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Johnson & Starley HI-SPEC J25 Installation, Commissioning & Servicing Instructions

Warm air heaters system e-t and basic control
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Johnson
& Starley
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
This appliance ha been tested and certified by G. L. Industrial Services UK Ltd. for use with natural gas G20.
Note: If a HIJAN 6 or SUPERJAN 6 circulator is fitted, the relevant Installation, Commissioning and Servicing instructions
provided with that appliance must also be observed.
1.
1
2
3
4
5
6
7
8
1.1
HI-SPEC J25 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with SYSTEM E-T or
Basic control. A HIJAN 6 or SUPERJAN 6 circulator is available as an option. A pilot burner incorporating an Atmospheric
Sensing Device (ASD) is fitted which responds to the presence of flue gases and shuts down the appliance.
1.2
The Air heater output can be adjusted between 5.6kW (20.0MJ/h, 19,000Btu/h) and 7.3kW (26.4MJ/h, 25,000Btu/h). "Summer
air circulation" of unheated air is available by manual selection (see User's Instructions). HIJAN 6 output is 3.81kW (13.7MJ/
h, 13,000Btu/h), whilst SUPERJAN 6 output is 6.0kW (21.6MJ/h, 20,470Btu/h).
These instructions are to be left with the User or adjacent to the Gas Meter
HI-SPEC J25 WARM AIR HEATERS
SYSTEM E-T and Basic Control
G.C. No 42 451 04
BRIEF DESCRIPTION
Fig. 1
THIS APPLIANCE CONFORMS TO BS EN 45014
13
1
Air filter
2
Air circulating fan
3
Heat exchanger access cover
4
Multifunctional control
5
Data Plate
6
Heat shield
12
7
Burner assembly
8
Pilot burner
9
Lighting port
10
Fan delay control/limit switch
11
Gas supply pipe
12
Piezo igniter unit
13
Time control
11
10
9
1
Publication No. ZZ 753/12
January 2010

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Summary of Contents for Johnson & Starley HI-SPEC J25

  • Page 1 Fig. 1 HI-SPEC J25 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with SYSTEM E-T or Basic control. A HIJAN 6 or SUPERJAN 6 circulator is available as an option. A pilot burner incorporating an Atmospheric Sensing Device (ASD) is fitted which responds to the presence of flue gases and shuts down the appliance.

  • Page 2: Ventilation And Combustion Air

    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) BS7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations BS6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases). BS5440 Pt.1 (Flues for Gas Appliances) BS5440 Pt.2 (Air Supply for Gas Appliances) BS5864 Installation of Gas Fired Ducted Air Heaters...

  • Page 3: Duct System

    Low level grille 284cm (44in Ventilated from inside building. High level grille 142cm (22in Low level grille 142cm (22in Ventilated from outside building. High level grille 71cm Table 1: Minimum Efective Areas DUCT SYSTEM (See British Design Manual- Gas Fired Warm Air Heating) RETURN AIR 4.1.1 It is NOT recommended that the return air duct be routed directly from the main living area, but from a convenient central area serving the remainder of the dwelling.
  • Page 4 5.1.5 A split collar should be fitted to provide for flue maintenance or inspection. 5.1.6 The flue shall be in accordance with the Building Regulations and British Gas Materials and Installations specifica- tion 3rd edition) with regard to clearance and shielding from combustible materials. 5.1.7 All materials shall be in accordance with Building Regulations requirements.
  • Page 5 Component Internal Size (mm) Resistance Components Internal Size (mm) Resistance 197 x 67 0.85 per metre 100mm pipe 0.61 per fitting 231 x 65 0.65 run 125mm pipe 0.25 per fitting 317 x 63 0.35 150mm pipe 0.12 per fitting Flue Blocks bend 140 x 102...
  • Page 6 Ridge Terminal 2 x 300 mm lengths 100 mm dia flue pipe (Example only) = 6.2m 4.6m 4 x 1000 mm lengths bend 300 mm length 1.6m bend 2 x 300 mm lengths Flue spigot Fig. 2 Worked example of equivalent flue hight Note: Ventilation of the compartment, room or internal space in which the appliance is to be installed must be checked for compli- ance with the requirements of BS 5440 Part 2 ( Ref.
  • Page 7 (1/2in BSP. external [taper] thread). DRAUGHT DIVERTER & DEFELCTOR PLATE: 5.4.1 The HI-SPEC J25 heater is supplied with a draught diverter that requires fitting to the rear of the heater prior to installation, using 3 x 4mm screws and lock washers (provided).
  • Page 8 5.5.4 Ensure that the smoke is drawn into the heat exchanger and not blown back from the burner opening. 5.5.5 If smoke is blown back from the burner opening, check for air leaks between the heater and the base plenum, paying Heater particular attention to the rear of the heater directly beneath the draught diverter.
  • Page 9 6.3.13 Test for gas leakage at the supply, Electrode Multifunctional Control, Pilot and Main Burners using a proprietary detection Pilot Burner fluid, sealing any leaks found. 6.3.14 Allow the heater to operate for a minimum Thermocouple of 15 minutes to ensure stability. MAIN BURNER PRESSURE TEST: NOTE: AIR HEATER BURNERS ARE FACTORY SET Aeration Port...

  • Page 10: Safety Checks

    SYSTEM E-T models: 6.7.4 Ensure that the fan speed increases to full speed. 6.7.5 When the temperature reaches the control setting, check that the Main Burner cycles ON and OFF, at approximately 75 to 120 seconds. BASIC CONTROL models: 6.7.6 When the temperature reaches the control setting, ensure that the Main Burner extinguishes followed by the fan switching off after a short period.

  • Page 11: Routine Maintenance

    Low Rate Medium Rate High Rate MJ/h Btu/h MJ/h Btu/h MJ/h Btu/h Input 27.1 25,780 31.2 29,560 35.1 33,250 Output 20.0 19,000 23.2 22,00 26.4 25,000 Gas rate CV 0.70 m /h (24.9ft 0.80m /h (28.5ft 0.91m /h (32.1ft 1037Btu/ft Burner setting 10.0 mbar (4.0 in wg) 14.0 mbar (5.6 in wg)
  • Page 12 8.1.7 Clean the heat exchanger flueways by thoroughly brushing from above and below. 8.1.8 By viewing through the Fan Aperture, and using a torch or similar, examine the heat exchanger externally for signs of cracks or holes, particularly around welded joints. 8.1.9 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.
  • Page 13 MULTIFUNCTIONAL CONTROL REMOVAL: 8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2 8.5.2 Disconnect the Thermocouple at the Multifunctional Control, avoiding damage to the capillary. 8.5.3 Disconnect the Pilot Feed Pipe from the Multifunctional Control. 8.5.4 Disconnect Multifunctional Control input and output supply feeds. 8.5.5 Refitting or replacement is in reverse order.
  • Page 14 ELECTRONIC MODULE REMOVAL (SYSTEM E-T models only): 8.9.1 Ensure that the electrical is isolated. 8.9.2 Remove the appliance front door, release the 3 x securing screws and hinge down the fan chamber door. 8.9.3 Disconnect terminals ‘21’ to ‘33’ from the Electronic Module. 8.9.4 Release the 2 x screws and nuts securing the Electronic Module to the Electrical assembly and remove the module.

  • Page 15: Defect Diagnosis

    DEFECT DIAGNOSIS IMPORTANT: If an electrical defect occurs after installation of the appliance; preliminary earth continuity, polarity, and resistance to earth checks should be carried out with a multimeter. On completion of any maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then checks of continuity, polarity, and resistance to earth must be repeated.
  • Page 16 ii. Controls not demanding heat Check that time control and room thermostat are operating correctly. iii. T3.15A fuse failed. Replace. If failure occurs again, check wiring for short circuits. iv. Loose connection to room thermo- Check connections. stat, limit switch, gas control lead, time control, or transformer.
  • Page 17 SYSTEM E-T DEFECT DIAGNOSTIC FLOW CHART MAIN BURNER NOT CYCLING ROOM TEMPERATURE TOO HIGH) DISCONNECT THERMISTA-STAT DOES REPLACE BURNER THERMISTA-STAT GO OUT? DISCONNECT MULTIFUNCTIONAL CONTROL AT TERMINAL 15 REPLACE DOES BURNER ELECTRONICS GO OUT? MODULE REPLACE MULTIFUNCTIONAL CONTROL FAN CONTINUES TO RUN, OR CYCLES AFTER HEATING IS TURNED OFF DISCONNECT TERMINALS ‘17’...
  • Page 18 MAIN BURNER NOT OPERATING TURN GAS PILOT LIT? ON ? IS 230V LIGHT SWITCH ON SUPPLY PILOT 230 V ON ? IS TIME CONTROL & SET CONTROLS THERMISTA-STAT CORRECTLY CORRECTLY SET? DISCONNECT THERMISTA-STAT AT TERMINALS ‘7’ & ‘8’, LINK TERMINALS ‘7’ & ‘TEST’ RECONNECT THERMISTA-STAT AT TERMINALS ‘7’...
  • Page 19 FAN OPERATES BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS REACHED DISCONNECT THERMISTA-STAT AT TERMINALS ‘7’ & ‘8’, LINK TERMINALS ‘7’ & ‘TEST’ DO NOT LINK ‘7’ &’8’ DOES THE BURNER REPLACE CONTINUE TO THERMISTA-STAT CYCLE? CHECK RETURN AIR PATH FOR RESTRICTIONS DOES THE BURNER CONTINUE TO...
  • Page 20 FAN RUNS BUT MAIN BURNER NOT OPERATING ‘SUMMER SET ‘SUMMER AIRFLOW’ AIRFLOW SWITCH TO SWITCH ‘0’ SET TO ‘0’ THERMISTA CONNECT -STAT THERMISTA-STAT CONNECTED THERMISTA -STAT SET TO SUMMER AIRFLOW SET THERMISTA-STAT TO REQUIRED TEMPERATURE SETTING DOES FAULT FAN STILL CLEARED RUN ? DISCONNECT THERMISTA-STAT AT...
  • Page 21 Park conns when no clock fitted or for external prog. 230V NO CLOCK OPTIONAL 230V 50Hz T3.15A 230V Cont. Supply FUSE AH(S5) N.B May be Timed MAINS Fan power fitted with start/run FILTER cap. capacitor. Timed Timed EXTERNAL PROG. Park S8 when no 230V OPTIONAL water htr.
  • Page 22 Park conns when no clock fitted or for external prog. 230V NO CLOCK OPTIONAL 230V Cont. AH(S5) Timed T3.15A 230V 50Hz Timed EXTERNAL PROG. Supply Park S8 when no FUSE OPTIONAL water htr. or for ext. prog. 230V Continuous TIMED 230V Cont.
  • Page 24 Fig. 8b Basic Control Circuit Diagram...

  • Page 25: Front View

    120 dia. FRONT VIEW SIDE VIEW BASE VIEW TOP VIEW Fig. 9 Principal Dimensions...
  • Page 26 WARM AIR HEATER AND CIRCULATOR COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the warm 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 28: Short List Of Spares

    SHORT LIST OF SPARES HI-SPEC J25 G.C No MFR’S No DESCRIPTION 232 878 BOS 02064 Fan Assembly 381 627 1000-0701140 Multifunctional Control (S.I.T. Nova) 379 837 1000-0704250 Pilot Assembly (S.I.T.) 378 466 BOS 02031 Time Control 245 503 T193-0751000 Burner Assembly...

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