Johnson & Starley HI-SPEC J25 User guide

HI-SPEC J25 WARM AIR HEATERS
SYSTEM E-T and Basic Control
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
G.C. No 42 451 04 Publication No. ZZ 753/12
January 2010
These instructions are to be left with the User or adjacent to the Gas Meter
1
28
Johnson
& Starley
1 Airfilter
2 Air circulating fan
3 Heat exchanger access cover
4 Multifunctional control
5 Data Plate
6 Heat shield
7 Burner assembly
8 Pilot burner
9 Lighting port
10 Fan delay control/limit switch
11 Gas supply pipe
12 Piezo igniter unit
13 Time control
2
3
5
10
8
9
7
6
12
4
13
1
11
Fig. 1
Thisappliancehabeentestedandcertified by G.L.IndustrialServicesUKLtd.forusewithnaturalgasG20.
Note: If a HIJAN 6 or SUPERJAN 6 circulator is fitted, the relevant Installation, Commissioning and Servicing instructions
provided with that appliance must also be observed.
1. BRIEF DESCRIPTION
1.1 HI-SPEC J25 is an open-flued, fan assisted downflow, ducted warm air heater, which may be supplied with SYSTEM E-T or
Basic control. A HIJAN 6 or SUPERJAN 6 circulator is available as an option. Apilot burner incorporating an Atmospheric
Sensing Device (ASD) is fitted which responds to the presence of flue gases and shuts down the appliance.
1.2 TheAir heater output can be adjusted between 5.6kW (20.0MJ/h, 19,000Btu/h) and 7.3kW (26.4MJ/h, 25,000Btu/h). “Summer
air circulation” of unheated air is available by manual selection (see User’s Instructions). HIJAN 6 output is 3.81kW (13.7MJ/
h,13,000Btu/h), whilst SUPERJAN 6 outputis6.0kW (21.6MJ/h, 20,470Btu/h).
THIS APPLIANCE CONFORMS TO BS EN 45014
10. SHORT LIST OF SPARES
HI-SPEC J25
KEY G.CNo MFR’S No DESCRIPTION QTY
1 232878 BOS02064 Fan Assembly 1
2 381627 1000-0701140 Multifunctional Control (S.I.T. Nova) 1
3 379837 1000-0704250 Pilot Assembly (S.I.T.) 1
4 378466 BOS02031 Time Control 1
5 245503 T193-0751000 Burner Assembly 1
6 398388 BOS02060 MainInjector (Bray 33/700) 1
7 395945 1000-0701160 PiezoUnit (High Energy) 1
8 245509 1000-0513820 Fuse T3.15A anti-surge 1
9 T193-0145000 Filter Tray 1
10 364835 S00832 Solenoid Valve 1
11 242228 S00174 Heat Exchanger 1
12 245542 1000-0515970 Capacitor 15 uF 1
SystemE-T Models only
13 245510 ET001 Electronic Panel Assembly with daughter board 1
14 245514 1000-0515620 Thermista-stat 1
15 245515 1000-0515455 Fan Delay/Overheat (limit) switch 1
16 1000-0515090 Mains Filter 1
18 T1930531000 CompleteElectrical panel 1
T1930131000 Cabinet Door Assembly 1
Basic Control Models only
19 T1930530000 ElectricalPanel 1
20 245520 1000-0516125 Fan delay/Overheat (limit) switch 1
21 245522 1000-0515200 Transformer Fan Speed 1
22 245525 1000-0515730 Transformer 24 volt 1
23 245413 1000-0511760 Relay Module 1
JohnsonandStarleypridesitselfonitsability to supply spareparts quicklyand efficiently.Ifyouhaveaprobleminobtaininga
sparepart,pleasecontactJohnsonandStarleySparesDepartmentattheaddressbelow.
JOHNSON&STARLEYLTD.
Telephone: [phone] RhosiliRoad,
Brackmills,
Fax: [phone] NorthamptonNN47LZ

227
Installationshallbein accordance withthecurrenteditionsof:
Building Standards (Scotland) (Consolidation) Regulations
Building Regulations
Gas Safety (Installation and Use) Regulations (as amended)
BS7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations
BS6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases).
BS5440 Pt.1 (Flues for GasAppliances)
BS5440 Pt.2 (Air Supply for GasAppliances)
BS5864 Installation of Gas Fired DuctedAir Heaters
British System Design Manual “Gas Fired Warm Air Heating”
Model and Local Authority Bye-laws
BS5546 Installation of Domestic Hot Water Supplies.
IMPORTANT:STATUTELAWDEFINESTHATALLGASAPPLIANCESMUSTBEINSTALLEDBYCOMPETENTPERSONS,
(i.e.GASSAFE REGISTEREDINSTALLERS)INACCORDANCEWITHTHEGASSAFETY
(INSTALLATIONANDUSE)REGULATIONS(CURRENTEDITION).FAILURETOCOMPLYWITHTHESE
REGULATIONSMAYLEADTOPROSECUTION.
2. HEATER COMPARTMENT AND CLEARANCES (SEE BS5864)
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 15mm at the sides and rear,
and 25mm 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 450mm (18ins) 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 be not less than 75mm (3 in). However, if 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.
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 BS5440: Part 1).
2.5 In under-stairs installations, the compartment must comply with the relevant section of BS5864, 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 than two storeys.
2.6 If the Air Heater is to be installed onto a combustible surface, a suitable base tray (BT25) is required. However, when a base
duct is used, this provides sufficient protection for combustible material and no further insulation is required.
3. VENTILATIONANDCOMBUSTIONAIR
3.1 The room or internal space in which the heater is installed requires a permanent air vent of minimum effective area 36cm2
(5in2). 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 100mm (4in) 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 0.0083m3/
s (17.6cfm), (i.e. 1.06m/s [210ft/min] velocity in a 100mm [4in] 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, and assuming that a HIJAN6
circulator is fitted. If a SUPERJAN 6 circulator is fitted, the minimum area is greater, and reference made to the relevant
installation instructions for the circulator.
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.

3
CONTROLS Tick the appropriate boxes if applicable
Time & Temperature Room Thermostat & Programmable Load/Weather Optimum Start
Control to Heating Programmer/Timer Roomstat Compensation Control
Time & Temperature Cylinder Thermostat & Warm Air
Control to Hot Water Programmer/Timer Unit
Heating Zone Valves Fitted Not Required
Hot Water Zone Valves Fitted Not Required
Thermostatic Radiator Valves Fitted Not Required
Automatic Bypass System Fitted Not Required
Warm Air Unit Interlock Yes No If YES, Volume Litres
* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent
Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
WARM AIR HEATER AND CIRCULATOR COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the warm air unit and associated equipment as a means of
demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name
Address
Telephone Number
Warm Air Unit Make and Model
Warm Air Unit Serial Number
Commissioned by (print name) Gas Safe Reg. No.
Company Name Telephone No.
Company Address
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate*:
Building Regulations Notification Number (if applicable)
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm demonstration of equipment and receipt of appliance instructions)
FOR WARM AIR HEATERS ONLY
Has the system been balanced in accordance with the heater manufacture’s instructions? Yes No
Was an anemometer used? Yes No
Have balancing dampers been fitted? Yes No
FOR WARM AIR HEATING: MEASURE AND RECORD
Burner operating pressure mbar
Heat input kW
Temperature difference between return air inlet and nearest outlet °C
FOR HOT WATER GENERATORS: MEASURE AND RECORD
Burner operating pressure mbar
Heat input kW
Water flow temperature °C
ALL INSTALLATIONS
The heating and hot water system complies with the appropriate Building Regulations Yes
The system and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
The efficient operation of system and its controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
4 DUCT SYSTEM
(See British Design Manual- Gas Fired WarmAir Heating)
4.1 RETURNAIR
4.1.1 It is NOT recommended that the return air duct be routed directly from the main living area, but from a convenient
central area serving the remainder of the dwelling.
4.1.2 All return air shall be POSITIVELY ducted from outside the compartment to the top of the unit via a return air duct.
Where required, return air can be ducted to the side of the heater by transferring the return air spigot. Refering to fig.
9 (page25), remove the 4 x knockouts and use the return air spigot as a template in order to mark out where to cut the
heater casing. Using a 2.9 mm bit, drill the fixing holes and secure using the previously removed screws. Fit the
supplied blanking plate to the top of the heater and secure using the screws supplied with the blanking plate. NB
removeswarfefromtheairheatercompartmentpriortoinstallationandcommissioning!
4.1.3 The return air system should be constructed of fire-resistant material. The flue shall not be run through an area
serving as a return air path. It is extremely important that the correct size of return air grilles and ducting is used. For
heaters on maximum output the return air duct size should not be less than the equivalent of 200mm x 200mm ( 8" x
8"). If flexible duct is used the duct diameter should not be less than 250mm (10") dia. The return air grille should
have a free area of not less than 645cm2(100in2).
4.1.4 An adequate and unobstructed return air path is essential from areas not served by a directly ducted return and to
which warm air is delivered.All such rooms should be fitted with relief grilles which have a free area of 0.0088m2/kW
(1in2/250Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms and WC.’s.
4.1.5 The return air duct should allow for ease of removal for access to the flue.
4.1.6 All duct work in the room or internal space in which the heater is installed shall be mechanically secured, and sealed
with ducting tape.
4.2 WARMDELIVEREDAIR
4.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (2in) fibreglass or similar. If short extended
duct runs are taken below floor level these should be similarly insulated, and in addition wrapped with a sound
vapour proof barrier, and protected from crushing.
4.2.2 The duct system should be carefully designed (as given in the 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 installed using the least number of fittings to minimise airflow resistance. The base duct,
which equalises the air pressure to supply ducts, shall be constructed to support the weight of the heater, which
shall be secured to the plenum with screws on at least two sides, and sealed using self-adhesive foam strip, ducting
tape or sealing compound. All ducting and blanking plates shall be mechanically secured and sealed.
5. INSTALLATION REQUIREMENTS
Note: For circulator Installation Instructions, refer to the relevant instructions provided with the circulator.
5.1 FLUES(SEEBRITISHSTANDARDSBS5440PT.1FLUES)
5.1.1 All joints shall be soundly sealed.
5.1.2 The flue should be kept as short and warm as possible.
5.1.3 Sufficient support brackets shall be installed to bear the weight of the total flue system.
5.1.4 The spigot connection of the heater draught diverter will accept internally the spigot end of a non-asbestos flue to
BS567ortwinwallmetalfluetoBS715ofnominal100mm(4in)diameter.
Ventilated from inside
building.
Low level grille 284cm2(44in2)
High level grille 142cm2(22in2)
Ventilated from
outside building.
Low level grille 142cm2(22in2)
High level grille 71cm2(112)
Table1:MinimumEfectiveAreas

254
SIDE VIEW
BASE VIEW
FRONT VIEW
TOP VIEW
995
32
60
88
300
51
2
0
6
5
0
1
0
254
376
120 dia.
90
440
6
9
5
300
38
413
25622
10
253
21
393
115
393
512
5
9
3
6
0
0
6
7
0
Fig. 9
Principal Dimensions
5.1.5 A split collar should be fitted to provide for flue maintenance or inspection.
5.1.6 The flue shall be in accordance with the Building Regulations and British Gas Materials and Installations specifica-
tion 3rd edition) with regard to clearance and shielding from combustible materials.
5.1.7 All materials shall be in accordance with Building Regulations requirements.
5.1.8 The flue should run as vertically as possible. Horizontal runs should be avoided if at all possible and any directional
change should be as gentle as possible. If there is any doubt about the flue configuration, the equivalent flue height
should be determined (see 5.1.10).
5.1.9 If the appliance to be fitted is a replacement, the old appliance should be checked for signs of spillage prior to
commencement of the installation and appropriate action taken, (i.e. check flue system and renew as necessary).
5.1.10 It is recommended that at least 600mm of vertical flue should be provided from the top of the draught diverter (for
new installations this shall be incorporated into the flue design). However, when carrying out replacement
installations, an existing flue system may be encountered, where the vertical flue above the appliance to the first
bend is less than 600mm. In the first instance, the installer must judge whether this distance 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). Every effort must be made, however, to ensure that the
existing flue complies in every other way to BS 5440 Part 1, including the visual inspection, flue flow and spillage test
described in 4.3.2 of the above standard. Flue configurations may be assessed in terms of equivalent vertical height -
details are given below. For air heaters, the minimum equivalent vertical height is 1 metre. The installer must make a
judgement based on his knowledge and experience and the examination and testing described above as to whether
an existing flue system can be used.
Note: Ventilation of the compartment, room or internal space in which the appliance is to be installed must be checked for
compliance with the requirements of BS 5440 Part 2, ( Ref. Section 3 of these instructions) and upgraded as
necessary.
5.1.11 Calculation methodforfluesizing:(BS5440: Part1,AppendixA)
a. This appendix provides a procedure for estimating whether a given flue design is likely to ensure full
clearance of combustion products.
b. The procedure is based on calculating the ‘equivalent height’ of the flue under consideration, i.e. that height
of the straight vertical circular flue pipe of specific size which will produce the same flow rate as the flue
under consideration. The equivalent height is calculated from the formula:
(Ki+ Ko )e
He= Hax
(Ki+ Ko)a- KeHa+ Sum K
where:
Heis the height of the equivalent flue;
Ha is the vertical height of the actual or proposed flue;
Kiis the inlet resistance of the flue;
Ko is the outlet resistance from the flue;
subscript e refers to the equivalent flue diameter;
subscript a refers to the actual or proposed flue diameter;
Keis the resistance per unit length of the equivalent flue;
Sum K is the resistance (other than the inlet and outlet resistance) of the actual or proposed flue.
Note: K and Sum K are obtained from Table 2. Koand Kiare obtained from Table 3.
c. Table 2 gives resistance factors for common flue components for use in the formula. Table 3 contains the
appropriate inlet and outlet flue resistances. The flue is likely to be satisfactory if its equivalent height exceeds 1m.
d. WorkedCalculationExample:
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):
Fromtable3:
Kia Inlet resistance of actual flue . . . . . . . . 2.5
Koa Outlet resistance of actual flue . . . . . . 2.5
Kie Inlet resistance of equivalent flue . . . . 2.5
Koe Outlet resistance of the actual flue . . . 2.5

24 5
Fig.8b
Basic Control Circuit Diagram
20 19 18 17 16 15 14 13 12 11 10 9 87 654 32 1
bk bk bbrr br br brb b
bk
0V NL LNLNGE T
24V
r
Cleanflow
Fan
Delay
Control
230v
Multi-
functional
control
230v
Limit
control
230v
Water
pump
230v
Water
Heater
230v
50Hz
Mains
Supply
Th/Stat.
230v
Timed
Test
br
br
Earth
1
Earth
2
ANCILLARIES
Link Cont. 230v
to A
A. N. N. L.
Continuous.
Fuse
T3.15A
g/y
p/r
or
or
bkbkbk br
r
bb
b
y
y
y
y
ybk v
w
r
p/r
wr
or v
y
or
ON OFF
r
y
bbr
b
b
b b
p/r gy
gy
br br
br
r
br
br
br
r
Sleeve
FROST
or
ANTI-HYPO.
Issue 02
Wire Colour Code
blue ----b black -----bk red ----r
brown ---br violet ---v black/white ---bk/w
grey ----gy white ----w purple/red ---p/r
orange ---or yellow ----y
b
Butt
Conn.
Butt
Conn.
TTB TTB
WH
S9
AH
S8 S7
Cont. Off
When
fitted
Timed
r
gy
S6
S3
S5
S2
SAC
S4
S1
w
w
nc
C5 When
fitted
gy
C3
b
C2
br br
Voltage Selector
b
C1
M
Fuse
T500mA
24v 0v
24v Relay
Module
N/C N/O
Comm.
TX1
TX2
24V 0V
L
N
230v
N
6VA Double Bobbin
Auto Transformer
g/y
bk
bk
FAN
Fromtable 2:
Other resistances of actual flue:
Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Pipebend ( 2 x0.61) . . . . . . . . . . . . . . . . . . . . 1.22
Pipe (4x 1m @ 0.78) . . . . . . . . . . . . . . . . . . . 3.12
(5x 0.3m @0.78) . . . . . . . . . . . . . . . . . . 1.17
SumK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01
Equivalent height :
Fromthe formula
(2.5 + 2.5)
He=6.2 x
(2.5 + 2.5) - (0.78 x 6.2) + 8.01
He= 3.793 This flue exceeds 1.0m equivalent height and is therefore satisfactory.
Component Internal Size (mm) Resistance Components Internal Size (mm) Resistance
Flue Blocks
197 x 67 0.85 per metre
45obend
100mm pipe 0.61 per fitting
231 x 65 0.65 run 125mm pipe 0.25 per fitting
317 x 63 0.35 150mm pipe 0.12 per fitting
140 x 102 0.60 197 x 67 0.30 per fitting
200 x 75 0.60 231 x 65 0.22 per fitting
183 x 90 0.45 317 x 63 0.13 per fitting
Pipe
100 0.78 Raking Block Any 0.30 per block
125 0.25
150 0.12 Adaptor Block Any 0.50 per block
Chimney 213 x 213 0.02
Terminal
100mm ridge 2.5
125mm ridge 1.0
90oBend
100mm pipe 1.22 per fitting 150mm ridge 0.48
125mm pipe 0.50 per fitting 100mm GCI 0.6
150mm pipe 0.24 per fitting 125mm GCI 0.25
150mm GCI 0.12
Appliance Inlet Resistance (Ki) Flue Outlet resistance (Ko)
100mm Dia Spigot 2.5 100mm 2.5
125mm Dia Spigot 1.0 125mm 1.0
150mm Dia Spigot 0.48 150mm 0.48
Table2
Resistance factors for use in calculating equivelent lengths
Table3
Inletandoutletresistance

6
1.6m
4.6m
Ha=6.2m
RidgeTerminal
2x300mmlengths
4x1000 mm lengths
45Obend
45Obend
2x300mmlengths
300mmlength
Flue spigot
100mmdiafluepipe
(Exampleonly)
23
Fig. 2
Workedexample of equivalent flue hight
Fig.8a
SystemETCircuitDiagram
Note: Ventilation of the compartment, room or internal space in which the appliance is to be installed must be checked for compli-
ance with the requirements of BS 5440 Part 2 ( Ref. Section 3 of these instructions) and upgraded as necessary
5.1.12 Consideration must be given to external flues with a view to prevention of condensation and weathering problems.
5.1.13 An approved terminal should always be used; a ridge terminal or “GC1” terminal is specifically recommended. The
latter should be positioned in a free air space where it is not shielded by any structure. A minimum of 1m (3ft.) from
any vertical or inclined roof structure must be allowed for.
5.1.14 Where flue blocks are used, builders should ensure that no obstruction is created during erection. The installer
should ensure that the connection flue does not project beyond the internal wall of the flue blocks and that there is
provision for examination and servicing.
5.1.15 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 and windows in the room in which the appliance is to be installed;
b. introduce some heat into the flue, using a blow torch or other means;
c. carry out a flow visualisation check with a smoke pellet at the intended position for the appliance. Ensure that
there is discharge of smoke from the correct terminal only, and no spillage into the room. Smoke coming out of
other than the correct terminal only, or a down draught or ‘no flow’ condition, indicates that the flue has failed
the test, and the appliance shall not be connected until the defect has been found and rectified, and the test
satisfactorily completed.

722
Fig.7b Basic Control
FunctionalDiagram
EXTERNAL PROG.
OPTIONAL
NO CLOCK
OPTIONAL
Park S8 when no
water htr. or
for ext. prog.
N
C1 230V
N
WH
Timed
230V Cont.
AH(S5)
Timed
C2
C3
C5
S8
CH
WH
Park conns when no
clock fitted or for
external prog.
M
M
4
18
14
12
19
7
8
15 230V
Multi-functional Control
20
10
6
Wire colour code where indicated
*FELV Functional Extra-Low Voltage
pink----------pk
red-----------r
blue---------b
black-------bk
brown------br
white-------w
grey-------gy
orange---or
violet------v
yellow-----y
black/white------bk/w
purple/red-------p/r
green/yellow----g/y
N
N
N
N
N
N
N
CLOCK
230V
Continuous
C4
C2
C5
C1
C3
Link
gy
gy
b
r
bk
w
w
br
br
or
or
br
br
bk
p/r
p/r
y
r
y
v
r
bk
bk
br b
w
or
r
r
r
r
bk
T3.15A
FUSE
br
br
S4
S6
S5
T
1
0
AIR
HTR.
S7
S9
S8
T
1
0
WATER
HTR.
L
Voltage
Selector
TX2
TX1
Summer
Air Flow
S3
ON S1
OFF
S2
10
0
Limit
Switch
Fan Delay
Control
Fan
24V
0V
(Optional)
SW
Comm.
n/o
24V
Cleanflow
Air
Cleaner
T500mA
Relay Module
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
230V 50Hz
Supply
TIMED
230V
Cont.
L
N
N
N
N
T
L
N
24V
0V
GE
L
L
Room Thermostat
Water Heater
(Optional)
Water Pump
(Optional)
Limit Switch
Multi-functional
Control 230v
Fan Delay
control
Cleanflow
(Optional)
A
24V Thermostat
(Not Fitted)
FELV * Connection
13
r
br
17
230V
PUMP
230V
(Optional)
Water
Htr
N
LN
(Optional)
5.2 ELECTRICAL
5.2.1 Mains.
a. The heater is supplied with mains cable (PVC sheathed, heat resisting to 85oC), 3-core Brown-Blue-Green/
Yellow, 6A, 0.75mm2), connected to a terminal block and exiting through the heater at the right hand top. 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. The Fan Delay Control and Limit Switch are not adjustable and are set as follows:
i. Basic Models: Fan Delay Control closes at 54OC± 4.5OC; opens at 40OC±3OC.
ii. All Models: Limit Switch opens at 80OC; closes at 60OC.
c. SYSTEM E-T MODELS: An electronic controller (Thermista-stat) is supplied which acts as a room thermostat.
d. BASICCONTROLMODELS:A24Vroom thermostat (not supplied),thatcomplies with BS800, BS3955 and
BS4201 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.
5.2.2 Thermista-stat/RoomThermostatanditslocation.
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. Connect Thermista-stat/Room thermostat wires to control panel terminals ‘7’ and ‘8’ (see Fig. 7a/b or 8a/b).
5.2.3 IMPORTANT:SUPERJAN6circulator.
a. If the air heater is fitted with a SUPERJAN 6 circulator, this will contain a pump overrun switch (CK6), which
is connected via the air heater terminal block terminals ‘6’, ‘10’ and ‘12’. Ensure that the red wire link
connecting terminals ‘10’and ‘12’ has been removed, as this would cause the effective short circuit of the
pump overrun switch.
5.3 GAS (SEE BS5864AND BS6891)
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 BS6891).
5.4.2 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).
5.4 DRAUGHTDIVERTER&DEFELCTORPLATE:
5.4.1 The HI-SPEC J25 heater is supplied with a draught diverter that requires fitting to the rear of the heater prior to
installation, using 3 x 4mm screws and lock washers (provided).
5.4.2 The deflector plate prevents spillage from the draught diverter in the event of a leak between the air heater and the
base plemum and MUST be fitted as shown in fig 3 using the pre-drilled holes and the 2 x No8 screws provided.
5.5 DEFLECTORPLATESAFETYCHECK:
In order to ensure that the deflector plate is preventing warm air from entering the draught diverter and therefore causing spillage,
the following test MUST be carried out BEFORE commissioning:
5.5.1 Turn on the power supply to the heater.
5.5.2 Set the summer airflow switch to “on”.
5.5.3 Using a smoke match, introduce smoke into the heat exchanger at the burner opening.

821
130mm
Heater
Deflector
Plate
Fig. 3
DeflectorPlate
Fig.7aSystemET
Functional Diagram
EXTERNAL PROG.
OPTIONAL
NOCLOCK
OPTIONAL
ParkS8 when no
water htr. or
for ext. prog.
N
C1230V
N
WH
Timed
230VCont.
AH(S5)
Timed
C2
C3
C5
S8
CH
WH
Parkconns when no
clockfittedor for
externalprog.
M
M
Spill
Switch
(TTB)
4
33 3
21
15
13
27
31
PCB
PCB
30
12
10
6
Wire colour codewhere indicated
*FELV FunctionalExtra-LowVoltage
NOTE:-
pink-----------pk
red------------r
blue----------b
black---------bk
brown--------br
white---------w
grey----------gy
orange-------or
violet---------v
yellow--------y
black/white------bk/w
green/yellow----g/y
N
N
N
N
CLOCK
230V
Continuous
C4
C2
C5
C1
C3
gy
gy
b
230V
Timed
PCB
PCB
22 PCB
29
PCB
br
w
br
bk
r
r
bk
br
If Superjan fittedremoveredwire link
between terminals. 10&12
br
or
S4
S6
S5
T
1
0
AIR
HTR.
230V
PUMP
r
r
br
S7
S9
S8
T
1
0
WATER
HTR.
230V
(Optional)
(Optional)
(See note)
SW
Water
Htr.
A
18
14
17
r
bkor
br br b
Multi-functional
Control
br
br bk
Limit
Switch
Fan Delay
Control
M
N.BMaybe
fittedwith start/run
capacitor.
Air
Fan
Fan power
cap.
230V
7
23 PCB
24PCB
pk
bk
pk
pk
r
ONS3
N.BBreaking conn
starts fan
1
O
0
Summer Air
Flow
OFF S1
S2
th
Room
Thermista-stat
FELV *
Connections
8
33
32
31
30
29
28
27
26
25
24
23
22
2117
18
S1
8
19
20
S5
4
N
System E-T
PCB
Suppressed
230VSupply
Fan
Gas
Cleanflow
24V
Thermista-stat
FDC
L
N
2
1
L
N
GE
N.C
PCB
Power
Link
N
Timed
230V
Cont.
A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
230V50Hz
Supply
N
T3.15A
FUSE
br
b
br
MAINS
FILTER
1
Lbr
N
N
T
L
N
24V
0V
GE
L
L
Room Thermista-stat
Water Heater
(Optional)
Water Pump
(Optional)
Limit Switch
Multi-functional
Control230v
Fan Delay
Control
Cleanflow
(Optional)
TEST
R1
27K0
25 19
26 20
yr
v
PCB
PCB
24V
0Vbk
(Optional)
Cleanflow
Air
Cleaner
N
(TTB)
Spill
Switch
5.5.4 Ensure that the smoke is drawn into the
heat exchanger and not blown back from
the burner opening.
5.5.5 If smoke is blown back from the burner
opening, check for air leaks between the
heater and the base plenum, paying
particular attention to the rear of the heater
directly beneath the draught diverter.
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 SYSTEMBALANCING:
6.2.1 Set the Air Heater electrical supply ON.
6.2.2 Set the SUMMERAIRFLOW switch to ‘1’.
6.2.3 Balance the system to provide the required volume proportions at the warm air outlets.
Note: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/min), except for very
small rooms, (i.e., bathrooms etc.). Outlet faces may require partial blanking in order to achieve this.
6.3 IGNITIONOFPILOTANDMAINBURNERS:
WARNING: IfthePilot Bight isextinguishedeitherintentionallyorunintentionally,noattemptshould be madetorelightthegas
fora minimum of3minutes.Ensurethatthe Electrical supply, timecontrolandSelectorswitches aresetto‘OFF’.
6.3.1 Set the Thermista-stat/room thermostat to its 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.
5).
6.3.3 Turn the heater Gas supply ON, test for gas soundness and purge the whole gas pipe as described in BS6891.
6.3.4 Referring to Fig. 5, partially depress the OPERATING CONTROL and set the control 1/4turn anti-clockwise to the
‘SPARK’symbol. Press and hold the OPERATING CONTROL, and whilst observing the Pilot Burner, repeatedly
press the Piezo igniter button until the Pilot Burner ignites.
Note: If the Piezo unit should fail to spark, the Pilot Burner may be lit by applying a lighted taper to the Pilot Burner whilst the
OPERATING CONTROL is pressed and held.
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 depressed for a longer period, until the Pilot Burner remains alight.
6.3.6 With the Pilot Burner lit, depress the OPERATING CONTROL and turn it to the position indicated by the flame
symbol.
6.3.7 Ensure that the pilot flame envelops the thermocouple tip, if not, check that the pilot orifices and aeration port are
free from obstruction. The pilot is factory set and is non-adjustable.
6.3.8 Set the air heater Electricity supply ON.
6.3.9 Set the Time Control to the required Heating On periods.
6.3.10 Set the Selector switch to ‘TIMED’.
6.3.11 Set the Thermista-stat or room thermostat to MAXIMUM.
6.3.12 Ensure that the Main Burner has now ignited.

920
FAN RUNS BUT MAIN BURNER NOT OPERATING
Y
IS
‘SUMMER
AIRFLOW’
SWITCH
SETTO
‘0’
NSET‘SUMMER
AIRFLOWSWITCHTO
‘0’
IS
THERMISTA
-STAT
CONNECTED
IS
THERMISTA
-STAT SET
TOSUMMER
AIRFLOW
Y
NCONNECT
THERMISTA-STAT
SETTHERMISTA-STATTO
REQUIRED
TEMPERATURESETTING
NFAULT
CLEARED
Y
Y
DISCONNECTTHERMISTA-STATAT
TERMINALS‘7’&‘8’,LINK
TERMINALS‘7’&‘TEST’
DONOTLINK‘7’&’8’
DOES
FANSTILL
RUN?
DOES
FANSTILL
RUNWITH
BURNER
LIT?
N
CHECKTHERMISTA-STATWIRING.IF
OK,REPLACETHERMISTA-STAT.IF
NOT,RECONNECTTERMINALS‘7’&
‘8’,ANDSETTHERMISTA-STATTO
DEMANDHEAT
Y
HAS
BURNER
LIT?
REPLACEELECTRONIC
MODULE.RECONNECT
THERMISTA-STAT
FANOPERATESAFTERBURNERHAS
RAISEDTHEINTERNAL
TEMPERATURETOCAUSETHEFAN
DELAYCONTROLTOOPERATE
HAS
FANSTOPPED
ANDBURNER
LIT?
Y
Y
Fig. 4
Pilot BurnerAssembly
Thermocouple
Electrode
PilotBurner
Aeration Port
1
2
3Sit
EV2
Fig. 5
MultifunctionalControl
1. Operating control
2. Burner pressure adjuster
3. Outlet pressure test pont
6.3.13 Test for gas leakage at the supply,
Multifunctional Control, Pilot and Main
Burners using a proprietary detection
fluid, sealing any leaks found.
6.3.14 Allow the heater to operate for a minimum
of 15 minutes to ensure stability.
6.4 MAINBURNERPRESSURETEST:
NOTE:AIRHEATERBURNERSAREFACTORYSET
TOPROVIDEANOMINALHIGHRATEOUTPUTAS
DETAILEDINSUB PARA1.2
6.4.1 Referring to Table 4 and Fig. 5 below,
ensure that the pressure test gauge
indicates the correct burner pressure,
resetting if required as follows:
At the Multifunctional Control:
i Remove the Burner Pressure
Adjuster cover.
ii. Set the Burner Pressure Adjuster
to provide a pressure test gauge indication for the correct burner pressure as detailed in Table 4.
iii. Refit the Burner Pressure Adjuster cover.
6.4.2 Apply the pressure set arrow to indicate the appropriate
burner pressure on the data badge.
6.5 EXTINGUISHINGOFPILOTANDMAINBURNERS:
6.5.1 On the Multifunctional Control, rotate the OPERATING
CONTROL clockwise to the ‘l’ position and ensure that
the OPERATING CONTROL fully resets and both Pilot
and Main Burners are extinguished.
6.5.2 On the Multifunctional control, remove the pressure test
gauge and refit the Outlet Pressure test point cover.
6.6 TEMPERATURERISECHECK:
6.6.1 Ignite the Pilot and Main Burners and allow 15 minutes
for stability before continuing.
6.6.2 Check that the temperature rise across the heater is
between 45oC - 55oC, setting the fan speed as follows:
i. SYSTEM E-T heaters: System E-T provides a fan
speed corresponding to the above temperature
rise, if the appliance is to be set to operate at the
minimum rate and the ducting has been sized
accordingly, set the ‘RATE SWITCH’to ‘MIN’,
thus reducing the fan speed.
ii BASIC Control heaters, the fan speed is adjusted
by selecting the fan speed at control panel
(decrease voltage selection to decrease fan
speed).
Note: Tapping1=230V,Tapping2 = 220V,Tapping 3 =210V,
Tapping4= 200V,Tapping 5 =190V,Tapping 6=170V.
6.7 AUTOMATICCONTROLSCHECK
6.7.1 Set the TIMECONTROL to ‘ON’.
6.7.2 Turn the Thermista-stat or room thermostat slowly
clockwise until the Main Burner ignites.
6.7.3 Ensure that the fan starts to operate after a short period
(approx.1-2 minutes).

1910
FAN OPERATES BUT BURNER CYCLES BEFORE REQUIRED TEMPERATURE IS REACHED
DOES
THEBURNER
CONTINUETO
CYCLE?
REPLACE
THERMISTA-STAT N
CHECKRETURNAIRPATH
FORRESTRICTIONS
Y
CHECKTEMPERATURERISE.IF
LESSTHAN60OC,LINK
TERMINALS‘13’&‘14’
Y
DOES
THEBURNER
CONTINUETO
CYCLE?
DOES
THEBURNER
CONTINUETO
CYCLE?
Y
NREPLACEFANDELAY/
LIMITCONTROL
REPLACE
ELECTRONICMODULE
DISCONNECTTHERMISTA-STATAT
TERMINALS‘7’&‘8’,LINK
TERMINALS‘7’&‘TEST’
DONOTLINK‘7’&’8’
REPLACE
ELECTRONICS
MODULE
N
CHECKFOR
VOLTAGEAT
TERMINALS30&31
MAIN BURNER ON BUT FAN NOT RUNNING
Y
N
BRIDGEOUT
FANDELAYAT
TERMINALS21 &22
Y
REPLACEFAN
DELAY/LIMIT
CONTROL
DOES
FAN
START?
DOES
FAN
START?
REPLACE
FAN
N
REPLACE
CAPACITOR
SYSTEME-Tmodels:
6.7.4 Ensure that the fan speed increases to full speed.
6.7.5 When the temperature reaches the control setting, check that the Main Burner cycles ON and OFF, at approximately
75 to 120 seconds.
BASICCONTROLmodels:
6.7.6 When the temperature reaches the control setting, ensure that the Main Burner extinguishes followed by the fan
switching off after a short period.
6.7.7 When the temperature falls below the control setting, ensure that the Main Burner re-ignites followed by fan
operation.
6.8 SAFETYCHECKS:
6.8.1 Check for gas soundness within the appliance.
6.8.2 Spillage test: Carry out a full spillage test as follows, and ensure that the flue operates effectively with all doors
closed and any extractor fans in operation.
NOTE: If an extractor fan is situated in an adjoining or adjacent room, carry out the spillage test with the interconnecting doors
open.
Ifthedraught diverterisaccessible:
a. Introduce smoke into the draught diverter adjacent to an exit from the heat exchanger, by means a smoke
match or puffer.
b. Ensure that there is no spillage present (indicated by displacement of smoke downwards and out of the
draught diverter).
If the Draught Diverter is not accessible:
a. Introduce smoke, by means of part of a smoke pellet on a non-combustible support, into the heat exchanger.
b. Extinguish the Main and Pilot burners.
c. Ensure that there is no spillage evident by visually observing the draught diverter location on the air heater.
d. If spillage is evident, further investigation and rectification is required before re-testing the appliance.
WARNING:Theappliance shallnot be leftconnected tothegas supplyunless it hassuccessfully passedthe above spillagetest.
6.8.3 Turn OFF the gas supply at the service cock and ensure that the Multifunctional Control fail-safe operates within 60
secs (indicated by loud click from Multifunctional Control).
6.8.4 Turn gas supply ON at service cock.
6.8.5 Switch the appliance electrical supply OFF.
6.8.6 Disconnect the Air Circulation Fan at the flying lead socket.
6.8.7 Switch the appliance electrical supply ON.
6.8.8 Ignite the Pilot and Main Burners as detailed in 6.3.1 to 6.3.5.
6.8.9 Ensure that the Limit Switch operates, indicated by the Main Burner extinguishing, within 120 and 180 seconds.
6.8.10 Switch the appliance electrical supply OFF.
6.8.11 Reconnect the Air Circulation Fan.
6.8.12 Switch the appliance electrical supply ON.
6.8.13 Ensure that the Main Burner re-ignites when the
appliance temperature reduces, (note: with the
Air Circulation Fan disconnected, there may be
some delay before the Main Burner re-ignites).
0.50
mbar
0.20
170V
190V
200V
210V
220V
In wg.
0.15
0.10
0.05
0.375
0.25
0.125
150
0.07200 0.09250 0.12300 ft /min 0.14m/sec
3
3
AirVolume
AirVolume
Table5
FanPerformanceCurve