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

Page: 14 / 36

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14
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 ?
8. MAINENANCE
17
8.3 BURNER AND CONTROL ASSEMBLY CLEANING:
8.3.1 Remove Burner and Controls Assembly as detailed in 8.2.
8.3.2
Clean burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR DAMAGE
BURNER HOLES .
8.3.3 Reassemble in reverse order.
8.4 MAIN INJECTORS REMOVAL, CLEANING AND REPLACEMENT:
8.4.1 Remove the Burner and Controls assembly as details in 8.2
8.4.2 Unscrew the 2 x Main injectors, and 1 x cross lighter injector from their housings.
8.4.3 Clean as necessary.
DO NOT ENLARGE, DISTORT OR DAMAGE MAIN INJECTOR HOLES.
8.4.4 If the injectors are to be replaced, ensure that they are correctly marked, referring to the Data Badge for details.
8.4.5 Refitment or replacement of injectors in reverse order.
8.5 PILOT BURNER, THERMOCOUPLE AND ELECTRODE, REMOVAL AND REPLACEMENT:
8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2
8.5.2 Disconnect the Igniter lead from the Piezo unit.
8.5.3 Disconnect the Thermocouple from the Thermocouple adapter on the Multifunctional Control, taking care to
avoid damage to the thermocouple capillary.
8.5.4 Release the Pilot Feed Pipe from the Multifunctional Control.
8.5.5 Remove 2 x 4mm screws securing the Pilot Burner assembly to the Burner arm, and withdraw the Pilot Burner
Assembly.
8.5.6 Release the Thermocouple securing nut from the Pilot Burner assembly and withdraw the Thermocouple, taking
care to avoid damage to the Thermocouple capillary.
8.5.7 Release the Electrode securing nut from the Pilot Burner assembly and withdraw the Electrode.
8.5.8 Release the Pilot Feed Pipe securing nut from the Pilot burner assembly and withdraw the Pilot Feed pipe and
Pilot Injector from the Pilot Burner assembly, and disconnect the Pilot Injector from the Pilot Feed Pipe hook.
8.5.9 Release 2 x 5mm screws securing the Pilot Burner Bracket to the Pilot Mounting bracket, and remove the Pilot
Burner Bracket.
8.5.10 Refitting or replacement is in reverse order.
NOTE: When refitting or replacing Thermocouple, tighten only to FINGER TIGHT + 1 FLAT.
8.6 MULTIFUNCTIONAL CONTROL REMOVAL:
8.6.1 Remove the Burner and Controls Assembly as detailed in 8.2
8.6.2 Disconnect the Thermocouple at the Multifunctional Control including adapter, avoiding damage to the capillary.
8.6.3 Disconnect the Pilot gas supply pipe from the Multifunctional control.
8.6.4 Disconnect the Multifunctional control input and output supply feeds.
8.6.5 Refitting or replacement is in reverse order.
8.7
PIEZO UNIT REMOVAL:
8.7.1 Disconnect 2 x conductors from Piezo unit.
8.7.2 Unscrew the Piezo retaining nut and remove the unit from its mounting bracket.
8.7.3 Refitting or replacement is in reverse order.
8.8 AIR CIRCULATING FAN, REMOVAL AND CLEANING:
8.8.1 Ensure that the electrical supply is isolated.
8.8.2 Remove the Air Filter and air heater cabinet doors.
8.8.3 Disconnect the Overheat limit device at the terminal block plug situated on the right hand side of the fan
chamber floor.
8.8.4 Disconnect the 230V connections (L/N/E) from the Fan Assembly.
8.8.5 Release the 2 x Fan Assembly securing screws and withdraw the Fan Assembly from the Heater cabinet.
8.8.6 Remove and discard the screw securing the Overheat limit device ‘P’ clip to the side of the Replacement Fan
Assembly, and discard the ‘P’ clip.
8.8.7 Remove the screw securing the Overheat limit device terminal block socket to the right hand side of the
Replacement Fan Assembly.
8.8.8 Refitting or replacement is in reverse order.
MAIN BURNER NOT OPERATING
IS
PILOT
LIT ?
IS 230V
SUPPLY
ON ?
IS TIME
CONTROL &
THERMISTA-STAT
CORRECTLY
SET ?
CHECK
TERMINAL
D9 IS
18V
CHECK
TERMINAL
C8 IS
230V
CHECK
TERMINAL
C10 IS
24V
REPLACE
ELECTRONIC
MODULE
IS
GAS
ON ?
N
TURN GAS
ON
N
LIGHT
PILOT
Y
Y
SWITCH ON
230 V
N
Y
N
Y
REPLACE
FUSE
N
Y
REPLACE
MULTIFUNCTIONAL
CONTROL
SET CONTROLS
CORRECTLY
Y
N
CHECK POLARITY OF
THERMISTA-STAT
CONNECTIONS
Y
IS
POLARITY
CORRECT ?
N
RECTIFY
DEFECT
Y
BRIDGE THERMISTA-STAT
TERMINALS ATHEATER
BRIDGE THERMISTA-STAT
TERMINALS ATHEATER
IS
BURNER
LIT ?
IS
BURNER
LIT ?
WIRING DEFECT
BETWEEN HEATER
&
THERMISTA-STAT
N
Y
N
N
Y
N
CHECK TTB,
LIMIT SWITCH
&
CONNECTIONS
Y
N
CHECK 230V I/P
& TIME CONTROL
OPERATION
REPLACE
THERMISTA-STAT
REPLACE
TRANSFORMER
Y
IS
FUSE
OK ?
CHECK
24V AT
MULTIFUNC-
TIONAL
CONTROL
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.