Johnson & Starley ECONOMAIRE 32/INTEJAN Installation, Commissioning & Servicing Instructions
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Johnson & Starley ECONOMAIRE 32/INTEJAN Installation, Commissioning & Servicing Instructions

Warm air heater
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INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
ECONOMAIRE 32/INTEJAN has been tested and certified by Advantica for use with NATURAL gas G20.
Note: These instructions have been written to service both the ECONOMAIRE 32 and the ECONOMAIRE 32/INTEJAN. If your
heater does not have the intejan circulator fitted, simply ignore the relevant section/s.
1
2
3
4
5
6
7
1.
1.1
ECONOMAIRE 32/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 as standard. In addition, a rear
rising duct kit is available for both models as well as an INTEJAN circulator kit for retro-fit to the ECONOMAIRE 32.
These instructions are to be left with the User or adjacent to the Gas Meter
ECONOMAIRE 32/INTEJAN
WARM AIR HEATER
Air Heater 42-416-14
Water Circulator 53-416-31
ON
12
9
3
ON
ma x
min
off
Fig. 1
Heater with Sealing Panel removed
G.C. Numbers:
20
19
18
17
16
6
15
14
13
12
11
10
9
8
BRIEF DESCRIPTION
1
Publication No. ZZ 1088/11
February 2008
1.
Thermista-stat
2.
Time control
3.
Air circulator fan
4.
Circuit diagram label
5.
Gas connection
6.
Circulator thermostat
7.
Gas cock
8.
Ignition burner
9.
Main burner assembly
10.
Intejan circulator
11.
Water return connection
12.
Water flow connection
13
Air heater multifuntion control
14.
Intejan multifunction control
(ECONOMAIRE 32 INTEJAN)
15
Flue gas test point
16.
LED diagonstics indicator
17.
Control module
18.
Combustion air fan
19.
Filter
20.
Flue adapter
Fig.2
Sealing Panel

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Summary of Contents for Johnson & Starley ECONOMAIRE 32/INTEJAN

  • Page 1 BRIEF DESCRIPTION ECONOMAIRE 32/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 as standard. In addition, a rear...
  • Page 2 The air heater output can be adjusted between 7.3kW (26.4MJ/h, 25,000 Btu/h) and 9.4kW (33.8MJ/h, 32,000 Btu/h) “summer air circulation” of unheated air is available by manual selection (see the user’s instructions). INTEJAN output is 3.5kW (12.6MJ/h; 11,900Btu/h).). 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)

  • Page 3: Ventilation Air

    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 NOTE: The ECONOMAIRE 32/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 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” or your local gas region. 5.2.6 Where the lowest part of the flue terminal is located less than 2 metres above the ground, a balcony, or above a flat roof across which there is access, the terminal MUST be fitted with a Tower Flue Components type K3 guard (or similar) such that the distance between the guard and the nearest part of the terminal is no less than 50mm.

  • Page 6: Not Recommended

    VERTICAL TERMINAL LOCATION: 5.3.1 The ECONOMAIRE 32/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 on either a flat or pitched...

  • Page 7: System Balancing

    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.). Terminal block 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

    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: Water Connections

    INTEJAN CIRCULATOR WATER CIRCULATION SYSTEM. Detailed recommendations for the water circulation system are given in BS6798, BS5449 (for small bore and microbore central heating systems), and BS5446. The maximum water side operating pressure (PMS) is 1bar. 7.1.1 To ensure good circulation in gravity circuits, flow pipes should be designed to run vertically from the water heater before running laterally.

  • Page 11: Intejan Circulator Commissioning

    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 15 x 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: Safety Checks

    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. 8) 8.3.2 Check the gauge reading against the information at paragraph 1.3. 8.3.3 If necessary, use the burner pressure adjuster to obtain the required gauge reading as shown at paragraph 1.3 8.3.4 Remove the pressure gauge and re-tighten the screw on the outlet pressure test point.
  • Page 13 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. 10.1.5 Remove the burner and controls assembly as detailed in para 10.2, inspect and clean the main burner and injector as necessary.

  • Page 14: Control Module Removal

    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 10.8.6 Refitting or replacement is in reverse order. LED Indicator (Daughter Board) 10.8.7 Disconnect the daughter board by unplugging the flylead from the control module board. 10.8.8 Release the 3 x fixing screws securing the clock mounting plate to the electrical door and withdraw the total assembly from the door.

  • Page 16: Defect Diagnosis

    10.11.9 Reassembly is in reverse order. 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 swich.
  • 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 Fig.13 Economaire 32 Flow Diagram...
  • Page 21 Fig.14 Economaire 32 Logic Diagram...
  • Page 22 Fig. 15 Schematic Diagram (showing connection of an external controller)

  • Page 23: Front View

    KNOCKOUTS FOR WATER CONNECTION (BOTH SIDES) KNOCKOUTS FOR GAS CONNECTION KNOCKOUTS FOR WATER CONNECTION (BOTH SIDES) 615 NOM SIDE VIEW FRONT VIEW ELECTRICAL ENTRY WATER ENTRY/EXIT (RETURN) WATER ENTRY/EXIT (FLOW) BASE VIEW PLAN VIEW Fig. 16 Economaire 32 - Principal Dimensions...
  • Page 24 LIST OF SPARES (SEE FIG.17) Item G.C. No Part No Description E69625 1000-0521020 Wiring harness E80119 1000-0521860 Wiring harness (air heater) N320-0350005 Heat exchanger N322-0350005 Heat Exchanger (from serial number 54000501) E69627 1000-0520990 FDC & limit switch 1000-0522340 FDC & Limit switch (from serial number 54000501) E69628 N320-0145000 Filter assembly...
  • Page 25 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 Provider

    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:...

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42-416-1453-416-31

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