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Johnson & Starley JB25P MK 5 Installation, Commissioning & Servicing Instructions

Warm air heater
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These instructions are to be left with the User or adjacent to the Gas Appliance
INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS
This appliance is for use with liquid petroleum gas G31, and is approved for use in GB, IE, FR, NL BE & NO,
IMPORTANT: STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED, COMMISSIONED
AND MAINTAINED BY COMPETENT PERSONS, (ie CORGI REGISTERED INSTALLERS) IN ACCORDANCE
WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO
COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
1.
1
4
12 3
6
7
13
10
1.1
JB25P is an open-flued, fan assisted downflow, ducted warm air heater. A Spillage Monitoring Device is fitted which
senses the temperature around 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 is 7.6kW (27.5MJ/h, 26,000Btu/h). "Summer air circulation" of unheated air is available by manual
selection (see User's Instructions).
1.3
For Caravan installations, Slot Fit Kit ATL30 is available for this appliance. For Permanent Dwellings, Free-Standing Kit
TC30 and Slot Fit Kits TS30 and TSA30 are available for this appliance.
JB25P MK 5 WARM AIR HEATER
G.C. No 42 416 13
WARNING: THIS APPLIANCE MUST BE EARTHED
BRIEF DESCRIPTION
16
15
2
14
11
5
9 8
Fig. 1
THIS APPLIANCE CONFORMS TO BS EN 55014
1 Air Filter
2 Air circulating fan
3 Fuse
4 Time control
5 Data plate
6 Fan Delay Control
7 Multifunctional control
8 Pilot burner
9 Main burner assembly
10 Gas connection
11 Limit Switch
12 Control panel
13 Piezo unit
14 Summer air circulation switch
15 Spillage monitor device (TTB) (at rear)
16 Draught Diverter
1
Publication No. ZZ 1031/4
August 2004

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  • Page 1 These instructions are to be left with the User or adjacent to the Gas Appliance JB25P MK 5 WARM AIR HEATER INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS G.C. No 42 416 13 Publication No. ZZ 1031/4 August 2004 WARNING: THIS APPLIANCE MUST BE EARTHED This appliance is for use with liquid petroleum gas G31, and is approved for use in GB, IE, FR, NL BE &...

  • Page 2: Ventilation And Combustion Air

    ZZ1031/4 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...
  • Page 3 ZZ1031/4 VENTILATED Low level grille 184cm (28in FROM INSIDE BUILDING High level grille 92cm (14in VENTILATED Low level grille 92cm (14in FROM OUTSIDE BUILDING High level grille 46cm (7in Table 1: Minimum Effective Areas DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating) RETURN AIR 4.1.1 All return air shall be POSITIVELY ducted from outside the compartment to the top of the unit via a return air duct, and mechanically secured.
  • Page 4 ZZ1031/4 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.
  • Page 5 ZZ1031/4 Appliance Inlet Flue Outlet Resistance (K Resistance (K 100 mm dia spigot 100 mm flue 125 mm dia spigot 125 mm flue 150 mm dia spigot 0.48 150 mm flue 0.48 Table 3 Inlet and outlet resistance Worked Calculation Example: A warm air unit with a 100 mm diameter flue spigot, fitted with a prefabricated flue system leading to a ridge tile (refer Fig.
  • Page 6 ZZ1031/4 Ridge Terminal 2 x 300 mm lengths 100 mm dia flue pipe = 6.2m 4.6m 4 x 1000 mm lengths bend 300 mm length 1.6m bend 2 x 300 mm lengths Flue spigot Fig. 2 Worked example of equivalent flue height ELECTRICAL: 5.2.1 Mains.

  • Page 7: System Balancing

    ZZ1031/4 5.2.2 Room Thermostat and its location. The Room Thermostat should be located where there is free air circulation approx. 1.5m (5ft) from the floor. Avoid the following locations:- 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.
  • Page 8 ZZ1031/4 6.3.10 Set the thermostat to MAXIMUM. 6.3.11 Ensure that the Main Burner has now ignited. 6.3.12 Test for gas leakage at the supply, Multifunctional Control, Pilot and Main burners using a proprietary detection fluid, and sealing any leaks found. 6.3.13 Allow the heater to operate for a minimum of 15 minutes to ensure stability.

  • Page 9: Safety Checks

    ZZ1031/4 EXTINGUISHING OF PILOT AND MAIN BURNERS: 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 secure the Pressure test point screw. AUTOMATIC CONTROLS CHECK 6.6.1 Ignite the Pilot burner.
  • Page 10 ZZ1031/4 MJ/h Btu/h INPUT 34.9 33,100 OUTPUT 27.5 26,000 PROPANE G31 Gas rate cv 0.705kg/h G31 cv(gross) 95.65MJ/m Gas Pressure 26mbar (10.2 in wg) Main Injector BRAY Cat 23/380 Table 4 Main Burner Pressure Settings mbar in wg 0.50 0.20 0.375 0.15 0.25 0.10 0.125 005...

  • Page 11: Maintenance

    ZZ1031/4 MAINTENANCE IMPORTANT: Ensure that the 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 carry out a complete functional test of the appliance in accordance with Commissioning Instructions at Sect 6.1 to 6.7 inclusive. ROUTINE MAINTENANCE: 8.1.1 Operate the appliance and check for the correct function of the burner and controls.
  • Page 12 ZZ1031/4 PILOT BURNER ASSEMBLY, REMOVAL AND REPLACEMENTS: 8.5.1 Remove the Burner and Control Assembly as detailed in 8.2 8.5.2 Disconnect the Igniter lead from the Piezo unit. 8.5.3 Release the Thermocouple locking nuts from the Pilot Assembly and Multifunctional Control, and withdraw the Thermocouple, taking care to avoid damaging the capillary.
  • Page 13 ZZ1031/4 8.10 TIME CONTROL REMOVAL: 8.10.1 Remove the Electrical Assembly as detailed in sect 8.9. 8.10.2 Disconnect the wiring from the Time Control connection block terminals as follows: BROWN conductor from terminal marked ‘L’, BLUE conductor from terminal marked ‘N’, GREEN/YELLOW conductor from terminal marked ‘E’, YELLOW conductor from terminal marked ‘3’, WHITE conductor from terminal marked ‘4’,...

  • Page 14: Defect Diagnosis

    ZZ1031/4 DEFECT DIAGNOSIS IMPORTANT: If an electrical defect occurs after installation of the appliance; preliminary earth continuity, polarity, and resistance to earth checks should be carried out with a multimeter. On completion of any maintenance/fault-finding task that has required the breaking and remaking of electrical connections, then checks of continuity, polarity, and resistance to earth must be repeated.
  • Page 15 ZZ1031/4 h. Pilot alight but main Mains electrical supply not Check mains supply. burner not igniting. connected to heater. Controls not demanding heat Check that time control (if fitted) and room thermostat are operating correctly. iii. T3.15A fuse failed. Replace. If failure occurs again, check wiring for short circuits.
  • Page 16 ZZ1031/4...
  • Page 17 ZZ1031/4 Fig. 6, JB25P Mk 5 FUNCTIONAL DIAGRAM...
  • Page 18 ZZ1031/4 Fig. 7, PRINCIPAL DIMENSIONS (mm)

  • Page 19: Short List Of Spares

    SHORT LIST OF SPARES ITEM G.C. MAKER’S DESCRIPTION 381 732 1000-0500130 Fan assembly 244 925 B300-0182000 Filter tray assembly 232 962 CL2S Time control CL2 244 926 1000-0000070 Time control cover 384 739 BOS 00105 Limit Switch Honeywell L4069C H26-712 1000-0709640 Multifunctional control Honeywell V8600C 1129...

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