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Installation & Maintenance Instructions
Models covered by these instructions
JT19-25 Mk 2 WARM AIR HEATER (MODAIRFLOW & Conventional Control)
(56.53)
UDC 697.
Publication ZZ 302/5
The JT19-25 Mk2 is a Gas Fired Warm Air Heater for open flue application. Output is adjustable between 5.6kW — 7.3kW (20MJ/h, 19,000 —
26.4MJ/h, 25,000 Btu/h) and there is 5 speed fan adjustment.
CIRCULATOR WATER HEATERS — all air heaters have provision for the internal fitting of a JANUS 3. or ELJAN or a HIJAN circulator.
If a water heater is provided factory fitted, the heater designation is JT19-25 Mk2 JAN ELJ or HIJ depending on requirement.
To fit a water heater on site, obtain from Johnson & Starley Ltd. a Janus 3 Water Heater and LK19 Fittings Kit.
To fit HIJAN order a HIJANS and LK19 and HEI192 Fittings Kit.
To fit ELJAN order an ELJAN S and LK19 and HEI192 Fittings Kit.
1
Components Check
2
Warm Air Installation requirements
3
Preparation
4
Air Heater Fixing
5
Water Connections
6
Commissioning
7
Maintenance
8
Fault Finding
9
Wiring Diagram
10
Short List of Spare Parts
1. COMPONENTS CHECK
NB: Check that Gas Group on heater data plate is as required JT19.25 Mk 2 AIR HEATER
Fig. 1
JT19-25 Mk 2 WARM AIR
HEATER
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Summarization of Contents
Warm Air Installation Requirements
Ventilation of Heater Compartment
Details ventilation requirements for heater compartments, including grille sizes for different air sources.
Ventilation of Building
Specifies the need for purpose-designed ventilation openings in an outside wall for the heater.
Return Air
Outlines requirements for connecting return air grilles or relief openings to the air heater.
Preparation
Flues
Specifies the requirement for a single 100mm (4") twin wall flue.
Electrical Connections
Covers mains cable requirements, fuses, and thermostat connection details.
Gas Supply
Details gas connection size, pipe entry, and compliance with regulations.
Heater Installation Clearances
Provides minimum clearance requirements for heater installation on sides, front, and back.
Installation on Suspended Floors
Discusses insulation requirements for combustible floors and base duct/plenum installations.
Maintenance
Main Burner Cleaning
Instructions for removing, cleaning, and reassembling the burner and crosslighter assembly.
Injector Cleaning
Guidance on cleaning or replacing main and pilot burner injectors.
Thermocouple
Checks for proper connection of the thermocouple to the gas control.
Fan and Fan Motor Cleaning
Procedures for removing and cleaning the fan impeller and motor, preserving balance.
Gas Pressure Check
Steps for checking gas pressure at the test point and confirming gas rate.
Gas Control 'fail-safe' Operation Check
Verifies that the gas control safely shuts off the main burner when the pilot flame is extinguished.
Pilot Flame Check
Instructions to ensure the pilot flame envelops the thermocouple probe.
Automatic Controls Inspection
General inspection of automatic control systems for proper function.
Time Control Removal
Steps to remove the time control unit by loosening screws and disconnecting leads.
Electrical Panel Removal
Procedure for removing the electrical panel, including disconnecting plugs and leads.
Air Circulating Fan Removal
Steps for disconnecting and removing the fan assembly with care.
Heat Exchanger Access
Instructions for accessing and inspecting the heat exchanger, including baffle removal.
Fault Finding
Pilot will not light
Diagnoses for pilot burner failure, including gas supply and orifice issues.
Pilot lights but goes out
Troubleshooting for pilot flame instability, checking thermocouple and gas control connections.
Pilot alight but main burner not igniting
Checks for conventional control heaters where the main burner fails to ignite after pilot is lit.
Main burner lights but fan fails to run
Diagnoses for main burner operation without fan activity, checking connections and settings.
Main burner operating intermittently with fan running
Troubleshooting intermittent main burner operation, checking gas pressure and temperature rise.
Main burner operating with intermittent fan operation
Diagnoses for main burner cycles with inconsistent fan operation, checking gas rate and settings.
Fan runs for excessive period or operates intermittently after main burner shuts down
Addresses issues with fan running too long or cycling erratically after burner shutdown.
Noisy operation
Troubleshooting causes of abnormal noise from the unit, including fan and gas pressure.
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