Air Heater

Publication No.
ZZ 1317 June 2009

A Service Engineers
Fault Finder
for Warm Air Heating
R E L I A B I L I T Y Y O U C A N T R U S T
Johnson & Starley

CONTENTS
1. General Ventilation Information 3
2. Modairflow Series 1 4
3. Modairflow Series 2 8
4. Non Modairflow Series 2 12
5. System E-T 16
6. Economaire 20
7. Proportional Balancing 24
8. Heat Exchanger Check 26
9. Spillage Test 27
Johnson & Starley

Warm Air Heaters are PART L
COMPLIANT
www.johnsonandstarley.co.uk
GENERAL VENTILATION INFORMATION
Having undersized grilles was not a major crisis as it was

deemed to be NCS (not to current standards). However,
since June 2008 the classification for undersized existing
ventilation had changed from NCS to AR (at risk).
From the 1st June 2008, all installations providing less than
90% of the ventilation requirements will be regarded as AR.
90% to 100% of the requirement is accepted under

standards.
Where a defect(s) is identified with the ventilation and it is

not possible to rectify it, reference should be made to the
requirements of the current Gas Industry Unsafe Situations
Procedure.
For Balanced Compartments and Fan Assisted

Provision of Combustion Air see Publication No.
ZZ1348 A guide to Size & Free Areas for Pressed Steel
Grilles, Aluminium Grilles and Registers
Telephone: 01604 762881

OPERATIONAL CHECKS
MODAIRFLOW SERIES
Models
1
J15-22 Mk 1, 2 & 3
J25-32 Mk 1, 2 & 3
JA33-43
J54-64
JT19-25
JTRS22-25
JWD38-50
Care must be taken during replacement and handling of electronic

assemblies, i.e. Electronic Panel, Fan Speed Regulator, Airflow Sensor,
Thermista-stat. It is not practical to rectify any defects within these
assemblies except in the factory, and any attempt to do so may render any
guarantee void.
MAIN BURNER NOT OPERATING
Check Pilot Burner is lit, Time Control is ON, Thermista-stat turned UP
Check mains electrical supply
Check 1.5A fuse on Electronic Panel
Check 24V at Multifunctional Control
No 24V 24V Present

Check for 24V across yellow and black Multifunctional Control faulty
leads at Electronic Panel
No 24V 24V Present

Check all connections at Electronic Panel are Check limit switch and connections
tightened for securely
Replace Electronic Panel Check Time Control and connections
FAN ON BUT MAIN BURNER CYCLES BEFORE

REQUIRED TEMPERATURE IS REACHED
Bridge out Thermista-stat
Burner continues to cycle Burner remains on

Check Limit Switch is operating Thermista-stat faulty
Limit Switch operating Limit Switch not open circuit

Check temperature rise, if less than 60˚C, Replace Electronic Panel
replace Limit Switch
Check return air path and air filter for restriction
Check burner bar pressure is not excessive
Fan speed too low
Check balancing knob on Electronic Panel
is not set too low
Check connections, especially at 6-way
fan plug
Put Fan Override Switch on Electronic Panel to
continuous position
Fan speeds up Fan remains at slow speed

Replace Electronic Panel Replace Electronic Panel
Replace Airflow Sensor
Telephone: 01604 762881

MAINS BURNER NOT CYCLING
(ROOM TEMPERATURE TOO HIGH)
Disconnect Thermista-stat
Burner goes out Burner remains on

Replace Thermista-stat Disconnect yellow wire at
Multifunctional Control
Burner goes out Burner remains lit

Replace Electrical Replace
Panel Multifunctional
Control
MAIN FAN CONTINUES TO RUN OR CYCLE

AFTER HEATING IS TURNED OFF
Check heater type. If it is a ventilation model fan will run continuously at low speed
Check that the Fan Override Switch on the Electrical Panel is set to AUTO
Disconnect Airflow Sensor
Fan stops Fan continues to run

Check the Pilot Flame is not too large Remove 6-way plug from the Electronic Panel
(Figure 2) or remove the 6 wires 1 to 6 (figure 1)

Replace Electronic Replace Fan Speed
Panel Regulator
6
5
4
PLEASE NOTE: The unit will have either 2
3
a 6 way and a 3 way plug (see figure 2) 1
or it will have a 9 way terminal strip (see Figure 1

figure 1) going to the fan speed regulator.
MAIN BURNER ON FOR BRIEF PERIOD ONLY
Check Thermista-stat control knob is on maximum setting
Bridge out Thermista-stat socket or connection at heater
Burner lights and remains on Burner not remaining on

Reconnect Thermista-stat at heater Replace Electronic Panel
Check polarity by interchanging the external

Thermista-stat leads
Bridge out Thermista-stat leads at
Thermista-stat
Burner remains on Burner not

Thermista-stat faulty remaining on
Open circuit in external
wiring to Thermista-stat
MAIN BURNER ON BUT FAN NOT RUNNING

Set Fan Override switch on control panel to continuous position
Fan operates Fan not operating

Check connections at the Electrical Panel Check fan connections, especially at 6 and 3
way plug
Check Airflow Sensor & connections
Check voltage at fan plug
Replace Electronic Panel
SOCKET ON ELECTRONIC PANEL No voltage Voltage present

Remove 6-way plug from Fan Motor fault
electronic panel, check for
Figure 2
+30V dc across contacts as
shown in figure 2 OR terminal 3
to 6 on figure 1
Fan voltage Voltage present

Replace Electronic Replace Fan Speed
Panel Regulator
30V dc
Telephone: 01604 762881

MODAIRFLOW SERIES
Models
2
OPERATIONAL CHECKS
J70-90
J55-65
JB40-50
JU40-50
JB16-20
JB25-30
Q44
HI-SPEC J30
HI-SPEC J50
HI-SPEC J65
HI-SPEC J90
HI-SPEC JU55

guarantee void.
Check Pilot Burner is lit, Time Control is ON, Thermista-stat turned UP
Check 1.5A fuse on Electronic Panel
Check 24V at Multifunctional Control
No 24V Detected 24V Present

Bridge out Thermista-stat terminal at heater Multifunctional Control faulty
Burner Remains OFF Burner lights

Check for 18V at D6 Check polarity by interchanging external
Thermista-stat
Burner remains OFF Burner lights

Wiring defect between heater and Thermista-stat faulty
thermista-stat
Check 230V from Check Limit Switch
connections and operationer
terminal C8

Check mains supply Check for 24V at C10
and operation of Time
Control
24V Detected at C10 No 24V Detected

Replace Electronic Replace Transformer
Module
Telephone: 01604 762881



Replace Electrical Replace Multifunctional
Module Control
MAIN FAN CONTINUES TO RUN OR CYCLE

AFTER HEATING IS TURNED OFF
Check Fan Selector Switch on Electronic Module
If set to VENTILATION , fan will run continuously at low speed
Check Fan Selector Switch is set to AUTO and SUMMER AIR CIRCULATION Switch is OFF
Disconnect Airflow Sensor

Check the Pilot Flame is not too large Replace Electronic Module

Check for voltage across black and pink leads at fan socket
No Voltage Voltage Detected

Bridge out Airflow Sensor Fan motor faulty
Fan Starts Fan fails to start

Replace Airflow Replace Electronic
Sensor Module
10 www.johnsonandstarley.co.uk
MAIN BURNER ON FOR BRIEF PERIOD ONLY
Check Thermista-stat control knob is on maximum setting
Bridge out Thermista-stat connection at heater
Burner lights and remains on Burner not remaining on

Reconnect Thermista-stat at heater Replace Electronic Module
Check polarity by interchanging the external
Thermista-stat
Burner remains on Burner not remaining on

Thermista-stat faulty Open circuit in external wiring to Thermista-stat

Bridge out Thermista-stat

Check Limit Switch is operating Thermista-stat faulty
Limit Switch operating Limit Switch not open circuit

Check temperature rise, if less than 60˚C, Replace Electronic Module
replace Limit Switch
Check return air path and air filter for restriction
Check burner bar pressure is not excessive
Fan speed too low
Check balancing knob on Electronic Panel
is not set too low
Put Fan Override Switch on Electronic Module
to continuous position
Fan speeds up Fan remains at slow speed

Bridge out Airflow Sensor and set Fan Sensor Replace Electronic Panel
Switch to AUTO
Fan reaches maximum speed Fan remains at slow speed

Replace Airflow Sensor Replace Electronic Module
Telephone: 01604 762881 11

NON MODAIRFLOW SERIES
Models
2
OPERATIONAL CHECKS
J70-90
J55-65
JB40-50
JU40-50
JB16-20
JB25-30
Q44
HI-SPEC J30
HI-SPEC J50
HI-SPEC J65
HI-SPEC J90
HI-SPEC JU55

guarantee void.
SYMPTOM POSSIBLE CAUSE REMEDY
Check for gas at inlet pressure
No gas supply to heater test point on Multifunctional
Control
Purge gas supply pipe in
Gas supply pipe not purged
Pilot will not light accordance with BS 6891
Clear pilot orifice or replace
Pilot orifice restricted
pilot injector
Check ignitor, lead and
Piezo system faulty
electrode
Connection between
Thermocouple and
Check connection is secure
Multifunctional Control not
Pilot lights but goes secured
out on releasing START Faulty power unit on Replace Multifunctional
button during initial Multifunctional Control Control
light-up, or after normal
Faulty Thermocouple Replace Thermocouple
operation
Pilot flame of insufficient
Adjust
length
Pilot orifice restricted Replace pilot injector
Loose electrical connection
Check connections
fan delay control
Fan control set incorrectly Check for correct settings
Main burner lights but
Replace, taking care not to
fan fails to run after Faulty fan assembly
damage impeller
approx 3 minutes
Faulty fan control Replace fan control
Burner setting pressure not
Adjust pressure as necessary
correct
Gas rate or burner pressure Check gas rate and burner
setting high pressure setting
Adjust fan speed or gas rate
Temperature rise excessive
accordingly
Air filter or return air path Check filter is clean and air
Main burner operating restricted path is clear
intermittently with fan
running Excessive number of outlets
Open additional outlets
closed
Carry out spillage test and
Spillage of flue gases
rectify
Spillage monitoring device
Replace spillage device
(TTB) faulty
Telephone: 01604 762881 13

SYMPTOM POSSIBLE CAUSE REMEDY
Gas rate or burner pressure Check gas rate and burner
Main burner operating setting too high setting
with intermittent fan
operation Fan delay control set
Check for correct setting
incorrectly
Fan runs for excessive

period or operates
intermittently after Fan delay control set correctly Check for correct settings
mains burner shuts
down
Gas pressure too high Check burner pressure setting

Noisy operation Noisy fan motor Replace fan assembly
Fan speed setting too high Adjust fan speed
Mains electrical supply not
Check mains supply
connected to heater
Controls not demanding heat. Check the time control (if
Room thermostat is operating fitted) and room thermostat
correctly are operating correctly
Loose connection to room
thermostat, overheat (limit)
Check connections
control, gas control lead, time
control or transformer
Check with test meter and
Pilot alight but main Transformer open circuit replace electrical panel if
burner not igniting necessary
Replace multifunctional
Multifunctional control faulty
control
Short circuit control and
Overheat (limit) control faulty
replace if necessary
Fit temporary loop to heater
Room thermostat or external thermostat socket. If heater
wiring faulty ignites, external circuit or
room thermostat is faulty
Check TTB and wiring for
TTB faulty
open circuit
Non-MODAIRFLOW CIRCUIT DIAGRAM
Telephone: 01604 762881 15

SYSTEM E-T
Models
OPERATIONAL CHECKS
HI-SPEC J25
HI-SPEC J25RS
HI-SPEC J25SC
HI-SPEC J32
HI-SPEC M31
HI-SPEC J40

guarantee void.
Telephone: 01604 762881 17

Check for voltage at fan terminals 30 & 31
No voltage Voltage detected

Link terminals 21 & 22 (FDC) Disconnect black leads from capacitor &
connect mains to fan
Fan runs Fan does not run Fan runs Fan does not run
Replace replace FDC/ Replace electronic Replace capacitor Replace fan
limit control module
MAIN BURNER CONTINUOUSLY ON

(ROOM TEMPERATURE TO HIGH)
Set Thermista-Stat to ‘SUMMER AIRFLOW’

Replace Thermista-stat Disconnect supply to Multifunctional Control at
terminal 15

Replace Thermista-stat Replace Multifunctional
Control
Disconnect Thermista-stat at terminals 7 & 8
Link terminals 7 and ‘TEST’. DO NOT LINK 7 & 8

Check Air Filter and Return Air path for Thermista-stat faulty
restrictions
Burner continues to cycle Limit Switch not operating

Check temperature rise, if less than 60˚C, link Replace Electronic Module
terminals 13 & 14 to bypass Limit Control
Burner continues to cycle Burner runs and room temperature rises

Replace electronic module Replace FDC/Limit Control


Replace Electrical Module Replace Multifunctional
control Control
FAN CONTINUES TO RUN OR CYCLES AFTER

HEATING IS TURNED OFF
Disconnect FDC
Replace fan delay/limit Replace electronic module

control
Check pilot is not too

large
Telephone: 01604 762881 19

ECONOMAIRE
Models
OPERATIONAL CHECKS
ECONOMAIRE 25
ECONOMAIRE 31
ECONOMAIRE 32
ECONOMAIRE 50
ECONOMAIRE 65
ECONOMAIRE 90
NOTE:
FAULTS 4, 5 & 6 RELATE TO THE AIR HEATER, WHILST
FAULTS 7, 8 & 9 RELATE TO THE WATER CIRCULATOR

guarantee void.
NO DISPLAY
NO DISPLAY
Heater continually cycles in rest sequence Disconnect main supply & check continuity
across terminals 3 & 4
Reset button stuck or
broken approx. 2.1k Ω Open circuit
Check reset button & Replace Economaire
replace if broken module
Pressure Remove bottom pipe

DISPLAY 1 switch Press reset Switch fails to on pressure switch to
closed release release
Check tubes for Replace pressure

blockage switch
Replace
DISPLAY 2 Economaire
module
Check venturi and

Blocked venturi clean if necessary
Incorrect flue
length
Check for
presence Check flue length and adjust if necessary
DISPLAY 3 of orifice &
Check for splits in air
remove where Replace
necessary pressure tubes
No orifice
Check flue protrusion Adjust
(if horizontal)
Ensure ignition Fails to reset Change Economaire

controller is correctly Press module
DISPLAY 4 fitted (eg. no pins reset
on MFC shorting Sparks but pilot Replace ignition
together) does not light controller
Telephone: 01604 762881 21

DISPLAY 5 Contact Johnson & Starley for advice whilst on site
(or 8)
Check gas Restore and

DISPLAY 6 supply purge as
(or 9) pressure necessary
Ignition sparks No ignition spark
Check voltage at Economaire

Ignition sparks Pilot fails to light module terminals:
5 & 6 Air Heater
Check polarity Check lead/electrode 8 & 9 Water Circulator
Check/replace Check for blockage in

ignition lead gas feed pipe/injector 230V 0V
Check/replace Replace ignition Replace

ignition electrode No blockage controller Economaire
module
Replace MFC
DISPLAY A Cabinet overheat protection

Check air circulation fan operation
Check compartment ventilation
Check return air filter for blockage
Check water pipe location and lag if necessary
Check duckwork for air leakage
DISPLAY C Airflow sensor out of range

Replace fan & limit stat
Contact Johnson & Starley for advice
DISPLAY E Airflow circulation fan circuit protection

Check fan connections for soundness
Contact Johnson & Starley for advice
DISPLAY F
Ignites on rest Fails to ignite
Air heater overheat Ignition controller lockput
Check filter for blockage Check wiring at pin 7
Check ductwork for restrictions Check limit switch wiring
Check return air path Fails to ignite
Check heat load for property Replace Economaire module/ignition
controller
DISPLAY H
Ignites on reset Fails to ignite on reset
Water circulator overheat Ignition controller lockout
Check water circulation Check wiring at pin 10
Check thermostat Check limit switch wiring
Fails to ignite
Replace Economaire module
ignition controller
DISPLAY L Fan & limit stat open circuit
Display shows L on restoration Display shows L during operation

of power
Check fan & limit stat & replace if faulty
Check low voltage terminal block location
on Economaire module
Check fan & limit stat wiring
AIR CIRCULATION FAN ON PERMANENTLY
Link between ‘8’ & test Check correct thermista-stat

Does fan stop Check thermista-stat wiring
YES NO
Rewire thermista-stat Replace Economaire
Thermista-stat
Telephone: 01604 762881 23
PROPORTIONAL BALANCING
(Use in conjunction with Johnson & Starley:- Balancing

procedure sheet using an airflow meter and thermometer.)
1. Set Heaters to Summer Airflow mode.
2. Calculate guide balancing velocities
BALANCING PROCEDURE SHEET

Room 1 Heat Required (kW) Register/ Diffuser Size Air Velocity Factor Guide Balancing Velocity
Column 1 Column 2 Column 3 Column 4 Column 2 x Column 4 =
Metres per second
3. Transfer the guide balancing velocities to column A

on the following table.
A B C D
Warm air Room Guide Measured Column B Balancing velocities
outlet number balancing Velocities Column A Column A x Av Column C
velocities
4. Partly close the balancing dampers of the registers

closest to the heater.
5. Measure the air velocity at each outlet and enter in

column B .
6. Divide the figures in column B by the figure in

column A and enter the result in column C.
7. Total the figures in column C and divide by the

number of outlets to give an average.
8. Multiply each guide velocity (A) by the average (note

7) and enter the result in column D.
9. Balancing the system using the velocities in column

D by adjusting the balancing dampers at the
registers or the balancing screws/levers on the
diffusers.
10. Set heater to heating mode and check temperature

rise as opposite.
Temperature rise checking across the heater
The temperature rise between the nearest available point in the
return air duct and the nearest available point on the supply air
duct must be between 45˚C and 55˚C; check as follows.
Ignite the pilot and main burners and allow 15 minutes of

operation.
Set the burner bar pressure to give the required heat

output as per the installation instructions.
If necessary adjust the maximum fan speed to give the

temperature rise as per installation instructions:-
On Basic Controlled Heaters select the correct

tapping at the control panel.
On Modairflow Heaters adjust the balancing screw at

the control Panel.
On System E-T Heaters set the rate switch at the

control Panel.
On Economaire Heaters the control system will

automatically adjust the fan speed.
AIR VELOCITY FACTORS

REGISTER SIZE Air Velocity DIFFUSER SIZE Air Velocity
in x in mm x mm Factor in x in mm x mm Factor
6x4 150 x 100 1.48 2.25 x 10 57 x 250 1.58

8X4 200 x 100 1.14 2.25 x 12 57 x 300 1.33
8X6 200 x 150 0.75 2.25 x 14 57 x 350 1.14
10 X 6 250 x 150 0.6 4 x 10 100 x 250 0.9
10 X 8 250 x 200 0.44 4 x 12 100 x 300 0.75
12 X 6 300 x 150 0.51 J&S Mini 3.4
12 X 8 300 x 200 0.37
Telephone: 01604 762881 25

HEAT EXCHANGER CHECK
With air circulation fan assembly and burner/controls

assembly, heat exchanger cover and inspection plates (if
fitted), removed, clean the heat exchanger flueways by
thoroughly brushing from above and below.
By viewing through the Fan Aperture, using a torch or

similar, examine the heat exchanger externally for signs of
cracks or holes, particularly around welded joints.
Using a torch or similar, introduce a light source into the

heat exchanger burner aperture and upper access port,
and again examine the heat exchanger for signs of cracks
or holes, particularly around welded joints, whilst again
viewing through the fan aperture. Refit the air circulation
fan, burner and controls assembly, and air filter / air
cleaner.
Light the appliance and note main burner flame profile. If

the flame profile is affected when the Air Circulation fan
switches on, check for any leaks between the air heater
and the base plenum, paying particular attention to heaters
with rear draught diverters. Rectify any air leaks before
continuing with this procedure.
Allow the air heater to operate for approximately 15 minutes

to ensure stability, and with the main burner lit, ensure that
the operation of the Air Circulation Fan does not affect the
main burner flame profile.
If no defaults are found and the appliance is working

correctly, servicing / commissioning should proceed.
SPILLAGE TEST
Carry out a full test as follows, and ensure that the flue
operates effectively with all doors and windows closed and any
extractor fans in operation.
NOTE: If an extractor fan is situated in an adjoining or adjacent

room, carry out the spillage test with the interconnecting doors
open.
If the draught diverter is accessible:

(With the appliance operating fully)
a) Introduce smoke, into the draught diverter adjacent to an

exit from the heat exchanger, by means of a smoke match
or puffer.
b) Ensure that there is no spillage present (indicated by

displacement of smoke downwards and out of the draught
diverter).
If the draught diverter is not accessible:

(With appliance pre-heated)
a) introduce smoke by means of part of a smoke pellet on a

non-combustible support, into the heat exchanger.
b) Extinguish both the Mains and Pilot burners.
c) Ensure that there is no spillage evident by visually

observing the draught diverter location on the air heater.
d) If spillage is evident, further investigation and rectification

is required before re-testing the appliance.
e) Repeat spillage tests but with the fan running, or summer

airflow switch set to ON.
WARNING: The appliance shall not be left connected to
the gas supply unless it has successfully passed the
above spillage test.
Telephone: 01604 762881 27

Rhosili Road, Brackmills, Northampton NN4 7LZ
Main Switchboard Tel: 01604 762881 Fax: 01604 767408
Spares Tel: 01604 707012 Fax: 01604 764879
Service Tel: 01604 707011 Fax: 01604 707017
Johnson & Starley

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Publication No.

ZZ 1317 June 2009

Johnson & Starley

1. General Ventilation Information 3

4. Non Modairflow Series 2 12

8. Heat Exchanger Check 26

Johnson & Starley

Having undersized grilles was not a major crisis as it was

90% to 100% of the requirement is accepted under

Where a defect(s) is identified with the ventilation and it is

For Balanced Compartments and Fan Assisted

Telephone: 01604 762881 

Care must be taken during replacement and handling of electronic

Check mains electrical supply

Check 1.5A fuse on Electronic Panel

Check 24V at Multifunctional Control

No 24V 24V Present

No 24V 24V Present

FAN ON BUT MAIN BURNER CYCLES BEFORE

Burner continues to cycle Burner remains on

Limit Switch operating Limit Switch not open circuit

Fan speeds up Fan remains at slow speed

Telephone: 01604 762881 

Burner goes out Burner remains on

Burner goes out Burner remains lit

MAIN FAN CONTINUES TO RUN OR CYCLE

Fan stops Fan continues to run

Fan stops Fan continues to run

a 6 way and a 3 way plug (see figure 2) 1

or it will have a 9 way terminal strip (see Figure 1

Burner lights and remains on Burner not remaining on

Check polarity by interchanging the external

Burner remains on Burner not

MAIN BURNER ON BUT FAN NOT RUNNING

Fan operates Fan not operating

SOCKET ON ELECTRONIC PANEL No voltage Voltage present

Fan voltage Voltage present

Telephone: 01604 762881 

Care must be taken during replacement and handling of electronic

Check mains electrical supply

Check 1.5A fuse on Electronic Panel

Check 24V at Multifunctional Control

No 24V Detected 24V Present

Burner Remains OFF Burner lights

Burner remains OFF Burner lights

No 230V Detected 230V Present

24V Detected at C10 No 24V Detected

Telephone: 01604 762881 

Burner goes out Burner remains on

Burner goes out Burner remains lit

MAIN FAN CONTINUES TO RUN OR CYCLE

Fan stops Fan continues to run

MAIN BURNER ON BUT FAN NOT RUNNING

No Voltage Voltage Detected

Fan Starts Fan fails to start

Burner lights and remains on Burner not remaining on

Burner remains on Burner not remaining on

FAN ON BUT MAIN BURNER CYCLES BEFORE

Burner continues to cycle Burner remains on

Telephone: 01604 762881

Telephone: 01604 762881

Telephone: 01604 762881

Telephone: 01604 762881