Johnson & Starley 42-451-15, Installation, Commissioning & Servicing Instructions

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3
Sales/Spares & Replacement Help Line 01604 762881
28
10. SHORT LIST OF SPARES
ITEM G.C. MAKER’S DESCRIPTION QTY
No No No
1 245-182 J900-0525000 Fan assembly 1
2 E02-430 J652-0182000 Filter tray assembly 1
3 244 985 CL3S Time control CL3 1
4 244 986 1000-0000040 Time control cover 1
5 384 739 BOS00105 Limit switch 1
Honeywell L4069C
6 393 412 BOS01301 Multifunctional control 1
Honeywell V8600C
7 232 948 BOS02061 Sealing ring (for item 6) 2
8 BOS02397/4 Pilot assembly 1
9 293 935 1000-0705140 Pilot Injector 1
10 E02-431 1000-0705390 Pilot Feed Pipe 1
11 386-820 1000-0703870 Thermocouple 1
12 386 775 BOS01970 Electrode 1
13 397 819 BOS02394 Electrode lead 1
14 244 898 BOS02406 Electrode Nut 1
15 E02-554 J652-0391000 Spillage switch (TTB) Assembly 1
16 E02-946 J903-0700000 Burner and Controls Assembly 1
17 E02-947 1000-0705300 Burner and Cross Lighter Assembly 1
18 398-360 BOS 01204/4 Main Injector 3
19 E02-948 1000-0705350 Cross Lighting Injector (Bray) 1 or
E02-949 1000-0705320 Cross Lighting Injector (Stereomatic) 1
20 245-185 J900-0350005 Heat Exchanger exchange kit 1
21 395 945 1000-0700570 Piezo Unit 1
22 244 971 B300-0706000 Igniter Bracket 1
23 230-394 BOS 00836 Gasket (for heat exchanger cap) 3
24 E02-557 J652-0161000 Lower Compartment Door 1
MODAIRFLOW MODELS
25 E02-951 J903-0156000 Fan Compartment Door 1
26 245 136 J900-0530005 Control Panel with Transformer 1
27 245 137 J650-0519005 Wiring Harness 1
28 245-180 R011 Electronics Module 1
29 230-496 S 00076 Airflow Temperature Sensor 1
30 E02-428 1000-0514230 Fuse 1A, (T) Anti-surge 2
31 386 475 BOS01242 Thermista-stat 1
32 245-181 1000-0503690 Transformer 1
NON-MODAIRFLOW MODELS
33 E02-952 J903-0157000 Fan Compartment Door
34 245 264 1000-0501650 Control Panel 1
35 245 094 J650-0520005 Wiring Harness 1
36 385 159 BOS00104 Fan Control Honeywell L4068C 1
37 245-509 1000-0513820 Fuse 3.15A, (T) 1
38 245 322 1000-0500910 Relay 24V (for external water heater) 1
Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. If you have a problem in obtaining a
spare part, please contact Johnson and Starley Spares Department at the address below.
JOHNSON & STARLEYLTD.
Telephone: (01604) 762881 Rhosili Road,
Brackmills,
Fax: (01604) 767408 Northampton NN4 7LZ
1.1 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
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 can be adjusted between 20.5kW (73.9MJ/h, 70,000Btu/h) and 26.4kW (95.0MJ/h, 90,000Btu/h)
“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions).
THIS APPLIANCE CONFORMS TO BS EN 45014
1 Air Filter
2 Air circulating fan
3 Spillage monitoring device (TTB) (at rear)
4 Fuse
5 Electrical Assembly
6 Gas connection
7 Limit Switch
8 Multifunctional Control
9 Burner and Control Assembly
10 Pilot Burner
11 Date Plate
12 Fan delay control (non-Modairflow)
13 Airflow sensor (Modairflow models)
14 Piezo unit
15 Electronics module (MODAIRFLOW)
16 Time control
2
3
5
6
7
8
9
10
11
13 12
14
15
16
4
1
Fig. 1
28
10. SHORT LIST OF SPARES
ITEM G.C. MAKER’S DESCRIPTION QTY
No No No
1 245-182 J900-0525000 Fan assembly 1
2 E02-430 J652-0182000 Filter tray assembly 1
3 244 985 CL3S Time control CL3 1
4 244 986 1000-0000040 Time control cover 1
5 384 739 BOS00105 Limit switch 1
Honeywell L4069C
6 393 412 BOS01301 Multifunctional control 1
Honeywell V8600C
7 232 948 BOS02061 Sealing ring (for item 6) 2
8 BOS02397/4 Pilot assembly 1
9 293 935 1000-0705140 Pilot Injector 1
10 E02-431 1000-0705390 Pilot Feed Pipe 1
11 386-820 1000-0703870 Thermocouple 1
12 386 775 BOS01970 Electrode 1
13 397 819 BOS02394 Electrode lead 1
14 244 898 BOS02406 Electrode Nut 1
15 E02-554 J652-0391000 Spillage switch (TTB) Assembly 1
16 E02-946 J903-0700000 Burner and Controls Assembly 1
17 E02-947 1000-0705300 Burner and Cross Lighter Assembly 1
18 398-360 BOS 01204/4 Main Injector 3
19 E02-948 1000-0705350 Cross Lighting Injector (Bray) 1 or
E02-949 1000-0705320 Cross Lighting Injector (Stereomatic) 1
20 245-185 J900-0350005 Heat Exchanger exchange kit 1
21 395 945 1000-0700570 Piezo Unit 1
22 244 971 B300-0706000 Igniter Bracket 1
23 230-394 BOS 00836 Gasket (for heat exchanger cap) 3
24 E02-557 J652-0161000 Lower Compartment Door 1
MODAIRFLOW MODELS
25 E02-951 J903-0156000 Fan Compartment Door 1
26 245 136 J900-0530005 Control Panel with Transformer 1
27 245 137 J650-0519005 Wiring Harness 1
28 245-180 R011 Electronics Module 1
29 230-496 S 00076 Airflow Temperature Sensor 1
30 E02-428 1000-0514230 Fuse 1A, (T) Anti-surge 2
31 386 475 BOS01242 Thermista-stat 1
32 245-181 1000-0503690 Transformer 1
NON-MODAIRFLOW MODELS
33 E02-952 J903-0157000 Fan Compartment Door
34 245 264 1000-0501650 Control Panel 1
35 245 094 J650-0520005 Wiring Harness 1
36 385 159 BOS00104 Fan Control Honeywell L4068C 1
37 245-509 1000-0513820 Fuse 3.15A, (T) 1
38 245 322 1000-0500910 Relay 24V (for external water heater) 1
Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. If you have a problem in obtaining a
spare part, please contact Johnson and Starley Spares Department at the address below.
JOHNSON & STARLEYLTD.
Telephone: (01604) 762881 Rhosili Road,
Brackmills,
Fax: (01604) 767408 Northampton NN4 7LZ
1.1 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
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 can be adjusted between 20.5kW (73.9MJ/h, 70,000Btu/h) and 26.4kW (95.0MJ/h, 90,000Btu/h)
“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions).
THIS APPLIANCE CONFORMS TO BS EN 45014
1 Air Filter
2 Air circulating fan
3 Spillage monitoring device (TTB) (at rear)
4 Fuse
5 Electrical Assembly
6 Gas connection
7 Limit Switch
8 Multifunctional Control
9 Burner and Control Assembly
10 Pilot Burner
11 Date Plate
12 Fan delay control (non-Modairflow)
13 Airflow sensor (Modairflow models)
14 Piezo unit
15 Electronics module (MODAIRFLOW)
16 Time control
2
3
5
6
7
8
9
10
11
13 12
14
15
16
4
1
Fig. 1
28
10. SHORT LIST OF SPARES
ITEM G.C. MAKER’S DESCRIPTION QTY
No No No
1 245-182 J900-0525000 Fan assembly 1
2 E02-430 J652-0182000 Filter tray assembly 1
3 244 985 CL3S Time control CL3 1
4 244 986 1000-0000040 Time control cover 1
5 384 739 BOS00105 Limit switch 1
Honeywell L4069C
6 393 412 BOS01301 Multifunctional control 1
Honeywell V8600C
7 232 948 BOS02061 Sealing ring (for item 6) 2
8 BOS02397/4 Pilot assembly 1
9 293 935 1000-0705140 Pilot Injector 1
10 E02-431 1000-0705390 Pilot Feed Pipe 1
11 386-820 1000-0703870 Thermocouple 1
12 386 775 BOS01970 Electrode 1
13 397 819 BOS02394 Electrode lead 1
14 244 898 BOS02406 Electrode Nut 1
15 E02-554 J652-0391000 Spillage switch (TTB) Assembly 1
16 E02-946 J903-0700000 Burner and Controls Assembly 1
17 E02-947 1000-0705300 Burner and Cross Lighter Assembly 1
18 398-360 BOS 01204/4 Main Injector 3
19 E02-948 1000-0705350 Cross Lighting Injector (Bray) 1 or
E02-949 1000-0705320 Cross Lighting Injector (Stereomatic) 1
20 245-185 J900-0350005 Heat Exchanger exchange kit 1
21 395 945 1000-0700570 Piezo Unit 1
22 244 971 B300-0706000 Igniter Bracket 1
23 230-394 BOS 00836 Gasket (for heat exchanger cap) 3
24 E02-557 J652-0161000 Lower Compartment Door 1
MODAIRFLOW MODELS
25 E02-951 J903-0156000 Fan Compartment Door 1
26 245 136 J900-0530005 Control Panel with Transformer 1
27 245 137 J650-0519005 Wiring Harness 1
28 245-180 R011 Electronics Module 1
29 230-496 S 00076 Airflow Temperature Sensor 1
30 E02-428 1000-0514230 Fuse 1A, (T) Anti-surge 2
31 386 475 BOS01242 Thermista-stat 1
32 245-181 1000-0503690 Transformer 1
NON-MODAIRFLOW MODELS
33 E02-952 J903-0157000 Fan Compartment Door
34 245 264 1000-0501650 Control Panel 1
35 245 094 J650-0520005 Wiring Harness 1
36 385 159 BOS00104 Fan Control Honeywell L4068C 1
37 245-509 1000-0513820 Fuse 3.15A, (T) 1
38 245 322 1000-0500910 Relay 24V (for external water heater) 1
Johnson and Starley prides itself on its ability to supply spare parts quickly and efficiently. If you have a problem in obtaining a
spare part, please contact Johnson and Starley Spares Department at the address below.
JOHNSON & STARLEYLTD.
Telephone: (01604) 762881 Rhosili Road,
Brackmills,
Fax: (01604) 767408 Northampton NN4 7LZ
1.1 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
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 can be adjusted between 20.5kW (73.9MJ/h, 70,000Btu/h) and 26.4kW (95.0MJ/h, 90,000Btu/h)
“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions).
THIS APPLIANCE CONFORMS TO BS EN 45014
1 Air Filter
2 Air circulating fan
3 Spillage monitoring device (TTB) (at rear)
4 Fuse
5 Electrical Assembly
6 Gas connection
7 Limit Switch
8 Multifunctional Control
9 Burner and Control Assembly
10 Pilot Burner
11 Date Plate
12 Fan delay control (non-Modairflow)
13 Airflow sensor (Modairflow models)
14 Piezo unit
15 Electronics module (MODAIRFLOW)
16 Time control
2
3
5
6
7
8
9
10
11
13 12
14
15
16
4
1
Fig. 1
1. GENERAL DESCRIPTION
2
2.
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 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).
BS 5440 Pt. 1 (Flues for GasAppliances)
BS 5440-2: 2000 (Air Supply for GasAppliances)
BS 5864 Installation of Gas Fired DuctedAir Heaters
Models and Local Authority bylaws.
I MPORTANT: STATUE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED 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.
HEATER COMPARTMENTAND CLEARANCES (See BS 5864)
2.1 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 any overhang or blanking off will be at the front and/or right hand side. In any event, blanking plates must be
mechanically secured and all joints sealed.
2.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 38mm (1
1
/
2
in) at the
rear, 75mm (3in) total at the sides (with a minimum of 25mm (1in) at any one side), and 63mm (2
1
/
2
in) at the front must
be left. Consideration should also be given to the space required for the removal and replacement of the filter tray and the
entry of the gas and electrical supplies.
2.3 For service access, a minimum of 600mm (24ins) is required at the front of the heater. Space must also be allowed, in a
compartment installation, to permit the removal of the heater. The clearance between the appliance and the compartment
should not be less that 75mm (3in). However, where clearances are less than 75mm, the internal surface of the
compartment must be lined with non-combustible material. The compartment must be of a fixed rigid structure.
Important: Ensure that the rear of the heater is at no time subjected to air pressure due to leaks from
underfloor, joists or roof spaces.
2.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant section of
BS5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the
perforations not exceeding 13mm (1/2in). The secondary flue must be a tight fit where it passes through the partition and
must be suitably protected (see BS 5440: Part 1).
2.5 In under-stairs installations, the compartment must comply with the relevant section of BS 5864, provided that in
addition, all internal surfaces, including the base, are non-combustible or lined with noncombustible material. This
requirement is applicable only to dwellings of more than two storeys.
2.6 In free-standing installations, (see instructions packed with free standing kit), only one or two walls will be in contact
with the air heater and therefore complying with the relevant section of BS 5864.
2.7 Where the Air Heater is to be insalled onto a combustible surface and under-floor ducting used, a suitable base tray (BT65/
90) MUST be used in order to provide edquate insulation.
NB where a base plenum is used no base tray is required!
2.8 For Slot Fix applications (see instructions packed with the Slot Fix Kit), it is important to ensure that the draught diverter
relief is maintained on both sides of the application.
3. VENTILATIONAND COMBUSTION AIR
3.1 The room or internal space in which the heater is installed requires a permanent air vent of minimum effective area
140cm
2
(21.6in
2
). 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.
3.2 Combustion air may be introduced, via a 125mm (5in) nominal bore pipe, connected to a return air duct or plenum from a
ventilated area and fitted with a lockable damper. The damper should be adjusted to control combustion airflow to
0.019m
3
/s (41cfm), (i.e. 1.56m/s [310ft/min] velocity in a 125mm [5in] bore pipe). If this arrangement is used, a non-
closeable warm air register MUST be provided in the same area as the front of the air heater or heater compartment if a
return air grille is not located in that area.
3.3 When installed in a compartment, two permanent ventilation openings into the compartment are required, one at high
level and one at low level, both communicating either directly with outside air or with a ventilated room or space. The
minimum effective areas specified in Table 1 are related to the rated heat input of the Air Heater.
3.4 If any room or area from which air is drawn for ventilation or combustion contains an extract fan, the permanent vents
must be sized to ensure that the operation of the appliance(s) at full rate is/are not adversely affected. A spillage test as
specified in sub-para 6.8 (Safety Checks) is carried out and any remedial work undertaken.
27
Fig. 7, PRINCIPAL DIMENSIONS (mm)
SIDE VIEW
PLAN VIEW
FRONT VIEW
BASE VIEW
GAS ENTRY
ELECTRICAL ENTRY
400
42.5 42.5
12
82
83
2
61
1
57
6
30
0
485
42
67
85
448 122 25
74
610 38
44
5
18
0
41
1
40
1
64
8
85
146 DIA.
30
25
24
3
37
37