Johnson & Starley 42-451-14, Installation, Commissioning & Servicing Instructions

Page: 12 / 36

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9
1. Operating control
2. Burner Pressure Adjuster
3. Outlet Pressure test point
4. Pilot Adjuster
Fig. 4
MULTIFUNCTIONAL CONTROL
6.7
AUTOMATIC CONTROLS CHECK
6.7.1 Set the TIME CONTROL to ‘ON’.
6.7.2 Turn the Thermista-stat or room thermostat slowly clockwise until the Main Burner ignites.
6.7.3 Ensure that the fan starts to operate after a short period (approx. 1-2 minutes).
MODAIRFLOW models :
6.7.4 Ensure that the fan speed increases to full speed.
6.7.5 When the temperature reaches the control setting, check that the Main Burner cycles ON and OFF, at approximately
75 to 120 seconds.
Non-MODAIRFLOW models
:
6.7.6 When the temperature reaches the control setting, ensure that the Main Burner extinguishes followed by the fan
switching off after a short period.
6.7.7 When the temperature falls below the control setting, ensure that the Main Burner re-ignites followed by fan
operation.
6.8 SAFETY CHECKS :
6.8.1 Check for gas soundness within the appliance.
6.8.2
Spillage test: Carry out a full spillage test as follows, and ensure that the flue operates effectively with all doors
closed and any extractor fans in operation.
NOTE: If an extractor fan is situated in an adjoining or adjacent room, carry out the spillage test with the interconnecting
doors open.
If the draught diverter is accessible:
a. Introduce smoke into the draught diverter adjacent to an exit from the heat exchanger, by means a smoke
match or puffer.
b. Ensure that there is no spillage present (indicated by displacement of smoke downwards and out of the
draught diverter.
If the Draught Diverter is not accessible:
a. Introduce smoke, by means of part of a smoke pellet on a non-combustible support, into the heat
exchanger.
b. Extinguish the Main and Pilot burners.
c. Ensure that there is no spillage evident by visually observing the draught diverter location on the air
heater.
d. If spillage is evident, further investigation and rectification is required before re-testing the appliance.
e. Repeat spillage tests but with the fan running, or Summer Airflow switch set to ON.
WARNING: The appliance shall not be left connected to the gas supply unless it has successfully passed
the above spillage test.
20
1
2
3
4
FAN CONTINUES TO RUN AFTER HEATING IS TURNED OFF
CHECK FAN SELECTOR
SWITCH SETTING
SET FAN SELECTOR
SWITCH TO
AUTO
N
Y
IS
SWITCH SET
TO AUTO ?
CHECK SUMMER AIR
CIRCULATION
SWITCH
IS
SWITCH SET
TO OFF ?
DOES
FAN STILL
RUN ?
DOES
FAN STILL
RUN ?
SET FAN SUMMER
AIR CIRCULATION
SWITCH TO OFF
N
Y
Y
Y
DOES
FAN STILL
RUN ?
DISCONNECT AIRFLOW
SENSOR
Y
DOES
FAN STILL
RUN ?
REPLACE
ELECTRONICS
MODULE
Y
IS
PILOT FLAME
TOO
BIG?
N
Y
ADJUST PILOT
FLAME TO CORRECT
SETTING
REPLACE
AIRFLOW SENSOR
N
6.8.3 Turn OFF the gas supply at the service cock and ensure that the Multifunctional Control fail-safe operates within
60 secs (indicated by loud click from Multifunctional Control).
6.8.4 Turn the gas supply ON at the service cock.
6.8.5 Switch the electrical supply to the appliance OFF.
6.8.6 MODAIRFLOW models , disconnect the air circulation fan at the flying socket
6.8.7 Non-MODAIRFLOW models , disconnect the air circulation fan at the electrical control panel .
6.8.8 Switch the electrical supply to the appliance ON.
6.8.9 Ignite the Main and Pilot Burners as detailed in sub para 6.3.1 to 6.3.5
6.8.10 Ensure that the Limit Switch operates, indicated by the Main Burner extinguishing, within 120 and 180 seconds.
6.8.11 Switch the electrical supply to the appliance OFF.
6.8.12 Reconnect the air circulation fan.
6.8.13 Switch electrical supply to the appliance ON.
6.8.14 Ensure that the Main Burner re-ignites when the appliance temperature reduces, (
note: with the fan disconnected,
there may be some delay before the Main Burner re-ignites).
LOW RATE MEDIUM RATE HIGH RATE
kW MJ/h Btu/h kW MJ/h Btu/h kW MJ/h Btu/h
INPUT 21.6 77.6 73,550 23.3 83.62 79,277 25.0 90.0 85,302
OUTPUT 16.1 58.0 55,000 17.6 63.3 60,000 19.1 68.6 65,000
Gas rate cv 2.05m
3
/h (72.62ft
3
/h) 2.21
3
/h (87.27ft
3
/h) 2.38m
3
/h (84.22ft
3
/h)
1037Btu/ft
3
Burner setting 11.5mbar (4.6 in wg) 13.2mbar (5.3 in wg) 15.5mbar (6.2 in wg)
pressure (hot)
Main Injector
BRAY CAT 23/850
10
Table 4
Main Burner Pressure Settings
19
MAIN BURNER ONLY FIRES FOR SHORT PERIODS
DEFECT IS IN
THERMISTA-STAT
INSTALLATION WIRING
DOES
BURNER
STAY
LIT?
Y
REPLACE
THERMISTA-STAT
BRIDGE TERMINALS AT
THERMISTA-STAT
Y
IS
POLARITY
OK ?
N
RECTIFY
CHECK THERMISTA-STAT
CONNECTIONS POLARITIES
Y
REPLACE
ELECTRONIC MODULE
N
DOES
BURNER
STAY
LIT?
BRIDGE THERMISTA-STAT
AT HEATER
Y
SET THERMISTA-STAT
TO MAX
IS
THERMISTA-
STAT
SET TO
MAX ?
N
N
mbar in.wg.
0.50 0.20
0.375 0.15
0.25 0.10
0.125 0.05
RESIST
ANCE EXTERNAL
T
O HEA
TER
300 400 500 600 700 800 ft
3
/min
0.14 0.19 0.24 0.28 0.33 0.38 m
3
/sec
AIR VOLUME
RESPONSE AREA
Table 5
Fan Performance Curve
6.8.3 Turn OFF the gas supply at the service cock and ensure that the Multifunctional Control fail-safe operates within
60 secs (indicated by loud click from Multifunctional Control).
6.8.4 Turn the gas supply ON at the service cock.
6.8.5 Switch the electrical supply to the appliance OFF.
6.8.6 MODAIRFLOW models , disconnect the air circulation fan at the flying socket
6.8.7
Non-MODAIRFLOW models
, disconnect the air circulation fan at the electrical control panel
.
6.8.8 Switch the electrical supply to the appliance ON.
6.8.9 Ignite the Main and Pilot Burners as detailed in sub para 6.3.1 to 6.3.5
6.8.10 Ensure that the Limit Switch operates, indicated by the Main Burner extinguishing, within 120 and 180 seconds.
6.8.11 Switch the electrical supply to the appliance OFF.
6.8.12 Reconnect the air circulation fan.
6.8.13 Switch electrical supply to the appliance ON.
6.8.14 Ensure that the Main Burner re-ignites when the appliance temperature reduces, (
note: with the fan disconnected,
there may be some delay before the Main Burner re-ignites).
LOW RATE MEDIUM RATE HIGH RATE
kW MJ/h Btu/h kW MJ/h Btu/h kW MJ/h Btu/h
INPUT 21.6 77.6 73,550 23.3 83.62 79,277 25.0 90.0 85,302
OUTPUT 16.1 58.0 55,000 17.6 63.3 60,000 19.1 68.6 65,000
Gas rate cv 2.05m
3
/h (72.62ft
3
/h) 2.21
3
/h (87.27ft
3
/h) 2.38m
3
/h (84.22ft
3
/h)
1037Btu/ft
3
Burner setting 11.5mbar (4.6 in wg) 13.2mbar (5.3 in wg) 15.5mbar (6.2 in wg)
pressure (hot)
Main Injector
BRAY CAT 23/850
10
Table 4
Main Burner Pressure Settings
19
MAIN BURNER ONLY FIRES FOR SHORT PERIODS
DEFECT IS IN
THERMISTA-STAT
INSTALLATION WIRING
DOES
BURNER
STAY
LIT?
Y
REPLACE
THERMISTA-STAT
BRIDGE TERMINALS AT
THERMISTA-STAT
Y
IS
POLARITY
OK ?
N
RECTIFY
CHECK THERMISTA-STAT
CONNECTIONS POLARITIES
Y
REPLACE
ELECTRONIC MODULE
N
DOES
BURNER
STAY
LIT?
BRIDGE THERMISTA-STAT
AT HEATER
Y
SET THERMISTA-STAT
TO MAX
IS
THERMISTA-
STAT
SET TO
MAX ?
N
N
mbar in.wg.
0.50 0.20
0.375 0.15
0.25 0.10
0.125 0.05
RESIST
ANCE EXTERNAL
T
O HEA
TER
300 400 500 600 700 800 ft
3
/min
0.14 0.19 0.24 0.28 0.33 0.38 m
3
/sec
AIR VOLUME
RESPONSE AREA
Table 5
Fan Performance Curve
Table 4 Main Pressure Settings