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 www.johnsonandstarley.co.uk 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. www.johnsonandstarley.co.uk 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). Sales/Spares 01604 707012 Replacement Help Line 01604 707011 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. www.johnsonandstarley.co.uk 4 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. Sales/Spares 01604 707012 Replacement Help Line 01604 707011 5 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. www.johnsonandstarley.co.uk 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 Sales/Spares 01604 707012 Replacement Help Line 01604 707011 7 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 www.johnsonandstarley.co.uk 8 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 Sales/Spares 01604 707012 Vertical Appliance Adaptor Required Extension Lengths Vertical Terminal FIGURE 6. VERTICAL FLUE Replacement Help Line 01604 707011 9 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 www.johnsonandstarley.co.uk 10 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 Sales/Spares 01604 707012 Replacement Help Line 01604 707011 11 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. www.johnsonandstarley.co.uk 12 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 Sales/Spares 01604 707012 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 Replacement Help Line 01604 707011 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 www.johnsonandstarley.co.uk 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. Sales/Spares 01604 707012 Replacement Help Line 01604 707011 15 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. www.johnsonandstarley.co.uk 16 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. Sales/Spares 01604 707012 Replacement Help Line 01604 707011 FLAME DETECTION 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 www.johnsonandstarley.co.uk 18 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. Sales/Spares 01604 707012 Replacement Help Line 01604 707011 19 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. www.johnsonandstarley.co.uk 20 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 Sales/Spares 01604 707012 Replacement Help Line 01604 707011 21 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. www.johnsonandstarley.co.uk 22 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 Sales/Spares 01604 707012 Replacement Help Line 01604 707011 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 www.johnsonandstarley.co.uk 24 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. Sales/Spares 01604 707012 Replacement Help Line 01604 707011 25 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 email@example.com firstname.lastname@example.org Reception 01604 762881 Johnson & Starley Dravo Division Industrial H&V Sales 01604 707022 email@example.com 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.
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project