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Johnson
& Starley
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
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1.1
HI-SPEC J50P is an open-flued, fan assisted downflow, ducted warm air heater. A Spillage Monitoring Device (TTB) is fitted
which senses the temperature in the draught diverter, and shuts down the appliance when this temperature rises due to the
presence of flue gases.
1.2
The air heater output is 14.65kW (57.75MJ/h, 50,000Btu/h). "Summer air circulation" of unheated air is available by manual
selection (see User's Instructions).
THIS APPLIANCE CONFORMS TO BS EN 55014
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)
BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations
BS 5482 Pt. 1 Domestic Butane- and Propane-gas-burning installations.
BS 5440 Pt. 1 (Flues for Gas Appliances)
BS 5440 Pt. 2 (Air Supply for Gas Appliances)
BS 5864 Installation of Gas Fired Ducted Air Heaters
British System Design Manual "Gas Fired Warm Air Heating"
Model and Local Authority Bye-laws
These instructions are to be left with the User or adjacent to the Gas Meter
HI-SPEC J50P WARM AIR HEATERS
This appliance is for use with PROPANE gas G31 only
BRIEF DESCRIPTION
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G.C. No 42 416 12
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Publication No. ZZ 1027/4
Air Filter
Air circulating fan
Fuse
Time control
Data plate
Limit Switch
Multifunctional Control
Pilot burner
Burner and Control Assembly
Gas connection
Fan Delay Control
Electrical Assembly
Piezo unit
Spillage monitoring device (TTB) (at rear)
October 2006
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Summary of Contents for Johnson & Starley HI-SPEC J50P
- Page 1 Fig. 1 HI-SPEC J50P is an open-flued, fan assisted downflow, ducted warm air heater. A Spillage Monitoring Device (TTB) is fitted which senses the temperature in the draught diverter, and shuts down the appliance when this temperature rises due to the presence of flue gases.
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Page 2: Ventilation And Combustion Air
IMPORTANT: STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS, (i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION. HEATER COMPARTMENT AND CLEARANCES (SEE BS 5864) IMPORTANT: If the heater is to be fitted to an existing base duct (warm air plenum), always ensure that installation is carried out such that the rear left hand corner of the heater is aligned with the rear left hand corner of the base duct, so that... -
Page 3: Duct System
337cm (52.3in Low level grille 448cm (69in Ventilated from inside building. 169cm (26.2in High level grille 224cm (34in 169cm (26.2in Low level grille 224cm (34in Ventilated from outside building. 85cm (13.1in High level grille 112cm Table 1 Minimum Effective Areas DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating) RETURN AIR... - Page 4 change should be as gentle as possible. If there is any doubt about the flue configuration, the equivalent flue height should be determined (see 5.1.10). 5.1.9 If the appliance to be fitted is a replacement, the old appliance should be checked for signs of spillage prior to commencement of the installation and appropriate action taken, (i.e.
- Page 5 5.1.11 Calculation method for flue sizing: ( from BS 5440: Part 1, Appendix A) 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 consideration, (i.e. that height of the straight vertical circular flue pipe of specific size which will produce the same flow rate as the flue under consideration).
- Page 6 Ridge 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 Flue spigot Fig. 2 Worked example of equivalent flue height Carry out a flow visualisation check with a smoke pellet at the intended position for the appliance.
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Page 7: System Balancing
DRAUGHT DIVERTER & DEFLECTOR PLATE: 5.4.1 The HI-SPEC J50P heater is supplied with a draught diverter which houses the TTB, and which requires fitting to the rear of the heater prior to installation, using 6 x 4mm screws and lock washers (provided). Connect the TTB to the terminal block situated on the rear upper left hand corner of the appliance. -
Page 8: Temperature Rise Check
IGNITION OF PILOT AND MAIN BURNERS: WARNING: If the Pilot Burner is extinguished either intentionally or unintentionally, no attempt should be made to relight the gas for a minimum of 3 Heater minutes. Ensure that the Electrical supply, time control and Selector switches are set to ‘OFF’. -
Page 9: Safety Checks
AUTOMATIC CONTROLS CHECK 6.7.1 Set the TIME CONTROL to ‘ON’. 6.7.2 Turn the room thermostat slowly clockwise until the Main Burner ignites. 6.7.3 Ensure that the fan starts to operate after a short period (approx. 1-2 minutes). 6.7.4 When the temperature reaches the control setting, ensure that Operating control the Main Burner extinguishes... -
Page 10: Air Volume
MJ/h Btu/h Input 18.72 67.4 63,900 Output 14.65 52.75 50,000 Gas Rate 1.81m /h (64.1ft Burner Setting 35.8mbar (14.3 in wg) Pressure Main Injector AMAL 187/001/290 Table 4 Main Burner Pressure Settings mbar in.wg. 0.50 0.20 0.375 0.15 Response Area 0.25 0.10 600 ft... -
Page 11: Maintenance
MAINTENANCE IMPORTANT: Ensure that the 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 the 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 12 PILOT BURNER, THERMOCOUPLE AND ELECTRODE, REMOVAL AND REPLACEMENT: 8.5.1 Remove the Burner and Control 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.
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Page 13: Defect Diagnosis
ZZ1027/3 8.9.6 Disconnect 2 x TTB connections. 8.9.7 Disconnect the Multifunctional Control connections. 8.9.8 Release 4 x 4mm screws securing the Electrical Assembly to the heater cabinet and remove the Electrical Assembly, releasing wiring from cable clamps and grommets as required.. 8.9.9 Refitting or replacement is in reverse order. - Page 14 SYMPTOM POSSIBLE CAUSE REMEDY a. Pilot will not light. No gas supply to heater. Check for gas at inlet pressure test point on Multifunctional Control. Gas supply pipe not purged. Purge gas supply pipe in accordance with BS 6891. Pilot orifice restricted. Clear pilot orifice or replace pilot injector.
- Page 15 Fig. 6 Circuit Diagram...
- Page 16 Fig. 7 Functional Diagram...
- Page 17 Fig. 8 Principal Dimensions (mm)
- Page 18 BENCHMARK Number WARM AIR HEATER AND CIRCULATOR COMMISSIONING CHECKLIST WARM AIR UNIT APPLIANCE SERIAL NUMBER: ............NOTIFICATION No: ......HOT WATER GENERATOR APPLIANCE SERIAL NUMBER: .
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Page 19: Service Provider
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate service interval record below. SERVICE PROVIDER Before completing the appropriate service interval record below, please ensure that you have carried out the service as described in the heater manufacturer’s instructions and in compliance with the Gas Safety Regulations Date . -
Page 20: Short List Of Spares
SHORT LIST OF SPARES ITEM G .C. MAKER’S DESCRIPTION 382 758 1000-0500725 Fan assembly E20-417 B502-0182000 Filter tray assembly 244 985 CL30-0500000 Time control CL3 244 986 1000-0000040 Time control cover 384 739 BOS00105 Overheat (limit Control) Honeywell L4069C 393 412 BOS02237 Multifunctional control Honeywell V8600D...
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