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

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Sales/Spares & Replacement Help Line 01604 762881
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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.
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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
15
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.