Publication ZZ1183-12 June 2010
Product Identification No: 87B 074
Johnson & Starley
COMBI SERIES
High Efficiency Combination Boilers
Installation, Maintenance & Service Instructions
Natural Gas G20:
Propane G31 Variants:
HE30C - GC No: 47-416-01
HE30CP - GC No: 47-416-04
from Serial No. 68009184
from Serial No. 71000116
HE37C - GC No: 47-416-02
HE37CP - GC No: 47-416-03
from Serial No. 74000328
from Serial No. 83000108
The Johnson & Starley Reno
range has an energy rating A on
a scale of A to G.
For more information see
www.boilers.org.uk
This is a certification mark.
www.energysavingtrust.org.uk
R E L I A B I L I T Y
Y O U
C A N
T R U S T
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CONTENTS
Section
Description
Page
1.
Important Information
3
2.
Appliance Description
3
3.
Fitting
9
4.
Commissioning and Handover
20
5.
Servicing Schedule
21
6.
Fault Finding & Repair
23
7.
Short Spare Parts List
32
THE BENCHMARK SCHEME
In order to comply with Building Regulations Part L (Part J in Scotland) the boiler MUST be fitted in accordance with
the manufacturer’s instructions.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance
with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate
Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations
and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark
Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the
Scheme. Visit www.centralheating.co.uk for more information.
Johnson & Starley Ltd, Rhosili Road, Brackmills, Northampton, NN4 7LZ
Tel: 01604 762881
Fax: 01604 767408
Sales Fax: 01604 764879
www.johnsonandstarley.co.uk
Johnson & Starley reserves the right to change specification without prior notice.
2
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1. IMPORTANT INFORMATION
IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, (i.e.
GAS SAFE REGISTERED INSTALLERS. GAS SAFE ENQUIRIES - 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.
This appliance has been Tested and Certified in order to meet the necessary European Directives and comply with the
latest Building Regulations, including the efficiency requirements of the SEDBUK scheme.
Efficiency of Hot Water Boilers Directive 92/42/EEC
Gas Appliance Directive
90/396/EEC
Low Voltage Directive
93/68/EEC
Electromagnetic Compatibility Directive
92/31/EEC
No modifications to this appliance should be made, unless they are fully approved by the manufacturer.
The installation of this appliance must be carried out by a competent person and must be in accordance with the current rules in force at the time of installation, in the country of destination.
The manufacturers instructions supplied must not be taken as overriding any statutory requirements.
The weight of this appliance exceeds that recommended for a one-man lift. It will therefore be necessary to gain assistance at times during the installation procedure.
It should be noted that this appliance may contain sharp edges. In order to prevent injury, care MUST be taken when
handling the appliance! We advise the engineer to wear suitable P.P.E.
A two year manufacturers warranty applies to this appliance.
GAS LEAKS. DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPLY. VENTILATE THE AREA BY OPENING DOORS AND WINDOWS. CALL THE NATIONAL GAS EMERGENCY SERVICE ON 0800 111 999.
2. APPLIANCE DESCRIPTION
The appliance is a high efficiency combination boiler that is designed to provide the user with both central heating and
domestic hot water on demand. Its design is such that it is room sealed, taking combustion air from outside and
expelling the products of combustion to the outside again. The heat exchanger is constructed of stainless steel, which
is corrosion free. Flueing options ensure that the appliance can be installed in many locations within a building and a
schematic diagram (2-3) shows the water flow through the boiler.
The appliance is controlled by fully featured microprocessor based electronics that monitor each of the operational procedures. An LCD display indicates the operational state of the appliance which illuminates for a short period when the
user control is operated. This starts with the full sequence automatic ignition and continues with monitoring the
demand requirements of either the central heating or the domestic hot water.
Whilst the appliance is in pre-heat mode it maintains a limited temperature in the heat exchanger in order to quickly
satisfy any domestic hot water demand. Should any fault occur the appliance will be shutdown to a safe condition
with the fault code being displayed on the LCD panel.
2.1 Appliance Safety Devices
Heating System Pressure Relief Valve
The appliance incorporates a pressure relief valve to protect the sealed water system from being over pressurised. The
discharge from this must be piped away to a safe place in accordance with the building regulations. Should there be a
discharge of water / steam from this device, the appliance should be switched off and a service engineer or the
installer called.
Frost Protection
The microprocessor based controls within the appliance monitor the water temperature in order to protect from freezing.
To ensure that this function is active the main switch on the appliance should be left on and the gas supply also left on.
This does not protect remote areas of the heating system, which should be protected by other means (e.g. an independent frost thermostat that is linked back to the appliance).
Overheating Safety
There are a number of overheat safety devices on the appliance. Should any of these operate (see the fault codes table
in section 6.1) you should call a service engineer or the installer
Electrical Supply Failure
In the event of electrical voltage supply failure, the appliance will stop operating but remain in a safe condition. When
the electrical supply is resumed, the appliance will start from its safe off condition and continue to operate in the normal manner under the control of the system components. Should the appliance fail to resume, press the RESET button
to allow the safety control to be reset. Normal operation should then continue.
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3
2.2 Technical Data
Maximum Lift Weight
HE30C
HE37C
34.45 kg
36.5 kg
Gas Connection
15 mm copper
Domestic hot water
15 mm copper
Heating flow and return
22 mm copper
Safety valve discharge
15 mm copper
Condensate Drain
3/4 inch plastic overflow pipe
Maximum heating system water content using fitted
expansion vessel, pressurised at 1 bar.
73 litres
Electrical supply
230V
Electrical rating
145W
IP classification
IP 40
External fuse rating
3A
Expansion vessel capacity
8 litres
Expansion vessel initial charge pressure
1.0 bar
Heating system minimum pressure
0.7 bar
DHW max. inlet pressure
10 bar
Min. inlet pressure for max. DHW flow rate.
1.0 bar
Min. inlet pressure for appliance to operate
0.2bar
Max. DHW flow rate at 35° rise
12.3 l/m
15.2 l/m
Min. domestic hot water flow rate
2.2 l/m
Maximum flow temperature.
63°C
DHW Specific Rate
14.3 l/min
17.7 l/m
Ball valves are fitted in water and gas connections.
For larger systems use an additional expansion vessel
Table 2-1
General Data
Nat Gas G20
HE30C
HE37C
Maximum
Range rating (kW) Output
30.0
37.1
HE30C
HE37C
Minimum
7.0
9.0
HE30C
HE30C
Maximum
30.0
HE37C
Minimum
37.1
7.0
9.0
Case off
9.3*
9.5*
8.4**
8.5**
10.2*
10.2*
9.4**
9.2**
Case on
9.5*
9.8*
8.6**
8.8**
10.4*
10.5*
9.6**
9.5**
* = +0.5
Max gas rate
HE37C
-3.0 (Minus three)**
Offset (Pascal)
Burner CO2 (%)
LPG G31
m3/h
3.2
3.92
0.74
** = Ref Only
0.95
1.28
1.56
0.30
0.34
Table 2-2
Performance Data
4
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Table 2-3
Performance Data (Central Heating)
Nat Gas G20
Maximum
Minimum
HE30C HE37C
HE30C
Maximum
HE37C HE30C HE37C
Minimum
HE30C
HE37C
Net
kW
25.5
30.7
7.14
9.18
26.06
30.7
7.29
9.18
Gross
kW
28.3
34.0
7.92
10.1
28.3
33.3
7.92
9.97
3
m /h
2.6
3.16
0.74
0.85
1.06
1.25
0.30
0.38
Non Condensing
kW
25.0
30.0
7.0
9.0
25.0
30.0
7.0
9.0
Condensing
kW
27.85
32.6
7.76
9.8
27.85
32.6
7.76
9.8
CH Input Q
Gas Consumption
CH Output P
LPG G31
SEASONAL EFFICIENCY (SEDBUK)
‘A’
NOX CLASSIFICATION
Class 5
CENTRAL HEATING SETPOINT TEMPERATURE RANGE
20-820c
Table 2-4
Performance Data
(Domestic Hot Water)
DHW Input Q
Nat Gas G20
Maximum
LPG G31
Minimum
Maximum
Minimum
HE30C
HE37C
HE30C
HE37C
HE30C
HE37C
HE30C
HE37C
Net
kW
30.6
38.0
7.14
9.18
31.3
38.0
7.29
9.18
Gross
kW
34.0
42.1
7.92
10.19
34.0
41.3
7.92
9.97
m3/h
3.2
3.92
0.74
0.95
1.28
1.56
0.30
0.34
Kw
30.0
37.1
7.0
9.0
30.0
37.1
7.0
9.0
Gas Consumption
DHW Output
Please Note:
Natural Gas (G20) consumption is calculated using gross CV of 38.7 MJ/m3 or 34.9 MJ/m3 net.
LPG (G31) consumption is calculated using gross CV of 95.6 MJ/m3 or 88.0 MJ/m3 net.
2.3 Dimensions and Clearances:
425mm
min 180mm
765mm
310mm
5mm
400mm*
5mm
200mm*
Work Surface
Fig. 2-1
Minimum Clearances
* Note: 200mm dimension is a desired workable clearance but can be reduced.
It is recommended that where the appliance is located in a kitchen, or next to other combustible materials, a gap of
5mm be left on either side and where the flue run is through a void in kitchen units, again a minimum gap of 5mm
should be left.
*NOTE - These are recommended clearances when servicing the appliance.
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5
2.4 General Information
Appliance Classification
The appliance is certified as a type C13 C33 C53. As such it can only be installed with the flue components specified
within this document. The flue types are:
and vertical balanced flue using concentric ducts.
• Horizontal
• Air entry and flue exit in zones of different pressure using twin (separate) flue and air ducts.
Gas Categories:
The appliance is certified as a CAT II 2H 3P appliance. This allows conversion between Natural gas (G20) and LPG
(G31). Their supply pressures are 20 mbar and 37 mbar respectively.
For Natural gas to LPG conversion kit number: NG30 (complete with instructions) is available.
For LPG to natural gas conversion kit number LPG30 (complete with instructions) is available.
Statutory Requirements:
The appliance must be installed in accordance with the current editions of:
Standards (Scotland)(Consolidation) Regulations.
• Building
Regulations
• Building
Safety (Installation and Use) Regulations (as amended)
• Gas
7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations
• BS
Installation of Low Pressure Gas Pipework of up to 28 mm (R1) in domestic premises (2nd family gases).
• BSBS 6891
Pt.1 (Flues for Gas Appliances)
• BS 5440
(Air Supply for Gas Appliances)
• Model5440andPt.2
Local
Authority Byelaws
• BS 5546 Installation
of Domestic Hot Water Supplies.
•
Gas Supply:
The gas installation must be completed in accordance with the relevant standards (BS 6891).
The supply must be capable of providing a steady inlet working pressure to the appliance of 20 mbar at a rate of 3.2
m3/h (HE30C) or 3.92 m3/h (HE37C) (Calculated with a Gas CV of 38.7MJ/m3)
The installation must be tested for gas tightness using suitable methods. The pipework should also be purged of air in
accordance with the above standard.
Additional Plumbing Kit for Top Outlet CH Pipes:
Should the installation require the heating flow and return pipes to exit the appliance upwards, provision has been
made to allow the installation of two pipes (flow & return) to pass up the rear left hand side. These pipes can be
made on site or a pre-fabricated pipe kit (VPK30) is available direct from Johnson & Starley should it be required.
Additional Control Options:
A single channel electro/mechanical or digital timing device can be fitted to control the heating periods. Wiring terminals are provided that may be used to connect a room thermostat.
Should an outside temperature compensation system be required, Opentherm kits are available direct from Johnson &
Starley. (Part No 1000-0019720)
2.5 Appliance Location:
The appliance is not suitable for external installation unless it is protected from the elements by a suitable enclosure.
The enclosure must provide the required clearances for installation, servicing and maintenance as well as the correct
level of ventilation. The selected position should allow for a suitable flue system to be installed.
When installed in a timber frame building guidance should be taken from the gas industry publication IGE/UP-7
(Guide for Gas Installations in Timber Frame Housing).
BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to be
installed. An existing cupboard may require modification.
If the appliance is installed in a room containing a bath or shower it is important to locate the electrical switch in a
position where it cannot be touched by anyone using the bath or shower. The current IEE Wiring Regulations (BS
7671) for England and the electrical provision of the Building Regulations for Scotland gives details.
Room ventilation for the appliance is not necessary as the appliance draws its combustion air from outside of the
building and cupboard or compartment ventilation is not necessary providing that the minimum clearances are maintained. However, reference should be made to BS 5440 Pt.2
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6
2.6 Heating System Requirements:
This appliance incorporates all the necessary components to allow it to be connected to a sealed central heating system. Fig 2-2 shows a typical system incorporating radiators, an automatic by-pass valve and a drain facility that must
be provided at the lowest point in the system to allow complete drain down. The domestic cold inlet and hot outlet
are also shown and Fig 2-3 shows the water flow through the boiler. The installation should be designed to operate
with a flow temperature of up to 90 deg.C.
BOILER
Cold Supply
Domestic Water
Hot Out
Filling Device
Expansion Vessel: The integral expansion vessel is precharged to a pressure of between 0.5 and 1.0 bar. This
should be checked before the water system is filled. Details
below show the water system volume that is acceptable for
this vessel. If the system water volume is larger then an
additional vessel must be fitted to the system. BS 5449
and BS 6798 give further details regarding expansion vessel sizing and sealed systems. See table 3-2.
Pressure Gauge: The appliance has two components that
monitor pressure. Firstly there is a mechanical pressure
gauge on the boiler, this allows the heating system to be
pre-plumbed and filled with a visual check on the pressure.
The second is an electronic device used by the microprocessor control to monitor the system pressure and block
the heat input, should there be a lack of pressure.
Additional
Expansion Vessel
(if required)
Heating
Circuit
Automatic Bypass
LCD Display: When the electrical supply is connected, the liquid crystal display indicates the system water pressure. This
pressure is also monitored by the microprocessor controls.
Pressure Relief Valve: The pressure relief valve protects the
system from over pressurisation. It is set to be fully open at
3 bar, however it will start to open at approximately 2.7
bar. It should not be used to flush the system.
Filling Loop: The boiler incorporates a filling loop that temporarily connects the DHW supply to the CH system. This
is used to fill the CH system on installation and whenever
Fig.2-2
Drain Point
the water pressure has been removed for system modificaHeating System
tions, etc. The filling loop complies with the water supply
(water fittings) regulations 1999 Section G24.1 and G24.2. After filling the system the pipe should be disconnected
and stored in a safe place for future use. Fit the cap over the open end.
Pipework Sizing: In order to keep the noise of the system to a minimum, the velocity of water should be kept below
1.5 m/s and it should be noted that the appliance is designed to operate with a temperature differential of 20oC
between flow and return. The maximum flow rates are 0.3 kg/s (HE30C) and 0.38 kg/s (HE37C) which, through a
22mm pipe, gives velocities of 1.00 m/s (HE30C) and 1.25 m/s (HE37C). Therefore, the recommended minimum
pipe size for the main carcass is 22mm.
Water Treatment: It is important that the system is flushed thoroughly before the appliance is left to operate (as recommended in BS 7593) in order to maintain an efficiently operating heating system. For replacement installations,
the system MUST be flushed with the old boiler in situ, in order to prevent the Reno becoming a trap for system
debris. Once the system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added.
Appropriate inhibitors are available, for example Sentinel, Fernox and Salamander.
Failure to carry out the above procedure will invalidate the guarantee!
NOTE: Water supplied from a water softener MUST NOT be used unless a specially formulated corrosion inhibitor is
added (see BS 6798)
Controls: As a minimum, a time clock and room thermostat must be installed to control the appliance. Thermostatic
radiator valves may be fitted to the system, however they must not be fitted in the room where the room thermostat is
fitted. There must be at least one radiator installed with lock shield valves that should not be closed. Further guidance
can be obtained from the Domestic Heating and Hot Water Guide to the building regulations and GPG 302.
NOTE: a differential pressure bypass valve MUST be installed to maintain a minimum flow rate of 18 L/min
(HE30C) or 23 L/min (HE37C) (20o differential at maximum heat input).
2.7 Domestic Hot Water System Requirements:
Domestic hot water circuits and their components, must be in accordance with the relevant standards and water supply regulations. Further guidance/recommendations can be found in building regulations G17 to 24 and R17 to 24.
The maximum domestic cold water supply pressure allowable for this appliance is 10 bar. If the supply pressure
exceeds this, a pressure-reducing valve must be installed in the supply to the appliance.
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7
Fig 2-3
Schematic Diagram
(Waterflow)
8
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3. FITTING
3.1 Unpacking the Appliance:
The appliance is supplied packaged complete in one carton
Caution: this appliance exceeds the recommended weight
for a one-man lift as detailed in the Manual Handling
Operations, 1992 Regulations.
NB: if the pipework is to run behind the boiler and into the
ceiling, you will require J & S kit number SOK1 which will
provide a void at the rear of the boiler.
CARTON CONTENTS
Paper Template
Boiler Kit
•
•
•
Filling Loop Pack
•
Guarantee Card
•
•
•
Combi Boiler
•
Wall Plate
Rawplug/Screw Pack
Installation Instructions
(inc. Benchmark Logbook)
& User Guide.
3.2 Preparing the Wall/Fitting Wall Bracket
Ensuring the wall is flat, unpack the wall template from its
protective sleeve and place it on the wall giving consideration
to: the flue position; water/gas connection positions and clearances. Use the plumb line on the template to ensure it is
square! Mark the positions on the wall of the flue and the fixing points. Using a 105 mm core drill make the hole through
the wall in the correct place. Installations that are made from
within the building only will require a 125 mm diameter hole
in order to fit the flue system.
Using a 7mm bit, drill a total of 4 fixing holes for the wall
plate and insert the rawplugs. Remove the template.
3.3 Wall Plate:
Fix the wall plate to the wall, ensuring it is level and secure
it with the screws provided.
Lift the appliance onto the wall plate and locate the unit on
the two lugs at the top. The boiler then drops into place and
needs no further fixing.
Table. 3-1
3.4 Fitting the Boiler Kit:
Ensure the gas and water connections are in correct alignment. (see Figure 3.1) Connect the gas and water swivel nut
joints. The two remaining connections must now be made.
These are the condensate drain and the pressure relief outlet.
Please note the gas pipe uses the blue washer.
It is acceptable to fit pipes vertically upwards without a
Vertical Pipe Kit (VPK-30) provided the correct route is used.
It is advisable to fit additional isolation valves at the top of
the appliance to allow complete removal of the appliance
and its wall plate. Once the heating system and the domestic water connections are complete the system can be filled,
checked for soundness and flushed. See COMMISSIONING
section.
Figure 3.1
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9
3.5 Condensate Drain:
The condensate drain utilises plastic 21.5mm push fit or adhesive overflow pipes and fittings. It should be piped to
drain, preferably within the building, maintaining a 44mm in 1m fall away from the appliance. If the drain is routed to
outside it should be to a drain or soak away. Protection from freezing in cold weather conditions is also advisable.
NOTE:
* External runs exceeding 3 metres the discharge pipe should be increased to 32mm diameter for complete peace of
mind.
Typical Condense Drain Arrangements:
Internal soil
& vent stack
Min dia 21.5mm no
restriction on length
Min dia 21.5mm no
restriction on length
Boiler
Sink (Constitutes
air break)
Boiler
450mm min
Invert
Min dia 21.5mm no
restriction on length
External length of
pipe 3m max.
(See Note*)
Sink
Boiler
Boiler
Open end of pipe
straight into gully
below ground but
above water level
Min dia 21.5mm
Open end of pipe straight
into gully below ground but
above water level
NB the boiler has a built in condense trap and it MUST be noted that fitting an additional trap to the configurations shown above, may have an edverse effect on the evacuation of condensate from the boiler.
Expansion Vessel Requirements
Vessel charge and initial system pressure
Total water content of system using 8 ltr (1.54 gal)
capacity expansion vessel supplied with appliance.
bar
0.5
0.75
1.0
1.5
ltr
95
84
73
50
0.0833
0.09
0.109
0.156
For systems having a larger capacity multiply the total
system capacity in litres by the factor to obtain the total
minimum expansion vessel capacity required litres.
Table 3-2
10
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3.6 Pressure Relief Outlet:
Using no less than 15 mm diameter copper pipe, the discharge pipe must be extended to a safe place outside the
building. The discharge position must be visible, not onto a public access area or above any window or entrance. The
pipe must have a continuous fall and discharge to a safe place. It is possible that boiling water and/or steam could be
discharged if the safety valve operates.
3.7 Preparing & Installing The Flue Components (100/60 Concentric):
With the appliance fitted to the wall and the gas and water connections complete
IMPORTANT NOTE: Before carrying out procedure ensure seal has not been dislodged from top of heat exchanger.
Horizontal Flues:
Fit the turret to the appliance with the outlet in the correct direction. Measure the distance between the turret centre
line and the outside wall face where the terminal is to be fitted. Using fig. 3-2 assemble and if necessary cut the flue
to the correct length and ensure any seals are made correctly. If fitting from outside the building assemble the outer
wall-sealing disc onto the flue to its correct position. Insert the flue from outside. Fit the inner wall-sealing disc. Using
the clamp arrangement join the flue to the turret, ensuring all the seals are made correctly. The terminal must be
installed with the flue outlet at the top. Brackets are provided for extended flues to locate and fix the flue in position
should they be necessary.
Vertical Flues.
Flat roof:
Measure the distance between the appliance top and the outer surface of the flat roof.
Pitched roof:
Measure the distance between the appliance top and the outer surface of the pitched roof at a point
that is central to the flue. Where necessary cut the flue to the correct length, ensuring that seals are
made correctly.
It is advisable to assemble the roof flashing onto the vertical terminal and inset this from outside the building.
Continue to assemble the remaining flue components and connect to the appliance using the vertical adaptor. Finally
make a good seal between the roof and the flashing piece. Brackets are provided to locate and fix the flue in position
should they be necessary
FOR FULL DETAILS OF FLUE COMPONENTS, PLEASE REFER TO ZZ1191
50.5
Overall Assembled
Flue Length
19
39.5
187.5
100mm
155
93.5
Wall
144
133
281
R.H.Side
Use this distance to
calculate assembled
flue length
Fig. 3-2
Overall Assembled Flue Length = Measured Distance - 93.5mm + 100mm
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11
3.8 Flue Terminal Location:
Both the horizontal and vertical terminals must be positioned on
the outside of the building and the free passage of air must be
available at all times.It is not recommended to position the terminal close to projections especially under a balcony or near to a
drainpipe.
Ensure that combustion products cannot enter the building where
the heater is installed or near to any other building where doors
or windows may be open.
Recommended terminal positions for both horizontal and vertical
flues are shown and flue components and installation options are
also detailed.
For the installation of a vertical flue either a flat or pitched roof
with an angle of between 25° and 50° should be used.
3.9 Flue Components & Fitting Options (60/100 Concentric
Flue System):
The appliance can be purchased with a standard flue kit that
includes: horizontal terminal; turret and fitting kit. Details of
optional flue components are listed in table 3-5 along with their
resistance in Pascals in order that flue length calculations can be
made.
Overall assembled flue length
Where the lowest part of the flue terminal is located less than 2
metres above the ground, a balcony or above a flat roof across
which there is access, the terminal MUST be fitted with a guard
(part No:1000-0019710) which is available from Johnson &
Starley. The distance between the guard and the nearest part of
the terminal must not be less than 50 mm.
Use this measurement to calculate flue length
Gas industry publication: "Guide for Gas Installations in Timber
Framed Housing DM2", or your local gas region, MUST be consulted when installing the appliance into a timber-framed building.
Horizontal and vertical concentric flues (60/100 diameter) with
balanced terminals and vertical and horizontal flues (twin 80
diameter) with the flue and air inlet terminals terminating at least
500 mm apart may be installed on this appliance.
Note: If a twin duct system is to be used (type C5) then the air
inlet and flue outlet must not be on the opposite sides of the
building.
If an extended horizontal flue is being used (any flue length
longer than the standard kit) it must have a continuous fall back
towards the appliance of 2.5°. This ensures that condensate runs
back into the appliance from the flue system.Reference should be
made to table 3.5 for relevant part numbers
The maximum length of flue permissible is calculated using the
component pressure drop and examples are given in table 3-5
which include the maximum lengths at 95% of input.
Fig.3-5
Overall Assembled Flue
Length
=
Measured Distance +
632mm
The minimum 60/100 concentric horizontal flue length measured from the centre line of the turret to the outside of
the wall is 247mm.
The minimum vertical flue length is 0.7m from the top of the appliance case to the top of the terminal.
The minimum combined 80 twin flue length is 600mm.
Longer flues may be fitted, however the input of the appliance will be reduced accordingly.
Elbows may be fitted within the flue system with a corresponding reduction in overall flue length based on the component pressure drop.Reference should be made to tables 3-3 to 3-5)
It is reccommended the terminals are not sited within 2 m of an opening in an adjacent building or within 2m of the
boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e’g dischargin over a walkway
or patio.
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Location
Fig. 3-3
Vertical Terminal Positions
Min Distance
A
Directly below (or above) a
window or other opening.
B
Above roof level (to base of ter300mm
minal).
C
From adjacent wall to flue
300mm
D
From internal corner to flue
400mm
E
From facing terminal
1200mm
F
Between terminals
300mm
G
Below eaves or balcony
200mm
300mm
(NOT RECOMMENDED)
Location
A
B
Fig.3-4
Horizontal Terminal Positions
Directly above or below a window or
other opening
Below gutters, soil pipes or drain
pipes.
Min Distance
300mm
75mm
C
Below eaves
200mm
D
Below balcony
200mm
E
From vertical drain/soil pipes
150mm
F
From internal or external corners.
300mm
G
Above ground or balcony level
300mm
H
From a surface facing terminal
600mm
I
From a terminal facing a terminal
1200mm
J
Vertically from a terminal on the
same wall.
1500mm
K
Horizontally from a terminal on the
same wall.
300mm
3.10 Plume Terminal Outlets
A flue duct outlet of an appliance should be at least 600mm from the boundary line when facing it and at least
300mm from the boundary line when running parallel to it. (see Fig 3.4a)
NOTE: When the flow of products is at an angle to the boundary, the 600mm dimension may be measured in the
direction of the flow, as long as the terminal is not less than 300mm from the boundary.
It is reccommended the terminals are not sited within 2 m of an opening in an adjacent building or within 2m of the
boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e.g discharging over a walkway
or patio.
Fig.3-4a
Plume Terminal Outlet Dimensions
1. Boundary
2. Terminal
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3. Building
4. Adjacent
5. Window
13
Typical Concentric Flue Configurations
Turret
Horizontal Terminal
Clamp
Sealing Rings
Fig. 3.6
Standard Horizontal Flue Kit
Fig.3-7
Horizontal Rear Flue
(Standard Flue Kit)
Fig.3-8
Offset Vertical Flue
(may be offset to the rear, left or right)
Turret
500 mm Extension
90o Elbow
Vertical Terminal
Fig.3-9
Horizontal Side Flue
(Can be left or right)
Standard Flue Kit
500 mm Extension
14
Fig.3-10
Vertical Flue
1m Extension
500 mm Extension
Vertical Appliance Adaptor
Vertical Terminal
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Fig.3-11
Offset Horizontal Rear Flue
(Can be offset to left or right)
Standard Flue Kit
90o Elbow
1m Extension
Typical Twin to Concentric Flue Configurations
Fig.3-13
Offset Twin to Vertical Concentric Terminal
Twin pipe adaptor
80mm x 500mm extensions (2 off)
80mm x 45o elbows (4 off)
80mm x 1000mm extension (2 off)
Twin to concentric adaptor
60/100mm vertical terminal
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Fig.3-12
Raised Horizontal Flue
(Can also be LH or RH)
Horizontal Terminal
90o Elbow
1m Extension
Vertical Appliance Adaptor
Fig.3-14
Offset Twin to Horizontal Concentric Terminal
Twin pipe adaptor
80mm x 500mm extensions (4 off)
80mm x 90o elbows (2 off)
Twin to concentric adaptor
60/100mm horizontal terminal
15
Table.3-3
Heat Input (%age)
102
101
100
99
98
97
96
95
94
HE30C MAXIMUM FLUE RESISTANCE 95Pa
10 20
PRESSURE DROP EXAMPLE
HE37C MAXIMUM FLUE RESISTANCE 160Pa
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Turret + Horizontal Terminal
Flue Pressure Drop (Pascals)
HE37C
HE30C
Description
x
x
x
x
x
x
= 45 Pa
500mm Extension
= 2.5 Pa
90 Elbow
= 10 Pa
100m Extension
= 5
90 Elbow
= 10 Pa
TOTAL
= 72.5 Pa
Pa
Pascal
30C
37C
Parts included
Application
Pt No
Turret.
Appliance seal.
60/80 adaptor.
EPDM wall cover plate.
100 mm diameter clamp.
800 mm horizontal terminal.
Horizontal
1000-0020070
45
60
Std flue kit (horizontal
terminal)
1
1
1
2
1
1
Turret
1 x Turret.
Horizontal
1000-0020020
40
45
Horizontal Terminal
1 x 800 mm horizontal terminal.
Horizontal
1000-0019830
5
15
Horizontal
Vertical
1000-0018940
5
15
Horizontal
Vertical
1000-0018950
2.5
7.5
Horizontal
Vertical
1000-0018960
1.25
4
Vertical
1000-0018930
5
10
1000-0018990
0
0
1000-0018980
10
25
1000-0018970
5
12.5
1000-0020060
N/A
N/A
1 x 1000 mm straight extension.
1000 mm straight extension
1 x 100 mm diameter clamp.
2 x screws.
1 x 500 mm straight extension.
500 mm straight extension
1 x 100 mm diameter clamp.
2 x screws.
1 x 250 mm straight extension.
250 mm straight extension
Vertical Appliance Adaptor
1
2
1
1
1
90° elbow
1 x Elbow
45° elbow
1 x Elbow
Flat Roof Weather Collar
1 x Aluminium circular flat roof seal
Vertical
Horizontal
Vertical
Horizontal
Vertical
Vertical
Pitched Roof Collar (Black)
Pitched Roof Collar
(Terracotta)
1 x Plastic & lead pitched roof seal
Vertical
1000-0020030
N/A
N/A
1 x Plastic & lead pitched roof seal
Vertical
1000-0020040
N/A
N/A
Horizontal
Vertical
1000-0020050
N/A
N/A
Vertical terminal 1140 mm
Fixing Bracket
x
x
x
x
x
100 mm diameter clamp.
screws.
vertical terminal assembly.
support bracket
Adaptor
Clamp for 100 mm tube
Table.3-5
60/100 Flue Components
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3.10 Electrical Connections:
External wiring must be correctly earthed, polarised and in
accordance with BS 7671 (current edition).
All system components must be an approved type and all electrical components should have been tested and meet the
requirements of BEAB or equivalent. All the electrical connections to the heating system must be through a common double
pole isolation switched spur that has a 3 mm separation on
each pole and has a 3A rated fuse. It should be used for the
heating system only and no other household components. A
fused three pin plug and shuttered outlet may also be used
provided they both comply with BS 1363.
IMPORTANT: This appliance must be earthed and it must be
wired in accordance with these instructions. In addition, it must
have a permanent electrical supply that is not interrupted by a
timing device or thermostat.
Fit the electrical supply cable as shown using the connection
plug provided. The cable must be at least 0.75 mm2, PVC
insulated to BS 6500.
As a minimum, a room thermostat MUST be fitted and therefore the link between L2 & L1 should be removed and the thermostat connected between these two connections. If the thermostat has a neutral connection, this should be used in order to
enhance the temperature control. Programmable thermostats
are wired in a similar way!
L3
N
Neutral
(Blue)
Line
(Brown)
Earth
(Green/Yellow)
Mains supply: fused at 3A 230V~50Hz
Fig.3-16
Basic electrical connections
L3
N
Line
(Brown)
A single channel external programmer can be fitted; in which
case, reference should be made to the appropriate diagram.
Mains supply
Remove the case components from their packaging and fit the
LH and RH case panels to the appliance. Each panel hooks
over the two lugs at the top of the appliance and screws to
the base with the screws provided. Remove the controls door
from the module panel and offer the controls module up to
the side case panels. The two hinge pins drop into the two
slots on the groupset support. Fit the support strap (green
cord) to the appliance to support the controls in the horizontal
position. Make the electrical harness connections to the rear
of the module, ensuring that the harness connections are
paired with their respective mates on the control module: X1;
X2 etc. Swing the controls up into their vertical position and
secure to the side case with the two screws provided. Refit
the controls door, fit the front outer case and secure with the
screw in the top of the boiler.
3.12 Electrical Testing:
L2
L1
Neutral
(Blue)
All cables entering/leaving the appliance MUST be restrained
by use of the cable clamps!
3.11 Fitting The Case & Control Module:
L1
Link
If a frost ‘stat is required to protect remote parts of the heating
system, this should be fitted as shown.
Optional System Controls: Opentherm protocol controls are
available for outside temperature compensation and room
temperature sensing and can be used to improve the heating
system control. They must be connected to the correct terminals as described in their own instructions. A room thermostat
MUST NOT be used with these controls.
L2
Room
Thermostat N
Optional Frost ‘stat
Fig.3-17
Electrical connections when
using a room thermostat
L3
N
L2
Room
Thermostat
L1
N
Mains supply
Carry out electrical checks:
• Polarity of the mains supply
• Insulation resistance to earth.
•
Earth continuity and short circuit of cables
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Optional Frost ‘stat
Fig.3-18
Electrical connections when using an external
timer and/or room thermostat
17
18
Fig.3-19
Functional Flow Diagram
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Fig.3-20
Illustrated Wiring Diagram
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19
4 COMMISSIONING AND HANDOVER
4.1 Commissioning the Appliance:
With all the pipe connections made, open the cold supply water valve and the CH
flow and return valves at the base of the appliance. Open the manual vent at the
top of the appliance and bleed, close the manual vent when all the air is removed
and ensure that the autovent cap is open.
Ensure that all isolating valves are open and that the system is pressurised to the
correct level.
Having tested for gas tighness, purge air from the gas supply and turn on the gas
service cock.
Ensure the domestic cold water system, all system radiators and the boiler have
been bled.
Turn the CH and DHW. controls to minimum, switch on the electricity supply to the
appliance and turn ON the ON/OFF switch on the boiler control panel.
NOTE
The gas valve is
factory preset and
must not be adjusted.
A replacement valve
must only be supplied
by Johnson & Starley
Ltd.
CH Temp. Control
DHW Temp.
Control
The LCD display will become active, whilst the microprocessor control completes a number of checks and sets the
appliance to a standby position. When the boiler reaches its temp. set point, the anti-cycle feature introduces a 180
second delay between cycles, indicated by an hour glass symbol on the display. The display will indicate the system
pressure in the lower RH corner of the LCD panel and a numerical display in the upper and lower LH side of the LCD
panel.
Check that any external controls are calling for heat, switch the integral time clock (if fitted) to the ON position and
turn the CH temperature knob clockwise. The set point temperature will be displayed on the LCD screen, set it to 60o.
The fan will start and the ignition sequence will take place. The display will indicate the burner is on and a stylised
flame will be displayed when the flame is established.
If ignition does not take place during the first ignition attempt, there will be a further 2 attempts. If the burner has still
not lit, a fault code will be displayed and this may be due to air being present in the gas supply. Pressing the reset
button will initiate a second sequence of ignition attempts.
When the boiler lights, allow the appliance to operate at low temperature and vent all the air from the boiler and system. If necessary, re-pressurise the system to between 1.1 and 1.5 bar.
Turn OFF the CH by turning the C.H control to the OFF position. Turn the DHW temperature control to maximum.
Open a DHW tap and allow the water to flow. The appliance will start an ignition sequence and light the burner. After
ignition, the control will monitor the water temperature and try to maintain the DHW set point.
When the above checks have been completed, a combustion performance test (as detailed in the SERVICING section)
can be carried out if required.
4.2 Handing over:
After commissioning, the installer should hand the appliance over to the occupier of the house by the following
procedure:
the User Instructions (ZZ1184) to the occupier and explain their responsibilities in respect of current legisla• Hand
tion and regulations, both national and local.
• Explain and demonstrate how to light and shut down the appliance.
to gain the best possible fuel economy in relation to the heating and hot water requirements of the house• Inhold,ordercarefully
explain the operation of the appliance and the use/adjustment of all the system controls.
on the precautions required to prevent damage to the appliance; the system and the building in the event
• Advise
of the appliance being shut down in very cold weather.
• Explain how to control the temperature of the radiators and domestic hot water by use of the controls on the appliance.
how, in the event of a fault, the appliance will display a fault code, emphasising that if a fault is indicated
• Explain
they should note the fault code, turn off the appliance and contact a “competent person” which in normal circumstances would be a Gas Safe registered engineer.
20
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and demonstrate the function/operation of time/temperature controls and thermostatic radiator valves,
• Explain
emphasising the economic use of the appliance.
• If a programmer has been fitted, hand the user instructions that were supplied with the programmer to the occupier.
out the water pressure guage and explain what it indicates and that if the pressure falls over a period of time
• Point
when the system is cold, a water leak should be suspected and that a “competent person” should be contacted.
the importance of a regular service and that servicing of the appliance MUST only be carried out by a
• Emphasise
“competent person” which in normal circumstances would be a GAS SAFE registered engineer.
the installer you may wish to offer a service contract yourself, or alternatively you may wish to explain to the
• Asoccupier
that they can take advantage of an extended warranty scheme offered by Johnson & Starley Ltd.
Reminder: At the time of commissioning, complete all relevant sections of the Benchmark Checklist located on the
inside back pages of this document prior to handing over the appliance to the occupier.
5. SERVICING SCHEDULE
To ensure that the appliance gives continued operation that is both safe and efficient, it is necessary to carry out regular service checks and whilst the period between servicing will depend on the installation condition and the demands
placed upon the appliance, it is recommended that the
appliance be serviced annually.
Test Mode
NOTE: it is a statutory requirement that ALL work be
carried out by a “competent person” which in normal
circumstances would be a GAS SAFE registered engineer.
5.1 Servicing Sequence:
the boiler and carry out a pre-service check,
• Light
noting any operational faults.
• Check the gas consumption.
the appliance in test mode and connect a suit• Put
able flue gas analyser to the sampling point on the
top of the boiler or into the flue terminal if access is
possible (optional test).
For correct boiler operation, the ratio of CO to CO2
in the flue gas should not be greater than 0.008.
To put the appliance in test mode, first press and
whilst holding it, press the MODE button and hold both
together until the display changes. (Possible 5 second time
delay.) If the display shows EHIS press RESET. and try
again. The flow and return temperatures are displayed
along with the flame current value and the fan speed.
Whilst in test mode, the appliance overrides all temperature setting and defaults to maximum rate. Pressing the
and buttons allows you to scroll between maximum
and minimum rates, whilst still overriding all temperature
settings*. Press RESET to take the appliance out of test
mode. If no changes are made, the appliance will stay in
test mode for 30 minutes.
*
On smaller heating systems, running at maximum output MIGHT cause the
boiler to go into lockout and display E3. Allow the heating system to cool and
press RESET.
Check that the gas input is at least 90% of the nominal.
• Clean the main burner.
• Clean the heat exchanger.
the condition of the combustion chamber insulation. Any
• Check
cracked or damaged pieces should be replaced.
possible, remove and clean the condensate 'S' trap (refer
• Wherever
to section 6.16) and check the drain for blockage.
that the flue terminal is unobstructed and that the flue sys• Check
tem is sealed correctly.
the DHW flow and if reduced, check the DHW filter for blockage. (Refer to section
• Check
5.2)
Flue gas test point
Note: In order to carry out either servicing or replacement of components the boiler front
panel and sealing panel must be removed. (Refer to section 6.2)
WARNING. Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity
supply to the appliance before servicing.
completing the servicing or exchange of components, always test for gas tightness and carry out functional
• After
checks as described above.
• When work is complete, the sealing panel MUST be correctly refitted, ensuring that a good seal is made.
servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located on the
• After
inside back pages of this document.
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21
5.2 Cold Water Inlet Filter
Close the mains inlet valve to the household, open a domestic hot
water tap at the lowest point in the system, allow the pressure to dissipate and close this tap. Unclip the plastic electronic component
from the top of the turbine, (the wires may be unplugged if necessary)
and pull it off. Remove the grommet from the sealed chamber above
the turbine and unscrew the complete turbine from the brass housing.
The turbine can now be removed upwards. The complete assembly
can now be flushed clean using water and re-assemble in reverse
order, ensuring that all seals are replaced correctly.
This operation will be made easier by removing the gas manifold / fan
assembly as described in section 6.23 to gain access to the cover
grommet. Unclip the plastic electronic component from the top of the turbine, the wires may be unplugged if necessary. Remove the grommet from the sealed chamber above the turbine. Unscrew the complete turbine from the
brass housing and remove it upwards through the hole in the sealed chamber. Replace in reverse order ensuring the
grommet is correctly seated.
5.3 Gas/Air Duct and Internal Volume of the Burner
Remove the cover from the gas / air manifold (8 screws) and inspect
the inside of the duct and burner for debris. Clean with a soft brush if
necessary. Inspect the 'O' ring seal. Re-assemble the cover ensuring
the seal is fitted correctly.
Gas/Air Duct
5.4 Combustion Assembly Complete
Remove the CVBC (refer to section 6.21) and disconnect the gas pipe at
the top of the isolation valve, which will already have been turned off.
Unscrew the six retaining nuts from the studs that hold the assembly to
the heat exchanger, supporting the assembly as the last one (bottom) is
removed and slowly withdraw the complete assembly, including the gas
inlet pipe and the case seal. As the assembly is withdrawn, disconnect
the two electrical connections from the fan. Inspect and clean the spark
ignition and flame sensing electrode, removing any debris and oxidization
and check the spark gap and position of the spark electrode and the position of the flame-sensing electrode. Refer to illustrations 6.18 and 6.19
and adjust if necessary. Inspect the two seals and the ceramic pad on the
inside of the mounting plate and clean or replace as necessary.
5.5 Combustion Chamber/Heat Exchanger
Inspect the inside of the combustion chamber for debris. If necessary, brush clean
the inside of the tubes with a soft brush. Do not brush the insulation at the rear, if
this part is damaged it will require replacement.
22
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5.6 Ignition and Detection Electrodes
Remove the plug cap from the top and the earth wire from the base of the spark
electrode. Unscrew the two screws that retain the electrode in the cover plate and
remove the assembly. Inspect and clean the electrode, removing any debris and oxidation. If necessary use an abrasive paper or cloth. Inspect the gasket and replace
if necessary during re-assembly. Repeat the sequence for the flame detection electrode with the exception of the earth lead.
5.7 Condensate Cap
(Where a siphon is fitted)
On some boilers an integral condensate siphon may have been fitted. This has a
removable cap that allows the removal of debris that may be caught within it.
Place a bowl under the cap to catch the condensate that is expelled and remove
the cap. Any debris inside will be expelled at this point. Replace the cap ensuring a
good seal is made. Discard the condensate and debris.
Note: The condensate is a weak acid with a pH value of between 4 and 6.
6.
FAULT FINDING AND REPAIR
CAUTION:
Before commencing any mechanical servicing the appliance should be isolated from the electrical supply and the gas
service cock on the appliance closed. All parts that are removed during a service operation should be replaced in
reverse order, ensuring correct seals are made and wires are connected correctly. During the service remove any debris
from within the appliance. When gas-carrying components are serviced the appliance must be tested for gas tightness
after re-assembly. On completion of a service carry out a full functional test of all appliance components and ensure
system controls are operating correctly.
Remove the upper front case that is retained by a screw in the top of the appliance.
Remove the control fascia by removing the plastic door, unscrewing the two screws that hold the control pod in place,
rotate downward. Unplug the wires, slide the hinge pins inwards and remove the fascia from the appliance.
Remove the sealed door by removing the three screws and lifting the door clear.
Should a fault occur, the boiler will shut down and the letter E followed by an error code will be displayed.
ATTENTION:
The flip door at the bottom of the boiler is held in the closed position. To gain access to the control panel, take hold
of the side of the panel at the corners and pull towards you, allowing the door to drop into the open position. To
close the flip door, lift up the panel and push shut until it clicks into place.
6.1 Fault Codes
Code
Fault
Reason
Action
LOCKOUT ERRORS
N/A
N/A
Boiler will not run
No DHW output
Check all external controls (if fitted)
No call for heat to boiler control board Check settings on time clock
Check settings of boiler controls
No call for DHW to boiler control
board. No or reduced water flow.
Check water flow from the appliance is correct.
Check cold water inlet filter.
Check wiring to the flow sensor
Check operation of flow turbine
Check gas supply and gas cock
If burner lights, check flame sensor and wiring to control
board
Check operation of gas valve
1
Flame lockout after several
attempts
Flame not detected
2
False flame
False flame sensed
Check wiring on ESYS
Air in boiler
No water
Vent boiler
Check automatic bypass setting
Check that flow temp sensor is clipped to flow pipe
Check pump
Check secondary heat exchanger for blockage
3
High water temp limit
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23
Code
Fault
Reason
Action
5
No tacho from fan
Fan not running or wiring fault
Check that fan runs
Check wiring between MMI X7 and fan
8
Flame circuit error
Flame sensing lead shorted to earth.
Check flame detection lead between sensing probe and
ignition control board.
9
Valve driver circuit error
Gas valve not detected
Check that ESYS is correctly fitted on gas valve
Replace ignition control board or gas valve
11
Flow/return sensor calibration
error
Flow/return sensors not within 5o of Check that there is a bypass in the system
each other, within calibration period. Check that the flow/return sensors are fitted to the pipes
12
Default lockout
Eprom memory fault
13
Elapsed the number of
retrials
Change ESYS
21
ADC error
Change ESYS
26
Flame signal lost 5 times in 4
minutes
Check flame detection lead between sensor and ignition
Flame sensing error. Falling gas pres- control board. Check gas supply
sure. Fan fault. Flue blockage.
does pressure fall when boiler fires?
Check that flue system is not blocked.
31
CH supply sensor error
(open or short)
Sensor out of normal range.
44
CH rerturn sensor error
(open or short)
Sensor out of normal range.
Check wiring and connections
Temperature sensor not connected or
Check sensor continuity
failed
Change ESYS
Check wiring and connections
Check sensor continuity
BLOCKING ERRORS
High flue gas temp
Reduced water flow
Check insulation at back of heat exchanger for
damage
Check water content and pump operation.
25
CRC error
Error between Hup and Lup CRC
codes
Check software versions
30
Boiler flow temperature sensor
short circuit
Temperature sensor shorted to earth
or failed.
Check wiring and connections for shorting to earth
Check sensor resistance
31
Boiler flow temperature sensor
open circuit
Temperature sensor not connected or Check wiring and connections.
failed
Check sensor continuity
32
DHW temperature sensor short
circuit
Temperature sensor shorted to earth
or failed
33
DHW temperature sensor open
circuit
Temperature sensor not connected or Check wiring and connections.
failed
Check sensor continuity
34
Low mains supply voltage
Electrical supply fault to property.
Faulty wiring to appliance
Check incoming mains supply and wiring to appliance
37
Low system water pressure
Water pressure low or sensor failed.
Check system pressure on dial gauge and if correct check
pressure sensor and wiring.
Re pressurise system.
40
High system water pressure
System water pressure too high.
Pressure sensor failed.
Check cold system pressure.
Check expansion tank charge pressure with system pressure
released. Check pressure sensor
41
No water pressure signal
recieved from MMI
The water pressure is not refreshed
often enough. Communication
problem.
Check wiring and connections
45
Flue gas temperature sensor
short circuit
Short circuit in wiring between sensor
and control board
Check wiring to sensor
Check the electrical resistance of the sensor
46
Flue gas temperature sensor
open circuit
Temperature sensor not connected or Check wiring and connections.
failed
Check sensor continuity
47
Water pressure sensor open
circuit
Water pressure sensor not
connected
Check wiring and connections.
Check sensor continuity
99
Communication MMI-ESYS lost
Connection between MMI & ESYS
incorrectly made
Check wiring and connections
7
24
Check wiring and connections for shorting to earth
Check sensor resistance
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FAULT FINDING FLOWCHART
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25
Error History Mode
The MMI stores the last 8 error codes and these can be viewed by putting the appliance into error history mode.
To do this, press the MODE button and “EHIS” will be displayed on the LCD display. The number in the top right
hand-corner is the error index (1 being the most recent) and the number in the bottom right hand corner is the error
code that applies to that index number.
The appliance will stay in error history mode for a period of 30
seconds and pressing the and buttons allows you to
scroll through the error codes stored.
Press RESET to manually take the appliance out of error history
mode.
EHIS
1
3
NOTE: all new boilers are shipped with pre-set error codes stored in the memory.
Replacement of Parts
6.2 Initial Disassembly
Front case retaining screw
Remove the upper front case that is retained by a
screw in the top of the appliance.
Remove the control facia by removing the plastic
door, unscrewing the two screws that hold the
control module in place, rotate downward. Unplug
the wires, slide the hinge pins inwards and
remove the fascia from the appliance.
Remove the sealed door by removing the three
screws and easing it to the left to disengage it
from the LH side of internal casing.
Control module fixing screws
6.3 Control Panel (Complete)
Because of the complexity and delicate nature of the control PCB, it is supplied as a complete kit with the plastic
facia.
Remove the control panel as described at section 6.2.and fit the new assembly in reverse order.
6.4 Electrical Switch
Unscrew the metal cover plate from the rear of the control panel. Unplug the
wires from the switch (NOTING THEIR POSITIONS) and remove the switch.
Fit the the new switch and reconnect the wires ensuring that they are in the
correct position.
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6.5 Mechanical/Electronic Timer
Unscrew the metal cover plate from the rear of the control panel. Unscrew
the timer retaining screws and any electrical plug connections. Remove the
timer. Replace with a new component in reverse order
6.6 Pump (Complete)
Close the CH flow and return valves, ensuring the drain point on the
flow valve is connected to the appliance side. Drain off the water from
within the appliance using the drain valve. Unplug the electrical connector from the flying lead and unscrew the lower screw that retains the
pump to the appliance. Withdraw the retaining clip securing the flexible
expansion pipe and pull the pipe from the pump. Withdraw the retaining clip at the rear of the body and remove the pump complete.
Replace with a new component in reverse order.
6.7 Diverter Valve (Motorised Head)
Carefully pull the three connectors from the electrical connections on
the motorised valve, having made a note of their respective positions.
Remove the retaining clip and withdraw the motorised head upwards
from the valve. Replace with a new component in reverse order.
6.8 Diverter Valve (Body)
Remove the diverter head as descibed in section 6.7 and drain the CH
and DHW circuits from the boiler. Disconnect the electrical supply to
the DHW sensor, the CH flow pipe to the radiators and the CH flow
pipe from the heat exchanger. Disconnect the DHW out pipe and
remove the 2 x M5 clamp head screws from the valve body (1 from the
centre of the body the second from below). Remove the complete valve
body and unscrew (and retain) the DHW sensor. To replace, refit the
DHW sensor in the new valve and refit the complete valve into the boiler following the above instructions but in reverse order.
NOTE: care MUST be taken to ensure that the replacement ‘O’ rings are correctly seated!
www.johnsonandstarley.co.uk
27
6.9 Expansion Vessel
Close the CH flow and return valves, ensuring the drain point on the
flow valve is connected to the appliance side. Drain off the water from
within the appliance using the drain valve. Remove the LH painted
case side. Unscrew the flexible hose connection from the expansion
vessel. Unscrew the upper retaining bracket and remove the expansion
vessel. Replace with a new component in reverse order
6.10 Pressure Relief Valve
Close the CH flow and return valves, ensuring the drain point on the flow
valve is connected to the appliance side. Drain off the water from within
the appliance using the drain valve. Remove the pump as described in
section 6.6. Unscrew the discharge connection and remove the pressure
relief valve. Replace with a new component in reverse order
6.11 Primary Water Temperature Sensors (2 off)
Unplug the two wires from the temperature sensor to be replaced and
unclip the sensor from the pipe. Replace with a new component in
reverse order. Ensure it is fitted in the same position.
6.12 Domestic Hot Water Temperature Sensor
Close the mains inlet valve to the household, open a domestic hot water
tap at the lowest point in the system and allow the pressure to dissipate.
Close this tap again, carefully remove the two spade connectors from the
sensor and unscrew the sensor from the brass body. Replace with a new
component in reverse order, ensuring the copper washer is fitted correctly.
28
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6.13 Primary Water Pressure Sensor
Close the CH flow and return valves, ensuring the drain point on the flow
valve is connected to the appliance side. Drain off the water from within
the appliance using the drain valve. Unplug the electrical plug connection.
Withdraw the retaining clip forwards and remove the pressure sensor.
Replace with a new component in reverse order.
6.14 Domestic Cold Water Flow Sensor (Turbine)
Close the mains inlet valve to the household, open a domestic hot water tap
at the lowest point in the system and allow the pressure to dissipate. Close
this tap again.
This operation will be made easier by removing the gas manifold / fan
assembly as described in section 6.23 to gain access to the cover grommet.
Unclip the plastic electronic component from the top of the turbine, the
wires may be unplugged if necessary. Remove the grommet from the sealed
chamber above the turbine. Unscrew the complete turbine from the brass
housing and remove it upwards through the hole in the sealed chamber.
Replace in reverse order ensuring the grommet is correctly seated.
6.15 Plate Heat Exchanger
Close the mains inlet valve to the household, open a domestic hot water tap
at the lowest point in the system and allow the pressure to dissipate. Close
this tap again. Close the CH flow and return valves, ensuring the drain point
on the flow valve is connected to the appliance side. Drain off the water
from within the appliance using the drain valve. Unscrew the two retaining
screws and remove the plate heat exchanger. Replace with a new component in reverse order.
6.16 Condensate Drain
Referring to s.5.4, remove the complete combustion assembly including the
burner arm. The flexible condensate pipe is a push fit and the grey plastic
fitting connects to the heat exchanger. The flexible pipe MUST be routed
through the two push fit retaining clips so that the pipe forms a “S” shaped
trap. With the burner arm removed, pour water into the heat exchanger in
order to fill the condensate drain pipe and check for leaks. Reassemble in
reverse order
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29
6.17 Condensate Siphon
(Where Fitted)
Fixing screw
Place a bowl under the cap on the condensate siphon and remove the cap in
order to drain the siphon.
Pull the condense pipe from the top of the siphon and remove the fixing screw
retaining the support bracket. Unscrew the knurled ring underneath the siphon
and remove the drain pipe from the bottom of the siphon. Unscrew the 1”
brass lock nut from the bottom of the siphon and remove the siphon from the
sub assembly. Replace with a new component in reverse order.
Knurled Ring
6.18 Ignition Electrode
Remove the plug cap and the earth wire from the electrode. Remove
the two retaining screws and withdraw the electrode. Replace with a
new unit, ensuring that the gasket is replaced with a new one, or that
the existing gasket reused if it is in good condition
6.19 Flame Detection Electrode
Remove the plug cap from the electrode. Remove the two retaining
screws and withdraw the electrode. Replace with a new unit, ensuring
the gasket is replaced with a new one, or the existing gasket reused if it
is in good condition.
IMPORTANT:
When either the ignition or flame detection electrodes have been serviced/replaced you MUST set
the clearances as shown.
0
1.
5
5.
5
4.
5
0.
Flame Detection Electrode
0
1.
5
5.
Ignition Electrode
Clearances
6.20 Burner
Unscrew the gas joint at the top of the gas cock. Unscrew the fan and
gas/air manifold assembly (3 screws) from the heat exchanger. Unplug the
multi pin plug connections from the top of the control and the fan.
Remove the assembly.
Remove the assembly to allow the burner to be withdrawn from the heat
exchanger assembly. Replace with a new component in reverse order.
Ensure the rotational position of the burner is correct (indicated by a
notch) Replace with a new component in reverse order ensuring that the
grommet sealing the casing is correctly positioned.
30
www.johnsonandstarley.co.uk
6.21 Main Ignition/Control PCB (ESYS Grey/Red Housing on Gas Valve)
Unplug the multi pin plug connections from the top of the control and
remove the spark detection wires. Unscrew the single retaining screw and
slide the housing off the gas valve electrical connections. Replace with a
new component in reverse order.
NOTE: The ESYS label is
identified with the addition
of an ‘E’ alongside the 3
stars.
6.22 Flue Temperature Sensor
Carefully remove the two spade connectors from the sensor and unscrew
the sensor from the plastic flue hood. Replace with a new component in
reverse order, taking care not to over tighten!
6.23 Fan
Unscrew the gas joint at the top of the gas cock and remove the ESYS (red box)
from the gas valve. Unscrew the fan and gas/air manifold assembly (3 screws)
from the heat exchanger. Unplug the multi pin plug connections from the top of
the control and the fan. Remove the assembly. Replace with a new component in
reverse order
6.24 Gas Valve & Venturi Assembly
NOTE: the gas valve is factory preset and a must not be adjusted. A replacement valve must only be supplied by Johnson & Starley Ltd.
Remove the complete fan assembly as shown at paragraph 6.23 and remove the
4 fixing screws holding the gas feed flange on the gas valve. Remove the 2 fixing
screws securing the venturi (and gas valve) to the fan and remove the assembly
from the fan carefully removing the gasket.
Replace with a new component in reverse order, ensuring that all seals are in
good condition and correctly positioned. Check the gas rate and combustion as
described in section 5 Servicing Instructions.
www.johnsonandstarley.co.uk
31
7 SHORT SPARE PARTS LIST
5
1
17
15
13
6
7
10
14
18
3
9
2
19
11
4
12
16
8
12a
32
www.johnsonandstarley.co.uk
Part No
Item
1
HE30C
GC No
HE37C
HE30C
R300-0500005 R380-0500005 H23-626
Description
HE37C
H39 968 Control Panel (complete)
2
1000-0301485
H23-609
Pump
3
1000-0301615
H23-627
Diverter Valve (motorised head)
4
1000-0301605
H38-662
Diverter Valve (Complete)
5
1000-0019005
H23-610
Expansion Vessel (with Washer)
6
1000-0019015
H23-612
Pressure Relief Valve (with nut & olive)
7
1000-0522595
H23-613
Water Temp Sensors
8
1000-0522605
H23-629
Domestic Hot Water Temp. Sensor
9
1000-0301535 1000-0301645 H23-630
H39 974
Plate Heat Exchanger (with O rings and fixing
screws)
10
1000-0301625
H23-631
Domestic Hot Water Flow Sensor (Turbine, flow
resistor, filter & hall effect sensor
11
1000-0019045
H23-614
CH Pressure Sensor, clip & ‘O’ Ring pre Serial No:
68000755
11
1000-0020325
H38 859
CH Pressure Sensor, clip & ‘O’ Ring
12
1000-0020895
H39 975
Tank Connector
12a
1000-0020905
H39 976
Tank Connector Nut
13
1000-0709655
H23-618
Ignition electrode, gasket & screws (2)
14
1000-0709665
H23-619
Detection electrode, gasket & screws (2)
15
1000-0709675 1000-0709825 H23-620
16
1000-0522575
16
1000-0523395 1000-0523405 H38 658
N/A
H23-621
H39 967 Burner (inc small seal)
H39 970
Main ignition/control PCB (ESYS) pre Serial No:
68000755
Main ignition/control PCB (ESYS)
17
1000-0522645
H23-622
Flue temp. sensor
18
1000-0522635
H23-623
Fan, gaskets (3) & fixing screws
19
1000-0709635 1000-0709875 H23-624
www.johnsonandstarley.co.uk
H39 972
Gas valve & venturi assy (inc fan gasket, pipe gasket & screws (4)
33
RENO BOILER RANGE
HOME COMFORT SOLUTIONS
Company Details
Fax Number
01604 762881 (Main switchboard)
01604 767408
Spares
Telephone
Fax
01604 707012
01604 762884
Telephone
Fax
01604 707012
01604 764879
Sales
HOME ‘N’ DRY
VEMTILATION
Telephone Number
www.johnsonandstarley.co.uk
sales@johnsonandstarley.co.uk
marketing@johnsonandstarley.co.uk
ECONOMAIRE BOILER RANGE
Website Address
Email
Service
01604 707011
01604 707017
Warm Air Upgrade Enquiry Service
Telephone
Fax
01604 707026
01604 707017
COMMERCIAL & INDUSTRIAL H&V SOLUTIONS
Company Details
Johnson & Starley Dravo Division Industrial H&V
Website Address
www.dravo.co.uk
Email
dravo@johnsonandstarley.co.uk
Telephone Number
01604 707022
R E L I A B I L I T Y
Y O U
C A N
T R U S T
Rhosili Road, Brackmills, Northampton NN4 7LZ
In the interests of continuous development Johnson & Starley reserve the right to change specification without prior notice.
DRYFLOW
Telephone
Fax
HEAT RECOVERY
Johnson & Starley are the leading UK
& European manufacturers of a complete
range of Domestic Warm Air Heaters.
All the heaters suit both Replacement
and Upgrade needs and are compliant
with the new (2006) amendments to
Part L of the Building Regulations.
HI-SPEC BOILER RANGE
Johnson & Starley
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