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www.johnsonandstarley.co.uk Aquair S-10 Aquair S-16 Aquair S-20 INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS AQUAIR S SERIES of Water to Air Space Heaters These instructions are to be left with the User Publication No. ZZ 1416-8 June 2017www.johnsonandstarley.co.uk 2 In the interest of continuous development Johnson and Starley reserves the right to change specification without prior notice. Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. CONTENTS 1. Features 3 2. Carton Content 3 3. General Information 4 4. Building Standards & Regulations 4 5. Safety Information 4 Handling the Unit Electrical Supply 6. Duct Information 5 7. Technical Data 5 8. Positioning & Preparation 5 9. Installation Instructions 6 Downflow Configuration Upflow Configuration Water Connections Upflow Automatic Air Vent Electrical Harness Ancillaries Available 10. Return Air System 7 11. Electrical 7 Summer Air Circulation 12. Circuit Diagram 8 13. Fan Performance 9 14. Operating Modes 9 High Temperature Mode Low Temperature Mode 15. Commissioning 10 Setting Maximum Speed Setting Minimum Speed With Thermista-stat fitted With no Thermista-stat fitted 16. Servicing & Maintenance 10 Routine Maintenance PCB Replacement PCB Removal Fan Removal Heat Exchanger Removal Air Filter Removal 17. Fault Finding 11 18. Dimensions 13 19. Spares List 14 20. Exploded Diagram 153 Sales/Spares & Replacement Help Line 01604 762881 1. FEATURES 2. CARTON CONTENT FIGURE 1A. DOWNFLOW CONFIGURATIONFIGURE 1B. UPFLOW CONFIGURATION 8 7 9 2 1 1 8 7 11 3 2 6 5 5 4 4 3 6 10 AQUAIR S-10 FEATURES 1Mains Supply 2Air Filter 3Air Circulation Fan with EC technology 4PCB Control Board 5Hot Water Return to Heat Source 6Hot Water Flow from Heat Source 7Flow Sensor 8Heat Exchanger 9Air Vent 10Finger Guard 11Spigot Frame ITEM DESCRIPTION QTY. 1Aquair S Unit1 2Decal2 3Installation Instructions1 4User Instructions1www.johnsonandstarley.co.uk 4 4. BUILDING STANDARDS & REGULATIONS NOTE: Installation shall be in accordance with the following • Building Standards (Scotland) (Consolidation) Regulations • Building Regulations Part L • The Water Fittings Regulations or Water Byelaws in Scotland • Model and Local Authority Byelaws • BS 5720 Mechanical Ventilation and Air Conditioning in Buildings • BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations • Health & Safety Document No. 635 • The Electricity at Work Regulations, 1989 IMPORTANT: This appliance is CE certificated for safety and performance. It is important that no modifications are made to this appliance, unless fully approved in writing by Johnson & Starley Ltd. If in doubt, please Ring Johnson & Starley Ltd on Telephone 01604 762881. * The manufacturer’s instructions supplied must not be taken as overriding any statutory requirements. * It is important that the system is flushed thoroughly before the appliance is left to operate (as recommended in BS 7593) in order to maintain an efficiently operating heating system and to prevent the boiler from becoming a trap for system debris. Once the system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added. Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. * We also recommend a Magnetic & Non Magnetic Filtration system be fitted between the last radiator and the boiler. This protects the boiler from debris blockages in the heat exchanger and prolongs the life of the boiler. * Failure to carry out the above procedure will invalidate the guarantee! 5. SAFETY INFORMATION 5.1 HANDLING THE UNIT 5.1.1 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 removal from its packaging and during installation procedure. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling. 5.1.2 It should be noted that this appliance may contain sharp edges. Care MUST be taken when handling the appliance to prevent injury. It is advised that engineers wear suitable P.P.E. when handling the unit. 5.1.3 Once the appliance has been fired beware that certain parts will be hot to the touch. 5.1.4 Do not install flues during rain, high winds or in severe weather conditions. 5.2 ELECTRICAL SUPPLY 5.2.1 Ensure the mains supply voltage, frequency, number of phases and power rating comply with details on the rating label. 5.2.2 All wiring must be in accordance with the appropriate standards. 5.2.3 Ensure safety regulations and practices are adhered to when installing and using this appliance. 3. GENERAL DESCRIPTION 3.1 AQUAIR S is a “water to air” heat exchanger unit with a heat output of 10, 16 and 20 kW (assuming a hot water supply at 80 ˚C is available). It is supplied as a downflow unit but it is also suitable for upflow installations. When used in upflow installations an “air vent” (see 9.6.2) must be fitted to the heat exchanger. Modairflow control is incorporated. A wire mesh filter is fitted as standard. The unit requires a supply of hot water at a minimum temp. of 60 °C. Water connections are left or right handed through knockouts in the sides of the cabinet. 3.2 The air is drawn in through the air filter or Cleanflow air cleaner (if fitted) and the heat exchanger by a centrifugal fan, and it is discharged through the opposite end of the unit. A Summer Air Circulation switch (optional) allows the facility to supply unheated air to the air outlets during warm weather. An external timer (not provided) will be required if it is necessary to set the periods of operation. 3.3 The Aquair S unit has been designed to allow downflow and upflow configurations. It also allows the airflow to be redirected through the side of the unit via a Side Return Air kit. 5 Sales/Spares & Replacement Help Line 01604 762881 7. TECHNICAL DATA 8. POSITIONING & PREPARATION 8.1 The unit should be positioned to suit any duct work. Mount on a plenum or frame strong enough to avoid any strain being placed on associated pipe and duct work. 8.2 Once the position of the unit has been decided, make sure all extra ancillaries are installed ready for the unit installation. For a list of the ancillaries available contact Johnson & Starley Ltd, Telephone 01604 762881. 8.3 Make sure all the electrical cables are in place. 8.4 It is important that the system is flushed thoroughly prior to installation. Failure to do so could produce a blockage, cause damage to the system and reduce the efficiency. This MUST comply with the water treatment guidelines. IMPORTANT: It is recommended that the water system be drained and flushed prior to the installation of the unit. A Magnetic & Non Magnetic Filtration system must be fitted upstream of the unit. 8.5 Clearance of 450 mm is required at the front of the casing for servicing and replacement of the heat exchanger. It is recommended that provision be made for complete removal of the unit. 8.6 Sufficient clearance must be provided for the assembly of ducting and pipework. ITEMS-10S-16S-20 Nominal Rated OutputkW101520 “Air on” Temperature˚C202020 “Air off” Temperature˚C676767 Water Supply Temperature˚C808080 Water Return Temperature˚C737271 Water Flow Ratel/s0.40.50.6 Air Volumem³/h5769361224 Water Connectionsbsp¾¾¾ Maximum Water PressureBar333 Maximum Power Consumption W150215530 Dimensions (H/W/D)mm768 x 300 x 550787 x 445 x 517787 x 485 x 631 Return Air Framemm204 x 380359 x 351366 x 372 Electrical SupplyA230V, 50Hz, fuse rated at 3A Weightkg2636.5042.51 6. DUCT INFORMATION 6.1 The duct system should be carefully designed (Guidelines taken from the British System Design Manual) to suit the needs specific to the heating requirements and building layout. 6.2 The duct work should be installed with the least number of fittings to minimise the airflow resistance and the ducting runs should be as straight as possible. They should be fully insulated and protected from any crushing. Ducting passing through unheated roof voids must be insulated. 6.3 It is an advantage to have all the compatible ductwork already installed and ready to connect to the appliance frame. The base duct must be constructed to support the weight of the unit. The appliance, duct work and blanking plate must be secured and sealed. www.johnsonandstarley.co.uk 6 9. INSTALLATION INSTRUCTIONS 9.1 The Aquair S unit is supplied as a downflow configured appliance as standard. It has been designed with the provision to be converted to an upflow unit. 9.2 The Aquair S-16 & S-20 appliances exceed the recommended weight for a one-man lift as detailed in the Manual Handling Operations,1992 Regulations. 9.3 Once the unit has been unpacked, unscrew the transit plate from the base of the unit and discard. NOTE: This unit could contain sharp edges and care MUST be taken when handling. 9.4 DOWNFLOW CONFIGURATION See Figure 2 9.4.1 Remove the filter to expose the two screws holding the door in place. Remove the screws and gently pull and lift the door off the unit. 9.4.2 Lift the appliance onto the plenum or base support and position correctly. Seal the join with the appropriate sealing material. 9.4.3 The water connections to the unit should be by compression. Fittings that are suitable for the duty and isolation valves must be fitted to facilitate the removal of the heat exchanger assembly. 9.4.4 If a return air duct is not to be fitted, the top of the unit must be suitably guarded to prevent any blockage. 9.4.5 Once the installation is complete, stick the Aquair decal in position on the front cover, top left hand side. 9.5 UPFLOW CONFIGURATION See Figure 3 9.5.1 To fit the upflow configuration you need the additional Aquair Upflow Kit (AQUP). 9.5.2 Remove the filter to expose the two screws holding the door in place. Remove the screws and gently pull and lift the door off the unit. 9.5.3 Remove the 10 screws holding return air frame and remove. 9.5.4 Invert the unit so the air filter is at the bottom of the unit. 9.5.5 In the AQUP Kit use the new spigot frame and screw to the top of the unit to form the duct connection spigot. 9.5.6 Lift the appliance onto the plenum or base support and position correctly. Seal the joint with the appropriate sealing material. 9.5.7 If a return air duct is not to be fitted, the top of the unit must be suitably guarded to prevent any blockage. 9.5.8 Once the installation is complete, stick the Aquair decal in position on the front cover top left hand side. FIGURE 2. DOWNFLOW CONFIGURATION FIGURE 3. UPFLOW CONFIGURATION SCREWS AIR FILTER AIR FILTER PLENUM PLENUM HARNESS KNOCKOUT SCREWS RETURN AIR RETURN AIR FIGURE 4. FITTING AUTOMATIC AIR VENT AIR VENT SWIVEL CAP INSIDE UNIT7 Sales/Spares & Replacement Help Line 01604 762881 9.6 WATER & ELECTRICAL CONNECTIONS 9.6.1 WATER CONNECTIONS The water connections to the unit should be compression type fittings that are suitable for the duty of the appliance. Isolation valves must be fitted to facilitate the removal of the heat exchanger assembly. 9.6.2 UPFLOW AUTOMATIC AIR VENT For upflow units an ALTECNIC 502 ROBOCAL Air vent (Part No. 1000-0302300) MUST be fitted to the top of the unit. This come as part of the AQUP Kit. Any queries contact Johnson & Starley Ltd for details, Telephone 01604 762881. 9.6.3 To fit the vent, swivel the disc cap by breaking the paint seal, tap the disc and swivel. Remove the cap in the end of the flow pipe and screw in the air vent. NOTE: Care must be taken with the heat exchanger matrix, as it is fragile and is easily damaged. 9.6.4 ELECTRICAL HARNESS Re-route the harness cable through the side knockout. Use the grommet attached to seal the hole. 9.7 ANCILLARIES AVAILABLE NOTE: When using a side return air kit (with either the downflow or upflow configuration) you need a blanking plate to cover the existing opening. 10. RETURN AIR SYSTEM 10.1 The return air system should be constructed of fire-resistant material. It is important that the cor- rect size of return air grilles and ducting is used. Refer to the table below for return air duct size, flexible duct size and the return air grille size at maximum output. 10.2 An adequate and unobstructed return air path is required 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 0.0088 m²/kW (1 in²/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms and WCs. 11. ELECTRICAL 11.1 The appliance is supplied with PVC sheathed, 3 core 0.75 mm 2 CSA rated at 6 A, connected to a terminal block and exiting through the casing at the top left hand front. The cable is suitable for a 230 V, 50 Hz single phase supply. 11.2 The means of isolating the appliance MUST be via a double pole switch with a contact separation of at least 3 mm in both poles, and fused at 3 A. If switched live is fitted, a triple pole switch should be used. 11.3 SUMMER AIR CIRCULATION To run the fan at full commissioned speed in warm weather and in order to circulate the air, a single pole, volt free switch (not supplied) must be connected across terminals 3-4 (see circuit diagram Figure 4). AQUAIRDUCT EQUIVALENT SIZEFLEXIBLE DUCT SIZERETURN AIR GRILLE S-10250 x 200mm (10” x 8”)300mm (12”) dia860cm² (137in²) S-16300 x 250mm (12” x 10”)350mm (14”) dia1266cm² (196in²) S-20 400 x 300mm (16” x 12”)406mm (16”) dia2118cm² (328in²) MODELUPFLOW KITCLEANFLOW PASSIVE SIDE RETURN AIR KIT SIDE AIR RETURN KIT TOP SLOT FIT KIT S-10AQUP-10CFA-10SRAQ-10PSRAQ-10TSQ-10 S-16AQUP-16CFA-16SRAQ-16PSRAQ-16- S-20AQUP-20CFA-20SRAQ-20PSRAQ-20-www.johnsonandstarley.co.uk 8 12. CIRCUIT DIAGRAM FIGURE 4. AQUAIR S CIRCUIT DIAGRAM COLOUR CODE bn BROWN bl BLUE bk BLACK g/y GREEN/YELLOW r RED w WHITE or ORANGE y YELLOW9 Sales/Spares & Replacement Help Line 01604 762881 13. FAN PERFORMANCE 14. OPERATING MODES 14.1 HIGH TEMPERATURE MODE 14.1.1 For high temperature mode, the J1 pins 1 + 2 have NO jumper. 14.1.2 With a Thermista-stat connected (see note below), the fan will run when a water temp. of 60 °C is reached and it stops when the water temperature falls to 42 °C. The fan speed is controlled by the Thermista-stat demand. 14.1.3 With no Thermista-stat connected, the fan will run when a water temperature of 44 °C is reached, the fan speed is controlled by the water temperature. The maximum fan speed is reached when the water temperature is at 60 °C. 14.2 LOW TEMPERATURE MODE 14.2.1 For low temperature mode, J1 has a jumper across pins 1 + 2. 14.2.2 With the Thermista-stat connected, the fan will run when a water temperature of 33 °C is reached and it stops when the water temperature falls to 20 °C. The fan speed is controlled by the Thermista-stat demand. 14.2.3 With no Thermista-stat connected, the fan will run when a water temperature of 22 °C is reached, the fan speed is controlled by the water temperature. The maximum fan speed is reached when the water temperature is 32 °C. NOTE: Thermista-stat to be ordered separately. IMPORTANT: On installations where there is a single Boiler & Aquair, the Johnson & Starley preferred method of control is to link between TPV + 3 (see Figure 4) and to fit the thermostat and time control to the boiler. The Aquair will then operate according to the pipe temperature. FIGURE 3. AQUAIR S FAN PERFORMANCE GRAPH 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200m³/h 180 160 140 120 100 80 60 40 20 0 AQUAIR 10 AQUAIR 16 AQUAIR 20 RESIS TA NCE EXTERNAL TO HEA TE R FAN PERFORMANCENext >