Johnson & Starley ECONOMAIRE 25 Installation, Commissioning & Servicing Instructions

Warm air heater

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INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS

ECONOMAIRE 25/INTEJAN has been tested and certified by Advantica Technologies for use with NATURAL gas G20.

Note: These instructions have been written to service both the ECONOMAIRE 25 and the ECONOMAIRE 25 INTEJAN. If your

heater does not have the intejan circulator fitted, simply ignore the relevant section/s.

Heater with Sealing Panel removed

BRIEF DESCRIPTION

1.1

The ECONOMAIRE 25/INTEJAN is a fan assisted downflow ducted warm air heater, which is fan flued and room sealed.

The heater is supplied with digital temperature control (for maximum comfort) and a water circulator is standard on the 25

INTEJAN. However, an INTEJAN circulator (retro-fit) kit is available for the ECONOMAIRE 25.

These instructions are to be left with the User or adjacent to the Gas Meter

ECONOMAIRE 25/INTEJAN

WARM AIR HEATER

Air Heater:

Water Circulator:

Fig. 1

G.C. Numbers:

25 42-416-15

53-416-32

Publication No. ZZ 1108/5

Thermista-stat

Time control

Air circulator fan

Circuit diagram label

Gas connection

Circulator thermostat

FDC & limit switch

Gas cock

Ignition burner

10.

Main burner assembly

11.

Intejan circulator

12.

Water return connection

13.

Water flow connection

Air heater multifuntion control

15.

Intejan multifunction control

(ECONOMAIRE 25 INTEJAN)

Flue gas test point

17.

LED diagnostics indicator

18.

Control module

19.

Combustion air fan

20.

Filter

21.

Flue adapter

Fig.2

Sealing Panel

February 2008

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Summary of Contents for Johnson & Starley ECONOMAIRE 25

Page 1 ECONOMAIRE 25/INTEJAN has been tested and certified by Advantica Technologies for use with NATURAL gas G20. Note: These instructions have been written to service both the ECONOMAIRE 25 and the ECONOMAIRE 25 INTEJAN. If your heater does not have the intejan circulator fitted, simply ignore the relevant section/s.
Page 2 PERSONS, (i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION. TECHNICAL DATA ECONOMAIRE 25 ECONOMAIRE 25 INTEJAN Weight: 45 Kg 51.5 Kg Air Heater...
Page 3 HEATER COMPARTMENT AND CLEARANCES (SEE BS 5864) IMPORTANT: If the heater is to be fitted to an existing base duct (warm air plenum), always ensure that installation is carried out such that the rear left hand corner of the heater is aligned with the rear left hand corner of the base duct, so that any overhang or blanking off will be at the front and/or right hand side.
Page 4 NOTE: THIS APPLIANCE MUST ONLY BE INSTALLED WITH THE SUPPLIED ACCESSORIES AND TERMINAL. FLUES The ECONOMAIRE 25/INTEJAN can be used with horizontal or vertical flue types C12 and C32. You should also consult (or be familiar with) British Standards BS 5440 Pt. 1 Flues 5.1.1 All joints must be soundly sealed.
Page 5 5.2.5 It is recommended that the flue is fitted so that the outer part is flush with the wall. However, where this is not the through the wall MUST NOT exceed 22mm (see Fig. 5) 5.2.5 If the heater is to be installed in a timber framed building you MUST consult British Gas publication “Guide for Gas Installations in Timber Framed Housing DM2”...
Page 6 VERTICAL TERMINAL LOCATION: 5.3.1 The ECONOMAIRE 25/INTEJAN is designed to be used with a vertical flue where the installation of a horizontal flue is either not possible or not desired. 5.3.2 Installation of a vertical flue can be achieved on either a flat or pitched...
Page 7 ELECTRICAL WARNING: THIS APPLIANCE MUST BE EARTHED! 5.4.1 Mains. The heater is supplied with mains cable (PVC sheathed, heat resisting to 85 C), 3 core: Brown; Blue; Green/ Yellow, 6A, 0.75mm ), connected to a terminal block and exiting through the heater at the right 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.
Page 8 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. LIGHTING IGNITION AND MAIN BURNER: 6.3.1 Turn on the gas supply to the heater.
Page 9 SAFETY CHECK: In order to check the correct operation of the control module, run the heater for a short period and introduce a fault condition by carrying out the following sequence: 6.6.1 Check for gas soundness within the appliance. 6.6.3 Turn on both the gas and electrical supplies to the heater. 6.6.4 Set the “AIR HEATER”...
Page 10 Feed Temp. stop 2 for direct Snap rivet Tank system. Remove for indirect system application. Temp. stop 1 Hot water Fixing screw Spindle Direct storage cylinder Fig. 9a Drain cock Position of temperature stops Circulator Fig. 9 Typical INTEJAN direct system application. NOTE: The circulator thermostat is factory set to provide a temperature range of 50 C to 82...
Page 11 INTEJAN CIRCULATOR COMMISSIONING PREPARATION: 8.1.1 Ensure that the gas and electrical supplies are OFF. 8.1.2 Fill the water circulation system, clear any air locks and check for water soundness, sealing any leaks detected. 8.1.3 Refit the sealing panel and secure using the fixing screws. NOTE: Whilst the sealing panel needs to be fixed in such a manner so as to ensure an air tight seal, care MUST be taken not to over tighten the fixing screws.
Page 12 8.2.16 Set the time control to the desired “on” and “off” periods. 8.2.17 Set the “WATER HEATER” switch on the time control to “TIMED”. WATER BURNER PRESSURE TEST: NOTE: THE WATER CIRCULATOR BURNERS ARE PRE-SET AND SHOULD NOT REQUIRE ADJUSTING. 8.3.1 Loosen the screw on the outlet pressure test point and fit a pressure test gauge (see Fig.
Page 13 10.1 ROUTINE MAINTENANCE: 10.1.1 Operate the appliance and check for the correct function of the burner and controls. 10.1.2 Turn OFF the gas and electrical supplies to the appliance. 10.1.3 Remove the air heater front panel. 10.1.4 Remove and check the return air filter/cleaner for cleanliness, remove and clean the air circulation fan as detailed in para 10.6.
Page 14 10.4. IGNITION BURNER AND ELECTRODE REMOVAL AND REPLACEMENT: 10.4.1 Remove the burner as detailed in 10.2 above. 10.4.2 Disconnect the igniter lead from electrode. 10.4.3 Break the gas feed at the burner end of the gas feed pipe. 10.4.4 Release the single screw, nut and washer securing the ignition burner to the main burner assembly and carefully remove the ignition burner assembly.
Page 15 10.8.4 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly from the door. 10.8.5 Remove the 3 X M3 bolts that secure the time clock mechanism and remove from the mounting plate. 10.8.6 Refitting or replacement is in reverse order.
Page 16 NOTE: When reassembling ensure that gaskets are soundly sealed and replaced where necessary (See cautionary note at paragraph 10) Prior to use, you MUST fully commission the heater in accordance with these instructions. 10.12. FLUE FAN, REMOVAL AND CLEANING 10.12.1 Remove the air circulation fan as detailed at 10.6 10.12.2 Disconnect the power supply to the pressure switch.
Page 17 START Water circulator Air heater Timed or continuous operation Thermostat Thermista-stat Demand Demand for water for air heat heat Module powers up RESET RESET Is no-flow LOCKOUT LOCKOUT provided? Fan starts Pressure switch operates Is flow provided? Thermostat Thermista-stat Demand Demand for water for air...
Page 20 --------pk pink --------pk yellow------y yellow------y orange-----or orange-----or black/white-----bk/w black/white-----bk/w green/yellow ---g/y green/yellow ---g/y WATER HEATER THERMISTA-STAT THERMOSTAT AIR HEATER GAS CONTROL COVER LIMIT SWITCH FDC ASSEMBLY WATER HEATER OVERHEAT AIR HEATER LIMIT SWITCH IGNITION ELECTRODE Fig.13 Economaire 25 Flow Diagram...
Page 21 Fig.14 Economaire 25 Logic Diagram...
Page 22 Fig. 15 Schematic Diagram (showing connection of an external controller)
Page 23 KNOCKOUTS FOR WATER CONNECTION (BOTH SIDES) KNOCKOUTS FOR GAS CONNECTION KNOCKOUTS FOR WATER CONNECTION (BOTH SIDES) FRONT VIEW SIDE VIEW BASE VIEW TOP VIEW Fig. 16 Economaire 25 - Principal Dimensions...
Page 24 LIST OF SPARES (see Fig. 17) ECONOMAIRE 25 and ECONOMAIRE 25 INTEJAN Item G.C. No Part No Description E69625 1000-0521020 Wiring harness E80119 1000-0521860 Wiring harness (air heater) 232 862 N250-0350005 Heat exchanger E80123 1000-0521820 FDC & limit switch E79272...
Page 25 31 19 4 12 13 Fig. 17 Exploded Diagram...
Page 26 BENCHMARK Number WARM AIR HEATER AND CIRCULATOR COMMISSIONING CHECKLIST WARM AIR UNIT APPLIANCE SERIAL NUMBER: ............NOTIFICATION No: ......HOT WATER GENERATOR APPLIANCE SERIAL NUMBER: .
Page 27 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate service interval record below. SERVICE PROVIDER Before completing the appropriate service interval record below, please ensure that you have carried out the service as described in the heater manufacturer’s instructions and in compliance with the Gas Safety Regulations Date .
Page 28 Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. If you have a problem in obtaining a spare part, please contact our Spares Department at the address below. JOHNSON & STARLEY LTD. Telephone: (01604) 762881 Rhosili Road, Brackmills, Fax:...

This manual is also suitable for:

Economaire 25 intejan Economaire 65 Economaire 65 intejan