Johnson & Starley JANSTAR Mk 2 Installation, Commissioning & Servicing Instructions

Warm air heater

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INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
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Key
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1.1
The Johnson & Starley JANSTAR Mk 2 is a wall mounted, room sealed, fan assisted, down flow warm air heater. It is
designed for use with a concentric air inlet/flue, which enables combustion air to be admitted to the burner, whilst
combustion products are discharged to the outside, via a concentric terminal.
1.2
The air heater output is 8.0 kW (27,300Btu/h) for horizontal flued installations, and 8.5 kW (96000Btu/h) for vertical
flued installations.
1.3
The appliance is supplied assembled for left hand return air entry. For conversion to right hand return entry, refer to
Section 4. If return air is via the top of the fan chamber, a side blanking plate (Pt No ****-*******) is required. The
appliance may be base duct mounted. JANSTAR Mk 2 is also provided with the facility for connection to a remote time
control (not supplied), with volt-free contacts (i.e. The switching supply is provided by JANSTAR Mk 2), to enable
selection of operating times.
1.4
A mesh filter, for air return duct mounting, is supplied as standard. However, a Cleanflow electronic filter is offered as an
alternative option.
JANSTAR Mk 2
WARM AIR HEATER
G.C. No 42 *** **
This appliance has been tested and certified for use with natural gas.
GENERAL DESCRIPTION
Description
Air circulating fan
Burner assembly
Ignition/detection electrode
Gas connection
Multifunctional control
Fan delay/ Overheat limit control
JANSTAR Mk2 Principal Components
THIS APPLIANCE CONFORMS TO BS EN 55014
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12
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Key
Description
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Air filter (L H shown)
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Flue outlet/combustion air inlet
9
Fan to flue connection
10
Flue gas test point
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Combustion air fan
12
Pressure switch
Fig. 1
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Publication No. ZZ 1019/1E
September 1999
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1
BURNER
ON
Air Heating
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0
I
Summer Airflow
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Summary of Contents for Johnson & Starley JANSTAR Mk 2

  • Page 1 JANSTAR Mk2 Principal Components The Johnson & Starley JANSTAR Mk 2 is a wall mounted, room sealed, fan assisted, down flow warm air heater. It is designed for use with a concentric air inlet/flue, which enables combustion air to be admitted to the burner, whilst combustion products are discharged to the outside, via a concentric terminal.
  • Page 2: Ventilation And Combustion Air

    ZZ 1019/1E 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 (IEE.) 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: Installation Requirements

    ZZ 1019/1E 5.1.2 The return air system should be constructed of fire-resistant material. It is extremely important that the correct size of return air grilles and ducting is used. The return air duct size should be NOT LESS THAN ***mm x ***mm (*in x *in).
  • Page 4 ZZ 1019/1E 6.2.10 Construction of flue joints. Coat the end of the inner tube with silicone sealant capable of withstanding temperatures of up to 200 (not provided), and insert it fully into the female end of the next tube. Using 3.3mm dia. drill, drill one hole through the assembly and secure with 1 x blind pop rivet (provided). Fit 1 x centring clip (provided) over the tube, immediately down flow of the joint.
  • Page 5 ZZ 1019/1E CONDENSATE 6.3.1 When firing , the unit may produce condensate which must be drained away. A JDT1 kit, which externally drains the condensate away from the flue terminal is available for horizontal flued applications. Vertical flued applications require the fitment of an in-line condensate trap within 0.5 m of the unit, in the first vertical flue run, and before any bends in the flue run.
  • Page 6: Safety Check

    ZZ 1019/1E 7.6.1 If the burner fails to light, re-initiate the ignition sequence setting the switching the electrical to supply to the appliance OFF and then ON again. 7.6.2 If the burner ignites but then extinguishes: An automatic purging sequence will take place, which lasts for approximately 30 seconds.
  • Page 7: Temperature Rise Check

    ZZ 1019/1E 7.12 TEMPERATURE RISE CHECK: 7.12.1 Ignite the Main burner and allow 15 minutes for stability before continuing. 7.12.2 Check that the temperature rise across the heater is between 45 C - 55 C, setting the fan speed accordingly, (decrease fan speed to increase temperature rise).
  • Page 8 ZZ 1019/1E SERVICING Ensure that the gas and electricity supplies are isolated before commencing any IMPORTANT: maintenance or replacement of components. After completion of any maintenance, always test for gas soundness and carry out a complete functional test of the appliance in accordance with the Commissioning Instructions.
  • Page 9 ZZ 1019/1E REMOVAL OF INJECTOR: 9.6.1 Referring to 9.3, remove the burner assembly. 9.6.2 Using 14mm A/F ring spanner, undo the nut and washer, and remove injector from burner manifold. 9.6.3 Refitting or replacement is in reverse order. FUSE REPLACEMENT: 9.7.1 Ensure that the electrical supply is switched off.
  • Page 10: Control Module Replacement

    ZZ 1019/1E 9.12 CONTROL MODULE REPLACEMENT: 9.12.1 Ensure that the electrical supply is switched off. 9.12.2 Remove the heater front cover. 9.12.3 Disconnect the Control Module as follows, and with reference to Fig. 7: PINK lead from the terminal marked ‘C1’, BLUE lead from the terminal marked ‘C2’, RED lead from the terminal marked ‘C3’, BROWN lead from the terminal marked ‘C4’,...
  • Page 11: Heat Exchanger Removal

    ZZ 1019/1E 9.16 HEAT EXCHANGER REMOVAL: 9.16.1 Referring to 9.3, remove the burner assembly. 9.16.2 Referring to 9.9, remove the Ignition/detection electrode. 9.16.3 Referring to 9.12, remove the combustion air fan, including complete removal of the two upper securing screws. 9.16.4 Referring to 9.13, remove the fan delay/overheat (limit) control.
  • Page 12 ZZ 1019/1E BURNER ON, BUT AIR CIRCULATION FAN NOT RUNNING AIR CIRCULATION FAN ON, BUT BURNER CYCLES BEFORE Check for 230 volts at fan terminals 11 & 12 REQUIRED COMFORT LEVEL IS REACHED Disconnect Thermostat at terminals 6 & 7. No 230 volts detected 230 volts detected Switch to ‘Summer Airflow’.
  • Page 13 ZZ 1019/1E 19 18 17 Burner ON indicator Fan speed Control Module selector Fuse BURNER Air Heating Summer Airflow Ignition Control Unit Air Heating/ Summer Airflow Fig. 6, Electrical panel switch...
  • Page 14: Control Module

    ZZ 1019/1E Limit Switch Summer Air Heating Air Flow 230V 50Hz Supply Fan Delay Fan Plug Control Fuse T3.15A AUTO 230V Continuous Thermostat (24V) CONTROL MODULE Pressure Switch GAS ON Indicator Light Ignition/flame Control Fig. 8 JANSTAR Mk2 functional flow diagram...
  • Page 15 ZZ 1019/1E Fig. 9 Principal dimensions (mm)
  • Page 16: Short List Of Spares

    ZZ 1019/1E SHORT LIST OF SPARES G.C. MAKER’S DESCRIPTION E00 124 W800-0701000 Burner assembly E00 125 W800-0774000 Burner metal fibre assembly 245 549 1000-1500840 Gasket - burner top plate *** *** 1000-0705480 Injector Bray Cat 15.3400 245 530 W800-0300000 Heat exchanger assembly *** *** 1000-0708060 Multifunctional control valve...

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