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Warm Air Replacement Fan Control Time Relay

Technical Bulletin Warm Air

Ref GB/TB/010/0207 Warm Air Fan Control Time Relay
Bulletin updated 19/02/2007
Re-updated 09/09/2013

Note: Bulletin to be used in conjunction with the relevant Warm Air Operating and Maintenance Manuals

Replacement Fan Control Relays for UDSA; UDSAV; UDSB-D, UPA, ST-2 series, UC series, T series and ST-1 series heaters have changed type.

The change involves the replacement of the standard Fan Control Relay with a fully automatic timed version. This will enable a wider tolerance of control over the axial fan by switching the motor between 20 seconds to a minute after the Venter had been energised. The axial fan will switch off one to two minutes after the Venter motor.

This technical bulletin describes in detail the procedure required to complete the replacement of the Fan Control Time Relay and wiring changes.

The information contained in this technical bulletin is designed to aid a qualified or competent service technician.

Factory fitted replacement Fan Control Time Relays on these heaters commenced as from March 2006 or serial number 06 4500080 for UDSA/UPA models and September 2006 or serial number 06 4501428 for ST/UC series. 


The following tools and equipment will be required to complete this task:
1. Fan Time Delay Relay kit* (Ambi-Rad pt no. FC0320409) 2. Flat head screwdriver 3. 8mm Nut runner (or spanner) 4. Electrical screwdriver 5. Drill 6. 3mm & 5mm drill bits 7. Crimping tool 8. Multi-meter. 9. Silicone sealant 10. kit* consists of: a 1 x time delay relay b 1 x white wire c 1 x blue wire d 2 red connectors e 2 blue connectors f 3 x self tapping screws g 1 x cover plate

ISOLATE ALL ELECTRICAL SUPPLY TO THE HEATER & CONTROLLER BEFORE PROCEDING.

Please take a minute to check the type of heater to be modified (this information can be found under ‘Model no.’ on the heater data badge.)
Find the heater type and follow the procedure under the headings shown.


UDSA, UDSAV, UDSB-D & UPA HEATERS

Kit components used: a, b, c, d(x2) & f(x1)

1. Open heater control section side panel by turning quarter turn screw anticlockwise. Allow door to hang.
2. Locate existing Fan Control Relay located on the back of the heat exchanger within the controls compartment. Please refer to the following photo for identification and exact location.

3. Release the ORANGE, BLUE and two BLACK wires and connectors from existing Fan Control Relay.
4. Remove the two retaining screws holding the original Fan Control Relay to the wall of the heat exchanger.
5. Locate the new Fan Control Time Relay (a) from the kit of parts. With the back plate facing the wall of the heat exchanger, position the relay over the hole left from the original control. Position the lip of the plate in the upper hole. Mark and drill a 3mm hole at the other hole of the plate. Fix using the taptite screw (f). Ensure original hole is completely sealed with silicone
6. Using cable cutters or wire snipers, cut short both the ORANGE and the BLUE wires on the original harness.
7. To make safe, locate the two red connectors (d) from the kit of parts and using the crimping tool fit one connector to each end of both the ORANGE and BLUE wires making them redundant
8. Locate both the spare BLUE (b) and the WHITE (c) cables from the kit of parts.
9. With the electrical screwdriver, loosen the terminal screws from terminals 11 and 12 of the mains terminal block.
10. Position the ‘boot laced’ end of the WHITE wire (b) into terminal 11 and tighten.
11. Position the ‘boot laced’ end of the BLUE wire (c) into terminal 12 and tighten.
12. With the connector ends approximately in line with the new connector ends of the BLUE and WHITE wires and, using the cable ties provided in the kit, arrange and clamp these additional wires along the harness towards the main heater terminal block.
13. At the other end of the harness, connect the new WHITE wire to one of the base terminals of the relay (as per sketch below).
14. Connect the new BLUE wire to the other base terminal of the relay (as per sketch below).
15. Reconnect the original BLACK wire to one of the top terminals of the relay (as per sketch below).
16. Reconnect the other original BLACK wire to the remaining top terminal of the relay (as per sketch below). 

17. Using the cable ties provided in the kit to arrange and clamp the additional wire along the harness.
18. Check for tightness of wires and continuity.
19. Restore power to the heater and turn on the gas.
20. Light the burner, following the instructions on the lighting instruction plate.
21. Check for proper operation.
22. Close and lock the access door.


ST series2 with Hot Surface Ignition (HSI)

Kit components used: a, c, d(x1), e, & f(x1)

1. Open heater control section side panel by turning quarter turn screw anticlockwise. Allow door to hang.
2. Locate existing Fan Control Relay located on the back of the heat exchanger within the controls compartment. Please refer to the following photo for identification and exact location. Please refer to the following photo for identification and exact location.

3. Release the BLUE, two BLACK and a joined GREY wires and connectors from existing Fan Control Relay.
4. Remove the two retaining screws holding the original Fan Control Relay to the wall of the heat exchanger.
5. Locate the new Fan Control Time Relay (a) from the kit of parts. With the back plate facing the wall of the heat exchanger, position the relay over the hole left from the original control. Position the lip of the plate in the upper hole. Mark and drill a 3mm hole at the other hole of the plate. Fix using the taptite screw (f). Ensure original hole is completely sealed with silicone
6. Using cable cutters or wire snipers, cut off the existing push on terminal from the BLUE wire.
7. To make safe, locate the red connector (d) from the kit of parts and using the crimping tool fit one connector to the end of the BLUE wire making it redundant.
8. Using cable cutters or wire snipers, cut off the existing push on terminal from the two GREY wires.
9. Locate the blue connector (e) from the kit of parts and using the crimping tool, fit the joined GREY wires to this connector.
10.Locate the spare BLUE (b) cable from the kit of parts. Position the ‘boot laced’ end of the into terminal 2 and tighten.
11. Reconnect the joined GREY wires to one of the base terminals of the relay (as per sketch below).
12. Connect the new BLUE wire to the other base terminal of the relay (as per sketch below).
13. Reconnect the original BLACK wire to one of the top terminals of the relay (as per sketch below).
14. Reconnect the other original BLACK wire to the remaining top terminal of the relay (as per sketch below).
 
15. Using the cable ties provided in the kit to arrange and clamp the additional wire along the harness.
16. Check for tightness of wires and continuity.
17. Restore power to the heater and turn on the gas.
18. Light the burner, following the instructions on the lighting instruction plate.
19. Check for proper operation.
20. Close and lock the access door.


ST series2 with Fast Response Ignition (FRI)

Kit components used: a, e(x2) & f(x1)

1. Open heater control section side panel by turning quarter turn screw anticlockwise. Allow door to hang.
2. Locate existing Fan Control Relay located on the back of the heat exchanger within the controls compartment. Please refer to the following photo for identification and exact location. Please refer to the following photo for identification and exact location.

3. Release the BLUE, two BLACK and a joined GREY wires and connectors from existing Fan Control Relay.
4. Remove the two retaining screws holding the original Fan Control Relay to the wall of the heat exchanger.
5. Locate the new Fan Control Time Relay (a) from the kit of parts. With the back plate facing the wall of the heat exchanger, position the relay over the hole left from the original control. Position the lip of the plate in the upper hole. Mark and drill a 3mm hole at the other hole of the plate. Fix using the taptite screw (f). Ensure original hole is completely sealed with silicone.
6. Using cable cutters or wire snipers, cut off the existing push on terminal from the BLUE wire.
7. Locate the blue connector (e) from the kit of parts and using the crimping tool, fit to the end of this BLUE wire.
8. Using cable cutters or wire snipers, cut off the existing push on terminal from the two GREY wires.
9. Locate the blue connector (e) from the kit of parts and using the crimping tool, fit the joined GREY wires to this connector.
10. Connect the two GREY wires wire to one of the base terminals of the relay (as per sketch below).
11. Connect the BLUE wire to the other base terminal of the relay (as per sketch below).
12. Connect the original BLACK wire to one of the top terminals of the relay (as per sketch below).
13. Connect the original BLACK wire to the other top terminal of the relay (as per sketch below).

14. Using the cable ties provided in the kit to arrange and clamp the additional wire along the harness.
15. Check for tightness of wires and continuity.
16. Restore power to the heater and turn on the gas.
17. Light the burner, following the instructions on the lighting instruction plate.
18. Check for proper operation.
19. Close and lock the access door


UC series with Thermoelectric Ignition (TE)

Kit components used: a, c, d(x1), e, & f(x1)

Obsolete T series 1 Permanent Pilot, ST series1 & T series Autospark
Kit components used: a, e(x2), f(x1) & g

1. Open heater control section side panel by turning quarter turn screw anticlockwise. Allow door to hang.
2. Locate existing Fan Control Relay located on the back of the heat exchanger within the controls compartment. Please refer to the following photos for identification and exact location.
 

 
1. Open heater control section side panel by turning quarter turn screw anticlockwise. Allow door to hang.
2. Locate existing Fan Control Relay located on the back of the heat exchanger within the controls compartment.
3. Remove the two retaining screws holding the original Fan Control Relay to the wall of the heat exchanger.
4. Locate the new Fan Control Time Relay (a) from the kit of parts. With the back plate facing the wall of the heat exchanger, position the relay to the right hand side of the wiring panel and mark the lip. Drill a 5mm hole. Position the lip of the plate in this hole. Mark and drill a 3mm hole at the other hole of the plate. Fix using the taptite screw (f).
5. Locate the cover plate (g) and position over original hole. Fix using taptite screw (f). Ensure original hole is completely sealed with silicone.
6. Individually remove cables from existing fan control relay and replace onto new Fan Control Time Relay exactly as noted below. 
 

7. Using the cable ties provided in the kit to arrange and clamp the additional wire along the harness.
8. Check for tightness of wires and continuity.
9. Restore power to the heater and turn on the gas.
10. Light the burner, following the instructions on the lighting instruction plate.
11. Check for proper operation.
12. Close and lock the access door.

Click on link below to follow the step by step instructions.

document added 13/07/06
document modified 19/02/07 and again 09/09/13

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Article Attachments
706010 TB010 WarmAir Replacement Fan Control Ben EN 0813 A3F GB.TB.010.0813.pdf

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well if i understood it, it must be ok!! Approved: 13/07/2006
Last Modified on 12/07/2016.
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