ZZ 1019/1E
5
6.3
CONDENSATE
6.3.1
When firing , the unit may produce condensate which must be drained away. A JDT1 kit, which externally drains
the condensate away from the flue terminal is available for horizontal flued applications. Vertical flued
applications require the fitment of an in-line condensate trap within 0.5 m of the unit, in the first vertical flue run,
and before any bends in the flue run. Such a trap, with a 32 mm male drainage connection, is available for this
purpose.
6.3.2
Condensate from vertical flued applications must be drained away using 32 mm or 20 mm internal diameter, rigid
plastic pipe, connected to the condensate drain using KUTERLITE 700 or similar straight coupling. The pipe
should be installed in such a manner, that it forms a continuous downward slope away from the unit at a minimum
3
o
angle (6 mm per 100 mm, or, 0.75 in per foot run), and that the risk of mechanical damage and interior
interference is minimised. The pipe is to be protected against frost damage.
6.4
ELECTRICAL
6.4.1
Mains:
The heater is supplied with mains cable (PVC sheathed, high temperature resistant, 3 core [Brown-
Blue-Green/Yellow], 6A, 0.75mm
2
), connected to a terminal block and exiting from the heater at the bottom right
hand rear. The cable is suitable for a 230V 50Hz single phase supply and must be protected by a 5A fuse, and an
earth wire must be connected. This cable must only be replaced by either the maunfacturer or a recognised and
qalified service engineer.A double pole switch or fused spur box should also be used. All wiring conform to I.E.E.
regulations, (current edition).
6.4.2
Thermostat:
A Thermostat is provided with the appliance. The Thermostat wiring is to be connected to
terminals 6 and 7 on the air heater control panel, (marked ‘THERMOSTAT’), polarity being unimportant. It should
be located where there is free air circulation, and approximately 1.5m (5ft) from the floor. The following
locations should be avoided.
a.
In a room where temperature is greatly affected by the sun or any other heat source (e.g. radiant fire, wall
light fitting or TV set).
b.
Near an outside door or windows, or on an outside wall.
c.
Where it can be affected by warm air ducts, diffusers, waste pipes or the heater itself.
d.
Where it can be subject to vibration.
6.4.3
Time Control:
If an external time control (not supplied) is to be fitted, connect the live supply to terminal 3,
the neutral to terminal 4, and the time-switch output to terminal 5. If no time control is fitted, link terminal 3
and 5.
6.5
GAS (see BS 5864 and BS 6891)
6.5.1
An independent gas supply pipe from the gas meter is to be preferred wherever possible. However, when this is
not possible, the pipe must be capable of taking the complete input of the heater and all other gas appliances being
served by this same pipe. This supply should be suitably sized to conform to British Standards requirements of no
more than 1.0 mbar (0.4 in. wg.) pressure drop (see table of discharge in BS 6891).
6.5.2
The
1
/
2
in union gas cock (supplied) must be fitted externally in the gas inlet of the heater for easy isolation during
servicing. The gas pipe should be fitted and installed as to be durable, substantial and gas tight. Gas entry to the air
heater may be through the left hand side, right hand side front, or rear, to an Rc
1
/
2
(
1
/
2
in B.S.P. internal (taper)
thread).
7.
COMMISSIONING
7.1
Ensure the following:
7.1.1
Gas and Electrical supplies are
OFF.
7.1.2
Filter, fan and fan compartments are free from obstructions.
7.1.3
All registers or grilles are open and conform to design specifications.
7.1.4
Return, relief and ventilation air installations are adequate.
7.1.5
Adhesive label is removed from the centre of the combustion air fan to expose the motor cooling slots.
7.2
Turn ON the gas supply to the heater.
7.3
Test for gas soundness at supply, Multifunctional control and the Main burner using proprietary detection fluid, sealing
any leaks found, and purge the whole gas pipe as described in BS 6891.
7.4
Set the Thermostat to its maximum setting.
7.5
Ensure that the time control (if fitted) is in an
ON
position.
7.6
Switch on the electrical supply to the heater. The combustion air fan will start up immediately; after a minimum of 30
seconds, the burner will automatically ignite and the green ‘
BURNER ON
’ indicator will illuminate.
12
ZZ 1019/1E
BURNER NOT OPERATING
Check that the time control is on and Thermostat is calling for heat.
Check mains electrical supply.
Link terminals 3 & 5 (shorts out clock).
Disconnect Thermostat at terminals 6 & 7.
No response
Burner lights
Link terminals 15 & 16.
Reinstate connections at 6 & 7.
Check wiring to, or replace
Thermostat.
No response
Burner lights
Check terminal 14 for 230 volts.
Replace fan delay/limit
control.
No 230 volts
230 volts detected
Check ICU terminal 5 for 230 volts.
Check wiring to, or replace
multifunctional control.
No 230 volts
230 volts detected
Check ICU terminal 8 for 230 volts.
Check wiring.
No 230 volts
230 volts detected
Check terminal C4 for 230 volts.
Replace Ignition Control
Unit.
No 230 volts
230 volts detected
Check terminal C3 for 230 volts.
Check wiring.
No 230 volts
230 volts detected
Check terminal 5 for 230 volts
Replace Control Module.
No 230 volts
230 volts detected
Check 3.15 A fuse, if OK check 230 volt
Check wiring and Air Heating
input at terminal 1
Switch.
Air Heating Switch and
Wiring OK
Replace Ignition Control unit
or Pressure switch
BURNER ON, BUT AIR CIRCULATION FAN NOT RUNNING
Check for 230 volts at fan terminals 11 & 12
No 230 volts detected
230 volts detected
Switch to ‘Summer Airflow’.
Switch to ‘Summer Airflow’.
230 volts detected
Replace air circulation fan.
Air circulation fan runs
Air circulation fan does
Replace fan delay/limit control.
not run
Replace Fan Speed Transformer
BURNER ON CONTINUOUSLY
(ROOM TEMPERATURE TOO HIGH)
Set the Air Heating Switch to ‘Summer Airflow’
Burner remains alight
Burner goes out
Disconnect solenoid plug at
Replace Thermostat.
multifunctional control.
Burner remains alight
Replace multifunctional control.
AIR CIRCULATION FAN CONTINUES TO RUN OR CYCLES
WHEN BURNER IS NOT ON
Check that Air Heating switch is not set to ‘Summer Airflow’.
Disconnect Thermostat and link terminals 6 & 7.
Disconnect the fan delay/limit control.
Air circulation fan stops
Air circulation fan continues to run
Replace fan delay/limit
Replace Control module
control
AIR CIRCULATION FAN ON, BUT BURNER CYCLES BEFORE
REQUIRED COMFORT LEVEL IS REACHED
Disconnect Thermostat at terminals 6 & 7.
Burner continues to cycle
Burner remains on
Check air filter, return air path
Thermostat defective.
and outlets for restrictions.
Burner continues to cycle
Link terminals 15 & 16 to bypass limit control.
Burner continues to cycle
Burner runs and room
Replace Thermostat.
temperature rises
Check temperature rise.
Less than 60 degrees C
More than 60 degrees C
Replace fan delay/overheat (limit)
Replace Thermostat
control.
PRESSURE SWITCH DEFECTIVE
