Johnson & Starley 47-416-14 Installation, Commissioning & Servicing Instructions Download Page 34

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19.

FAULT FINDING FLOWCHARTS

Should a fault occur, the boiler will shut down and these error codes will be displayed.

IGNITION LOCKOUT

OVERHEAT LOCKOUT

FALSE FLAME LOCKOUT

YES

Check siphon and condensate drain pipe

work for blockage and rectify if necessary. Is

boiler working?

Check routing and integrity of internal boiler

wiring.

Check the gas supply

Check wiring connection from gas valve to

PCB for continuity. If the wiring is OK then

replace the PCB.

Replace the pump, the reset the boiler.

Replace the gas valve

Replace board and harness as necessary.

Replace PCB and associated harness as

necessary.

YES

Check the pressure control pipe between fan

and gas valve for continuity, visual condition,

replace as necessary. Is boiler working?

Check the Flow & Return thermistors.

Check resistance using a suitable multi-meter

connection across the thermistor’s terminal

pins

RESET PROCEDURE

To reset the boiler,

press the reset button.

Is the gas pressure available at the boiler

inlet (>18mbar)?

Fill & vent the system & open all isolation

valves, then reset boiler.

Check routing and integrity of the internal boiler

wiring is working OK. Check condition of the Flame

Sensor Electrode and replace if necessary.

Is approx 24 VDC supply available at the

gas valve?

Check that the pump is rotating freely. Is the

differential now below 20°C?

Replace flame detection electrode.

Unplug the gas valve. Is resistance between

outside pins 114

Reset the boiler.

Check board and associated harness for:

continuity and visual condition. Are these

functioning correctly?

Check ignition and associated harness for :

continuity visual condition and position. Are

these functioning correctly?

Replace the Gas Valve.

If the boiler is reset does the boiler ignite for

a short time and then extinguish?

Is the boiler & CH system filled with water

and all isolation & radiator valves open?

Reset the boiler. Is the boiler working?

Check the detection electrode and associated

harness for: continuity, visual condition and

position. Check if the condensate pipe is

blocked. Replace if necessary.

Is the Flow/Return differential across the boiler

in excess of 30°C?

Remove ignition lead and earth tag. Is

there continuity between the terminal pins

connected to the electrode?

FAN FAULT

YES

Replace the Fan.

Rectify wiring & connections

Replace the PCB.

Does the wiring from the fan to the PCB have secure connections at both

ends and has not deteriorated? Does the wiring have continuity?

Is there 230Vac at the Blue Brown connections to the 3 way connection on

the fan

Summary of Contents for 47-416-14

Page 1: ...TION COMMISSIONING SERVICING INSTRUCTIONS QUANTEC HR28CPErP High Efficiency Boiler with Passive Flue Gas Heat Recovery Quantec HR28CP ErP G C No 47 416 14 These instructions are to be left with the User Publication No ZZ 1585 2 June 2016 ...

Page 2: ...estic Hot Water Check the Operational Gas Inlet Pressure General Checks DHW Mode CH DHW Mode Flushing the System Water Circulation Balance the System Water Temperatures 16 Handing Over 27 Instructing the User Loss of Water Pressure 17 Servicing Maintenance 27 Service Schedule Initial Inspection Servicing Sequence Flue Inspection Checks Gaining Access to the Boiler Control Panel Front Door Removal ...

Page 3: ...o maintain the DHW calorifier in a heated condition This only occurs if pre heat is in the ON period When there is a demand for CH the heating system is supplied at the selected temperature of between 45 C and 80 C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw off of 12 31 l min at 35 C temper...

Page 4: ...ng of water based heating systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BS 6891 Installation of Low Pressure Gas Pipework of up to 28 mm R1 in domestic premises 2nd family gases IMPORTANT This appliance is CE certificated for safety and performance It is important ...

Page 5: ...nowledge unless they have supervision or been given instruction concerning use of the appliance by a person responsible for their safety 4 3 2 Children should be supervised to ensure they do not play with the appliance 4 4 ELECTRICAL SUPPLY 4 4 1 Ensure the mains supply voltage frequency number of phases and power rating comply with details on the rating label 4 4 2 All wiring must be in accordanc...

Page 6: ...at output and low temperature regime Ŋ1 98 8 AUXILIARY ELECTRICITY CONSUMPTION At full load elmax 0 068 kW At part load elmin 0 048 kW In standby mode PSB 0 002 kW OTHER ITEMS Standby heat loss PSB 0 099 kW Ignition burner power consumption Pign 0 kW Sound power level indoors LWA 45 dB ADDITIONAL DATA FOR COMBINATION HEATERS Declared load profile M Daily electricity consumption Qelec 0 069 kWh Ann...

Page 7: ...vessel 73lts Electrical supply 230V 50Hz Electrical rating 100W External fuse rating 3A Expansion vessel capacity 8 litres Expansion vessel initial charge pressure 1 0 bar Heating system minimum pressure 0 5 bar DHW maximum inlet pressure 6 bar Minimum inlet pressure for appliance to operate 0 2 bar Maximum flow rate at 35 C 12 3 l m Minimum domestic hot water flow rate 2 0 l m Maximum flow temper...

Page 8: ...ings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Any external runs must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 5mm overflow pipe TABLE 3 PERFORMANCE DATA MAXIMUM MINIMUM Burner CO case off 10 1 9 2 case on 9 7 9 5 0 5 Maximum gas rate m3 h 1 17 PERFORMANCE DATA FOR CENTRAL HEATING CH input Q Net k...

Page 9: ...ade to the current ETCI rules for electrical installations and I S 813 6 2 4 TIMBER FRAME BUILDINGS 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 cupboar...

Page 10: ...e conditions TABLE 3 EXPANSION VESSEL REQUIREMENTS Vessel charge and initial system pressure bar bar 0 5 0 75 1 0 1 5 Total water content of system using 8 litres 1 45 gals capacity expansion vessel supplied with appliance L 95 84 73 50 For system having a larger capacity multiply the total system capacity in litres by the factor to obtain the total minimum expansion vessel capacity required litre...

Page 11: ...HW supply to the CH system This is used to fill the CH system on installation and whenever the water pressure has been removed for system modifications etc The filling loop complies with the water supply water fittings regulations 1999 Section G24 1 and G24 2 After filling the system the hose should be disconnected and stored in a safe place for future use 8 6 PIPEWORK SIZING In order to keep the ...

Page 12: ...www johnsonandstarley co uk 12 FIGURE 6 QUANTEC HR28C WATER FLOW SCHEMATIC ...

Page 13: ...CTIONS PACK RETURN VALVE PACK FLOW VALVE PACK ACCESSORIES PACK WALL BRACKET DHW PACK CARTON CONTENT 1 Quantec Combi Appliance 1 2 Group Set Components Pack 1 Gas Valve Pack 1 Filling Loop pack 1 Return Valve Pack 1 Flow Valve Pack 1 DHW Pack 1 Accessory Pack 1 Copper connection pack 1 3 Wall Mounting Plate 1 4 Wall Mounting Template 1 5 Installation Users Instructions 1 INSTRUCTIONS WALL TEMPLATE ...

Page 14: ...eating boiler with corresponding flue systems according to EU Directive 90 396 EEC on gas fired devices These installation instructions are covered by this certification and are referred to in the design approval test certificate 10 2 The installation of the boiler and flue system must be in accordance with the Gas Safety Installation and Use Regulations 1998 and the Building Regulations If no spe...

Page 15: ...al drain pipe or soil pipe 150mm H From an internal or external corner Greater than 450mm protrusion 300mm H From an internal or external corner Greater than 450mm protrusion 300mm I Above ground roof or balcony level 300mm J From a surface facing the terminal 600mm K From a terminal facing the terminal 1 200mm M Vertically from a terminal on the same wall 1 200mm N Horizontally from a terminal on...

Page 16: ...ailable from Johnson Starley The distance between the guard and the nearest part of the terminal must not be less than 50 mm 10 7 6 The flue MUST NOT be installed under a car port 10 8 PLUME TERMINAL OUTLETS 10 8 1 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 Figure 11 NOT...

Page 17: ...cal 1000 0020740 16 Plume Management Kit Black 1 Horizontal Vertical 1000 0020730 17 1000mm Extension Flue 60mm Black 1 Horizontal Vertical 1000 0020740 18 90 Elbow 60mm Ø Black 1 Horizontal Vertical 1000 0020680 19 45 Elbow 60mm Ø Black 2 Horizontal Vertical 1000 0020670 20 Wall Fixing Bracket 60mm 1 Horizontal Vertical 1000 0020770 21 Flexible Flue Kit 60 100mm Black 1 Flexible FFK5 22 Flexible ...

Page 18: ...ef 1000 2217950 3 ITEM DESCRIPTION QTY 1 Turret 1 2 Appliance Seal 1 3 60 80 Adaptor 1 4 EPDM Outside Wall Cover Plate 1 5 Inside Wall Cover Plate 1 6 100mm Diameter Clamp 1 7 800mm Horizontal Terminal 1 10 11 OPTIONAL ROOF OUTLETS FLAT ROOF PITCHED ROOF PITCHED ROOF PITCHED ROOF SIDE VIEW 500mm PITCHED ROOF WEATHER COLLAR 500mm 1140mm FLAT ROOF WEATHER COLLAR 20 to 50 RIDGE TERMINAL CLAMPS FLUE E...

Page 19: ... 10 14 1 If no access is available from outside the building drill a 125mm diameter hole 10 14 2 Mount the wall bracket and the boiler on the wall as detailed para 9 1 10 14 3 a For a rear flue measure the wall thickness and add 40mm for a standard rear flue 90mm for a rear flue if the standoff bracket is used b For a side flue measure the distance from the outside wall to the side of the boiler a...

Page 20: ... might collect The external pipe should be insulated using suitable waterproof and weatherproof insulation Class O pipe insulation is suitable for this purpose 11 6 The use of fittings elbows etc should be kept to a minimum and any internal burrs on cut pipework should be removed so that the internal pipe section is as smooth as possible 11 7 The customer householder should be advised that even wi...

Page 21: ...rews provided in hardware pack 12 4 5 Connect wires to terminal block 12 4 6 Swing the control box back up into the operating condition and re fit the front panel ensuring a good seal is made 12 5 THERMOSTATS TIMER KITS Telephone Johnson Starley on 01604 762881 for details 12 5 1 MECHANICAL TIMER 24 HR KIT 24 hour mechanical CH timer fits into the control box of the boiler This can be fitted in co...

Page 22: ...www johnsonandstarley co uk 22 FIGURE 22 WIRING DIAGRAM 13 WIRING DIAGRAM COLOUR Red RD Brown BN White WH Grey GY Yellow YE Pink PK Black BK Violet VT Orange OG Green Yellow GNYE Blue BU ...

Page 23: ...e pressure gauge reads between 1 to 1 5 bar When reached closed the isolation valves 14 5 5 Disconnect the left hand filling loop retain the top hat washer and using the blanking caps cap off the connection and the end of the filling loop 14 5 6 Connect extended blanking cap and top hat washer to filling loop pipe NOTE Fully open all DHW taps and ensure water is flowing freely 15 COMMISSIONING 15 ...

Page 24: ...T CH RETURN CH DRAIN POINT ITEM DESCRIPTION ITEM DESCRIPTION A CH Central heating flow Black handle E CH Central heating return Black handle B DHW Domestic hot water outlet F Filling loop isolation valves Black handle C Gas Valve Yellow handle G D DHW Domestic hot water inlet Blue handle H Gas valve test point H E D F G A B C H FILTER WASHER FIGURE 25 VALVES TAIL PIPES CONNECTIONS FLEXIBLE FILLING...

Page 25: ... E 01 will be displayed 15 6 4 Reset the boiler see paragraph 15 3 The boiler will repeat its ignition sequence If reset occurs 5 times within 15 minutes then F 15 will be shown If power is removed this will be reset 15 6 5 When the burner is established the display will show the flame symbol 15 7 DOMESTIC HOT WATER 15 7 1 With the boiler firing set the DHW Temperature Control to maximum and fully...

Page 26: ...ricity supplies to the boiler and drain down to complete the flushing process NOTE A flushing solution should be used during the flushing procedure Flushing solutions Fernox Superfloc Sentinel X300 new systems or X400 existing systems 15 11 3 Refill and vent the system add inhibitor clear all air locks and again check for water tightness 15 11 4 With the system COLD check that the initial pressure...

Page 27: ...ocedure and if unable to re pressurise or if the pressure continues to drop a registered local heating installer should be consulted 16 10 Explain Boiler reset procedure 16 11 After installation and commissioning please complete the Commissioning Checklist before handover to the customer For IE it is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 IMPORTANT 16 1...

Page 28: ...t The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS 7927 or BS EN 50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CP...

Page 29: ...verse order 17 9 CONDENSATE TRAP Refer to paragraph 17 5 17 9 1 Unscrew the 2 pipes and pull off the third pipe 17 9 2 Remove the trap and clean by removing the cleaning plug Flush out any deposits with clean water 17 9 3 Refit the trap and the pipes 17 9 4 Refit in reverse order FIGURE 34 CONDENSATE TRAP RETURN TEMPERATURE SENSOR DHW FLOW TURBINE AUTOMATIC AIR VENT PRESSURE RELIEF VALVE at the re...

Page 30: ...19 3 7 Refit in reverse order 19 3 8 Check the operation of the boiler See Section 15 18 4 FLOW RETURN THERMISTOR SENSORS 19 4 1 Refer to paragraph 17 5 19 4 2 Unclip the thermistor sensor from the flow return pipe and withdraw it from the boiler 19 4 3 Disconnect the electrical leads from the thermistors 19 4 4 Reconnect the electrical leads to the new thermistors and re assemble in reverse order...

Page 31: ...INING THE APPLIANCE 18 11 CENTRAL HEATING CIRCUIT 18 11 1 Refer to paragraph 17 5 See Figure 24 18 11 2 Close all the CH water isolating valves A and E on the boiler inlet 18 11 3 To drain the primary heat exchanger circuit Attach a length of hose to the CH drain point I then open the drain valve 18 11 4 After replacing any component on the boiler close the drain valve remove the hose and open all...

Page 32: ...oiler See Section 15 18 17 DHW PLATE HEAT EXCHANGER 18 17 1 Refer to paragraph 17 5 See Figure 47 18 17 2 Drain the boiler See paragraph 18 11 and 18 12 18 17 3 Remove the fan See paragraph 17 6 18 17 4 Remove 2 allen screws securing the plate heat exchanger to the housings enough to remove 18 17 5 Manoeuvre the plate heat exchanger out through space left by the fan 18 17 6 Fit the new plate heat ...

Page 33: ...nd flow regulator 18 20 5 Replace and refit in reverse order 18 20 6 Refill the boiler See paragraph 12 4 18 20 7 Check operation of the boiler See Section 15 18 21 EXPANSION VESSEL RECHARGING 18 21 1 Refer to paragraph 17 5 18 21 2 Relieve system pressure through a CH drain point 18 21 3 Remove the charge point cover 18 21 4 Recharge the tank pressure to 0 75 1 bar 18 21 5 Refit in reverse order ...

Page 34: ...ing is working OK Check condition of the Flame Sensor Electrode and replace if necessary Is approx 24 VDC supply available at the gas valve Check that the pump is rotating freely Is the differential now below 20 C Replace flame detection electrode Unplug the gas valve Is resistance between outside pins 114Ω Reset the boiler Check board and associated harness for continuity and visual condition Are...

Page 35: ...ation valves check as supply then reset boiler Check and replace wiring as necessary Replace the Flow Return Sensor Secure Sensors and reset Replace Sensor Check pump is rotating Remove the return thermistor from the CH return pipe and disconnect the wires Check the resistance using a suitable multi meter connected across the thermistor s terminal pins Is the thermistor valve correct Is the boiler...

Page 36: ...NO NO Fill and vent the system and open all isolation valves check as supply then reset boiler Replace the flue thermistor Secure to PCB Is the boiler CH system filled with water and all isolation radiator valves open Check flue thermistor Check resistance using a suitable multi meter connection across the thermistor s terminal pins Refer to graph on E03 REMOTE RESET LOCKOUT Turn power on and off ...

Page 37: ...ns Replace DHW sensor Correct the wiring Is the water system pressure under 2 8bar Is the wiring securely connected to sensor Is the boiler a system type with heat recovery Does the resistance of the flow and return sensors correspond to a temperature value of less than 5 Are the connections on water sensor secure Is wiring secure on to X5 at PCB Replace the PCB OUTDOOR SENSOR ERROR YES YES Replac...

Page 38: ... Are the timer and room thermostat switched on Is there 24V at A see diagram YES NO YES NO NO YES YES YES YES YES Is the hot cold pipework crossed Replace the PCB Is the wiring connected between PCB DHW sensor Re connect wiring Replace turbine sensor Remove the turbine check for debris in the turbine filter Replace turbine if necessary IS DHW working NO NO NO NO NO NO NO YES Is the turbine working...

Page 39: ...ts 4 1000 3004580 J24 238 13 Ignition Detection Electrode Includes 14 15 1 1000 0711785 J21 229 14 Electrode Gasket 1 1000 2501270 H38 677 15 M4 x 8 Torx Screws 2 1000 3003390 J21 240 16 Plate Heat Exchanger Includes 17 1 1000 0301955 J21 287 17 Sealing Rings 4 1000 2501940 J21 288 18 Gas Valve Includes 19 21 1 1000 0710925 J21 261 19 Top Sealing Washer 1 1000 3004280 J21 231 20 Bottom Sealing Was...

Page 40: ...00 0019600 35 CH Pressure Sensor Harness 1 1000 0526940 J21 278 36 DHW Temperature Sensor Includes 37 1 1000 0302195 J21 267 37 Clip 1 1000 3003920 37 Flow Return Temperature Sensor 1 1000 0526515 J24 700 38 Flue Sensor 1 1000 0526525 J21 253 39 3 Way Diverter Valve Cartridge Wilo 1 1000 0025015 J21 265 40 Diverter Head Clip 1 1000 0525575 J21 263 41 Condensate Trap 1 1000 0024525 J21 264 42 Expan...

Page 41: ...t to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full...

Page 42: ...quired Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Yes No CENTRAL HEATING MODE measure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar C Central heating return temp...

Page 43: ... Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Gas safe register No Record At ma...

Page 44: ... sales johnsonandstarley co uk marketing johnsonandstarley co uk Reception Customer Service 01604 762881 Fax 01604 767408 Anniversary 1922 2012 In the interest of continuous development Johnson Starley reserve the right to change specifications without prior notice ...

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