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ECONOMAIRE 65
Warm Air Heater
with Intejan Water Circulator
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
Economaire 65
Intejan Water Circulator
These instructions are to be left with the User
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G.C. No. 42-416-18
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G.C. No. 42-416-99
www.johnsonandstarley.co.uk
Publication No. ZZ 1133-7
October 2016
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Summary of Contents for Johnson & Starley ECONOMAIRE 6
- Page 1 Publication No. ZZ 1133-7 October 2016 ECONOMAIRE 65 Warm Air Heater with Intejan Water Circulator INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS Economaire 65 G.C. No. 42-416-18 Intejan Water Circulator G.C. No. 42-416-99 These instructions are to be left with the User www.johnsonandstarley.co.uk...
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Page 2: Table Of Contents
CONTENTS 15 Intejan Circulator Commissioning The Benchmark Scheme Preparation Lighting Ignition & Main Burner Features Water Burner Pressure Test Safey Check General Description 16 Users Instructions Building Standards & Regulations 17 Servicing & Maintenance Safety &Gas Information Routine Maintenance General Safety Information Multi Functional Control &... -
Page 3: Features
FEATURES Appliance Classification: ECONOMAIRE 65/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 65 and the ECONOMAIRE 65 INTEJAN. If your heater does not have the intejan circulator fitted, simply ignore the relevant section/s. -
Page 4: Building Standards & Regulations
BUILDING STANDARDS & REGULATIONS STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE 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. -
Page 5: Technical Data
TECHNICAL DATA ECONOMAIRE 65 ECONOMAIRE 65 TABLE 1 INTEJAN WEIGHT 48kg 86kg GAS SUPPLY PRESSURE 20mbar GAS CATEGORY COUNTRIES OF INSTALLATION GB & IE ELECTRICAL SUPPLY 230v ~ 50Hz fused 5A (150 watts) NOx Class MAXIMUM WATER SIDE 3 bar OPERATING PRESSURE (PMS) OPEN VENTED SYSTEM SEALED SYSTEM... -
Page 6: Ventilation Air
VENTILATION AIR When installed in a compartment two permanent ventilation openings into the compartment are required, one at high level and one at low level. The minimum effective areas specified in Table 1 are related to the rated heat input of the air heater and assume that an INTEJAN circulator is fitted. DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating) RETURN AIR... -
Page 7: Flue Instructions
FLUE INSTRUCTIONS NOTE: THIS APPLIANCE MUST ONLY BE INSTALLED WITH THE SUPPLIED ACCESSORIES AND TERMINAL. 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. - Page 8 FIGURE 4. TERMINAL POSITIONS TERMINAL POSITION MINIMUM DISTANCE Directly below an opening, air brick, opening window etc 300mm Above an opening, air brick, opening window, etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes. 75mm Below eaves.
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Page 9: Horizontal Terminal Location
HORIZONTAL TERMINAL LOCATION 9.6.1 The terminal must be positioned on the outside of the building and allow for the free passage of air across it at ALL times. 9.6.2 The flue MUST be fitted with the protrusion as shown in Figure .5. 9.6.3 Avoid positions where the terminal is adjacent to projections, particularly under a balcony or immediately adjacent to a drain pipe. - Page 10 FIGURE 6. PLUME TERMINAL OUTLET DIMENSIONS CONVENTIONAL 80/125mm FLUE ACCESSORY PARTS No’s ITEM DESCRIPTION PART No. COLOUR 90˚ Standard Flue Elbow 1000-0016520 White 45˚ Flue Elbow 1000-0016530 White 500mm Extension 1000-0016550 White 1000mm Extension 1000-0016540 White Vertical Terminal & Support Bracket 1000-0016560 Anthracite Vertical Terminal &...
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Page 11: 10. Electrical
10. ELECTRICAL WARNING: THIS APPLIANCE MUST BE EARTHED! 10.1 MAINS SUPPLY The heater is supplied with mains cable (PVC sheathed, heat resisting to 85°C), 3 core: Brown; Blue; Green/Yellow, 6A, 0.75mm ), connected to a terminal block and exiting through the heater at the right hand top. -
Page 12: Air Heater Commissioning
AIR HEATER COMMISSIONING 13.1 PREPARATION After installation of the appliance, you MUST do the following: 13.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found. 13.1.2 Carry out preliminary electrical system checks. 13.1.3 Ensure that: a. filter, fan and fan compartments are free from obstructions. b. -
Page 13: Main Burner Pressure Test
13.3.10 If, after the 60 second period, the main burner has ignited the LED indicator will show “0” and the green LED “ON” light on the indicator panel will remain steady. 13.3.11 If the main burner fails to ignite, the red LED marked “LOCKOUT” will illuminate on the display panel and the LED status indicator will display an alphanumeric character relevant the fault detected. -
Page 14: Intejan Circulator
INTEJAN CIRCULATOR 14.1 WATER CIRCULATION SYSTEM Detailed recommendations for the water circulation system are given in BS 6798, BS 5449 (for small bore and microbore central heating systems), and BS 5446. The maximum water side operating pressure (PMS) is 1bar. 14.1.1 To ensure good circulation in gravity circuits, flow pipes should be designed to run vertically from the water heater before running laterally. -
Page 15: Intejan Circulator Commissioning
INTEJAN CIRCULATOR COMMISSIONING 15.1 PREPARATION 15.1.1 Ensure that the gas and electrical supplies are OFF. 15.1.2 Fill the water circulation system, clear any air locks and check for water tightness, sealing any leaks detected. 15.1.3 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 16: Water Burner Pressure Test
15.2.12 In the event of a lockout and the 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. 15.2.13 Test for gas leakage at the supply, multifunction control, ignition burner and main burner using proprietary detection fluid, sealing any leaks found. -
Page 17: Servicing & Maintenance
SERVICING & MAINTENANCE NOTE: It is recommended that this appliance be serviced at intervals of no less than 12 months. IMPORTANT: Ensure that the gas and electricity supplies are isolated before commencing any servicing & maintenance or replacement of components. Because the appliance is room sealed, it is also imperative that if at any stage of repairs the gasket on the sealing plate is damaged it MUST be replaced! After completion of any maintenance, always test for gas tightness and carry out a complete functional test of the appliance in accordance with the Commissioning Instructions at paragraphs 6.1 to 6.6 inclusive. -
Page 18: Ignition Burner & Electrode Removal & Replacement
17.4. IGNITION BURNER & ELECTRODE REMOVAL 7 REPLACEMENT 17.4.1 Remove the burner as detailed in paragraph 17.3. 17.4.2 Disconnect the igniter lead from electrode. 17.4.3 Break the gas feed at the burner end of the gas feed pipe. If, at any time, the gas supply feed pipe is removed from the multifunction control, the ‘O’ ring MUST NOTE: be replaced. -
Page 19: Fan Delay Control/Limit Switch Removal
TIME CONTROL REMOVAL 17.8.3 Disconnect spade terminal connectors “C1”, “C2”, “C3” and “C5” from the time control. 17.8.4 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly from the door. 17.8.5 Remove the 3 x M3 bolts that secure the time clock mechanism and remove from the mounting plate. -
Page 20: Flue Fan Removal & Cleaning
17.12 FLUE FAN, REMOVAL & CLEANING 17.12.1 Remove the air circulation fan as detailed at 17.6 17.12.2 Carefully open the plastic insulators on the fan fly-lead and break the electrical connections such that the spade connectors can be fed through the grommet on the sealing plate. 17.12.3 Remove the fixing screws holding the flue fan sealing plate in place and remove the plate. -
Page 21: Fault Finding Flowcharts
FAULT FINDING FIGURE 14. CONTROL FLOWCHART Sales/Spares & Replacement Help Line 01604 762881... - Page 22 FIGURE 15. AIR HEATER DIAGNOSIS FLOWCHART www.johnsonandstarley.co.uk...
- Page 23 FIGURE 16. WATER CIRCULATOR FLOW CHART Sales/Spares & Replacement Help Line 01604 762881...
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Page 24: Logic Diagram
LOGIC DIAGRAM FIGURE 17. LOGIC DIAGRAM www.johnsonandstarley.co.uk... -
Page 25: Schematic Diagram
SCHEMATIC DIAGRAM FIGURE 19. SCHEMATIC DIAGRAM Sales/Spares & Replacement Help Line 01604 762881... -
Page 26: Circuit Diagram
CIRCUIT DIAGRAM Showing connections of an external controller FIGURE 19. SCHEMATIC DIAGRAM (showing connection of an external controller) www.johnsonandstarley.co.uk... -
Page 27: Dimensions
DIMENSIONS FIGURE 20. ECONOMAIRE 65 DIMENSIONS Sales/Spares & Replacement Help Line 01604 762881... - Page 28 EXPLODED SPARES DIAGRAMS SORT LIST OF SPARES ITEM G.C. No. PART No. DESCRIPTION E69625 1000-0521020 Wiring Harness E80119 1000-0521860 Wiring Harness (air heater) N650-0101000 Heat Exchanger (cabinet sub assembly) E80123 1000-0521820 FDC & Limit Switch E82818 N650-0182000 Filter Assembly E82947 N650-0702000 Burner &...
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Page 29: Exploded Diagram
EXPLODED DIAGRAM FIGURE 21. ECONOMAIRE 65 EXPLODED DIAGRAM Sales/Spares & Replacement Help Line 01604 762881... - Page 30 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.
- Page 31 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 SERVICE 02 Date:...
- Page 32 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 01604 767408 Anniversary 1922 - 2012...
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