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ZZ757/9

5.1.2

The return air system should be constructed of fire-resistant material. It is extremely important that the correct

size of return air grilles and ducting is used. The return air duct size should be NOT LESS THAN 225mm x

200mm (9in x 8in). If flexible duct is used, the duct diameter should be NOT LESS THAN 250mm (10in) dia. The
return air grille should have a free area of not less than 645cm

(100in

5.1.3

An adequate and unobstructed return air path is essential from areas not served by a directly ducted return and to
which warm air is delivered. All such rooms should be fitted with relief grilles which have a free area of
0.0088m

/kW (1in

/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms, and

WC’s.

5.1.4

For top return, a ‘starter’ knockout is provided to assist in creating the required aperture in the fan chamber top.

5.2

WARM DELIVERED AIR

5.2.1

All duct work, including riser ducts, should be fully insulated with 50mm (2in) glass fibre or similar. If extended
duct runs are taken below floor level, these should be similarly insulated and in addition, wrapped with a sound
proof barrier, and protected from crushing.

5.2.2

The duct system should be carefully designed (as detailed in the guidelines in the British Design Manual) to suit
the needs of its specific heating requirements and building layout. The type of duct system, i.e. radial/extended/
stepped plenum should be installed using the least number of fittings to minimise air flow resistance.

INSTALLATION REQUIREMENTS

6.1

AIR HEATER

6.1.1

Heater mounting is by means of five screws (provided) into a wall or structure sufficiently rigid to support the
appliance without deflection (for mounting hole positions see Fig. 8. The weight of the appliance is 25kg.
Recommended screw size is No 10 x 2 in with suitable wall plugs. Attach the plenum to the underside of the
appliance using the four M4 x 16 screws and gasket provided.

NOTE:

Ensure that the aperture in the gasket is

correctly aligned with the warm air outlet on the underside of the appliance. Position the return air and warm air
outlet spigots to suit the application before mounting the assembly on the wall. For replacement, the appliance
may be fitted to an existing base plenum, with any blanking plates being mechanically secured and sealed.

6.2

FLUES

(See BS 5440 Pt. 1 Flues)

6.2.1

The maximum allowable flue length is 5.0m plus one 90

bend for horizontally flued appliances, and 11.0m plus

terminal for vertically flued appliances.

6.2.2

The minimum allowable flue length is 350mm plus one 90

bend for horizontally flued appliances, and the length

of the terminal (1240mm) for vertically flued appliances. For applications where the flue exits directly through a
wall, the telescopic flue supplied with the heater may be used, as shown in Fig. 2.

6.2.3

The horizontal flue shall be installed with horizontal runs having a continuous fall to the terminal of at least 1.:50
(refer to Table 2 below).

Flue Length

Fall

1 m

20mm

2 m

40mm

3 m

60mm

4 m

80mm

5 m

100mm

Table 2

1:50 flue fall

6.2.4

The overall flue shall be kept as short as possible, with the minimum number of bends. The flue should terminate

in its direction, with the terminal section meeting the outer side of the wall, or roofing at the point where it begins
to flare out, (refer to Fig. 2). One 90

horizontal bend is equivalent to 1m of straight flue, a 45

horizontal bend is

equivalent to 0.5m of straight flue. One 90

vertical bend, where the bend radius is equal to the flue diameter, is

equivalent to 1.3m of flue; one 90

vertical bend, where the bend radius is equal to 0.5 flue diameter, is equivalent

to 2.9m of flue; and a 45

bend, where the bend radius is equal to the flue diameter, is equivalent to 0.85m of flue.

6.2.5

Sufficient support brackets (not supplied) shall be fitted to bear the weight of the total flue system.

6.2.6

The annular space between the flue assembly and surrounding structure

must

be sealed. If a cement sealant is

used, then the flue pipe must be coated with a suitable varnish a that point, to prevent corrosive attack of the
aluminium pipe.

6.2.7

For a vertical flue, a 60/100mm dia. concentric flue available from Johnson & Starley must to be used.

6.2.8

For a horizontal flue, the terminal supplied must be used. It shall be positioned in accordance with the
recommendations of BS 5440 Pt. 1, Clause 8 and Appendix B, and be guarded against damage and for
protection of passers-by, by using a terminal guard (Tower Flue Components Type K4), obtainable from builders’
merchants and Johnson & Starley (Pt No 1000-0002870).

Fig. 6, Electrical panel

Fuse

Transformer

EMC Filter

Overheat cutout device

Terminal strip

Ignition module

Electronics control
module

ZZ757/9

BURNER NOT OPERATING

Check that the time control is on and Thermista-stat is calling for heat.
Check mains electrical supply.
Link terminals 5 & 7 (shorts out clock).
Disconnect Thermista-stat at terminals 3 & 4 and link terminal 3 to ‘TEST’
terminal.

Do not link terminals 3 & 4.

No response

Burner lights

Link terminals 10 & 11.

Reinstate connections at 3 & 4.
Check wiring to, or replace
Thermista-stat.

No response

Burner lights

Check terminal 9 for 230 volts.

Replace fan delay/overheat
(limit) control.

No 230 volts

230 volts detected

Check terminal C4 for 230 volts.