORE REQUIRED TEMPERATURE IS REACHED BRIDGE THERMISTA-STAT DOES BURER STA LIT? IS OVERHEAT COTROL OK? THERMISTA-STAT ELECTROIC MODULE CHECK TEMPERATURE RISE ACROSS HEATER IS LESS THA 60 c CHECK AIR FILTER & RETUR AIR PATH FOR RESTRICTIOS CHECK, TTB LIMIT SWITCH & COECTIOS IS PATH CLEAR? CLEAR RESTRICTIOS AD BLOCKAGES CHECK MAI BURER PRESSURE SETTIGS ARE CORRECT CHECK FA BALACIG SCREW IS CORRECTL SET SET FA SELECTOR SWITCH TO COTIUOUS SET TO CORRECT PRESSURE SETTIG SET FA BALACIG SCREW DOES FA SPEED UP? SET FA SELECTOR TO AUTO & BRIDGE AIRFLOW SESOR ELECTROIC MODULE DOES FA SPEED UP? AIRFLOW SESOR ELECTROIC MODULE 18

19 FA COTIUES TO RU AFTER HEATIG IS TURED OFF CHECK FA SELECTOR SWITCH SETTIG IS SWITCH SET TO AUTO? SET FA SELLECTOR SWITCH TO AUTO DOES FA STILL RU? CHECK SUMMER AIR CIRCULATIO SWITCH IS SWITCH SET TO OFF? SET FA SUMMER AIR CIRCULATIO SWITCH TO OFF DOES FA STILL RU? DOES FA STILL RU? DISCOECT AIRFLOW SESOR DOES FA STILL RU? ELECTROICS MODULE IS PILOT FLAME TOO BIG? ADJUST PILOT FLAME TO CORRECT SETTIG AIRFLOW SESOR 19

20 MAI BURER OL FIRES FOR SHORT PERIODS IS THERMISTA- STAT SET TO MAX? SET THERMISTA-STAT TO MAX BRIDGE THERMISTA-STAT AT HEATER DOES BURER STA LIT? ELECTROIC MODULE CHECK THERMISTA-STAT COECTIOS POLARITIES IS POLARIT OK? RECTIF BRIDGE TERMIALS AT THERMISTA-STAT DOES BURER STA LIT? THERMISTA-STAT DEFECT IS I THERMISTA-STAT ISTALLATIO WIRIG 20

21 MAI BURER OT CCLIG (ROOM TEMPERATURE TOO HIGH) DISCOECT THERMISTA-STAT DOES BURER GO OUT? THERMISTA-STAT DISCOECT ELLOW WIRE AT MULTIFUCTIOAL COTROL DOES BURER GO OUT? ELECTROICS MODULE MULTIFUCTIOAL COTROL 21

22 g/ 230V 24V 24V g r or g g k g r g pk w 18V g/ w w nc L pk w pk g/ k w w w k k g/ pk k g/ pk L Issue 10 k red own lue lack r k COLOUR CODE:- ellow white green green/ellow w g g/ pink gre orange pk g or FA TRASFORMER MA HAVE ITERWIDIG EARTHED SCREE FITTIG 'C' FITTIG 'D' 12 wa connector 10 wa connector V w 18V k 0V 0V k CL2 TIME COTROL L E 3 4 Summer Switch TTB T 1(A) T 1(A) or AIRFLOW SESOR g/ g/ MULTI-FUCTIOAL GAS COTROL g/ g/ EARTH STUD OVERHEAT LIMIT COTROL k g/ nc - + L THERMISTA-STAT COECTIOS 230V MAIS COECTIOS Fig. 5a, MODAIRFLOW CIRCUIT DIAGRAM

23 w 170 v or 140 v g 150 v Issue 14 v 130 v FUSE T 3.15(A) 24V TRASFORMER MA HAVE ITERWIDIG EARTHED SCREE Transformer voltage tappings Hi-Spec JU55 T1=130V T2=140V T3=150V T4=170V T5=230V COLOUR CODE:- Red r Brown Blue Black k Orange or Violet v ellow White w Gre g Green/ellow g/ L r FA g/ k 0V g Summer Switch g g/ EARTH STUD g/ 230V 23 CL2 TIME COTROL L E 3 4 g/ g/ g/ g/ g r r g/ g/ g/ r r L r TAP CHAGER MAIS SUPPL 230V 50Hz MULTI-FUCTIOAL GAS COTROL OVERHEAT LIMIT COTROL TTB g/ FA DELA COTROL r r Room Th'stat Connections g/ Fig. 5, on-modairflow CIRCUIT DIAGRAM

24 Conn. 'D' Conn. 'C' M L M3 TC5 230V 50 Hz Suppl M1 TC3 TC4 CLOCK T7 T3 T10 Summer Switch g g 230V 24V g r or k M5 M4 TTB F3 * Functional Extra low voltage * - + Overheat Limit Control Thermista-stat (External connection) Air flow sensor g/ Multi-functional Gas Control 24V T 1(A) FUSE T8 18V w w T k T1 k w T11 T 1(A) FUSE k w T9 w 0V 18V 24V 230V pk T6 pk F1 Air Fan M F3 k Wire colour code where indicated pink pk red r lue lack k own white w gre g orange or ellow green g green/ellow ---- g/ F = Fan terminal lock T = Transformer terminal lock M = Main terminal lock TC = Time control connections Issue 03 Fig. 6a, MODAIRFLOW FUCTIOAL DIAGRAM 24

25 L M M12 M10 230V 50 Hz Suppl M1 TC3 TC4 M8 M5 Room Thermostat (External connection) CLOCK T5 TTB Overheat Limit Control Multi-functional Gas Control 24v g/ M4 T 3.15(A) FUSE k Transformer voltage tappings Hi-Spec JU55 T1=130V T2=140V T3=150V T4=170V T5=230V 0V 24V 230V v or g w T1 T2 T3 T4 T5 r g M6 r Summer Switch Fan Dela Control g Air Fan r M7 r M Wire colour code where indicated red r lue lack k own white w gre g orange or ellow violet v green g green/ellow ---- g/ F = Fan terminal lock T = Transformer terminal lock M = Main terminal lock TC = Time control connections Issue 03 Fig. 6, non-modairflow FUCTIOAL DIAGRAM 25

26 TOP VIEW BASE VIEW FROT VIEW SIDE VIEW Fig. 7, PRICIPAL DIMESIOS (mm) 26

27 10. SHORT LIST OF SPARES ITEM G.C. MAKER S DESCRIPTIO QT o o o Fan asseml 1 2 U Filter tra asseml CL2/0100 Time control CL Time Control Cover BOS00105 Overheat (limit Control) 1 Honewell L4069C BOS01301 Multifunctional control valve 1 Honewell V8600C BOS02061 Sealing ring (for item 6) 2 8 BOS02397/4 Pilot asseml Pilot Injector Pilot Feed Pipe Thermocouple BOS01970 Electrode BOS02394 Electrode lead BOS02406 Electrode ut 1 15 U Spillage switch (TTB) 1 16 U Burner and Controls Asseml Burner and Cross Lighter Asseml Main Injector Cross Lighting Injector (Bra) 1 or Cross Lighting Injector (Stereomatic) 1 20 U Heat Exchanger exchange kit Piezo Unit B Igniter Bracket Rope Ring Seal (for heat exchanger cap) 2 24 U Draught Diverter Asseml 1 MODAIRFLOW MODELS 25 U Upper Cainet Door 1 26 U Lower Cainet Door 1 27 U Control Panel with Transformer Wiring Harness R006 Electronics Module S00076 Airflow Temperature Sensor Fuse 1A x 1.25 inch (T) BOS01242 Thermista-stat Transformer 1 O-MODAIRFLOW MODELS 34 U Upper Cainet Door 1 25 U Lower Cainet Door Control Panel Wiring Harness BOS00104 Fan Control Honewell L4068C 1 39 BOS Fuse 3A x 1 inch, (T) 1 27