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

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8.9 ELECTRICAL ASSEMBLY REMOVAL:
8.9.1 Ensure that the electrical supply is isolated.
8.9.2 Remove the appliance lower and upper doors.
8.9.3 Release 2 x 4mm screws securing the Limit switch cover and the withdraw cover.
8.9.4 Release 2 x Electrical Assembly cable clamps.
MODAIRFLOW models:
8.9.5 Disconnect the following
a. Disconnect 230V connections (L/N/E) from Fan Assembly,
b. 230V mains ‘ L ’, ‘ N ’ and ‘ E ’ from connection block terminals ‘ 1 ’, ‘ 3 ’ and ‘ 2 ’ respectively,
c. Thermista-stat connections from connection block terminals ‘ 4 ’ (+ve) and ‘ 5 ’ (-ve),
d. Limit switch ‘ LOAD ’ and ‘ COMMON ’ connections,
e. 2 x Airflow sensor connections,
NON-MODAIRFLOW models:
8.9.6 Disconnect the following:
a. Disconnect 230V connections (L/N/E) from Fan Assembly,
b. 230V mains ‘ L ’, ‘ N ’ and ‘ E ’ from connection block terminals ‘ 1 ’ and ‘ 3 ’, and earth stud respectively,
c. Room thermostat from connection block terminals ‘ 5 ’ and ‘ 6 ’,
d. Limit switch ‘LOAD’ and ‘ COMMON ’ connections,
e. Fan Delay Control ‘ LOAD ’, ‘ COMMON ’ and ‘ EARTH ’ connections,
Both model types:
8.9.7 Disconnect 2 x TTB connections from the terminal block on the fan compartment diaphragm..
8.9.8 Disconnect the Multifunctional control connections.
8.9.9 Disconnect the Circulator electrical connections (if fitted).
8.9.10 Release 4 x 4mm screws securing the Electrical assembly to the heater cabinet and remove the Electrical
assembly, releasing wiring from cable clamps and grommets as required..
8.9.11 Refitting or replacement is in reverse order.
8.10 ELECTRONIC MODULE REMOVAL (MODAIRFLOW models only)
8.10.1 Remove the Electrical assembly as detailed in sect 8.9.
8.10.2 Disconnect the Electronic module from the Electrical assembly.
8.10.3 Release 3 x screws securing the Electronic module to the Electrical assembly and remove the module.
8.10.4 Refitting or replacement is in reverse order.
8.11 TRANSFORMER REMOVAL (MODAIRFLOW models only):
8.11.1 Remove the Electrical assembly as detailed in sect 8.9.
8.11.2 Disconnect the Transformer from the Electrical assembly terminal block, and fuse from the Earth stud.
8.11.3 Release 2 x screws and nuts securing the Transformer to the Electrical assembly, and remove the Transformer.
8.11.4 Refitting or replacement is in reverse order.
8.12
TIME CONTROL REMOVAL:
8.12.1 Ensure that the electrical supply is isolated.
8.12.2 Release the securing screw situated on the lower face of the Time Control and remove by partially withdrawing
the bottom of the Time Control and then lifting upwards.
8.12.3 Disconnect the Time Control electrical connections from the integral terminal strip.
8.12.4 Refitting or replacement is in reverse order.
8.12.5 Set the Time Control to the required ON and OFF times.
8.12.6 Set the Time Control to correct time.
8.13 FAN DELAY CONTROL, LIMIT SWITCH AND AIRFLOW SENSOR REMOVAL:
NOTE: Airflow Sensor applies to MODAIRFLOW models only, whilst Fan Delay Control applies solely to non-
MODAIRFLOW models.
8.13.1 Ensure that the electrical supply is isolated.
8.13.2 Remove the appliance lower and upper doors.
8.13.3 Release 2 x 4mm screws securing the Limit switch cover and withdraw the cover.
8.13.4 Disconnect the required control/switch.
8.13.5 Release 2 x securing screws and remove required control/switch.
8.13.6 Refitting or replacement is in reverse order.
MODAIRFLOW DEFECT DIAGNOSIS FLOW CHART
MAIN BURNER NOT CYCLING
(
ROOM TEMPERATURE TOO HIGH)
N
CHECK FOR VOLTAGE AT
FAN LIVE TO EARTH
REPLACE
ELECTRONICS
MODULE
Y
N
IS
FUSE
OK ?
REPLACE FUSE
N
Y
CHECK FOR VOLT-
AGE
AT FAN LIVE TO
NEUTRAL
MAIN BURNER ON, BUT FAN NOT RUNNING
Y
REPLACE FAN
DOES
FAN
START?
N
BRIDGE OUT
AIRFLOW SENSOR
Y
REPLACE
AIRFLOW SENSOR
REPLACE
TRANSFORMER
REPLACE
MULTIFUNCTIONAL
CONTROL
N
Y
REPLACE
ELECTRONICS
MODULE
DISCONNECT
YELLOW WIRE AT
MULTIFUNCTIONAL
CONTROL
N
DOES
BURNER
GO
OUT?
DISCONNECT
THERMISTA-STAT
REPLACE
THERMISTA-STAT
Y
DOES
BURNER
GO OUT?
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c. Main burner lights i. Loose electrical connection Check connections.
but fan fails to run Fan Delay Control.
after approx. 3 min.
ii. Fan control set incorrectly. Check for correct settings.
iii. Faulty fan assembly. Replace, taking care not to damage
impeller.
iv. Faulty Fan Delay Control. Replace
d. Main burner opera- i. Gas rate or burner pressure Check gas rate and burner pressure
ting intermittently setting high. setting.
with fan running.
ii. Temperature rise excessive. Adjust fan speed or gas rate accordingly.
iii. Air filter or return air path Check filter is clean and air path is clear.
restricted.
iv. Excessive number of outlets Open additional outlets.
closed.
v. Spillage of flue gases. Carry out spillage test and rectify.
vi. Spillage monitor device (TTB) Replace Spillage device (TTB)
faulty.
e. Main burner operating i. Gas rate or burner pressure Check gas rate and burner pressure
with intermittent setting too low. setting.
fan operation.
ii. Fan Delay Control set incorrectly. Check for correct settings.
f. Fan runs for excessive i. Fan Delay Control set incorrectly. Check for correct settings.
period or operates
intermittently after
main burner shuts down.
g. Noisy operation. i. Gas pressure too high. Check burner pressure setting.
ii. Noisy fan motor. Replace fan assembly.
iii. Fan speed setting too high. Adjust fan speed.
MODAIRFLOW models:
h. Incorrect operation Fault related to Modairflow Consult diagnostic chart and follow
of fan or main burner. Control system (refer to pages 16-20) recommended procedure.
Non-MODAIRFLOW models:
j. Pilot alight but main i. Mains electrical supply not Check mains supply.
burner not igniting. connected to heater.
ii. Controls not demanding heat Check that time control and room thermostat
are operating correctly.
iii. 3A fuse failed. Replace. If failure occurs again, check
wiring for short circuits.
iv. Loose connection to room thermo- Check connections.
stat, Limit Switch, Multifunctional
Control lead, Time Control, or
transformer.
v. Transformer open circuit. Check with test meter and replace transformer
(Modairflow) or electrical assembly (non-
Modairflow).
vi. Multifunctional Control faulty. Replace Multifunctional Control.
vii. Limit Switch faulty. Short circuit control and replace if necessary.
viii.Room thermostat or external Fit temporary loop in heater thermostat
wiring faulty. socket. If heater ignites, external circuit
or room thermostat is faulty.
ix. TTB faulty Check TTB and wiring for open circuit
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8.14 SPILLAGE MONITORING DEVICE (TTB) REMOVAL:
8.14.1 Ensure that the electrical supply is isolated.
8.14.2 Remove the appliance lower and upper doors.
8.14.3 Remove the Air Circulation fan as detailed in para 8.8.
8.14.4 Cover the aperture to the heat exchanger in the top shelf to prevent objects falling into the heat exchanger.
8.14.5 Release and remove the 6 x screws securing the fan compartment rear plate, and withdraw the rear plate.
8.14.6 Release and remove the 6 x screws securing the draught diverter access panel, and withdraw the access panel.
8.14.7 Whilst holding the TTB Access Panel, release the 2 x securing screws and withdraw the TTB access panel.
8.14.8 Release the screw securing the TTB bracket assembly, and withdraw the bracket assembly.
8.14.9 Release the 2 x M4 screws securing the TTB Bracket to the TTB Assembly and withdraw the Bracket
8.14.10 Disconnect the TTB from its conductors.
8.14.11 Refitting or replacement is in reverse order.
8.15 HEAT EXCHANGER ACCESS:
8.15.1 Ensure that the electrical supply is isolated.
8.15.2 Remove the appliance lower and upper doors.
8.15.3 Remove the Electrical assembly as detailed in sect 8.9.
8.15.4 Release the 6 x screws securing the Heat Exchanger Access panel and remove the access panel cap and gasket.
8.15.5 Release the 4 x screws securing each end cap and remove the end caps and gaskets.
8.15.6 Remove the Heat Exchanger baffles.
8.15.7 Reassembly is in reverse order.
NOTE: When reassembling, ensure that the baffle is pushed fully home and that the access cap is fully sealed. In the event of heat
exchanger replacement being necessary, contact Johnson and Starley Service Department.
9.
DEFECT DIAGNOSIS
9.1 IMPORTANT: If an electrical defect 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
maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then
checks of continuity, polarity, and resistance to earth must be repeated.
9.2 WARNINGS:
9.2.1 When purging or checking gas supplies, ensure that the ventilation to the room or cupboard is adequate, and all
naked lights are extinguished.
9.2.2 MODAIRFLOW models: Before commencing defect diagnosis, ensure that the Thermista-stat is set to
maximum, the mains supply is ‘ON’ and the Time Control is at an ‘ON’ position.
9.2.3 Care is to be taken during the replacement and handling of electronic assemblies (i.e. electronic panel, airflow
sensor or Thermista-stat), it is not practical to rectify defects on these assemblies, except at the manufacturer,
and any attempt to do so may render the guarantee or factory replacement arrangement invalid.
SYMPTOM POSSIBLE CAUSE REMEDY
a. Pilot will not light. i. No gas supply to heater. Check for gas at inlet pressure test
point on Multifunctional Control.
ii. Gas supply pipe not purged. Purge gas supply pipe in accordance
with BS 6891.
iii Pilot orifice restricted. Clear pilot orifice or replace pilot injector.
iv. Piezo system faulty. Check igniter, lead, and electrode.
v. Excessive gas supply pressure. Check that mains gas pressure is 20mbar,
and reduce if necessary.
b. Pilot lights but goes i. Connection between thermo- Check connection is secure.
out on releasing START couple and Multifunctional
button during initial Control not secure.
light-up, or after
normal operation. ii. Faulty power unit on Replace Multifunctional Control.
Multifunctional Control.
iii. Faulty thermocouple. Replace Thermocouple.