Johnson & Starley HI-SPEC J90 Installation, Commissioning & Servicing Instructions
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Johnson & Starley HI-SPEC J90 Installation, Commissioning & Servicing Instructions

Warm air heater
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H E A T I N G
H O T W A T E R
V E N T I L A T I O N
Publication No. ZZ 0944-9
June 2016
HI-SPEC J90
Warm Air Heater
with Modairflow or
Non Modairflow Control
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
Hi-Spec J90
-
G.C. No. 42-451-15
These instructions are to be left with the User
www.johnsonandstarley.co.uk

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  • Page 1 H E A T I N G H O T W A T E R V E N T I L A T I O N Publication No. ZZ 0944-9 June 2016 HI-SPEC J90 Warm Air Heater with Modairflow or Non Modairflow Control INSTALLATION, COMMISSIONING &...

  • Page 2: Table Of Contents

    CONTENTS Defect Diagnosis Benchmark Scheme 10 Fault Finding General Description 11 Wiring Diagrams Heater Compartment & Clearances 12 Functional Diagrams Ventilation & Combustion Air 13 Dimensions Duct System 14 Notes Return Air Warm Delivered Air 15 Short List of Spares Installation Requirements 16 Exploded Diagram Flues...

  • Page 3: General Description

    Time control Fig. 1 HI-SPEC J90 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with MODAIRFLOW control. A non-MODAIRFLOW version is available as an option. A Spillage Monitoring Device (TTB) is fitted which senses Fig.

  • Page 4: Heater Compartment & Clearances

    Building Regulations BS 7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations BS 5440 Pt. 1 (Flues for Gas Appliances) Gas Safety (Installation and Use) Regulations (as amended) BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases). BS 5440-2: 2000 (Air Supply for Gas Appliances) BS 7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations BS 5440 Pt.

  • Page 5: Duct System

    VENTILATED Low level grille 627cm (97in FROM INSIDE BUILDING High level grille 314cm (49in VENTILATED Low level grille 314cm (49in FROM OUTSIDE BUILDING High level grille 157cm (25in Table 1 Minimum Effective Areas DUCT SYSTEM RETURN AIR 4.1.1 All return air shall be POSITIVELY ducted from outside the compartment to the top of the unit via a return air duct, and mechanically secured.

  • Page 6: Installation Requirements

    suit the needs of its specific heating requirements and building layout. The type of duct system, (i.e. radial/ extended plenum/stepped) should be installed using the least number of fittings to minimise airflow resistance. INSTALLATION REQUIREMENTS 5.1 FLUES (see British Standards BS 5440 Pt.1 Flues) 5.1.1 All joints shall be soundly sealed.
  • Page 7 subscript a refers to the actual or proposed flue diameter; is the resistance per unit length of the equivalent flue; Sum K is the resistance (other than the inlet and outlet resistance) of the actual or proposed flue. Note: K and Sum K are obtained from Table 2. K and K are obtained from Table 3.
  • Page 8 STET Terminal 2 x 300 mm lengths 100 mm dia flue pipe = 6.2m 4.6m 4 x 1000 mm lengths bend 300 mm length 1.6m bend 2 x 300 mm lengths Appliance draught Fig. 2 diverter Worked example of equivalent flue height 5.1.12 Special consideration must be given to external flues with a view to prevention of condensation and weathering problems.

  • Page 9: Electrical

    ELECTRICAL 5.2.1 Mains. The heater is supplied with mains cable (PVC sheathed, heat resisting to 85 C), 3-core Brown-Blue-Green/ Yellow, 6A, 0.75mm ), connected to a terminal block and exiting through the heater at the right hand top front. The cable is suitable for a 230V 50Hz supply and shall be connected to the fixed wiring using a double pole switched, fused spur, incorporating a protective earth link.

  • Page 10: Commissioning

    6. COMMISSIONING COMMISSIONING PREPARATION: 6.1.1 Ensure that: Gas and Electrical supplies are OFF. Filter, fan and fan compartments are free from obstructions. All registers or grilles are open and conform to design specifications. Return, relief and ventilation air installations are adequate. SYSTEM BALANCING: 6.2.1 Set the Air Heater electrical supply ON.

  • Page 11: Main Burner Pressure Test

    MAIN BURNER PRESSURE TEST: NOTE: AIR HEATER BURNERS ARE FACTORY SET TO PROVIDE A NOMINAL HIGH PRESSURE OUTPUT AS DETAILED IN SUB PARA 1.2 6.4.1 Referring to Table 4 and Fig. 4 below, ensure that the pressure test gauge indicates the correct burner pressure, resetting if required as follows: At the Multifunctional Control: Remove the Burner Pressure Adjuster cover.

  • Page 12: Safety Check

    SAFETY CHECKS: 6.8.1 Check for gas soundness within the appliance. 6.8.2 Spillage test: Carry out a full spillage test as follows, and ensure that the flue operates effectively with all doors 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.

  • Page 13: Instructions For User

    mbar in.wg. 0.625 0.25 0.50 0.20 0.375 0.15 0.25 0.10 0.125 0.05 1000 ft /min 0.23 0.28 0.33 0.38 0.43 0.47 m /sec AIR VOLUME Table 5 Fan Performance Curve INSTRUCTIONS FOR USERS If the building is unoccupied, ensure that the Instructions for User are left taped to the air heater for the User, and Installation Instructions are left at or near the air heater for use on future service calls.

  • Page 14: Maintenance

    8. MAINENANCE MAINTENANCE IMPORTANT: Ensure gas and electricity supplies are isolated before commencing any 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 Commissioning Instructions at Sect 6.1 to 6.8 inclusive. ROUTINE MAINTENANCE: 8.1.1 Operate the appliance and check for the correct function of the burner and controls.
  • Page 15 PILOT BURNER, THERMOCOUPLE AND ELECTRODE, REMOVAL AND REPLACEMENT: 8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2 8.5.2 Disconnect the Igniter Lead from the Piezo Unit. 8.5.3 Disconnect the Thermocouple from the Thermocouple Adapter on the Multifunctional Control, taking care to avoid damage to the Thermocouple Capillary.
  • Page 16 NON-MODAIRFLOW models: 8.9.6 Disconnect the following: 230V connections (L/N/E) from the Fan Assembly, 230V mains ‘L’, ‘N’ and ‘E’ from connection block terminals ‘1’ and ‘3’, and earth stud respectively, Room thermostat from connection block terminals ‘17’ and ‘18’, Limit switch ‘LOAD’ and ‘COMMON’ connections, Fan Control ‘LOAD’, ‘COMMON’...
  • Page 17 8.14.4 Cover the aperture to the Heat Exchanger in the top shelf to prevent objects falling into the Heat Exchanger. 8.14.5 Release and remove the 6 x screws securing the Fan Compartment rear plate, and withdraw the rear plate. 8.14.6 Release and remove the 6 x screws securing the Draught Diverter Access Panel, and withdraw the access panel. 8.14.7 Whilst holding the TTB Access Panel, release the 2 x securing screws and withdraw the TTB Access Panel.
  • Page 18 9. 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 19 PILOT BURNER, THERMOCOUPLE AND ELECTRODE, REMOVAL AND REPLACEMENT: 8.5.1 Remove the Burner and Controls Assembly as detailed in 8.2 Fan runs for excessive Fan Delay Control set incorrectly. Check for correct settings. 8.5.2 Disconnect the Igniter Lead from the Piezo Unit. period or operates intermittently after 8.5.3...
  • Page 20 MODAIRFLOW DEFECT DIAGNOSIS FLOW CHART 10. FAULT FINDING MODAIRFLOW FAULT FINDING MAIN BURNER ON, BUT FAN NOT RUNNING CHECK FOR VOLTAGE REPLACE FAN AT FAN LIVE TO NEUTRAL BRIDGE OUT AIRFLOW SENSOR DOES REPLACE AIRFLOW SENSOR START? REPLACE CHECK FOR VOLTAGE AT ELECTRONICS FAN LIVE TO EARTH MODULE...
  • Page 21 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 ? REPLACE FUSE FUSE OK ? CHECK 24V AT REPLACE MULTIFUNC- MULTIFUNCTIONAL...
  • Page 22 FAN OPERATES, BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS REACHED BRIDGE THERMISTA-STAT DOES REPLACE BURNER THERMISTA-STAT STAY LIT? REPLACE OVERHEAT CONTROL ELECTRONIC MODULE OK ? CHECK TTB, LIMIT CHECK TEMPERATURE SWITCH & RISE ACROSS HEATER IS °c CONNECTIONS LESS THAN 60 CHECK AIR FILTER &...
  • Page 23 MAIN BURNER ONLY FIRES FOR SHORT PERIODS THERMISTA- SET THERMISTA-STAT STAT TO MAX SET TO MAX ? BRIDGE THERMISTA-STAT AT HEATER DOES REPLACE BURNER ELECTRONIC MODULE STAY LIT? CHECK THERMISTA-STAT FAN CONTINUES TO RUN AFTER HEATING IS TURNED OFF CONNECTIONS POLARITIES FAN CONTINUES TO RUN AFTER HEATING IS TURNED OFF CHECK FAN SELECTOR SWITCH SETTING...
  • Page 24 11. WIRING DIAGRAMS www.johnsonandstarley.co.uk...
  • Page 25 Sales/Spares & Replacement Help Line 01604 762881...
  • Page 26 12. FUNCTIONAL DIAGRAMS Fig 6a. Non-MODAIRFLOW FUNCTIONAL DIAGRAM www.johnsonandstarley.co.uk...
  • Page 27 Fig 6b. Non-MODAIRFLOW FUNCTIONAL DIAGRAM Sales/Spares & Replacement Help Line 01604 762881...
  • Page 28 13. DIMENSIONS Fig 7. HI-SPEC J90 DIMENSIONS www.johnsonandstarley.co.uk...
  • Page 29 14. NOTES Sales/Spares & Replacement Help Line 01604 762881...
  • Page 30 15. SHORT LIST OF SPARES SHORT LIST OF SPARES ITEM G.C. MAKER’S DESCRIPTION 245-182 J900-0525000 Fan assembly E02-430 J652-0182000 Filter tray assembly 244 985 CL3S Time control CL3 244 986 1000-0000040 Time control cover 384 739 BOS00105 Limit switch Honeywell L4069C 393 412 BOS01301 Multifunctional control Honeywell V8600C...
  • Page 31 16. EXPLODED DIAGRAM Fig 8. HI-SPEC J90 EXPLODED DIAGRAM Sales/Spares & Replacement Help Line 01604 762881...
  • Page 32 British Standard BS 5864 by following the guidance in the HEATING COMPLIANCE GUIDE and the For further information contact Johnson & Starley Ltd on Telephone: 01604 762881 HI-SPEC J90 ANCILLARIES ITEMS DESCRIPTION PART No. Base Tray BT 65 Base Duct...
  • Page 33 Code Of Practice For the installation, commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on Standards of Work both manufacturers and installers.* • Be competent and qualified to undertake the work required. The purpose is to ensure that •...
  • Page 34 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.
  • Page 35 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specifi ed spare part when replacing controls.
  • Page 36 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 01604 767408 Anniversary 1922 - 2012 In the interest of continuous development Johnson & Starley reserve the right to change specifications without prior notice.

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42-451-15

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