Johnson & Starley HE16S, HE25S, HE31S, HE16SP, HE25SP Installation, Maintenance & User Instructions
...
Johnson & Starley
Publication ZZ1186-13 June 2010
Product Identification No: 87B 074
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.johnsonandstarley.co.uk
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Installation, Maintenance & Service Instructions
RELIABILITY YOU CAN TRUST
SYSTEM SERIES
Natural Gas G20:
HE16S - GC No: 41-416-05
from Serial No. 76000247
HE25S - GC No: 41-416-02
from Serial No. 69000778
HE31S - GC No: 41-416-04
from Serial No. 77000182
Propane G31 Variants:
HE16SP - GC No: 41-416-09
from Serial No. 82000102
HE25SP - GC No: 41-416-12
from Serial No. 72000112
HE31SP - GC No: 41-416-08
from Serial No. 84000101
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CONTENTS
Section Description Page
1. Important Information 3
2. Appliance Description 3
3. Fitting 10
4. Commissioning and Handover 21
5. Servicing Schedule 22
6. Fault Finding & Repair 24
7. Short Spare Parts List 33
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.
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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 MEMBERSHIP 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 done 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 contains 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 manufactures 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 system boiler that is designed to provide the user with both central heating and
domestic hot water. 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 (fig. 2-4) 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.
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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HE16S
HE25S
HE31S
Maximum Lift Weight 33.0 Kg 33.0 Kg 34.0
Gas Connection 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 3 A
Expansion vessel capacity 8 litres
Expansion vessel initial charge pressure 1.0 bar
Heating system minimum pressure 0.7 bar
Ball valves are fitted in water and gas connections
For larger systems use an additional expansion vessel
2.2 Technical Data
Table 2-1
General Data
Nat Gas G20 LPG G31
16S 25S 31S 16S 25S 31S 16S 25S 31S 16S 25S 31S
Maximum Minimum Maximum Minimum
Burner
CO2 (%)
Case off
9.5* 9.3* 9.5* 8.5** 8.4** 8.5** 10.1* 10.2* 10.2* 9.2** 9.4** 9.2**
Case on 9.8* 9.5* 9.8* 8.8 ** 8.6** 8.8** 10.3* 10.4* 10.5* 9.4** 9.6** 9.5**
*
= +0.5
**
= Ref Only
Offset (Pascal)
-
3.0 (Minus three)**
Table 2-2
Performance Data
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Table 2-3
Performance Data (Central Heating)
Please Note:
Natural Gas (G20) consumption is calculated using gross CV of 38.7 MJ/m
3
or 34.9 MJ/m3net.
LPG (G31) consumption is calculated using gross CV of 95.6 MJ/m
3
or 88.0 MJ/m3net.
Nat Gas G20
Maximum Minimum
CH Input Q
16S 25S 31S 16S 25S 31S
Net kW 16.3 25.5 30.7 3.81 7.14 9.18
Gross kW 18.1 28.3 34.0 4.23 7.92 10.1
Gas Consumption m3/h 1.7 2.6 3.16 0.40 0.74 0.85
CH Output P
Non Condensing kW 16.0 25.0 30.0 4.08 7.0 9.0
Condensing kW 17.8 27.85 32.6 3.75 7.76 9.8
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION Class 5
LPG G31
Maximum Minimum
CH Input Qm
16S 25S 31S 16S 25S 31S
Net kW 16.3 26.06 30.7 3.81 7.29 1.18
Gross kW 17.7 28.3 33.3 4.14 7.92 9.97
Gas Consumption m3/h 0.67 1.06 1.25 0.16 0.30 0.38
CH Output P
Non Condensing kW 16.0 25.0 30.0 3.75 7.0 9.0
Condensing kW 17.2 27.85 32.6 4.02 7.76 9.8
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION Class 5
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2.3 Dimensions and Clearances:
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.
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:
•
Horizontal and vertical balanced flue using concentric ducts.
•
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:
•
Building Standards (Scotland)(Consolidation) Regulations.
•
Building Regulations
•
Gas Safety (Installation and Use) Regulations (as amended)
•
BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations
•
BS 6891 Installation of Low Pressure Gas Pipework of up to 28 mm (R1) in domestic premises (2nd family gases).
•
BS 5440 Pt.1 (Flues for Gas Appliances)
•
BS 5440 Pt.2 (Air Supply for Gas Appliances)
•
Model and 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 1.7
m
3
/h (HE16S) 2.7 (HE 25S) and 3.16 m3/h (HE31S) (Calculated with a Gas CV of 38.7MJ/m3)
5mm
200mm*
425mm
5mm
310mm
765mm
Work Surface
Fig. 2-1
Minimum Clearances
400mm*
min 180mm
* Note: 200mm dimension is a desired workable clearance but can be reduced.
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The installation must be tested for gas soundness 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. Pre-fabricated pipes (kit number VPK30) are available direct from Johnson & Starley if required.
Additional Control Options:
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 BS5440 Pt.2
2.6 Heating System Requirements:
This appliance incorporates all the necessary components to allow it to be connected to a sealed central heating system. A typical system is shown at fig. 2.2 which incorporates 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 installation should be
designed to operate with a flow temperature of up to 90 deg.C.
Expansion Vessel: The integral expansion vessel is pre-charged 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 plumbing jig, 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.
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: Provision for filling the CH system must be made and three methods are shown in fig. 2.3 Connections to the
mains supply must not be permanent, even through a non-return valve. Fittings used for connection to potable water
must comply with the water supply (water fittings) regulations 1999 Section G24.1 and G24.2.
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 20
o
C
between flow and return. The maximum flow rate is 0.19 kg/s (HE16S) 0.3 kg/s (HE25S) and 0.38 kg/s (HE31S)
which through a 22mm pipe gives a velocity of 0.75 m/z (HE16S) 1.00 m/s. (HE25S) and 1.25 m/s (HE31S)
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 and Fernox.
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)
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Controls: As a minimum it is recommended that a 2 channel timer and room thermostat is installed to control the
appliance. Thermostatic radiator valves may be fitted to the
system but 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 the following minimum flow rates:
12 L/min - HE16S
18 L/min - HE25S
23 L/min - HE31S
(20
o
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 and recommendations
can be found in the building regulations G17 to 24 and
R17 to 24.
Additional
Expansion Vessel
(if required)
BOILER
Drain
Point
Bypass
(if required)
Flow Control
Valve
Heating
Circuit
Fig.2-2
Heating System
Method 1
Method 2
Method 3
Supply
Hose
Unions
Hose Unions
Service
Val ve
Service Valve
Heating System
Heating
System
Heating
System
Service Valve
Service
Valve
Double Check
Valve System
Double Check
Valve System
Stop
Val ve
Stop
Valve
Hose
Unions
Supply
Temp
Hose
Temp
Hose
Combined Check
Valve & Vacuum
Breaker
Supply
Stop
Val ve
Overflow
Pressure
Reducing
Valve
Fig. 2-3
Filling Methods
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Fig 2-4
Schematic Diagram
(Waterflow)
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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.
3.2 Preparing the Wall/Fitting Wall Plate
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.
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.
•
System Boiler
•
Paper Template
•
Wall Plate
•
Rawplug/Screw Pack
•
Boiler Kit
•
Installation Instructions
(inc. Benchmark Logbook)
& User Guide.
•
Filling Loop Pack
•
Guarantee Card
Table. 3-1
CARTON CONTENTS
Figure 3.1
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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 chould be increased to 32mm diameter for complete peace of
mind.
If the pipework is to run from the boiler into the ceiling, you will require J & S kit number SOK1 which will provide a
void at the rear of the boiler.
Typical Condense Drain Arrangements:
Expansion Vessel Requirements
Vessel charge and initial system pressure bar 0.5 0.75 1.0 1.5
Total water content of system using 8 ltr (1.54 gal)
capacity expansion vessel supplied with appliance.
ltr 95 84 73 50
For systems having a larger capacity multiply the total
system capacity in litres (gallons) by the factor to obtain
the total minimum expansion vessel capacity required
litres.
0.0833 0.09 0.109 0.156
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.
Table 3-2
Internal soil
& vent stack
Invert
Sink (Constitutes
air break)
450mm min
Min dia 21.5mm no
restriction on length
Min dia 21.5mm no
restriction on length
Min dia 21.5mm no
restriction on length
External length of
pipe 3m max.
(See Note*)
Min dia 21.5mm
Sink
Open end of pipe straight
into gully below ground but
above water level
Open end of pipe
straight into gully
below ground but
above water level
Boiler
Boiler
Boiler
Boiler
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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 roo:f 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
R.H.Side
133
39.5
187.5
155
Wall
144
93.5
50.5
281
Use this distance to
calculate assembled
flue length
Overall Assembled
Flue Length
19
Fig. 3-2
Overall Assembled Flue Length = Measured Distance - 93.5mm + 100mm
100mm
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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.
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.
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.
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.
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.
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
Overall assembled flue length
Use this measurement to calculate flue length
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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.
Location Min Distance
A
Directly above or below a window or
other opening
300mm
B
Below gutters, soil pipes or drain
pipes.
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
Fig.3-4
Horizontal Terminal Positions
Location Min Distance
A
Directly below (or above) a
window or other opening.
300mm
B
Above roof level (to base of terminal).
300mm
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
(NOT RECOMMENDED)
Fig. 3-3
Vertical Terminal Positions
Fig.3-4a
Plume Terminal Outlet Dimensions
1. Boundary 2. Terminal 3. Building 4. Adjacent 5. Window
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15
Typical Concentric Flue Configurations
Fig. 3-7
Horizontal Rear Flue
(Standard Flue Kit)
Fig. 3.9
Horizontal Side Flue
(Can be left or right)
Standard Flue Kit
500 mm Extension
Fig. 3.8
Vertical Flue
(may be offset to the rear, left or right)
Turret
500 mm Extension
90
o
Elbow
Vertical Terminal
Fig. 3-10
Vertical Flue
1m Extension
500 mm Extension
Vertical Appliance Adaptor
Vertical Terminal
Fig. 3.6
Standard Horizontal Flue Kit
Horizontal Terminal
Turret
Sealing Rings
Clamp
Table.3-5
60/100 Flue Components
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16
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 45
o
elbows (4 off)
80mm x 1000mm extension (2 off)
Twin to concentric adaptor
60/100mm vertical terminal
Fig.3-11
Offset Horizontal Rear Flue
(Can be offset to left or right)
Standard Flue Kit
90
o
Elbow
1m Extension
Fig.3-12
Raised Horizontal Flue
(Can also be LH or RH)
Horizontal Terminal
90
o
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 90
o
elbows (2 off)
Twin to concentric adaptor
60/100mm horizontal terminal
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Description Parts included Application Pt No
Pascal
30C 37C
Std flue kit (horizontal
terminal)
1 x Turret.
Horizontal 1000-0020070 45 60
1 x Appliance seal.
1 x 60/80 adaptor.
2 x EPDM wall cover plate.
1 x 100 mm diameter clamp.
1 x 800 mm horizontal terminal.
Turret 1 x Turret. Horizontal 1000-0020020 40 45
Horizontal Terminal 1 x 800 mm horizontal terminal. Horizontal 1000-0019830 5 15
1000 mm straight extension
1 x 1000 mm straight extension.
Horizontal
Vertical
1000-0018940 5 15
1 x 100 mm diameter clamp.
2 x screws.
500 mm straight extension
1 x 500 mm straight extension.
Horizontal
Vertical
1000-0018950 2.5 7.5
1 x 100 mm diameter clamp.
2 x screws.
250 mm straight extension
1 x 250 mm straight extension.
Horizontal
Vertical
1000-0018960 1.25 4
1 x 100 mm diameter clamp.
2 x screws.
Vertical terminal 1140 mm
1 x vertical terminal assembly.
Vertical 1000-0018930 5 10
1 x support bracket
Vertical Appliance Adaptor 1 x Adaptor Vertical 1000-0018990 0 0
90° elbow 1 x Elbow
Horizontal
Vertical
1000-0018980 10 25
45° elbow 1 x Elbow
Horizontal
Vertical
1000-0018970 5 12.5
Flat Roof Weather Collar 1 x Aluminium circular flat roof seal Vertical 1000-0020060 N/A N/A
Pitched Roof Collar (Black) 1 x Plastic & lead pitched roof seal Vertical 1000-0020030 N/A N/A
Pitched Roof Collar
(Terracotta)
1 x Plastic & lead pitched roof seal Vertical 1000-0020040 N/A N/A
Fixing Bracket Clamp for 100 mm tube
Horizontal
Vertical
1000-0020050 N/A N/A
PRESSURE DROP EXAMPLE
Turret + Horizontal Terminal = 45 Pa
500mm Extension = 2.5 Pa
90 Elbow = 10 Pa
100m Extension = 5 Pa
90 Elbow = 10 Pa
TOTAL = 72.5 Pa
Table.3-5
60/100 Flue Components
Table.3-3
94
95
96
97
98
99
100
101
102
10 20 30 40 50 60 70 80 90 100
110
120
130 140 150 160 170 180
Flue Pressure Drop (Pascals)
Heat Input (%age)
HE16S & HE25S
HE31S
HE16S & HE25S MAXIMUM FLUE RESISTANCE 95Pa
HE31S MAXIMUM FLUE RESISTANCE 160Pa
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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 mm
2
, PVC
insulated to BS 6500 table 16.
If a frost ‘stat is required to protect remote parts of the heating system, this should be fitted as shown.
All cables entering/leaving the appliance MUST be
restrained by use of the cable clamps.
An external controller can be fitted, in which case reference
should be made to the appropriate diagram.
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.
3.11 Fitting The Case & Control Module:
Remove the case components from their packaging. 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
and offer the control module up to the side panels. The two
hinge pins drop into the two slots on the goupset support. Fit
the support strap (green cord) to the appliance LH side 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 and fit the front outer case and secure with the
screw in the top of the boiler.
3.12 Electrical Testing:
Carry out electrical checks:
•
Earth continuity and short circuit of cables
•
Polarity of the mains supply
•
Insulation resistance to earth
NL2L1
L3
Line
(Brown)
Neutral
(Blue)
Earth
(Green/Yellow)
Mains supply: fused at 3A 230V~50Hz
Link
Fig.3-16
Basic electrical connections
NL2L1L3
Line
(Brown)
Neutral
(Blue)
Mains supply
System
Controls
Optional Frost ‘stat
Fig.3-17
Electrical connections to system controls
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Fig.3-18
Functional Flow Diagram
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Fig.3-19
Illustrated Wiring Diagram
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4 COMMISSIONING AND HANDOVER
4.1 Commissioning the Appliance:
With all the pipe connections made, open the cold supply water valve on the filling loop
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.
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
using the manual vent at the top of the appliance.
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.
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, and turn the CH temperature control clockwise. The set point temperature will be displayed on the LCD screen, set it to 60
o
. The fan will start and the ignition sequence will take place. The display will indicate the burner is on as well as an indication of fan speed. 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 appliance by turning the Central Heating Temp. Control to the OFF position.
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 completion of the commissioning procedure, the installer should hand the appliance over to the occupier of the house
by the following procedure:
•
Hand the User Instructions (ZZ1187) to the occupier and explain their responsibilities in respect of current legislation
and regulations, both national and local.
•
Explain and demonstrate how to light and shut down the appliance.
•
In order to gain the best possible fuel economy in relation to the heating and hot water requirements of the household,
carefully explain the operation of the appliance and the use/adjustment of all the system controls.
•
Advise on the precautions required to prevent damage to the appliance; the system and the building in the event of the
appliance being shut down in very cold weather.
•
Explain how to control the temperature of the radiators by use of the controls on the appliance.
•
Explain how, in the event of a fault, the appliance will display a fault code, emphasising that if a fault is indicated 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.
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
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22
•
Explain and demonstrate the function/operation of time/temperature controls and thermostatic radiator valves,
emphasising the economic use of the appliance.
•
If a programmer has been fitted, hand the user instructions that were supplied with the progammer to the occupier.
•
Point out the water pressure guage and explain what it indicates and that if the pressure falls over a period of time
when the system is cold, a water leak should be suspected and that a “competent person” should be contacted.
•
Emphasise the importance of a regular service and that servicing of the appliance MUST only be carried out by a
“competent person” which in normal circumstances would be a Gas Safe registered engineer.
•
As the installer you may wish to offer a service contract yourself, or alternatively you may wish to explain to the
occupier 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.
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:
•
Light the boiler and carry out a pre-service check,
noting any operational faults.
•
Check the gas consumption.
•
Put the appliance in test mode and connect a suitable 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 CO
2
in the flue gas should not be greater than 0.008.
Check that the gas input is at least 90% of the
nominal. * See test mode inputs.
•
Clean the main burner.
•
Clean the heat exchanger.
•
Check the condition of the combustion chamber
insulation. Any cracked or damaged pieces should
be replaced.
•
Wherever possible, remove and clean the condensate 'S' trap (refer to section 6.12) and check the drain for blockage.
•
Check that the flue terminal is unobstructed and that the flue system is sealed correctly.
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.
•
After completing the servicing or exchange of components always
test for gas tightness and carry out functional checks as described
above.
•
When work is complete, the sealing panel MUST be correctly refitted, ensuring that a
good seal is made.
•
lf, for any reason, the condensate 'S' trap has been removed ensure the trap is refilled with
water before reassembling.
•
After servicing, complete the relevant Service Interval Record section of the Benchmark
Checklist located on the inside back pages of this document.
Test Mode
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.
When in max test mode the unit will run at 100% fan
speed. This will give an input of -
*
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.
16S 25S 31S
INPUT NET Kw 16.3 30.6 38.0
GROSS Kw 18.1 34.0 42.1
Flue gas test point
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5.2 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.
5.3 Combustion Assembly Complete
Remove the CVBC (refer to S6.16) 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 the illustration 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.
5.4 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.
Gas/Air Duct
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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 two screws and lifting the door clear.
Should a fault occur the boiler will shut down and the letter E followed by a two digit 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.
5.5 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.
5.6 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.
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6.1 Fault Codes
Code Fault Reason Action
N/A Boiler will not run No call for heat to boiler control board
Check all external controls (if fitted)
Check settings on time clock
Check settings of boiler controls
1 Flame lockout after several attempts Flame not detected
Check gas supply and gas cock
If burner lights, check flame sensor and wiring to control
board
Check operation of gas valve
2 False flame False flame sensed Check wiring on ESYS
3 High water temp limit
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
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 5oof each
other, within calibration period.
Check that there is a bypass in the system
Check that the flow/return sensors are fitted to the pipes
12 Default lockout Eprom memory fault Change ESYS
13
Elapsed the number of
retrials
Change ESYS
21 ADC error Change ESYS
26
Flame signal lost 5 times in 4 minutes
Flame sensing error. Falling gas pressure.
Fan fault. Flue blockage.
Check flame detection lead between sensor and ignition control board. Check gas supply
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.
Check wiring and connections
Check sensor continuity
44
CH rerturn sensor error
(open or short)
Sensor out of normal range.
Temperature sensor not connected or failed
Check wiring and connections
Check sensor continuity
BLOCKING ERRORS
7 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 failed
Check wiring and connections.
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 failed
Check wiring and connections.
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
1
2
3
5
7
8
9
1
10-
2
3
3
3
35/
3
3
4
4
4
4
4
9
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Do
symbols show
on the
MMI?
Is there
a fault
code?
No
No
No
No
No
No
No
Is radiator
symbol and temp
displayed?
Is there a
switched supply
on L1?
Check for a
switched supply on pin 4
of the integral
clock (if fitted)
Refer to table
of fault codes
Check external
controls
Replace MMI
Establish
power supply
Replace MMI
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Check connections
between MMI & boiler
Set a call
for CH on
Is there
a mains supply
to boiler?
Is there
a fault
code?
Does
boiler
fire?
Refer to table
of fault codes
Normal
operation
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Replacement of Parts
6.2 Initial Disassembly
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 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 two
screws and easing it to the left to disengage it from
the LH side of internal casing.
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 descibed 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.
6.5 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.
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.
NOTE: all new boilers are shipped with pre-set error codes stored in the memory.
EHIS
1
3
Front case
retaining screw
Control module fixing screws
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6.7 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 and
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.
6.11 Condensate Drain
Referring to s.5.3, remove the complete combustion assembly including the
burner arm. The flexible condensate pipe is a push fit and the grey 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.
6.9 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, ensuring it is fitted in the same position.
6.10 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.
6.8 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
6.5 and unscrew the discharge connection. Withdraw the retaining clip and
remove the pressure relief valve. Replace with a new component in reverse
order.
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29
6.13 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.
6.14 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.
5.5
1.0
5.5
1.0
4.5
0.5
Flame Detection Electrode Ignition Electrode
Clearances
6.15 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. Replace with a new
component in reverse order ensuring that the grommet sealing the casing
is correctly positioned.
6.12 Condensate Siphon
(Where Fitted)
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.
Fixing screw
Knurled Ring
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30
NOTE: The ESYS label is
identified with the addition
of an ‘E’ alongside the 3
stars.
6.16 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.
6.18 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.
6.19 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 section 6.18 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.
6.17 Flue Temperature Sensor
Carefully pull the two spade connectors from the sensor and unscrew the
sensor from the plastic flue hood. Replace with a new component in
reverse order.
www.johnsonandstarley.co.uk
31
NOTES:
www.johnsonandstarley.co.uk
32
1
2
11
7
7a
13
4
6
5
10
12
3
8
9
7 SHORT SPARE PARTS LIST
14
www.johnsonandstarley.co.uk
33
Item Par t No GC No Description
HE25S
1 R300-0510005 H23-607 Control Panel (complete)
2 1000-0301485 H23-609 Pump
3 1000-0019005 H23-610 Expansion Vessel (with Washer)
4 1000-0019015 H23-612 Pressure Relief Valve
5 1000-0522595 H23-613 Water Temperature Sensors
6 1000-0019045 H23-614 CH Pressure Sensor, Clip & ‘O’ Ring
7 1000-0020895 Tank Connector
7a 1000-0020905 Tank Connector Nut
8 1000-0709655 H23-618 Ignition Electrode, Gasket & Screws (2)
9 1000-0709665 H23-619 Detection Electrode, Gasket & Screws (2)
10 1000-0709675 H23-620 Burner and Small Seal
11 1000-0522575 H23-621 Main Ignition/Control PCB (ESYS)
11 1000-0523395
Main Ignition/Control PCB (ESYS)
from serial No: 69000240
12 1000-0522645 H23-622 Flue Temp. Sensor
13 1000-0522635 H23-623 Fan, Gaskets (3) & Fixing Screws
14 1000-0709635 H23-624 Gas Valve & Venturi Assy (inc fan gasket, pipe gasket & screws (4)
HE31S (as HE25S with the following variations)
1 R320-0510005 Control Panel (complete)
10 1000-0709825 Burner and Small Seal
11 1000-0523405 Main Ignition/Control PCB (ESYS)
14 1000-0709875 Gas Valve & Venturi Assy (inc fan gasket, pipe gasket & screws (4))
HE16S (as HE25S with the following variations)
1 R160-0510005 Control Panel (complete)
10 1000-0709805 Burner and Small Seal
11 1000-0523415 Main Ignition/Control PCB (ESYS)
14 1000-0709865 Gas Valve & Venturi Assy (inc fan gasket, pipe gasket & screws (4))
Johnson & Starley
RELIABILITY YOU CAN TRUST
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.
HOME COMFORT SOLUTIONS
Company Details
Website Address www.johnsonandstarley.co.uk
Email sales@johnsonandstarley.co.uk
marketing@johnsonandstarley.co.uk
Telephone Number 01604 762881 (Main switchboard)
Fax Number 01604 767408
Spares
Telephone 01604 707012
Fax 01604 762884
Sales
Telephone 01604 707012
Fax 01604 764879
Service
Telephone 01604 707011
Fax 01604 707017
Warm Air Upgrade Enquiry Service
Telephone 01604 707026
Fax 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
Fax Number 01604 706467
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Rhosili Road, Brackmills, Northampton NN4 7LZ
In the interests of continuous development Johnson & Starley reserve the right to change specification without prior notice.
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