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18.

PARTS REPLACEMENT

18.1

IMPORTANT:

Before commencing with any part replacement the appliance should be isolated from the electrical

supply and the gas service cock on the appliance closed.
18.1.1

All parts that are removed should be replaced and refitted in reverse order, ensuring correct seals are
made and wires are connected correctly.

18.1.2

Remove any debris from within the appliance.

18.1.3

When gas-carrying components are replaced the appliance must be tested for gas tightness.

18.1.4

On completion carry out a full functional test of all appliance components and ensure system controls
are operating correctly.

PART REPLACEMENTS MADE WITHOUT DRAINING THE SYSTEM

18.2

BURNER INJECTOR

18.2.1

Refer to paragraph 17.5

18.2.2

Remove the gas pipe securing clip from venturi. See Figure 36.

18.2.3

Undo the gas pipe union from the gas valve.

18.2.4

Withdraw gas pipe from venturi.

18.2.5

Remove injector from gas pipe.

18.2.6

Replace and refit in reverse order.

18.2.7

Check the operation of the boiler. See Section 15.

18.3

BURNER ASSEMBLY/VENTURI

18.3.1

Refer to paragraph 17.5

18.3.2

Remove the burner assembly. See paragraph 17.7.

18.3.3

To replace the venturi, remove the 4 screws and replace with new.

18.3.4

Inspect the ignition/detection electrode and check the electrode gaps.

18.3.5

Replace with new burner assembly.

18.3.6

Replace the sealing gasket around the burner.

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, ensuring that the thermistors are securely.

19.4.5

Check the operation of the boiler. See Section 15.

18.5

IGNITION/DETECTION ELECTRODE

18.5.1

Refer to paragraph 17.5

18.5.2

Remove the burner. See paragraph 17.7.

18.5.3

Remove the 2 torx screws holding the ignition electrode to the combustion
chamber.

18.5.4

Remove the electrode.

18.5.5 Fit the new ignition electrode, using the new gasket supplied. Check

dimensions as shown.

18.5.6

Refit in reverse order.

18.5.7

Check the operation of the boiler. See Section 15

18.6

GAS VALVE

19.6.1

Refer to paragraph 17.5

19.6.2

Unplug the electrical lead connection from the gas control valve, disconnect
the PDT tube.

19.6.3

Undo the union nut on the top of the gas control valve.

19.6.4 Undo the gas inlet pipe union underneath the cabinet to the gas control

valve.

19.6.5

Remove the 2 screws retaining the valve to the bracket and withdraw.

19.6.6

Fit the new gas control valve ensuring the two sealing washers are in place
and reconnect gas, electrical connection and PDT tube.

19.6.7

Check operation of the boiler. See Section 15.

FIGURE 38. ELECTRODE GAP

FIGURE 39. GAS VALVE

FIGURE 37. THERMISTOR SENSOR

FIGURE 36. BURNER INJECTOR

CLIP

INJECTOR

‘O’ RING

3.5mm ±1

PDT TUBE

NUT

Содержание 47-416-14

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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