WARMCAIR C46U INSTALLATION INSTRUCTIONS

WARMCAIR C46U INSTALLATION INSTRUCTIONS
Publication No. ZZ 1415-2
August 2013
WARMCAIR C46U
Condensing Air Heater
High Efficiency Upflow
Condensing Air Heater
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
WarmCair C46U - G.C. No. 42-415-29
These instructions are to be left with the User
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CONTENTS
CONTENTS
The Benchmark Scheme
2
1
Features
3
2
General Description
3
3
Building Standards & Regulations
4
4
Safety & Gas Information
4
5
Technical Data
5
6
Heater Positioning
5
7
Heater Compartment Clearances
5
8
Duct System
6
9
Flue Instructions
7
10
Condensate Pump & Drain Tube
11
11
Gas
12
12
Electrical
12
13
Fitting Instructions
13
14
Commissioning
13
15
Handling Over
15
16
Servicing & Maintenance
16
17
Replacement Parts
19
18
Control Panel Modes
22
19
Fault Code Table
23
20
Faut Finding Flow Chart
24
21
Defect Diagnosis for the Circulation Air Fan
25
22
Functional Wiring Diagrams
26
23
Dimensions
28
24
Exploded Spare Diagrams
29
25
Important Information & Ancillaries
32
26
Benchmark Log Book
33
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION. LEAVE THESE INSTRUCTION WITH
THE USER OR AT THE GAS METER AFTER INSTALLATION
The Benchmark Scheme
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the
manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the
customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
In the interest of continuous development Johnson and Starley reserve the right to change specification without prior notice.
Johnson and Starley prides itself on it’s ability to supply spare parts quickly and efficiently.
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2
1.FEATURES
Appliance Classification:
1
The WarmCair C46U has been tested
and CE certified by B.S.I Ltd for use with
NATURAL gas G20.
2
3
27
FEATURES
1. 60/100mm to 80/125mm Adapter
2. 60/100mm Flue Turret
3. Combustion Measuring Point
4. Time Control
5. Condensing Pump Drain Tube
6. Inspection Glass
7. Sliding Flue Connector
8. Flue Sensor
9. Condense Outlet
10.Condense Pipe
11. Condensate Trap
12.Air Pressure Switch
13.Condensate Pump
14.Return Air Filter
15.Air Circulation Fan
16
PCB Control Wiring Panel
17.Return Air Sensor
18.Flue Collector Box
19.Combustion Air fan Assembly
20.High Limit Temperature Sensor
21.Gas Cock
22.ESYS
23.Burner Assembly
24.Gas Valve
25. Ignition & Detection Electrodes
26.MMI Control Panel
27.Duct Temperature Sensor (behind control panel)
26
4
25
24
5
23
22
6
21
7
20
19
8
18
9
10
17
16
15
11
12
14
13
FIGURE 1. C46U FEATURES
2.
GENERAL DESCRIPTION
2.1
The Warmcair C46U is a highly efficient condensing gas fired upflow forced convection air heater. Significant
reductions in Low Carbon and NOX emissions are achieved.
It has been designed to provide the user with on demand Warm Air Central Heating. Using sophisticated
controls, enabling it to provide the precise amount of heat output to match demand. It is room sealed, with a
stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System.
The WarmCair C46U air heater is ideally suited for new built dwellings and the replacement of existing noncondensing air heaters.
2.2
The air heater output modulates 40.48kW (145.73MJ/h, 138,118 Btu/h) down to 13.2kW (47.52MJ/h,
33,028Btu/h) “Summer Air Circulation” of unheated air is available by manual selection (see the user’s
instructions).
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3
3. BUILDING STANDARDS & REGULATIONS
Installation shall be in accordance with the current editions of:
•
Building Standards (Scotland) (Consolidation) Regulations
•
Building Regulations
•
Gas Safety (Installation and Use) Regulations (as amended)
•
BS 7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations
•
BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).
•
BS 5440 Pt. 1 (Flues for Gas Appliances)
•
BS 5440 Pt. 2 (Air Supply for Gas Appliances)
•
BS 5864 Installation of Gas Fired Ducted Air Heaters
•
British System Design Manual “Gas Fired Warm Air Heating”
•
Model and Local Authority Bye-laws
•
EN 1196 Supplementary Instructions - Condensing Air Heaters
IMPORTANT: IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE
INSTALLED BY COMPETENT PERSONS, (i.e. GAS SAFE REGISTERED INSTALLERS.
GAS SAFE MEMBERSHIP ENQUIRIES - TEL: 0800 408 5500) IN ACCORDANCE WITH
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION).
FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
GAS LEAKS
DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME. TURN OFF GAS SUPPLY.
VENTILATE THE AREA BY OPENING THE DOORS AND WINDOWS.
CALL THE NATIONAL GAS EMERGENCY SERVICES ON 0800 111999
4.
SAFETY & GAS INFORMATION
4.1 SAFETY INFORMATION
4.1.1
Ensure the mains supply voltage, frequency, number of phases and power rating comply with
details on the rating label.
4.1.2
All wiring must be in accordance with the appropriate standards. The equipment must be supplied
with a double pole isolator switch.
4.1.3
Ensure safety regulations and practices are adhered to when installing and using this
equipment
4.1.4
The weight of this appliance exceeds that recommended for a one-man lift. It will therefore be
necessary to gain assistance at times during the installation procedure.
4.1.5
It should be noted that this appliance may contain sharp edges. Care MUST be taken when
handling the appliance to prevent injury.
4.1.6
Once the appliance has been fired beware that certain parts will be hot to the touch.
4.1.7
Do not install flues during rain, high winds or in severe weather conditions.
4.2 GAS INFORMATION
4.2.1 Gas Categories
The appliance is certified as a CAT I 2H (20) appliance.
a.
Gas Supply
4.2.2 a.
The gas installation must be completed in accordance with the relevant standards (BS 6891).
b.
The supply must be capable of providing a steady inlet working pressure to the appliance of 20 mbar at a rate of 4.29m³/h or 151.34 ft²/h (Calculated with a Gas C of 38.7MJ/m³)
c.
The installation must be tested for gas tightness using suitable methods. The Pipework should also be purged of air in accordance with the IG Publication Standard.
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5.
TECHNICAL DATA
C46U
WEIGHT
96kg
GAS
G20
GAS SUPPLY PRESSURE
20mbar
I2H
GAS CATEGORY
COUNTRIES OF INSTALLATION
GB & IE
ELECTRICAL SUPPLY
250v ~ 50Hz fused 5A 670 watts
MAXIMUM
INPUT (GROSS)
OUTPUT
GAS RATE CV 1037Btu/FT³
BURNER % CO²
MINIMUM
kW
MJ/h
Btu/h
kW
MJ/h
Btu/h
46
165.6
156,952
15
54
51,180
40.48
145.73
1138,118
13.2
47.52
45,038
4.29m³/h (151.34ft³/h)
1.4m³/h (49.35ft³/h)
9±1
9±1
TABLE 1. C46U TECHNICAL DATA
6.
HEATER POSITIONING
6.1 This heater is not suitable for external installation unless it is protected from the elements by a suitable
enclosure. The enclosure must provide the clearance for installation, servicing and maintenance as well as
the correct level of ventilation. The selected position should allow for a suitable flue system to be installed.
6.2
When installed in a timber frame building guidance should be taken from the Gas Industry Publication IGE/
UP-7 (Guide for Gas Installations in Timber Frame Housing).
6.3
BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to
be installed. An existing cupboard may require modification.
6.4
If the heater is installed in a room containing a bath or shower it is important to locate the electrical switch
in a position where it cannot be touched by anyone using the bath or shower. The current IEE Wiring
Regulations (BS 7671) for England and electrical provision of the Building Regulations for Scotland gives
details.
6.5
Room ventilation for the heater is not necessary as the heater draws its combustion air from the outside of
the building, cupboard or compartment ventilation is not necessary providing that the minimum clearances
are maintained. However, reference should be made to BS 5440 Pt. 2.
IMPORTANT: This appliance must be completely level. It MUST NOT lean in any direction. Otherwise it will
cause problems with the condense draining.
7.
HEATER COMPARTMENT CLEARANCES (see BS 5864)
7.1 IMPORTANT - If the heater is to be fitted to an existing base duct (warm air plenum), always ensure when
installing the appliance, the rear of the heater is aligned with the rear of the base duct. If there is any overhang
or blanking off it will be at the front of the heater. In any event, blanking plates must be mechanically secured
and all joints sealed.
7.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 3mm
(1/8”) at the sides, rear and front must be left. Where clearances are less than 75mm, internal surface must
be lined with non-combustible material and the compartment must be of a fixed rigid structure. However,
there is no requirement for the use of non-combustible material at the front of the unit. Consideration should
also be given to the space required for the removal and replacement of the filter tray and the entry of the
gas and electrical supplies. If gas connections are made from a side entry, a minimum clearance of 75mm
(3”) is required at that side.
7.3 For service access, a minimum of 450mm (18”) is required at the front of the heater. Space must also be
allowed, in a compartment installation, to permit the removal of the heater.
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7.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant
section of BS 5864 and must be completely separated by either a non-combustible partition or a perforated
metal partition with the perforations not exceeding 13mm (½”). The secondary flue must be a tight fit where
it passes through the partition and must be suitably protected. See BS 5440: Part 1.
7.5
In under-stairs installations, the compartment must comply with the relevant section of BS 5864, provided
that in addition all internal surfaces (including the base) are non-combustible or lined with non-combustible
material. This requirement is applicable only to dwellings of more than two storeys.
7.6 In free-standing installations, (refer to the instructions packed with top closure kit), only one or two walls will
be in close proximity to the air heater; these must be non-combustible.
7.7
Where the air heater is to be installed onto a combustible surface and under-floor ducting used, a suitable
base tray MUST be used in order to provide insulation.
NB. Where a base plenum is used no base tray is required!
7.8
Although two permanent ventilation openings are not required, consideration should be given to the amount
of heat emitted by any ductwork present in the compartment, otherwise the compartment temperature could
increase and will affect the safe operation of the appliance and its controls.
8.
DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating)
8.2
RETURN AIR
8.2
8.1.1
Room-sealed appliances may be installed without return air ducting, provided that the path
between the return air grille and the appliance return air inlet is protected in such a manner that
the required air-flow will be maintained at all times. The return air grille MUST have a free area of
not less than 4200cm2 (652in2). It is recommended that the return air duct not be routed directly
from the main living area, but from a convenient central area serving the remainder of the dwelling.
8.1.2 The return air system should be constructed of fire-resistant material. The flue shall not be run
through an area serving as a return air plenum. It is extremely important that the correct size of
return air grilles and ducting is used. The return air duct area should not be less than 2059cm²
(320in²). If flexible duct is used the duct diameter should not be less than 508mm (20”) diameter.
8.1.3 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 0.0088m2/kW (1in2/250Btu/h) of heat supplied to the room. The only
exceptions are kitchens, bathrooms and WC.’s.
8.1.4 The return air duct should allow for ease of removal, for access to the flue.
8.1.5 All duct work in the room or internal space in which the heater is installed shall be mechanically
secured and sealed with ducting tape.
WARM DELIVERED AIR
8.2.1
All duct work, including riser ducts, should be fully insulated with 50mm (2”) fibre-glass or similar.
If short extended duct runs are taken below floor level these should be similarly insulated and in
addition wrapped with a sound vapour proof barrier. They must also be protected from crushing.
8.2.2 The duct system should be carefully designed (as given in the guidelines in the British System
Design Manual) to suit the needs of specific heating requirements and building layout. The type of
duct system (e.g. radial/extended plenum stepped) should be installed using the least number of
fittings to minimise airflow resistance. The base duct, which equalises the air pressure to supply
ducts, must be constructed to support the weight of the heater, which must be sealed using selfadhesive foam strip, ducting tape or sealing compound. All ducting and blanking plates must be
mechanically secured and sealed.
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6
9.
FLUE INSTRUCTIONS
9.1
The WarmCair C46U Condensing Air Heater is certified as a warm air heater with corresponding flue systems
according to EU Directive 2009/142/EC on gas-fired devices. These installation instructions are covered by
this certification and are referred to in the design approval test certificate.
9.2
The installation of the warm air heater and flue system must be in accordance with the Gas Safety (Installation
and Use) Regulations 1998 and the Building Regulations. If no specific instructions are given, reference
should be made to the relevant codes of practice.
THESE RELEVANT STANDARDS SHOULD BE FOLLOWED
BS 5440:1 Flues and ventilation for gas appliances of rated heating input not exceeding 70kW (net) :
Flues
BS 5440:2 Ensure all legislation, regulations and directives mentioned are observed.
9.3
The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air
duct and the adjacent services.
9.4
Ensure while installation work is being carried out that no debris such as swarf, filings or fragments of mortar
are allowed to remain in the air/flue duct.
9.5
TYPE OF FLUE SYSTEM
The flue system available for the C46U.
i)
9.6
FLUE TERMINAL POSITIONS
9.6.1
The following information provides the general requirements for siting flue terminals. As part of the
recommendation given in BS 1550 Part 1. For IE recommendations, see the current issue of I.S. 813
“Domestic Gas Installations.” Also publication a “Guide for Gas Installations in Timber Framed Housing
DM2” or consult your local gas region, they MUST be consulted when installing the appliance into a timberframed building.
Flues and ventilation for gas appliances of rated heating input not exceeding 70kW (net) :
Air Supply
The standard concentric flue system 80/125mm (125mm diameter)
NOTE: Due to the nature of the warm air heater, water vapour will discharge from the flue. This should be taken into
account when siting the flue
9.6.2
Both the horizontal and vertical terminals must be positioned on the outside of the building and the free passage of air must be available at all times. It is not recommended to position the terminal close to projections
especially under a balcony or near to a drainpipe. See Figure 3.
9.6.3
Ensure that combustion products cannot enter the building where the heater is installed or near to any other
building where doors or windows may be open.
9.6.4
Recommended terminal positions for both horizontal and vertical flues are shown and flue components and
installation options are also detailed.
9.6.5
The flue MUST NOT be installed under a car port.
100mm
19mm
CORRECT
POSITION OF
HORIZONTAL
TERMINAL END
FIGURE 2. HORIZONTAL TERMINAL DIMENSIONS & POSITION
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P
B
D, E
Q
A
K
M
I
C
F
N
M
G
J
N
H
H
FIGURE 3. TERMINAL POSITIONS
TERMINAL POSITION
MINIMUM DISTANCE
A
Directly below an opening, air brick, opening window etc
300mm
B
Above an opening, air brick, opening window, etc.
300mm
C
Horizontally to an opening, air brick, opening window etc.
300mm
D
Below gutters, soil pipes or drain pipes.
E
Below eaves.
200mm
F
Below balconies.
200mm
G
From a vertical drain pipe or soil pipe.
150mm
H
From an internal or external corner. Greater than 450mm protrusion.
300mm
I
Above ground, roof or balcony level.
300mm
J
From a surface facing the terminal.
600mm
K
From a terminal facing the terminal.
1,200mm
M
Vertically from a terminal on the same wall.
1,500mm
N
Horizontally from a terminal on the same wall.
300mm
Q
Above intersection with roof.
530mm
P
From a vertical structure on the roof
300mm
R
From the terminal to the boundary
300mm
75mm
TABLE 2. TERMINAL DIMENSIONS
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9.7
PLUME TERMINAL OUTLETS
9.7.1
A flue duct outlet of an appliance should be at least 600mm from the boundary line when facing it and at
least 300mm from the boundary line when running parallel to it. See Figure 4.
NOTE: When the flow of products is at an angle to the boundary, the 600mm dimension may be measured in the
direction of the flow, as long as the terminal is not less than 300mm from the boundary.
9.7.2
It is recommended the terminals are not sited within 2m of an opening in an adjacent building or within 2m
of the boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e.g discharging
over a walkway or patio.
FIGURE 4. PLUME TERMINAL OUTLET DIMENSIONS
9.8
TYPICAL FLUE CONFIGURATIONS
Note: Vertical Appliance adaptor is fitted as part of the air heater.
VERTICAL FLUE
HORIZONTAL FLUES
EXTENDED HORIZONTAL REAR FLUE
Can be fitted to the left or the right.
Vertical Appliance Adaptor
Horizontal Terminal
90˚ Elbow
Required Extension Length
FIGURE 5. EXTENDED HORIZONTAL REAR FLUE
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Vertical Appliance Adaptor
Required Extension Lengths
Vertical Terminal
FIGURE 6. VERTICAL FLUE
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ITEM
DESCRIPTION
1
HORIZONTAL TERMINAL WHITE
QTY
PARTS INCLUDED
1
800mm Horizontal Terminal
1
Inside Wall Cover Plate
1
Outside Wall Cover Plate
APPLICATION
PART No.
Horizontal
1000-0023830
2
45˚ ELBOW WHITE
1
Elbow
Horizontal + Vertical
1000-0023850
3
90˚ ELBOW WHITE
1
Elbow
Horizontal + Vertical
1000-0023860
1
500mm Straight Extension
1
125mm Diameter Clamp
Horizontal + Vertical
1000-0025590
2
Screws
1
1000mm Straight Extension
1
125mm Diameter Clamp
Horizontal + Vertical
1000-0023840
2
Screws
1
2000mm Straight Extension
1
125mm Diameter Clamp
Horizontal + Vertical
1000-0025600
2
Screws
1
Clamp for 125mm tube
Horizontal + Vertical
1000-0016620
1
Vertical Terminal Assembly
Vertical
1000-0023820
1
Support Bracket
5
500mm STRAIGHT EXTENSION WHITE
6
1000mm STRAIGHT EXTENSION WHITE
6
2000mm STRAIGHT EXTENSION WHITE
7
WALL FIXING BRACKET 125mm
8
1140mm VERTICAL TERMINAL
TABLE 3. 80/125 FLUE COMPONENTS
9.9 FLUE PERFORMANCE & GENERAL INFORMATION
9.9.1 Horizontal and vertical concentric flues (80/125mm diameter) with balanced terminals may be
installed on WarmCair C46U warm air heater.
9.9.2 If an extended horizontal flue is being used it must have a continuous fall back towards the appliance
of 3˚ (52mm) per meter. This ensures that condensate runs back into the appliance from the flue
system for safe discharge via the condensate waste pipe.
9.9.3 The maximum length of flue permissible is 12 meters excluding terminal
9.9.4
The minimum vertical flue length is 1.25m from the top of the appliance case to the top of the
terminal.
9.9.5
Elbows may be fitted within the flue system with a corresponding reduction in overall flue length.
9.9.6
Guidelines for the maximum flue length are as follows.
1 x 90˚ Elbow + 12 metres straight
2 x 90˚ Elbow + 10 metres straight
3 x 90˚ Elbow + 8 metres straight
4 x 90˚ Elbow + 6 metres straight
When using 45˚ elbows
1 x 90˚ Elbow is equivalent to 2 x 45˚ Elbows
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10.
CONDENSATE PUMP & DRAIN TUBE
10.1
CONDENSATE PUMP
10.1.1 Supplied with 6mm x 10m condense tube. Condense adapter and 2 x clips
SAFETY NOTE: If the pump fails, the safety float switch will shut off the heater operation.
10.1.2 DO NOT HANDLE PUMP IN WET CONDITIONS OR WITH WET HANDS
10.1.3 To reduce the risk of electric shock, ensure the electrical supply is permanently wired to earth
10.1.4 TECHNICAL DATA
a)
Tank capacity : 0.7L
b)
High level safety cut out.
c)
Outlet size 6mm I.D.
d)
Maximum water temperature: 60°
10.1.5 Where the tubing from the pump is connected directly to the soil
stack or waste pipe, there must always be either a waste trap after
the tubing connections, or a 75mm U trap formed within the tubing.
10.1.6
Where the tubing from the pump is connected to an external soil and
vent stack extra care is necessary to ensure that the condense pipe
could not be blocked through the condense freezing.
10.1.7 The tank pump uses small bore (6mm) flexible hose which can be
routed above or below doors, windows and under kitchen cabinets.
10.2
FIGURE 7. CONDENSE PUMP
CONDENSE TUBE ROUTING OPTIONS
Option A.
Routing to outside drain via sink
Option B.
Routing to drain pipe via roof
Option C.
Routing to bath waste
Option D.
Routing under floor to sink waste
B
A
C
NOTE:
7m MAXIMUM
HEAD LENGTH OF
CONDENSE TUBE
D
FIGURE 8. CONDENSATE ROUTING OPTIONS
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11.GAS (See BS 5864 and BS 6891)
11.1
The local gas supply conditions MUST be adequate for the specified burner pressures as stated in the
technical specification (section 5).
11.2
An independent gas supply pipe from the meter is to be preferred wherever possible. Where 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 the same pipe. This supply should be suitably sized to conform to British Standards
requirements of no more than 1.0 mbar (0.4” wg) pressure drop (See table of discharge in BS 6891).
11.3
The ¾” union gas cock (supplied) MUST be fitted to the gas inlet of the heater for easy isolation during
servicing. The gas pipe should be fitted and installed so as to be durable, substantial and gas tight. To
assist in determining where a gas connection may not be tight, a leak detection fluid should be applied
around the connection. Under no circumstances should a flame be used to locate a gas leak. Gas entry to
the air heater is through either side or the base, to a 22mm compression fitting.
12.
ELECTRICAL
WARNING: THIS APPLIANCE MUST BE EARTHED!
12.1 MAINS SUPPLY
The heater is supplied with mains cable (PVC sheathed, heat resisting
to 85˚C), 3 core: Brown; Blue; Green/Yellow, 6A, 0.75mm²), connected
to a PCB contril panel and exiting through the heater at the left hand top.
The cable is suitable for a 230V 50Hz supply and requires connection to
the fixed wiring using a double pole switched, fused spur with a contact
separation of at least 3mm in ALL poles. The fuse fitted must be rated
5A to BS 1362. Connections must also be in accordance with the current
edition of I.E.E Regulation BS 7671.
NOTE: If, for any reason, the heater is re-wired, then 3 core cable that meets the
above specification MUST be used. Under NO circumstances, should 5
core cable be used for the combined purpose of supplying power to the
heater and connecting the thermista-stat!
a. Fan delay and overheat (limit controls) are not adjustable and are
factory set.
b. An Open Therm Controller is supplied which acts like a room
thermostat.
12.2
THERMISTA-STAT AND ITS LOCATION
This appliance can be interfaced with the following:-
1)
Open therm room units (supplied).
2)
33k NTC room temperature sensor.
3)
230 VAC room thermostats.
CONDENSATE DRAIN
TUBE
MAINS SUPPLY
OPEN THERM CABLE
FIGURE 9. CABLE POSITIONING
12.2.1
The room-stat should be located where there is free air circulation and positioned approx. 1.5m (5ft) from the floor.
12.2.2
Avoid the following locations:
a.
In a room where temperature is greatly affected by the sun or any other heat source, e.g. radiant fire, wall light fittings or TV set.
b.
Near an outside door or windows, or on an outside wall.
c.
Where it will be affected by warm air ducts, diffusers, waste pipes or the heater itself.
d.
Where it will be subjected to vibration.
12.2.3 Refer to wiring diagram 1 for the installation of the thermista-stat. See Figure 25.
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13.
FITTING INSTRUCTIONS
CAUTION: This appliance exceeds the recommended weight for a one man lift as detailed in the Manual Handling
Operations, 1992 Regulations.
It should be noted that this appliance could contain sharp edges and care MUST be taken when handling.
13.1
FITTING THE APPLIANCE
13.1.1Making sure the plenum is clear from all debris, lift the appliance into place.
13.1.2Using a spirit level it is important the appliance is completely level, this appliance MUST NOT lean
or tilt in any direction. This will cause problems with the condense draining.
13.1.3Seal the unit to the plenum, using ducting tape (not supplied). Ensure a good seal is made.
13.1.4Installation of the condense tube is a maximum of 10 meters. There should be no trapped kinks in
this length of tube.
13.1.5 Fix all connections to the appliance ready for commissioning.
14.COMMISSIONING
14.1
After installation of the appliance, you MUST do the following:
14.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found.
14.1.2 Carry out preliminary electrical system checks.
14.1.3 Ensure that:
a. the filter, fan and fan compartments are free from obstructions.
b. all registers or grilles are open and conform to design specifications.
c. the return, relief and ventilation air installations are adequate.
14.2
Switch the air heater electrical Supply ON.
14.3.
To fill the flue condensate trap, disconnect the sliding flue connector and slowly pour tap water into the elbow until you hear the condensate pump operating. Failure to do this will result in a whistling sound. Check
for leaks.
NOTE: The appliance must be connected to the mains for the pump to operate.
14.4
SYSTEM BALANCING
14.4.1
Press button ‘7’ to put the appliance into Summer Air Circulation mode.
14.4.2
Balance the system to provide the required volume proportions at the warm air outlets.
FIGURE 10. CONTROL PANEL
1
CONTROL PANEL
2
3
4
5
7
8
3
4
5
1
6
11
10
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9
8
Time control
2
A+
3
B-
4
LED Display
5
E+
6
D-
7
Summer Air Circulation
8
C
9
Reset
LED READ OUT
9
FIGURE 11. LED READ OUT
2
6
1
7
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1
Open therm symbol
2
Installer mode
indicator
3
Service indicator
4
Stand by
5
Degrees
6
Error - ‘e’ or celsius - ‘c’
7
Reset button indicator
8
Flame indicator
9
Button ‘c’ indication
10
Summer circulation
11
Central heating
13
NOTE: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/
min), except for very small rooms, (i.e. bathrooms etc.). Outlet faces may require partial blanking in order to
achieve this.
14.5
LIGHTING MAIN BURNER
14.5.1
Turn on the gas supply to the heater.
14.5.2
Set both switches on the time control unit to the “OFF” position.
14.5.3
Set the thermista-stat to “MAX”.
14.5.4
Turn on the mains power supply to the heater.
14.5.5
Set the “AIR HEATER” switch on the time control to “ON” and observe the ESYS status indicator.
14.5.6
The ESYS on the control panel will run through the ID setting, when finished it shows a flashing “--”
sign. This shows its ready.
14.5.7 The ignitor will spark for 5 seconds during which time the main burners SHOULD ignite and the
igniter will stop.
14.5.8
If, after the 5 second period, the main burner has ignited the ESYS will show “ON” and the blue LED
“ON” light on the indicator panel will remain steady.
14.5.9
If the main burner fails to ignite, 4 more attempts at ignition will occur.
14.5.10 In the event of a lockout “1” (ignition and main burners failing to ignite), reference should be made
to Table 4 in the fault finding section of these instructions in order to establish the fault condition.
14.5.11 Allow the air heater to operate for a minimum of 15 minutes to ensure stability.
14.5.12 Reset the thermista-stat to the desired comfort level.
14.5.13 Set the time control to the desired “on and “off” periods.
14.6
GAS RATE CHECK
14.6.1
14.6.2
There is no burner pressure test with this air heater. It has a 1-1 ratio
Valve.
Natural Gas (G20) consumption is calculated using gross CV 38.7 MJ/m³ or 34.9 MJ/m³ net. Maximum rate 4.29m³/h (151.34ft³/h) and
minimum rate 1.4m³/h (49.35ft³/h).
14.7 Complete all relevant sections of the Benchmark Commissioning Checklist
located on the inside back pages.
NOTE
The gas valve is factory
preset and must not be
adjusted. A replacement
valve must only be supplied
by Johnson & Starley Ltd.
PASCALS
175
Resistance External to Heater
150
125
100
FAN MODULATION RANGE
75
50
25
0
1000
1200
1400
1600
1800
2000
2100
2400
2600
2800
3000m³/h
Fan Performance
FIGURE 12. C46U FAN PERFORMANCE GRAPH
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14
15.
HANDING OVER
15.1
After commissioning, the installer should hand the appliance over to the occupier of the house by the
following procedure:
15.2
Hand the User Instructions ZZ1340 to the occupier and explain their responsibilities in respect of current
legislation and regulations, both national and local.
15.3
Explain and demonstrate how to light and shut down the appliance.
15.4
In order to gain the best possible fuel economy in relation to the heating requirements of the household,
carefully explain the operation of the appliance and the use/adjustment of all the system controls.
15.5
Advise on the precautions required to prevent damage to the appliance; the system and the building in the
event of the appliance being shut down in very cold weather.
15.6
Explain how, in the event of a fault, the appliance will display a fault code, emphasising that if a fault is
indicated they should note the fault code, turn off the appliance and contact a “competent person” which in
normal circumstances would be a GAS SAFE registered engineer.
15.7
Explain and demonstrate the function/operation of time/temperature controls, emphasising the economic
use of the appliance.
15.8
A comprehensive service should be carried out ANNUALLY. Stress the importance of regular servicing by a
Gas Safe Registered Engineer. In IE servicing work must be carried out by a Registered Gas Installer (RGI).
NOTE
This appliance is not intended for use by persons (including children) with reduced physical, sensory
or mental capabilities, or lack of experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
REMINDER: At the time of commissioning, complete all
relevant sections of the Benchmark Checklist located on the
inside back pages of this document prior to handing over the
appliance to the occupier.
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16.
SERVICING & MAINTENANCE
16.1
SERVICING SCHEDULE
To ensure that the appliance gives continued operation that is both safe and efficient,
it is necessary to carry out regular service checks and whilst the period between
servicing will depend on the installation condition and the demands placed upon
the appliance, it is recommended that the appliance be serviced annually.
IMPORTANT: It is a statutory requirement that ALL work be carried out by a “competent
person” which in normal circumstances would be a GAS SAFE registered engineer.
NOTE: In order to carry out either servicing or replacement of components the heater front
door must be removed.
16.2 SERVICING SEQUENCE
16.2.1
Light the heater and carry out a pre-service check, noting any operational
faults.
16.2.2Check the gas consumption.
FLUE GAS TEST
POINT
FIGURE 13.
GAS FLUE TEST POINT
16.2.3Put the appliance in test mode. Refer to paragraph 18.1.
Connect a suitable flue gas analyser to the sampling point on
the top of the air heater or into the flue terminal if access is
possible (optional test). See Figure 13.
16.2.4For correct air heater operation, the CO to CO² ratio should be
checked at the maximum and minimum in test mode.
1
16.2.5Check that the gas input is at least 90% of the nominal.
WARNING. Always turn OFF the gas supply at the gas service cock and
switch OFF. Disconnect the electricity supply to the appliance before
servicing.
1
2
16.2.6
Clean and check the main burner and electrodes. See paragraph
16.4.
16.2.7 Visually check combustion chamber, removing any debris. See
section 16.8.
2
16.2.8 Remove the Combustion Air Fan (CAF) and clean. See section
16.8.
16.2.9
Check the condensate pipes and tubes for blockages. 16.2.10 Check that the flue terminal is unobstructed and that the flue
system is fully assembled correctly.
3
16.2.11 Remove the Air Circulation Fan (ACF) and filter, inspect and
clean. See paragraph 16.7.
16.2.12After completing the servicing or exchange of components,
always test for gas tightness and carry out functional checks as
described above.
3
16.2.13 When work is complete, check the condition of the sealing foam
in the inside of the front door panel. When the door is refitting you
must make ensure a good seal is made.
16.2.14 After servicing, complete the relevant Service Interval Record
section of the Benchmark Checklist located on the inside back
pages of this document.
16.3
GAINING ACCESS FOR SERVICING
AIR FILTER
FIGURE 14.
SERVICING SEQUENCE
16.3.1Ensure the electrical & gas supply is isolated as needed.
16.3.2Remove the return air filter and pull off the top trim.
16.3.3Remove the front panel by unscrewing the 4 retaining screws at
top and bottom of the panel.
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16.4
MAIN BURNER ASSEMBLY
16.4.1
Refer to section 16.3.
16.4.2
Disconnect the gas pipe at the top of the isolation valve.
16.4.3
Disconnect the electrode, igniter and earth leads from the ESYS, then remove the screw and panel
on the ESYS and rmove,. Disconnect the electrical connections.
16.4.4
Remove the two screws from the valve/venturi assembly and withdraw.
16.4.5
Remove the 4 nuts and washers securing the burner assembly to the heat exchanger and withdraw
the assembly, taking care not to damage the internal ceramic pad.
16.4.6
Inspect the inside of the burner assembly for debris. Clean with a soft brush if necessary.
16.4.7
Inspect the gaskets and replace if necessary.
16.4.8 Inspect and clean the spark ignition and flame sensing electrode, removing any debris and
oxidization. Check the spark gap and position of the spark electrode and the positioning of the
flame sensing electrode.
16.4.9
Once reassembled re-check electrode and igniter nuts are tight.
16.4.10 Refit in reverse order ensuring a good seal is made.
Flame Detection Electrode
Combustion
Chamber
Ignition Electrode
Burner Arm
Burner
Assembly Nuts
ESYS
Electrode Nuts
Gas Valve
Electrical
Connections
ESYS
Panel
Screw
Venturi
Burner
Assembly Nut
Gas Cock
FIGURE 15. MAIN BURNER ASSEMBLY REMOVAL
16.5
IGNITION & FLAME DETECTION ELECTRODES
16.5.1Refer to section 16.3.
16.5.2Follow 16.4.4 to remove the valve/venturi.
16.5.3Unscrew the two nuts that retain the electrode to the cover
plate and remove the assembly.
16.5.4Inspect and clean the electrode, removing any debris and
oxidization. If necessary use an abrasive paper or cloth.
16.5.5Inspect the gasket and replace if necessary during reassembly.
16.5.6Repeat sequence for the flame detection electrodes with
the exception of the earth lead.
16.5.7Refit in reverse order and tighten nuts.
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ELECTRODE GAP
4.5mm
IGNITION
ELECTRODE
GAP
4.4mm
FIGURE 16. ELECTRODE GAPS
17
16.6
COMBUSTION CHAMBER/HEAT EXCHANGER
16.6.1 Refer to section 16.3 and 16.4.
16.6.2Inspect the inside of the combustion chamber for debris. If the
inner insulation is damaged, do NOT try to clean. Replace the heat
exchanger.
16.7
AIR CIRCULATING FAN (ACF)
16.7.1 Refer to section 16.3.
16.7.2 Unplug sensor wires and tubes from the air pressure switch, main
power connector and low voltage flying leads.
16.7.3 Release the fan assembly securing screws, slide the fan assembly
forwards on the runners and drop down, remove from the heater
cabinet. Avoid damaging the fan blades. See Figure 17.
16.7.4 Remove all dust from both the impellor and motor, taking care not to
disturb the balance of the fan.
16.7.5 Refitting in reverse order.
16.8
COMBUSTION AIR FAN (CAF)
FIGURE 17.
FILTER & AIR CIRCULATION FAN
16.8.1 Isolate the gas supply and refer to section 16.3.
16.8.2To release the sliding flue connection, slide upwards.
16.8.3Unplug the multi pin plug connections from the fan and carefully remove the 2 spade connectors
from the flue sensor. See Figure 18.
16.8.4Carefully remove the condensate pipe from the bottom of the flue
elbow. This will contain water.
16.8.5Rotate the CAF and elbow assembly 45˚clockwise and withdraw complete assembly.
16.8.6Carefully inspect both the impellor and the mesh in the collectio box for debris.
16.8.7Refit in reverse order.
Flue Seal
Sliding Flue
Pipe
Flue Sensor
45°
Electrical
Connection
Combustion
Air Fan
Condense
Pipe Outlet
FIGURE 18. COMBUSTION AIR FAN
16.9
CONDENSING DRAIN PIPE
16.9.1
Refer to section 16.3.
16.9.2
16.9.3
These pipes will contain water, drain as necessary.
The flexible condensate pipe are push fit. Cut the cable ties on the bottom bends and disconnect
the pipes.
16.9.4
The flexible pipe MUST be routed so the pipe forms a ‘U’ shaped trap. Cable tie the “U” to hold in
place. Cable tie the bottom of the bends.
16.9.5
16.9.6
Reconnect the condense drain pipe to the condense pump.
Disconnect the flue outlet disconnected and pour water into the flue pipe outlet to fill the condensate
drain pipe and check for leaks. Re-connected the pipe to the flue outlet.
Refit in reverser order.
16.9.7
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16.10 CONDENSE PUMP
16.10.1Refer to section 16.3.
16.10.2 Remove the filter which is located behind the condensate inlet pipe.
16.10.3Clean the filter rinsing it with clear water and remove any debris.
16.10.4Re-fit in reverse order.
Return Air
Temperature
Sensor
17.
REPLACEMENT PARTS
17.1
IMPORTANT: Before commencing with any part replacement the appliance
should be isolated from the electrical supply and the gas service cock on the
appliance closed.
Flying Leads
FIGURE 19.
AIR CIRCULATION FAN ASSEMBLY
17.1.1 All parts that are removed should be replaced and refitted in reverse
order, ensuring correct seals are made and wires are connected
correctly.
17.1.2
Flue Temperature
Sensor
Remove any debris from within the appliance.
17.1.3 When gas-carrying components are replaced the appliance
must be tested for gas tightness.
17.2
High Limit
Temperature Sensor
CONTROL PANEL
17.2.1
Refer to section 16.3.
17.2.2 Because of the complexity and delicate nature of the control
panel assembly, it is supplied as a complete kit in a plastic
housing.
17.3
17.2.3
Remove the control panel by unscrewing the 2 screws that hold
the module in place, withdraw the module and unplug the flying
leads at the rear and remove the assembly
17.2.4
Fit new and re-fit in reverse order.
AIR CIRCULATION FAN ASSEMBLY
17.3.1 Refer to section 16.3.
17.3.2 Unplug sensor wires and tubes from the air pressure switch,
main power connector and low voltage flying leads.
17.3.3 Release the fan assembly securing screws, slide the fan
assembly forwards on the runners and drop down, remove from
the heater cabinet. Avoid damaging the fan blades. See Figure 17.
17.3.4 Fit the new fan assembly and re-fit in reverser order.
17.4
RETURN AIR TEMPERATURE SENSOR
17.4.1
17.4.2
17.4.3
17.4.4
17.5
Refer to section 16.3.
Remove the air circulation fan assembly as described in section
16.7.
Unscrew securing nut and remove sensor.
Fit new and re-fit in reverse order.
FLUE TEMPERATURE SENSOR
17.5.1 Refer to section 16.3
17.5.2 Carefully remove the 2 spade connectors from the sensor and
unscrew the sensor from the plastic flue elbow.
17.5.3 Fit new and re-fit in reverse order.
17.6
Condense Drain
Tube
Condense Drain
Pipe
FIGURE 20.
SENSORS & CONDENSE DRAIN PIPE
HIGH LIMIT TEMPERATURE SENSOR
17.6.1 Refer to section 16.3.
17.6.2 Unplug the 2 wires from the temperature sensor and remove the 2
retaining screws.
17.6.3 Fit the new high limit temperature sensor and re-fit in reverse order.
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Flame Detection Electrode
Ignition Electrode
Burner Assembly Nuts
Burner Arm
ESYS
Gasket
Combustion
Chamber
Electrode Nuts
Gas Valve
Burner Assembly
Nut
ESYS
Panel
Screw
Electrical Connections
Venturi
Valve/Venturi
Screws
Gas Inlet
FIGURE 21. MAIN BURNER ASSEMBLY
17.7
AIR PRESSURE SWITCH
17.7.1
Refer to section 16.3.
17.7.2
Disconnect the wire connectors.
17.7.3
Unscrew the 2 screws and remove the air pressure switch.
17.7.3
Fit new and re-fit in reverse order.
17.8
CONDENSATE PUMP
17.9
17.8.1
Refer to section 16.3.
17.8.2
Remove the wires from the terminal strip in fan compartment marked float
switch condensate pump.
17.8.3
Unscrew the 2 fixing screws. See Figure 22.
17.8.4
Disconnect the condensate pipe, condense drain tube from the top of the
pump and lift out of the bottom of the unit.
MAIN IGNITION/CONTROL PCB (ESYS Red Housing on Gas Valve)
17.9.1
Refer to section 16.3.
17.9.2
Unplug the connections from the top of the control and remove the ignition
spark detection wires. See Figure 21.
17.9.3
Unscrew the single retaining screw. Remove cover & unplug the multi pin
connections from the control. Slide the housing off the gas valve electrical
connections.
17.9.4
Replace with the new ignition control PCB and re-fit in reverser order.
Screws
FIGURE 22.
CONDENSE PUMP REMOVAL
17.10 GAS VALVE & VENTURI ASSEMBLY
NOTE: The gas valve is factory preset and must not be adjusted. A replacement valve must only be
supplied by Johnson & Starley Ltd.
17.10.1 Refer to section 16.3.
17.10.2 Unscrew the gas joint at the top of the gas cock and remove the ESYS (red ignition box). Refer to
17.9 & Figure 21.
17.10.3 Remove the 2 fixing screws securing the venturi (and gas valve to the burner and remove the
assembly from the burner carefully removing the gasket.
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17.10.4 Replace with the new component and re-fit in reverse order, ensuring all the seals are in good
condition and correctly positioned.
17.10.5 Check the gas rate and combustion as described in paragraph 14.4.
17.11 BURNER ASSEMBLY
17.11.1 Refer to section 16.3.
17.11.2 Unscrew the gas joint at the top of the gas cock.
17.11.3 Remove the ESYS (red ignition box) & gas valve venturi assembly. Refer to 17.10 & 17.9 and Figure
21.
17.11.4 Remove the 4 nuts which secure the burner assembly.
17.11.5 Carefully withdraw the assembly from the heat exchanger.
17.11.6 Remove the spark detection electrodes, allowing the burner sealing plates to be separated.
17.11.7 Replace with new component. Ensure the gaskets are replaced with new ones and re-fit in reverse
order.
17.11.8 Ensure the rotation position of the burner is correct (indicated by a notch).
17.11.9 Refit in reverse order ensuring the viewing window is correctly positioned.
17.12 IGNITION ELECTRODES
17.12.1 Refer to section 16.3.
17.12.2 Unplug the lead from the ESYS (red ignition box) and earth wire from the back of the electrode. See
Figure 21.
17.12.3 Remove the 2 remaining nuts and withdraw the electrode.
17.12.4 Replace with a new unit, ensuring the gasket is replaced with a new one.
17.13 FLAME DETECTION ELECTRODES
17.13.1 Refer to section 16.3.
17.13.2 Unplug the lead from the ignition control. See Figure 21.
17.13.3 Remove the two retaining nuts and withdraw the electrode.
17.13.4 Replace with new unit, ensuring the gasket is replaced with a new one.
IMPORTANT: When either the ignition or flame detection electrodes have been serviced or replaced you
MUST set the clearances as shown.
17.14 COMBUSTION AIR FAN (CAF)
17.14.1 Refer to section 16.3.
17.14.2 To remove the CAF refer to 16.8.2 to 16.8.6 and Figure 18 and 23.
17.14.3 Remove the 4 retaining screws that attach the CAF to the flue elbow.
17.14.4 Replace with new components and re-fit in reverse order.
Electrical
Connections
Flue Seal
Gasket
Seal
Ring
Flue Elbow
Combustion
Air Fan
Condense Pipe Outlet
Flue Sensor
FIGURE 23. COMBUSTION AIR FAN ASSEMBLY
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18. CONTROL PANEL MODES
FIGURE 24. CONTROL PANEL
1
2
3
CONTROL PANEL
4
7
5
8
6
1
Time control
2
A+
3
B-
4
LED Display
5
E+
6
D-
7
Summer Air Circulation
8
C
9
Reset
9
18.1
TEST MODE
18.1.1To put the appliance in test mode, press Summer Air Circulation (SAC) and C buttons together for
more than 3 seconds, until the display changes. (Possible 5 second time delay.) t100 is displayed
along with the flame symbol.
18.1.2Whilst in test mode, the appliance overrides all temperature setting and defaults to maximum rate.
Pressing the D and E buttons allows you to scroll between maximum and minimum rates, whilst
maintaining all protection and error conditions.
18.1.3Press RESET to take the appliance out of test mode. If no changes are made, the appliance will
stay in test mode for 30 minutes.
18.2
AIR CIRCULATION FAN MODE
18.2.1This mode can be used to adjust the maximum and minimum fan speed output value allowed to
drive the ACF fan. (minimum value of 50 to 100 being maximum)
18.2.2Put into ACF mode by pressing ‘C’ and ‘RESET’ for 3 seconds. The ACF fan will run with the fan
speed value showing on the LCD display, the Value from the ESYS is bypassed.
18.2.3On the display, letter F and the fan speed value will display, this value can be changed by pressing
the A and B buttons accordingly. Once the required value is reached the values can be saved as:
- minimum by pressing button D
- maximum by pressing button E
18.2.4The display will flash for 2 seconds to confirm it has been saved to the ESYS.
18.2.5Timeout mode is set for 30 minutes, this can be terminated by pressing RESET.
18.2.6The backlight stays on when the test mode is active.
18.3
ERROR HISTORY MODE
18.3.1The control panel can store the last 8 error codes. To access these codes press the RESET button
for more than 1 second, this will then flash ‘H1’ on the LCD display.
13.3.2Error 1 being the most recent, along with the error code after the dot. To scroll though the error
history press the ‘C’ button.
18.3.3The unit will stay in error history mode for 30 seconds.
18.3.4To take the unit out of the error history mode press RESET.
18.3.5
In order to limit the warm air temperature the heater will shut off the burner and Lt will be displayed
in the centre of the display. This will be stored as Error 57.
18.3.6Check the filter is clean and the warm air outlets are open.
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19.
FAULT CODE TABLE
19.1CAUTION
Before commencing any mechanical servicing the appliance should be isolated from the electrical supply
and the gas service cock on the appliance closed. All parts that are removed during a service operation
should be replaced in reverse order, ensuring correct seals are made and wires are connected correctly.
During the service remove any debris from within the appliance. When gas-carrying components are serviced
the appliance must be tested for gas tightness after re-assembly. On completion of a service carry out a full
functional test of all appliance components and ensure system controls are operating correctly.
TABLE 4
CODE
ERROR CODES
SYMPTOM
POSSIBLE CAUSE
ACTION
Check all external controls (if fitted)
N/A
Heater will not run
No call for heat to heater control board
Check setting on time clock
Check setting of heater controls
Check gas supply and gas cock
1
Flame lockout after several
attempts
Flame not detected
If burner lights, check flame sensor and wiring to
control board
Check operation of gas valve
2
False flame lockout
False flame detected
Check wiring on ESYS
3
Condense pump failure
Power to the pump
Check for any blockages or restrictions
4
Air pressure switch open
Circulation air fan not running
Check for any dust restrictions or blocked filter
5
No tacho from fan
Fan not running or wiring fault
7
Flue gas protection
High flue gas temperature
Check airflow and fan operation
Check flame detection lead between sensing probe
and ignition control board
8
Flame circuit error
Flame sensing lead shorted to earth
9
Valve driver circuit error
Gas valve not detected
13
Remote reset lockout
Exceeded 5 remote resets per hour
21
ADC error
25
CRC error
Check that fan runs
Check wiring between ESYS and fan
Check that ESYS is corrected fitted on gas valve
Replace ignition control board or gas valve
Reset it by power off/on
Change ESYS
Different software versions
Change ESYS
Check flame detection lead between sensor and
ignition control board
26
Flame lost signal lost 5 times in 4
minutes
Flame sensing error. Failing gas
pressures. Fan fault. Flue blockage.
Check the gas supply, does pressure fall when
burner fires?
Check that flue system is not blocked
BLOCKING CODES
30
Duct air temperature sensor short
circuit
Temperature sensor shorted to earth or
failed
Check wiring and connections for shorting to earth
31
Duct air temperature sensor open
circuit
Temperature sensor not connected or
failed
Check wiring connections
34
Low mains supply voltage
Electrical supply fault to property
Check incoming mains supply
Faulty wiring to appliance
Check wiring to appliance
43
Return air temperature short circuit
Temperature sensor shorted to
44
Return air temperature sensor
open circuit
Temperature sensor not connected or
failed
Check wiring connections
45
Flue gas temperature sensor short
circuit
Short circuit in wiring between sensor and
control board
Check wiring to sensor
46
Flue gas temperature sensor open
circuit
Temperature sensor not connected or
failed
Check wiring connections
57
Restricted airflow
Blocked filter and return air filter/Duct
Cheak blockage from filter and return air filter/ducts
Communication MMI-ESYS lost
Connection between MMI & ESYS
incorrectly made
Check wiring and connections
99
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Check sensor resistance
Check sensor continuity
Check wiring connections not shorting to earth
Check sensor resistance
Check sensor continuity
Check electrical resistance of the sensor
Check sensor continuity
23
20.
FAULT FINDING FLOW CHART
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21.
DEFECT DIAGNOSIS FOR THE CIRCULATION AIR FAN
21.1
CIRCULATION AIR FAN
21.1.1 Ensure Air Circulation Fan is runnning at maximum.
21.1.2 A voltage should be measured and blue (-) and yellow (+). Voltage approx. 10 VDC.
21.1.3 If voltage is present and fan is not running at maximum. Replace ACF.
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22.
FUNCTIONAL WIRING DIAGRAMS
()
DSP (MMI)
CONTROL PANEL
TIMER
n
5
4
3
2
X5
X1
M
1
X4
or
1 2 3
3
1
GNYE
CONDENSATE PUMP
1 2
BN
X3
X2
3
1
1 2 3 4
VT
4
4 5 6
BN BN BU
3
5
BN
BU
RD
YE
BK
BU
GY
BU GR
N/C
GR GN OG OG
BU
COLOUR
ABR
OR
BK
BLACK
PCB INTERFACE
BLUE
BU
GREEN
GN
BROWN
BN
RED
RD
RD
BU
1
2
3
A2
A1
BN
X6
X7
RD
OPENTHERM
UNIT
FLOAT SWITCH
PCB - INTERFACE
ROOM STAT HTR
YE
VIOLET
VT
WHITE
WH
SUMMER
SWITCH
(OPTIONAL)
25
26
27
28
29
30
31
32
BU
10 9
5 4
BN
8
3
PLEASE NOTE:-
7
2
X1
6
1
link between 21 & 23
* Remove
when fitting a room stat
ESYS
ESYS X1
YELLOW
CLEANFLOW
OG
YE
OG
6 5 4
3 2 1
GN
Remove link between 25 & 26
when fitting an open therm
BU
X2
YE
BK
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
RD
YE
r
RD
2
4
1
3
CAF
ORANGE
r
RD
X3
RD
GN
GN
BU
BN
GNYE
BU
BN
GNYE
CLEANFLOW
(OPTIONAL)
N Transformer
24V
GY
L
OR
E
0V
BN
6
E
L
N
5
1
2
3
1
4
GNYE
y/g
B2
BK BK
ROOM STAT
(OPTIONAL)
2
GAS
VALVE
BURNER ARM
B1
24 SL
23 O/P
22 N
21 L
20 N
19 L
18 N
17 L
16 E
15 N
14 L
13 E
12 N
11 L
10 E
N
9
L
8
E
7
N
6
L
5
E
4
3
OG
or OG
or
YE
ACF
GY
COND/PUMP CLOCK
AMBIENT
ROOM
SENSOR
(OPTIONAL)
GREY
*
RD
GNYE
GREEN/YELLOW
A3
BU
BN
GNYE
BN
br BU
bl
MAINS 230V - AC
GNYE
GNYE
EARTH
FIGURE 25. WIRING DIAGRAM No. 1
TIMER
DSP (MMI)
GAS VALVE
WIRE COLOUR
TERMINAL
L/N/E
TO UNIT
TERMINAL
WIRE COLOUR
TERMINAL
TO UNIT
TERMINAL
red
1
L
PCB INTERFACE
18
brown
X1 - 5
PCB INTERFACE
14
blue
2
N
PCB INTERFACE
19
blue
X1 - 10
PCB INTERFACE
15
L/N/E
blue
2
DSP (MMI)
X1 - 1
yellow
X2 - 1
DSP (MMI)
X4 - 4
3
PCB INTERFACE
22
orange
X2 - 2
DSP (MMI)
X4 - 2
brown
4
DSP (MMI)
X1 - 3
green
X2 - 3
DSP (MMI)
X4 - 3
green
X2 - 1
PCB INTERFACE
X2 - 1
black
X2 - 4
DSP (MMI)
X4 - 4
green
X2 - 2
PCB INTERFACE
X2 - 2
blue
X2 - 5
DSP (MMI)
X4 - 5
orange
X2 - 3
PCB INTERFACE
X2 - 4
yellow
X3 - 2
PCB INTERFACE
X3 - 1
orange
X2 - 4
PCB INTERFACE
X2 - 5
red
X3 - 3
PCB INTERFACE
X3 - 3
red
X3 - 10
PCB INTERFACE
X3 - 4
yellow
X3 - 13
PCB INTERFACE
X3 - 2
orange
B1
PCB INTERFACE
30
green/yellow
1
E
PCB INTERFACE
green/yellow
1
E
ELECTRODE
E
PCB INTERFACE
10
L
PCB INTERFACE
N
PCB INTERFACE
orange
CLEANFLOW
FROM UNIT
brown
Transformer
FROM UNIT
WIRING ROUTING TABLE
grey
-
www.johnsonandstarley.co.uk
ESYS
13
violet
B2
PCB INTERFACE
29
blue
A3
N
PCB INTERFACE
18
11
brown
A2
L
PCB INTERFACE
17
9
green/yellow
A1
E
PCB INTERFACE
16
CONDENSATE
PUMP
26
FIGURE 26. WIRING DIAGRAM No. 2
FROM UNIT
COMBUSTION
AIR FAN
(CAF)
WIRE COLOUR
TERMINAL
L/N/E
TO UNIT
TERMINAL
white
A1 - 2
ESYS
X3 - 1
black
A1 - 3
ESYS
x3 - 12
yellow
A1 - 4
ESYS
X3 - 5
brown
A2 - 1
L
PCB INTERFACE
8
green/yellow
A2 - 2
N
PCB INTERFACE
7
blue
A1 - 3
E
PCB INTERFACE
9
CAF FLUE
PROTECTION
SENSOR
black
B1
ESYS
X3 - 9
black
B2
ESYS
X3 - 6
BULKHEAD
LIMIT SWITCH
violet
D1
ACF LIMIT SWITCH
E2
violet
D2
ESYS
X3 - 15
BULKHEAD DUCT
AIR SENSOR
orange
C1
ESYS
X3 - 8
orange
C2
ESYS
X3 - 16
Sales/Spares 01604 707012
WIRING ROUTING TABLE
FROM UNIT
WIRE COLOUR
AIR
CIRCULATION
FAN
(ACF)
ACF RETURN
AIR SENSOR
AIR PRESSURE
SWITCH
Replacement Help Line 01604 707011
TERMINAL
L/N/E
TO UNIT
TERMINAL
blue
X9 - 2
N
PCB INTERFACE
6
green/yellow
X9 - 3
E
PCB INTERFACE
4
brown
X9 - 4
L
PCB INTERFACE
5
black
X10 - 1
DSP (MMI)
X3 - 3
yellow
X10 - 2
DSP (MMI)
X3 - 1
green
F1
ESYS
X3 - 6
green
F2
ESYS
X3 - 14
green
1
ACF
F2
green
2
ESYS
X3 - 7
27
23.DIMENSIONS
SIDE VIEW
97
64
316
1400
1254
142
FRONT VIEW
89
34
FRONT
509
500
BASE VIEW
533
55
TOP VIEW
198
93
800
600
128
617
708
FIGURE 27. C46U DIMENSIONS
www.johnsonandstarley.co.uk
28
24.
EXPLODED SPARES DIAGRAMS
ITEM
PART No.
1
C10D-0501005
ITEM
PART No.
2
C10D-0140005
G. C. No.
DESCRIPTION
QTY
CONTROL PANEL ASSEMBLY
G. C. No.
1
DESCRIPTION
QTY
COMBUSTION FAN ASSEMBLY
1
FLANGE
CONNECTION
3
7
6
5
COMBUSTION
AIR FAN
EXHAUST
FLUE
4
LIST OF SPARES
ITEM
PART No.
3
1000-2501505
Flue Seal
1
4
1000-0522645
Flue Gas Sensor
1
Exhaust Flue Drain Elbow
1
Flue Seal
1
Gasket Seal Ring
1
Combustion Air Fan
1
Gasket Seal Ring
1
‘O’ Ring
1
‘O’ Ring
1
5
4
6
7
Sales/Spares 01604 707012
Replacement Help Line 01604 707011
1000-0022195
1000-0525215
1000-2501675
G.C.No.
DESCRIPTION
QTY
29
ITEM
PART No.
8
C46D-0700005
G. C. No.
DESCRIPTION
QTY
BURNER ASSEMBLY
1
9
11
10
12
LIST OF SPARES
ITEM
9
10
ITEM
PART No.
13
C46U-0503005
G. C. No.
PART No.
G.C.No.
1000-0710745
1000-0710775
11
1000-0710455
12
1000-0710445
DESCRIPTION
QTY
Burner Arm Assembly
1
Burner Gasket A
1
Burner Gasket B
1
Valve/Venturi Assembly
1
Venturi Gasket
1
Cork Gasket
1
Ignition Electrode
1
Ignition Electrode Gasket
1
Detection Electrode
1
Detection Electrode Gasket
1
DESCRIPTION
QTY
AIR CIRCULATION FAN ASSEMBLY
1
ITEM
PART No.
14
1000-0522645
G.C.No.
14
FLYING LEAD
www.johnsonandstarley.co.uk
RETURN AIR SENSOR &
DUCT TEMPERTURE SENSOR
1
30
14
15
COMBUSTION AIR PASSAGE ASSEMBLY
CONDENSATE PUMP ASSEMBLY
SEALING
FRAME
CONDENSATE
BOX
FLANGE
SOCKET
BACK NUT
SEAL
CONDENSATE CONNECTOR
RING SEAL
G.C.No
C46D-0132005
16
EYSY CONTROL BOX
1000-0526605
G. C. No.
23
G. C. No.
1
HIGH LIMIT
TEMPERATURE SENSOR
1000-0516835
G. C. No.
1
Sales/Spares 01604 707012
CONDENSATE TRAP
ASSEMBLY
20
1000-0024525
G. C. No.
24
1
ELECTRICAL PCB
PANEL
C26U-0137005
G. C. No.
21
1
G.C.No
1000-0025035
17
C46U HEAT EXCHANGER
C46D-0300005
20
1
18
1
OPEN THERM SWITCH
1000-0525305
G. C. No.
1
TELESCOPIC FLUE
TUBE
1000-0022225
G. C. No.
22
1
1
VERTICAL FLUE
ADAPTOR 60/100mm
1000-0022225
G. C. No.
1
AIR PRESSURE SWITCH
1000-0526495
G. C. No.
1
Replacement Help Line 01604 707011
31
25. IMPORTANT INFORMATION
Fully complies with
Part L of the Building Regulations
by following the guidance in the
British Standard BS 5864
and the
Heating Compliance Guide
For further information contact
Johnson & Starley Ltd
on Telephone 01604 762881
These kits are readily available from Johnson & Starley Ltd
Telephone the Sales Office for further information
WARMCAIR C46U ANCILLARY’S
Description
Product Code
1
Cleanflow Air Filter
CFSR36
2
Side Return Air Kits
SR36
www.johnsonandstarley.co.uk
32
26. BENCHMARK LOG BOOK
C46U
COMMISSIONING CHECKLIST
& SERVICE RECORD
This Log Book should be
filled out at each annual
service
Sales/Spares 01604 707012
Replacement Help Line 01604 707011
33
CONDENSING WARM AIR HEATING AND WATER HEATING COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the wsnn air unit and associated
equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for
future reference
Failure to Install and commission this equipment to the manufacturer's instructions may Invalidate the warranty but does not affect statutory rights.
Customer name:
Telephone number:
Address:
Warm Air Unit Make and Model:
Warm Air Unit Serial Number:
Commissioned by (PRINT NAME):
Gas safe register number:
Company name:
Telephone number:
Company address:
Commissioning date:
CONTROLS (tick the appropriate boxes)
Time and temperature control to heating
Room thermostat and programmer/timer
Programmable Roomstat
Load/weather compensation
Optimum start control
Fitted
Not required
Heating zone control
WARM AIR HEATER
Has the system been balanced in accordance with the heater manufacture's instructions?
Yes
No
Was an anemometer used?
Yes
No
Yes
No
WARM AIR HEATING: measure and record:
Bumer operating pressure (at maximum rate)
mbar
Heat input
kW
Temperature difference between return air inlet and nearest outlet
°C
WATER HEATING: (If fitted)
Water inlet temperature
°C
Water outlet temperature
°C
CONDENSATE
The condensate drain has been installed in accordance with the manufacture's instructions and/or BS 5546/BS6798
Yes
INSTALLATION
The heating and hot water system complies with the appropriate Building Regulations
Yes
The system and associated products have been installed and commissioned in accordance with the manufacturers instructions
Yes
Yes
The manufacturer's literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer’s Signature
Customer’s Signature
*
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
SERVICE 01
Date:
Engineer name:
SERVICE 02
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
CO² %
CO² %
Signature
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Date:
Engineer name:
SERVICE 04
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
CO² %
CO² %
Signature
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Date:
Engineer name:
SERVICE 06
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Date:
Engineer name:
Company name:
Comments:
CO² %
CO² %
Signature
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
CO² %
CO² %
Signature
SERVICE 07
Date:
Engineer name:
SERVICE 08
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Date:
Engineer name:
Company name:
Comments:
CO² %
CO² %
Signature
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
CO² %
CO² %
Signature
SERVICE 09
Date:
Engineer name:
SERVICE 10
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Date:
Engineer name:
Company name:
Record:
CO² %
CO² %
Signature
SERVICE 05
Record:
Date:
Engineer name:
Company name:
Record:
CO² %
CO² %
Signature
SERVICE 03
Record:
Date:
Comments:
Signature
CO² %
CO² %
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
CO² %
CO² %
Signature
to Local Authority Building Control (LABC) either directly or through a
*All installations in England and Wales must be
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Johnson & Starley Ltd
Rhosili Road, Brackmills,
Northampton NN4 7LZ
sales@johnsonandstarley.co.uk
marketing@johnsonandstarley.co.uk
Reception
01604 762881
Johnson & Starley Dravo Division Industrial H&V
Sales
01604 707022
dravo@johnsonandstarley.co.uk
www.dravo.co.uk
Sales/Spares
01604 707012
Service/Warm air upgrade
01604 762881
Warm air upgrade
01604 707011
Anniversary 1922 - 2012
In the interest of continuous development Johnson & Starley reserve the right to change specification without prior notice.
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