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Johnson & Starley HI-SPEC J65 - User Manual

Johnson & Starley HI-SPEC J65
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HEATING HOT WATER VENTILATION
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 No. ZZ 0941-9
June 2016
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
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Summary

General Description and Specifications

HI-SPEC J65 Product Overview

Details the HI-SPEC J65 warm air heater, its output, and compliance.

Installation Standards and Regulations

Lists the Building Regulations and British Standards the appliance adheres to.

Heater Compartment and Clearances

Compartment Clearances and Service Access

Specifies minimum clearances for installation compartments and service access requirements.

Specific Installation Location Requirements

Outlines requirements for airing cupboards and under-stairs installations.

Ventilation and Combustion Air

Airflow Requirements for Ventilation and Combustion

Details minimum air vent areas for proper ventilation and combustion, including extract fan impact.

Duct System Requirements

Return Air Ducting Requirements and Design

Covers the requirements for return air duct size, material, installation, and access.

Delivered Air Ducting Insulation and Installation

Details duct insulation, design principles, and base duct installation for warm air delivery.

Installation Instructions: Flue System

Flue Installation Requirements and Sizing Methodology

Covers flue sealing, support, material, verticality, and the calculation method for flue sizing.

Flue Specific Checks and Terminal Recommendations

Details special considerations for external flues, terminals, and pre-installation flue performance tests.

Electrical Installation

Mains Supply and Thermostat Connections

Details mains supply connection, thermostat location, and wiring for both models.

Gas Installation

Gas Supply Pipe Requirements and Isolation

Outlines gas supply pipe requirements, union gas cock fitting, and leak detection.

Commissioning Procedures

Preparation, System Balancing, and Ignition Sequence

Initial checks, preparation, system balancing, and step-by-step burner ignition.

Commissioning Tests and Automatic Controls Checks

Performs main burner pressure test, temperature rise check, and verifies automatic controls.

Safety Checks

Gas Soundness and Spillage Tests

Performing gas leak checks and flue spillage tests for safety assurance.

Operational Safety Checks and Re-ignition

Verifying fail-safe operation, limit switch, and re-ignition after power interruptions.

Instructions for Users

User Guidance for Occupied and Unoccupied Buildings

Explains operation of controls, maintenance, and safety for both building states.

Maintenance Procedures

Routine Maintenance Tasks and Checks

Step-by-step guide for regular servicing, including cleaning and inspections.

Component Removal: Burner, Injectors, Pilot

Procedures for removing and replacing burner assembly, main injectors, and pilot burner system.

Component Maintenance and Removal

Control and Piezo Unit Removal

Steps for removing Multifunctional Control, Piezo Unit, and related connections.

Fan and Electrical Assembly Removal

Procedures for removing the air circulation fan and electrical assembly.

Component Maintenance and Removal (Cont.)

Modairflow Module and Transformer Removal

Steps for removing electronic module and transformer on Modairflow models.

Time Control, Fan Delay, TTB, and Sensor Removal

Procedures for removing Time Control, Fan Delay, Limit Switch, Airflow Sensor, and TTB.

Heat Exchanger Access

Heat Exchanger Panel, End Cap, and Baffle Removal

Steps to access and remove heat exchanger baffles, end caps, and access panels.

Defect Diagnosis

Electrical Fault Diagnosis and Safety Warnings

Preliminary checks and safety warnings for electrical fault diagnosis.

Common Symptoms and Causes: Pilot & Burner Issues

Lists symptoms like pilot failure, burner issues, and their potential causes.

Continued Defect Diagnosis

Fan Operation, Noise, and Model-Specific Faults

Addresses fan issues, noise, and troubleshooting for Modairflow/non-Modairflow models.

Fault Finding Flowcharts

Modairflow Fan and Burner Cycling Fault Finding

Flowcharts for diagnosing fan failure and burner cycling in Modairflow models.

Fault Finding Flowcharts (Continued)

Main Burner Not Operating Fault Finding

Flowchart for diagnosing the main burner not operating.

Fault Finding Flowcharts (Continued)

Burner Cycling Before Temperature Reach Fault Finding

Flowchart for diagnosing premature burner cycling.

Fault Finding Flowcharts (Continued)

Short Burner Firing Periods and Fan Operation Faults

Flowcharts for short burner firing and continuous fan operation issues.

Wiring Diagrams

Modairflow Circuit Diagram

Electrical wiring diagram for Modairflow models, showing component connections.

Wiring Diagrams (Continued)

Non-Modairflow Circuit Diagram

Electrical wiring diagram for non-Modairflow models, showing component connections.

Functional Diagrams

Non-Modairflow Functional Diagram

Functional diagram illustrating system operation and signal flow for non-Modairflow.

Functional Diagrams (Continued)

Modairflow Functional Diagram

Functional diagram illustrating system operation and signal flow for Modairflow.

Dimensions

HI-SPEC J65 Unit Physical Dimensions

Provides detailed physical dimensions, including plan and base views, of the HI-SPEC J65 unit.

Short List of Spares

Exploded Diagram

Information and Ancillaries

Code of Practice

Standards of Work for Installers and Competence

Requirements for installers regarding competence, regulations, and documentation.

Customer Service and Communication Guidelines

Guidelines for customer interaction, explanation, and support from installers.

Commissioning Checklist

Controls and System Configuration Checks

Checks for control settings, zone valves, and system balancing.

Heater Performance Measurements and Installation Verification

Records burner pressure, heat input, temperature difference, and confirms installation compliance.

Service Record

Johnson & Starley HI-SPEC J65 Specifications

General IconGeneral
ModelHI-SPEC J65
ManufacturerJohnson & Starley
Fuel TypeNatural Gas
Flue Size100 mm
Electrical Supply230V ~ 50Hz

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