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9

Sales/Spares & Replacement Help Line 01604 762881

6

23

1.6m

4.6m

H

a

 = 6.2m

STET Terminal

2 x 300 mm lengths

4 x 1000 mm lengths

45

O

 bend

45

O

 bend

2 x 300 mm lengths

300 mm length

Appliance draught

diverter

100 mm dia flue pipe

Fig. 2

Worked example of equivalent flue height

5.2

ELECTRICAL

5.2.1

Mains.

a.

The heater is supplied with mains cable (PVC sheathed, heat resisting to 85

o

C), 3-core Brown-Blue-

Green/Yellow, 6A, 0.75mm

2

), 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. The fuse fitted shall be

rated 5A to BS1362. Connections shall be in accordance with the current edition of I.E.E Regulations BS

7671.

b.

MODAIRFLOW Models: An electronic controller (Thermista-stat) is supplied which acts as a room

thermostat.

c.

Non-MODAIRFLOW models: A 24V room thermostat (not supplied), that complies with BS 800,

BS 3955 and BS 4201 is essential to ensure close control of comfort conditions. An anticipator is located

within the thermostat and is graded in amps. The anticipator should be checked and adjusted to 0.2A.

Fig. 6a, MODAIRFLOW FUNCTIONAL DIAGRAM

7

22

Fi

g.

 5

b,

 N

on

-M

O

D

A

IR

FL

O

W

 C

IR

C

U

IT

 D

IA

G

RA

M

5.2.2

Thermista-stat/Room Thermostat and its location.

a.

The Thermista-stat/Room Thermostat should be located where there is free air circulation approx. 1.5m

(5ft) from the floor.
b.

Avoid the following locations:-
i)

In a room where temperature is greatly affected by the sun or any other heat source, e.g. radiant

fire, wall light fittings or TV set.

ii)

Near an outside door or windows, or on an outside wall.

iii)

Where affected by warm air ducts, diffusers, waste pipes or the heater itself.

iv)

Where subject to vibration.

c.

For MODAIRFLOW models, connect Thermista-stat wires to control panel terminals ‘4’ and ‘5’ (see Fig.

5a and 6a), connection polarity being important, cve side on control panel to +ve side on

Thermista- stat.

d.

For non-MODAIRFLOW models, connect room thermostat wires control panel terminals ‘16’ and ‘17’

5.3

GAS 

(See BS 5864 and BS 6891)

5.3.1

An independent gas supply pipe from the meter is to be preferred wherever possible. When this is not possible,

the pipe must be capable of taking the complete input of the heater and all other gas appliances being served by

this same pipe. This supply should be suitably sized to conform to British Standards requirements of no more than

1.0 mbar (0.4in wg) pressure drop (See table of discharge in BS 6891).

5.3.2 The 1/2in union gas cock (supplied) must be fitted to the gas inlet of the heater for easy isolation during

servicing. The gas pipe should be so fitted and installed as to be durable, substantial and gas tight. To assist in

determining where a gas connection may not be tight, a leak detection fluid should be applied around the

connection. Under no circumstances should a flame be used to locate a gas leak.  Gas entry to the air heater is

through either side to a Rc1/2 (1/2in BSP. external [taper] thread).

6.

COMMISSIONING

6.1

PREPARATION:

6.1.1

Ensure that:
a.

Gas and Electrical supplies are 

OFF.

b.

Filter, fan and fan compartments are free from obstructions.

c.

All registers or grilles are open and conform to design specifications.

d.

Return, relief and ventilation air installations are adequate.

6.2

SYSTEM BALANCING:

6.2.1 Set the Air Heater electrical supply ON.
6.2.2 Set the ‘SUMMER AIR CIRCULATION’ switch to ‘

ON

’.

6.2.3 Balance the ducting system to provide the required volume proportions at the warm air outlets.

NOTE:

   If the system includes ceiling diffusers, air velocities through these should be NOT LESS THAN 1.5m/s (300 ft/

min), except for very small rooms (i.e., bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.

6.3

IGNITION OF PILOT AND MAIN BURNERS:

WARNING:  

If the pilot light is extinguished either intentionally or unintentionally, no attempt should be made to

relight the gas for a minimum of 3 minutes. Ensure that the Electrical supply, Time Control and Selector switches  are set

to

‘OFF’.

6.3.1

Set the Thermista-stat/room thermostat to lowest or 

OFF

 setting.

6.3.2

On the Multifunctional Control, remove the Outlet Pressure test point cover, and fit a pressure test gauge

(refer Fig. 4).

6.3.3 Turn the heater Gas supply 

ON

, test for gas soundness and purge the whole gas pipe as described in BS 6891.

6.3.4 Referring to Fig .4,  press and hold the OPERATING CONTROL, and whilst observing the Pilot Burner, repeatedly

press Piezo igniter button until Pilot Burner ignites.

6.3.5

After 20 seconds release the OPERATING CONTROL and let it spring out; ensure that the Pilot Burner remains

alight. If the Pilot Burner extinguishes, rotate the OPERATING CONTROL clockwise to the ‘

l

’ position and

ensure that the OPERATING CONTROL is fully reset. Wait three minutes and repeat steps 6.3.4 and 6.3.5,

holding the OPERATING CONTROL pressed for a longer period, until Pilot Burner remains alight.

Summary of Contents for 42-451-14

Page 1: ...N G H O T W AT E R V E N T I L AT I O N HI SPEC J65 Warm Air Heater with Modairflow or Non Modairflow Control Hi Spec J65 G C No 42 451 14 These instructions are to be left with the User Publication...

Page 2: ...ill be required in the event of any warranty work and as supporting documentation relating to home improvements in the optional documents section of the Home Improvements In the interest of continuous...

Page 3: ...culating fan 3 Fuse s 4 Time control 5 Data plate 6 Limit switch 7 Multifunctional control 8 Pilot burner 9 Burner and Control Assembly 10 Gas connection 11 Airflow sensor Modairflow models 12 Fan Del...

Page 4: ...on of BS 5864 provided that in addition all internal surfaces including the base are non combustible or lined with non combustible material This requirement is applicable only to dwellings of more tha...

Page 5: ...guidelines in the British System Design Manual to suit the needs of its specific heating requirements and building layout The type of duct system i e radial extended plenum stepped should be installe...

Page 6: ...istance can be achieved practicably by some means Where this is not practicable the existing flue system may be used providing there is no evidence of spillage from the old appliance see 5 1 9 above E...

Page 7: ...ion Example A warm air unit with a 100 mm diameter flue spigot fitted with a pre fabricated flue system leading to a ridge tile in the loft refer Fig 2 From table 3 Kia Inlet resistance of actual flue...

Page 8: ...Important Before installing the appliance carry out a visual check of the flue system as directed in the relevant section of BS5440 Pt 1 then check the flue performance as follows a Close all doors a...

Page 9: ...nt gas supply pipe from the meter is to be preferred wherever possible When this is not possible the pipe must be capable of taking the complete input of the heater and all other gas appliances being...

Page 10: ...luid sealing any leaks found 6 3 13 Allow the heater to operate for a minimum of 15 minutes to ensure stability 7 servicing The gas pipe should be so fitted and installed as to be durable substantial...

Page 11: ...efore continuing 6 6 2 With the Main Burner operating continuously check that the temperature rise across heater is between 45o C 55o C setting the fan speed accordingly decrease fan speed to increase...

Page 12: ...iance ON 6 8 9 Ignite the Main and Pilot Burners as detailed in sub para 6 3 1 to 6 3 5 6 8 10 Ensure that the Limit Switch operates indicated by the Main Burner extinguishing within 120 and 180 secon...

Page 13: ...NCE 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 carr...

Page 14: ...5 minutes to ensure stability and with the main burner lit ensure that the operation of Air Circulation fan does not affect the main burner flame profile 8 2 BURNERAND CONTROLASSEMBLY REMOVAL 8 2 1 En...

Page 15: ...the Piezo retaining nut and remove the unit from its mounting bracket 8 7 3 Refitting or replacement is in reverse order 8 8 AIR CIRCULATINGFAN REMOVALAND CLEANING 8 8 1 Ensure that the electrical sup...

Page 16: ...trol and remove by partially withdrawing the bottom of the Time Control and then lifting upwards 8 12 3 Disconnect the Time Control electrical connections from the integral terminal strip 8 12 4 Refit...

Page 17: ...d In the event of heat exchangerreplacement being necessary contact Johnson and Starley Service Department 9 DEFECT DIAGNOSIS 9 1 IMPORTANT If an electrical defect occurs afterinstallation of the appl...

Page 18: ...trical defect occurs afterinstallation of the appliance preliminary earth continuity polarity and resistance to earth checks should be carried out with a multimeter On completion of any maintenance fa...

Page 19: ...ommended procedure Non MODAIRFLOW models j Pilot alight but main i Mains electrical supply not Check mains supply burner not igniting connected to heater ii Controls not demanding heat Check that time...

Page 20: ...CHECKFORVOLT AGE ATFANLIVETO NEUTRAL MAIN BURNER ON BUT FAN NOT RUNNING Y REPLACEFAN DOES FAN START N BRIDGEOUT AIRFLOWSENSOR Y REPLACE AIRFLOWSENSOR REPLACE TRANSFORMER REPLACE MULTIFUNCTIONAL CONTRO...

Page 21: ...230 V N Y N Y REPLACE FUSE N Y REPLACE MULTIFUNCTIONAL CONTROL SET CONTROLS CORRECTLY Y N CHECK POLARITY OF THERMISTA STAT CONNECTIONS Y IS POLARITY CORRECT N RECTIFY DEFECT Y BRIDGETHERMISTA STAT TER...

Page 22: ...C CHECK TTB LIMIT SWITCH CONNECTIONS Y Y CHECKMAINBURNER PRESSURESETTINGS ARECORRECT SET TO CORRECT PRESSURE SETTING N Y SET FAN BALANCING SCREW Y DOES FAN SPEED UP N Y REPLACE ELECTRONIC MODULE REPL...

Page 23: ...SENSOR Y DOES FAN STILL RUN REPLACE ELECTRONICS MODULE Y IS PILOT FLAME TOO BIG N Y ADJUST PILOT FLAME TO CORRECT SETTING REPLACE AIRFLOW SENSOR N MAIN BURNER ONLYFIRES FOR SHORT PERIODS DEFECT IS IN...

Page 24: ...www johnsonandstarley co uk 24 11 WIRING DIAGRAMS Fig 5a MODAIRFLOW CIRCUIT DIAGRAM...

Page 25: ...25 Sales Spares Replacement Help Line 01604 762881 Fig 5b Non MODAIRFLOW CIRCUIT DIAGRAM...

Page 26: ...www johnsonandstarley co uk 26 12 FUNCTIONAL DIAGRAMS Fig 6a Non MODAIRFLOW FUNCTIONAL DIAGRAM...

Page 27: ...27 Sales Spares Replacement Help Line 01604 762881 Fig 6b MODAIRFLOW FUNCTIONAL DIAGRAM...

Page 28: ...www johnsonandstarley co uk 28 13 DIMENSIONS Fig 7 HI SPEC J65 DIMENSIONS...

Page 29: ...29 Sales Spares Replacement Help Line 01604 762881 14 NOTES...

Page 30: ...ss Lighting Injector Bray 1 or E02 423 1000 0705310 Cross Lighting Injector Stereomatic 1 20 E02 556 J652 0350005 Heat Exchanger exchange kit 1 21 395 945 1000 0700570 Piezo Unit 1 22 244 971 B300 070...

Page 31: ...31 Sales Spares Replacement Help Line 01604 762881 16 EXPLODED DIAGRAM Fig 8 HI SPEC J65 EXPLODED DIAGRAM...

Page 32: ...Adapter Kit PAK65 4 Return Air Kit RAK65 5 Cleanflow Electronic Air Cleaner CF 90H 6 Replacement Pads A0354X0357 Warm Air Heating fully complies with PART L OF THE BUILDING REGULATIONS by following t...

Page 33: ...to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults...

Page 34: ...Automatic bypass system Fitted Not required Warm Air Unit Interlock Yes No If YES Volume Litres FOR WARM AIR HEATERS ONLY Has the system been balanced in accordance with the heater manufacture s instr...

Page 35: ...Comments Signature SERVICE 05 Date Engineer name Company name Telephone No Operative ID No Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Operative ID No Comments Signatur...

Page 36: ...sales johnsonandstarley co uk marketing johnsonandstarley co uk Reception Customer Service 01604 762881 Fax 01604 767408 Anniversary 1922 2012 In the interest of continuous development Johnson Starley...

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