Johnson & Starley HI-SPEC J50 - User Manual

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Fig. 1
FEATURES
1 Air circulation fan
2 Fuse/s
3 Electronics module (MODAIRFLOW)
4 Spillage monitoring device (TTB) (at rear)
5 Multifunctional control
6 Limit Switch
7 Airflow sensor (Modairflow models)
8 Fan delay control (non modairflow models)
9 Pilot burner
10 Burner and control assembly
11 Data plate
12 Piezo unit
13 Gas connection
14 Electrical assembly
15 Time control
16 Air filter
1.1 HI-SPEC J50 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with MODAIRFLOW
control and in combination with an ELJAN 6 water circulator. 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 11.72kW (42.2MJ/h, 40,000Btu/h) and 14.65kW (57.75MJ/h, 50,000Btu/h).
“Summer air circulation” of unheated air is available by manual selection (see User’s Instructions). ELJAN 6 output is 3.32kW
(11.5MJ/h, 11.340Btu/h).
THIS APPLIANCE CONFORMS TO BS EN 45014
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 Gas Appliances)
BS 5440 Pt. 2 (Air Supply for Gas Appliances)
BS 5864 Installation of Gas Fired Ducted Air Heaters
Model and Local Authority Bye-laws
This appliance has been tested and certified for use with natural gas
1. BRIEF DESCRIPTION
These instructions are to be left with the User or adjacent to the Gas Meter
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 & STARLEY LTD.
Telephone: (01604) 762881 Rhosili Road,
Brackmills,
Fax:(01604) 767408 Northampton NN4 7LZ
Publication No. ZZ 851/6
October 2006
HI-SPEC J50 WARM AIR HEATERS
with MODAIRFLOW and non-MODAIRFLOW Control
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
G.C. No 42 451 13

Summary

BRIEF DESCRIPTION

FEATURES

Lists key components and functions of the Hi-Spec J50 heater.

HEATER COMPARTMENT AND CLEARANCES

Installation Clearances and Requirements

Specifies minimum clearances for installation and compartment types.

VENTILATION AND COMBUSTION AIR

DUCT SYSTEM

Return and Delivered Air Ducting

Specifies requirements for return air ducting and installation of delivered air ductwork.

INSTALLATION REQUIREMENTS

Flue Installation and Checks

Covers flue system requirements, sizing, performance, and safety checks.

Flue Sizing and Performance

Explains how to calculate equivalent flue height for performance.

Flue System Checks

Outlines visual checks and performance tests for the flue system.

ELECTRICAL SYSTEM

Mains Supply and Thermostat Wiring

Details mains connections, thermostat placement, and wiring for control.

GAS SUPPLY AND CONNECTIONS

DRAUGHT DIVERTER AND DEFLECTOR PLATE

Fitting and Safety Checks

Describes fitting the draught diverter and deflector plate, including safety tests.

COMMISSIONING PROCEDURES

Preparation, Balancing, and Ignition

Ensures readiness, balances ducting, and ignites pilot and main burners.

Burner Pressure, Extinguishing, and Temperature Checks

Tests burner pressure, procedures for extinguishing, and temperature rise verification.

Automatic Controls Verification

Tests operation of thermostats, timers, and fan cycling.

Safety Checks and Testing

Includes gas soundness, spillage tests, and automatic controls verification.

USER INSTRUCTIONS

User Guidance and Operation

Covers leaving manual with user, operation, and basic maintenance.

MAINTENANCE PROCEDURES

Routine Maintenance and Burner Servicing

Outlines regular checks, cleaning, and servicing of the burner assembly.

Component Servicing and Removal

Details injector, pilot, control, fan, and electrical assembly maintenance.

Electronic Module, Time Control, and Fan Component Removal

Procedures for removing electronic module, time control, and fan controls.

Spillage Monitor, Heat Exchanger Access, and Defect Diagnosis Precautions

Procedures for TTB removal, heat exchanger access, and safety for defect diagnosis.

DEFECT DIAGNOSIS

General Precautions and Warnings

Safety advice for electrical checks and handling electronic assemblies.

TROUBLESHOOTING GUIDE

Pilot, Burner, and Fan Issues

Addresses problems with pilot ignition, main burner, fan operation, and noise.

Control System Faults

Diagnoses issues related to Modairflow and non-Modairflow control systems.

DIAGNOSTIC FLOWCHARTS

Fan and Burner Cycling Faults

Flowcharts for fan not running and burner cycling issues.

Main Burner Operation and Premature Cycling Faults

Flowcharts for main burner not operating and premature burner cycling.

Short Burn Period Faults

Flowchart for troubleshooting when the main burner fires for short periods only.

Continuous Fan Operation Faults

Flowchart for diagnosing why the fan continues to run after heating is turned off.

WIRING DIAGRAMS

Modairflow Circuit Diagram

Detailed wiring diagram for Modairflow models.

Non-Modairflow Circuit Diagram

Detailed wiring diagram for non-Modairflow models.

Modairflow Functional Diagram

Functional wiring diagram for Modairflow models.

Non-Modairflow Functional Diagram

Functional wiring diagram for non-Modairflow models.

TECHNICAL SPECIFICATIONS

Principal Dimensions

Technical drawings showing the physical dimensions of the heater.

SPARE PARTS LIST

Common Spare Parts

Lists common replacement parts for the heater.

Modairflow Specific Spares

Lists spare parts specific to Modairflow models.

Non-Modairflow Specific Spares

Lists spare parts specific to non-Modairflow models.

COMMISSIONING CHECKLIST

SERVICE INTERVAL RECORD

Johnson & Starley HI-SPEC J50 Specifications