Johnson & Starley HI-SPEC J40 Installation, Commissioning & Servicing Instructions
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Johnson & Starley HI-SPEC J40 Installation, Commissioning & Servicing Instructions

Warm air heater with system e-t & conventional control
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HI-SPEC J40
Warm Air Heater
with System E-T &
Conventional Control
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
Hi-Spec J40
-
These instructions are to be left with the User
G.C. No. 42-451-09
www.johnsonandstarley.co.uk
Publication No. ZZ 0815-10
October 2016

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Summary of Contents for Johnson & Starley HI-SPEC J40

  • Page 1 Publication No. ZZ 0815-10 October 2016 HI-SPEC J40 Warm Air Heater with System E-T & Conventional Control INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS Hi-Spec J40 G.C. No. 42-451-09 These instructions are to be left with the User www.johnsonandstarley.co.uk...

  • Page 2: Table Of Contents

    CONTENTS 14 Users Instructions The Benchmark Scheme Features 15 Servicing & Maintenance Routine Maintenance General Description Burner & Control Assembly Removal Burner & Control Assembly Cleaning Building Standards & Regulations Main Ignition Removal, Cleaning & Replacement Pilot Burner, Thermocouple & Electrode Removal & Replace- Safety &Gas Information ment General Safety Information...

  • Page 3: Features

    FEATURES Appliance Classification: This Hi-Spec J40 has been tested and certified by B G Technology for use with NATURAL gas G20. NOTE: If an ELJAN 6 water circulator is fitted, the relevant Installation, Commissioning and Servicing instructions provided with that appliance must also be observed.

  • Page 4: Building Standards & Regulations

    BUILDING STANDARDS & REGULATIONS STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS, i.e. GAS SAFE REGISTERED INSTALLERS. GAS SAFE MEMBERSHIP ENQUIRIES TEL: 0800 408 5500 IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.

  • Page 5: Technical Data

    TECHNICAL DATA HI-SPEC J40 TABLE 1 GAS SUPPLY PRESSURE 20mbar GAS CATEGORY COUNTRIES OF INSTALLATION GB & IE ELECTRICAL SUPPLY 230v ~ 50Hz fused 5A (150 watts) AIR HEATER LOW RATE MEDIUM RATE HIGH RATE MJ/h Btu/h MJ/h MJ/h Btu/h INPUT (GROSS) 11.75...

  • Page 6: Ventilation & Combustion Air

    VENTILATION & COMBUSTION AIR 37.1 The room or internal space in which the heater is installed requires a permanent air vent of minimum effec- tive area 62cm (9in ). The air vent should be either direct to outside air or to an adjacent room or internal space (other than a toilet or bathroom) that itself has an equivalent air vent direct to outside.

  • Page 7: Flue Instructions

    Ensure while installation work is being carried out that no debris such as swarf, filings or fragments of mortar are allowed to remain in the air/flue duct. FLUE INSTALLATION The Hi-Spec J40 is designed to be used with a 60/100mm (4”) flue. 9.5.1 All joints must be soundly sealed.
  • Page 8 FIGURE 3. TERMINAL POSITIONS TABLE 3 TERMINAL POSITION MINIMUM DISTANCE Directly below an opening, air brick, opening window etc 300mm Above an opening, air brick, opening window, etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes. 75mm Below eaves.

  • Page 9: Resistance Factors

    This appendix provides a procedure for estimating whether a given flue design is likely to ensure full clearance of combustion products. The procedure is based on calculating the ‘equivalent height’ of the flue under considera- tion, i.e. that height of the straight vertical circular flue pipe of specific size which will pro- duce the same flow rate as the flue under consideration.
  • Page 10 APPLIANCE INLET RESISTANCE (K FLUE OUTLET RESISTANCE (K 100mm Flue 100mm Dia Spigot 125mm Dia Spigot 125mm Flue 150mm Dia Spigot 0.48 150mm Flue 0.48 TABLE 5. INLET & OUTLET RESISTANCE Worked Calculation Example A warm air unit with a 100mm (4”) diameter flue spigot, fitted with a prefabricated flue system leading to a ridge tile in the loft.
  • Page 11 Ridge Terminal 2 x 300mm Extensions 100mm Diameter Flue Pipe 4 x 1000mm Extensions 45˚ Elbow 300mm Extension 45˚ Elbow 2 x 300mm Extensions Appliance Draught Diverter TABLE 4. WORKED EXAMPLE OF EQUIVALENT FLUE HEIGHT Sales/Spares & Replacement Help Line 01604 762881...
  • Page 12 10. ELECTRICAL WARNING: THIS APPLIANCE MUST BE EARTHED! 10.1 MAINS SUPPLY 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.
  • Page 13 COMMISSIONING 13.1 PREPARATION After installation of the appliance, you MUST do the following: 13.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found. 13.1.2 Carry out preliminary electrical system checks. 13.1.3 Ensure that: a. filter, fan and fan compartments are free from obstructions. b.
  • Page 14 13.4 MAIN BURNER PRESSURE TEST NOTE: AIR HEATER BURNERS ARE FACTORY SET TO PROVIDE A NOMINAL HIGH RATE OUTPUT AS DETAILED IN PARAGRAPH 2.2 13.4.1 Referring to Table 1 and Figure 9 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 Adjust cover.

  • Page 15: 14. Users Instructions

    IF THE DRAUGHT DIVERTER IS ACCESSIBLE Introduce smoke into the draught diverter adjacent to an exit from the heat exchanger, by means a smoke match or puffer. Ensure that there is no spillage present (indicated by displacement of smoke downwards and out of the draught diverter.

  • Page 16: Servicing & Maintenance

    SERVICING & MAINTENANCE IMPORTANT: Ensure that the gas and electricity supplies are isolated before commencing any servicing & maintenance or replacement of components. Because the appliance is room sealed, it is also imperative that if at any stage of repairs the gasket on the sealing plate is damaged it MUST be replaced! After completion of any maintenance, always test for gas tightness and carry out a complete functional test of the appliance in accordance with the Commissioning Instructions at paragraphs 13.1 to 13.6 inclusive.

  • Page 17: Piezo Unit Removal

    15.5.6 Release the two screws securing Pilot Burner Assembly to the main burner, and remove Pilot Burner Assembly. 15.5.7 Refitting or replacement is in reverse order. NOTE: When refitting or replacing Thermocouple, tighten only to FINGER TIGHT + 1 FLAT. 15.6 MULTIFUNCTIONAL CONTROL REMOVAL 15.6.1...

  • Page 18: Transformer Removal

    15.10 ELECTRONIC MODULE REMOVAL (SYSTEM E-T models only) 15.10.1 Ensure that the electrical supply is isolated. 15.10.2 Remove the appliance upper and lower doors, release the securing screw and hinge down the fan chamber door. 15.10.3 Disconnect terminals ‘21’ to ‘33’ from the Electronic Module. 17.10.4 Release the 2 x screws and nuts securing the Electronic Module to the Electrical Assembly and remove the module.

  • Page 19: Defect Diagnosis

    DEFECT DIAGNOSIS 16.1 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 20 Mains electrical supply not Check mains supply. connected to heater Check that time control and room Controls not demanding heat thermostat are operating correctly. Replace. If failure occurs again, T3.15A fuse failed. check wiring for short circuits. Loose connection to room thermostat, limit switch, gas Check connections.

  • Page 21: Dimensions

    DIMENSIONS FIGURE 11. HI-SPEC J40 DIMENSIONS Sales/Spares & Replacement Help Line 01604 762881...

  • Page 22: Fault Finding Flowcharts

    FAULT FINDING FLOWCHARTS MAIN BURNER ON, BUT FAN NOT WORKING FAN OPERATES, BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS REACHED FAN CONTINUES TO RUN, OR CYCLES AFTER HEATING IS TURNED OFF MAIN BURNER NOT CYCLING (ROOM TEMPERATURE TOO HIGH) www.johnsonandstarley.co.uk...
  • Page 23 MAIN BURNER NOT OPERATING Sales/Spares & Replacement Help Line 01604 762881...
  • Page 24 DEFECT DIAGNOSIS FLOWCHART FIGURE 12. SYSTEM E-T FUNCTIONAL DIAGRAM www.johnsonandstarley.co.uk...
  • Page 25 FIGURE 13. BASIC FUNCTIONAL DIAGRAM Sales/Spares & Replacement Help Line 01604 762881...
  • Page 26 LOGIC DIAGRAM FIGURE 14. SYSTEM E-T CONTROL CIRCUIT DIAGRAM www.johnsonandstarley.co.uk...
  • Page 27 FIGURE 15. BASIC CONTROL CIRCUIT DIAGRAM Sales/Spares & Replacement Help Line 01604 762881...
  • Page 28 EXPLODED SPARES DIAGRAMS SORT LIST OF SPARES ITEM G.C. No. PART No. DESCRIPTION 245 502 1000-0516580 Fan Assembly 381 627 1000-0701140 Multifunctional Control (Honeywell) 232 903 BOS 02061 O Ring Seal A432-0852000 Pilot Mounting Bracket 173 096 1000-0704810 Pilot Burner Assembly 381 712 1000-0705140 Pilot Injector...
  • Page 29 EXPLODED DIAGRAM FIGURE 16. HI-SPEC J40 EXPLODED DIAGRAM Sales/Spares & Replacement Help Line 01604 762881...
  • Page 30 CONDENSING WARM AIR HEATING AND WATER HEATING COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the wsnn 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 31 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. SERVICE 01 SERVICE 02 Date:...
  • Page 32 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...

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