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

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Sales/Spares & Replacement Help Line 01604 762881
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
7. INSTRUCTIONS FOR USERS
7.1 If the building is unoccupied, ensure that the Instructions for User are left taped to the air heater for the User, and
Installation Instructions are left at or near the air heater for use on future service calls.
7.2 If the building is occupied, hand the User Instructions over and ensure the User understands:
7.2.1
How to ignite the Pilot and Main Burners.
7.2.2 How to operate the Thermista-stat/room thermostat, time and heater ON/OFF switch and summer air circulation
switch, and that the Time Control must be reset following a power failure.
7.2.3 How to extinguish the Pilot and Main Burner at the Multifunctional Control, and switch off electrical supply to the
heater.
7.2.4 How to remove, clean and re-fit the air filter and at what intervals (i.e. fortnightly, or for new houses, weekly).
7.2.5 How to control the heating system by opening and closing warm air outlets.
7.2.6 How to obtain summer air circulation.
7.2.7 That the air grilles on the heater or heater compartment; grilles and ventilators in the walls, windows or doors of
the building must not be obstructed.
7.2.8 That the heater must be serviced at least once a year by a competent person to ensure efficient and safe operation.
7.2.9 That the red instructions for safe use have been pointed out and understood.
7.2.10 That expert help must be obtained if persistent failure of the pilot burner occurs.
8. MAINTENANCE
IMPORTANT: Ensure gas and electricity supplies are isolated before commencing any maintenance or replacement of
components. After completion of any maintenance, always test for gas soundness and carry out a complete functional test of the
appliance in accordance with Commissioning Instructions at Sect 6.1 to 6.8 inclusive.
8.1
ROUTINE MAINTENANCE:
8.1.1 Operate the appliance and check for the correct function of the burner and controls.
8.1.2 Turn OFF the gas and electrical supplies to the appliance.
8.1.3 Remove the air heater front panel.
8.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the Air Circulation fan as
detailed in para 8.7.
8.1.5 Remove the Burner and Controls Assembly as detailed in para 8.2. Inspect and clean the Main Burner and injector
as necessary. Examine the Main Burner for cracks, including hairline cracks, exchanging the burner as necessary.
8.1.6 Inspect and clear the pilot burner orifice.
8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below.
8.1.8 By viewing through the Fan Aperture, and using a torch or similar, examine the heat exchanger externally for signs
of cracks or holes, particularly around welded joints.
8.1.9 Using a torch or similar, introduce a light source into the heat exchanger burner aperture and upper access port,
and again examine the heat exchanger for signs of cracks or holes, particularly around welded joints, whilst again
viewing through the Fan Aperture.
8.1.10 Refit the Air Circulation fan, Burner and Controls Assembly, and air filter/air cleaner.
8.1.11 Light the appliance and note the main burner flame profile. If the flame profile is affected when the Air
Circulation fan switches on, check for any air leaks between the air heater and the base plenum, paying particular
attention to heaters with rear draught diverters. Rectify any air leaks before continuing with this procedure.
8.1.12 Allow the air heater to operate for approximately 15 minutes to ensure stability, and with the main burner lit,
ensure that the operation of Air Circulation fan does not affect the main burner flame profile.
8.2 BURNER AND CONTROL ASSEMBLY REMOVAL:
8.2.1 Ensure Gas and Electrical supplies are switched OFF
8.2.2 Remove appliance lower front door.
8.2.3 Disconnect igniter at the piezo unit.
8.2.4 Disconnect Multifunctional Control electrical connections.
8.2.5 Disconnect the gas supply by breaking the union at the input side of the Multifunctional Control.
8.2.6 Whilst supporting the Burner and Control Assembly, remove 2 x Burner assembly fixing screws and withdraw the
Burner and Control Assembly
8.2.7 Refit Burner and Control Assembly in reverse order, ensuring that the guide plates on the end of each burner arm
engage in the slots at the rear of the heat exchanger, and that the spillage baffle above the burner assembly contacts
the top of each burner arm.
11 18
FAN OPERATES, BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS
REACHED
BRIDGE
THERMISTA-STAT
N
CHECK AIR FILTER &
RETURN AIR PATH FOR
RESTRICTIONS
SET FAN SELECTOR TO AUTO
& BRIDGE AIRFLOW SENSOR
N
CHECK TEMPERATURE
RISE ACROSS HEATER IS
LESS THAN 60°C
CHECK TTB, LIMIT
SWITCH & CONNECTIONS
Y
Y
CHECK MAIN BURNER
PRESSURE SETTINGS
ARE CORRECT
SET TO CORRECT
PRESSURE SETTING
N
Y
SET FAN
BALANCING SCREW
Y
DOES
FAN
SPEED
UP?
N
Y
REPLACE
ELECTRONIC MODULE
REPLACE
ELECTRONIC MODULE
REPLACE
AIRFLOW SENSOR
IS
PATH
CLEAR?
N
CLEAR RESTRICTIONS
AND BLOCKAGES
CHECK FAN BALANCING
SCREW IS CORRECTLY
SET
N
DOES
FAN
SPEED
UP?
N
Y
SET FAN SELECTOR
SWITCH TO
CONTINUOUS
DOES
BURNER
STAY
LIT?
REPLACE
THERMISTA-STAT
Y
REPLACE
ELECTRONIC MODULE
N
Y
IS
OVERHEAT
CONTROL
OK ?
7.2.8 Help must be obtained if persistent failure of the pilot burner occurs.
7.2.9 Make sure you understand the instructions for safe use and they have been understood.
7.2.10 After installation and commissioning the Benchmark Checklist is filled in. For IE, it is
necessary the complete a ‘Declaration of Conformity’ to indicate compliance to I.S. 813.
7.2.11 Safe registered engineer. In I.E. servicing work must be carried out by a Registered Gas Installer (RG11).