Johnson & Starley ECONOMAIRE 32, Installation, Commissioning & Servicing Instructions

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15.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below.
15.1.8 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.
15.1.9 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.
15.1.10 Refit the air circulation fan, burner and controls assembly, and air filter/air cleaner.
15.1.11 Allow the air heater to operate for approximately 15 minutes to ensure stability and, with the main burner lit,
ensure that the operation of the air circulation fan does not affect the main burner flame profile.
15.1.12 Locate the flue gas test point (see figure 1) and attach a flue gas analyser to the test point in accordance with
the manufacturer’s instructions.
NOTE: The CO/CO
2
ratio should be no greater than 0.008
15.1.13 Fully commission the appliance in accordance with paragraphs 11 and 13.
NOTE: The flue gas test MUST NOT be used as an alternative to servicing the heater!
15.2 MULTIFUNCTION CONTROL AND AIR HEATER/WATER CIRCULATOR BURNER ASSEMBLY REMOVAL:
NOTE:
Both the air heater and water circulator burner assemblies, as well as their respective ignition burner assemblies, MUST
be removed as a complete unit together with their respective multifunction control.
PROCEDURE
15.2.1 Ensure that the gas and electrical supplies are switched OFF.
15.2.2 Remove the front door from the heater.
15.2.3 Remove the fixing screws that hold the sealing panel in place and carefully remove the panel.
15.2.4 Disconnect the electronic module from the relevant multifunction control by removing the securing bolt and
sliding it towards the left of the heater unit, taking care not to cause damage.
15.2.5 Disconnect the gas supply to the water circulator multifunction control at the flared connection on the top of
the gas supply feed.
15.2.6 For removal of the air heater multifunction control, remove the relevant burner assembly fixing screws.
15.2.7 Break the gas supply at the gas union and remove the gas feed pipe fixing screw.
15.2.8 Whilst supporting the assembly, carefully remove the fixing screws securing the multifunction control.
15.2.9 Carefully remove the complete assembly, by sliding the sealing grommet out of the bulkhead, taking care not
to cause damage to the grommet!
15.2.10 Refitting the burner assembly is a reverse procedure of the above instructions.
15.3 BURNER ASSEMBLY CLEANING
15.3.1 Remove the burner assembly as detailed above.
15.3.2 Disconnect the ignition burner gas feed pipe from the ignition burner
15.3.3 Release the single screw, nut and washer securing the ignition burner to the main burner and remove the
ignition burner.
15.3.4 Release the 2 screws, nuts and washers securing the main burner to the mounting bracket and remove the
main burner.
15.3.5 Clean the burner thoroughly both inside and out with a soft brush. DO NOT ENLARGE, DISTORT OR
DAMAGE BURNER HOLES.
15.3.6 Reassemble in reverse order.
15.4. IGNITION BURNER AND ELECTRODE REMOVAL AND REPLACEMENT
15.4.1 Remove the burner as detailed in paragraph 15.2 above.
15.4.2 Disconnect the igniter lead from electrode.
15.4.3 Break the gas feed at the burner end of the gas feed pipe.
15.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and
carefully remove the ignition burner assembly.
15.4.5 Release the electrode securing nut from the ignition burner assembly and withdraw the electrode.
15.4.6 Release the ignition burner feed pipe securing nut from the ignition burner assembly and withdraw the feed
pipe and injector from the ignition burner assembly. Disconnect the ignition burner injector from the ignition
burner feed pipe hook.
15.4.7 Release the 2 x 5mm screws securing the ignition burner bracket to the ignition burner mounting bracket and
remove the ignition burner bracket.
15.4.8 Refitting or replacement is in reverse order.
NOTE: If, at any time, the gas supply feed pipe is removed from the multifunction control, the ‘O’ ring MUST be replaced.
15.6 AIR CIRCULATING FAN - REMOVAL AND CLEANING
15.6.1 Ensure that the electrical supply is isolated.
15.6.2 Remove the front door from the heater and remove the 3 x fixing screws on the electrical door assembly.