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sustainable solutions under one roof
H E A T I N G
H O T W A T E R
V E N T I L A T I O N
Publication No. ZZ 1430-6
September 2015
QUANTEC HR28C
ErP
High Efficiency Boiler
with Passive Flue
Gas Heat Recovery
INSTALLATION, COMMISSIONING
OMMISSIONING
& SERVICING INSTRUCTIONS
Quantec HR28C
ErP
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G.C. No. 47-416-11
These instructions are to be left with the User
www.johnsonandstarley.co.uk
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Summary of Contents for Johnson & Starley Quantec HR28C ErP
- Page 1 sustainable solutions under one roof H E A T I N G H O T W A T E R V E N T I L A T I O N Publication No. ZZ 1430-6 September 2015 QUANTEC HR28C High Efficiency Boiler with Passive Flue Gas Heat Recovery INSTALLATION, COMMISSIONING...
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Page 2: Table Of Contents
CONTENTS 12 Electrical The Benchmark Scheme Drop Down Control Panel Features Electrical Connections Internal Wiring General Description To Add Thermostat/Programmer Thermostats & Timer Kits Building Standards & Regulations Operational System Control Electrical Testing Safety & Gas Information General Safety Information 13 Wiring Diagram Handling the Unit Operating the Appliance... -
Page 3: Features
FEATURES Appliance Classification: The QuanTec HR28C has been tested and CE certified by B.S.I Ltd for use with NATURAL Gas G20. FEATURES Rain Trap Flue Test Point Flue Sensor View Port Heat Exchanger Ignition/Detection Electrode Flow Thermistor Sensor Condensate Trap Combustion Fan Diverter Valve Control Panel... -
Page 4: Building Standards & Regulations
BUILDING STANDARDS & REGULATIONS STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS, i.e. GAS SAFE REGISTERED INSTALLERS. GAS SAFE MEMBERSHIP ENQUIRIES TEL: 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. -
Page 5: Handling The Unit
HANDLING THE UNIT 4.2.1 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 removal from its packaging and during installation procedure. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling. 4.2.2 It should be noted that this appliance may contain sharp edges. - Page 6 TECHNICAL DATA EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. TABLE 1. ErP TECHNICAL DATA HR28C PRODUCT DATA SYMBOL VALUE UNIT Condensing boiler Low temperature boiler B11 Boiler Cogeneration space heater Combination Heater Rated heat output rated Seasonal space heating energy efficiency Energy efficiency class USEFUL HEAT OUTPUT At rated heat output and high temperature regime...
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Page 7: Gas Supply
TABLE 2. TECHNICAL DATA HR28C Maximum weight lift 40kg Gas supply 2H - G20 - 20mbar Gas connection 15mm copper Injector size 3.65mm Domestic hot water flow and return 15mm copper Heating flow and return 22mm copper Safety valve discharge 15mm copper Flue terminal diameter 100mm (4”) -
Page 8: Performance Data
MAXIMUM MINIMUM TABEL 3. PERFORMANCE DATA case off case on Burner CO² (%) ± 0.5 2.89 Maximum gas rate PERFORMANCE DATA FOR CENTRAL HEATING 21.6 CH input Q Gross 23.87 4.99 m³/h Gas Consumption Non condensing 21.1 4.41 CH Output Condensing 23.07 4.08... -
Page 9: Positioning
BOILER CONTROL INTERLOCK: Central heating system controls should be installed to ensure the boiler 6.1.9 is switched off when there is no demand for heating, in compliance with Building Regulations. 6.1.10 THERMOSTATIC RADIATOR VALVES: Central heating systems utilising thermostatic radiator valve controls in individual rooms, need one space heating temperature control over a living/dining area or hallway having a heating requirement of at least 10% of the minimum boiler heat output with a minimum 500W radiator, which should be achieved using a room thermostat. -
Page 10: Dimension & Clearances
DIMENSIONS & CLEARANCES DIMENSIONS 7.1.1 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. -
Page 11: Heating System
HEATING SYSTEM The installation must comply with all relevant national and local regulations. All components of the system must be suitable for a working pressure of 3 bar and temperature of 110°C. Extra care should be taken in making all connections so that the risk of leakage is minimised. NOTE: a. -
Page 12: Filling Loop
FLOW THERMISTOR RETURN THERMISTOR DHW FLOW TURBINE DIVERTER VALVE PLATE TO PLATE HEAT EXCHANGER DHW COLD INLET FILTER DHW FLOW AUTOMATIC RESTRICTOR THERMISTOR AIR VENT PRESSURE SWITCH PRESSURE RELIEF VALVE PUMP DRAIN FILLING LOOP CH FLOW DHW OUTLET GAS INLET DHW INLET CH RETURN FIGURE 6. -
Page 13: Installation Instructions
INSTALLATION INSTRUCTIONS GAS VALVE PACK FILLING LOOP PACK CARTON CONTENT Quantec Combi Appliance Group Set Components Pack Gas Valve Pack RETURN VALVE PACK Filling Loop pack Return Valve Pack Flow Valve Pack DHW Pack WALL Accessory Pack BRACKET FLOW VALVE PACK Copper connection pack Wall Mounting Plate Wall Mounting Template... -
Page 14: Flue Instructions
FLUE INSTRUCTIONS 10.1 The QuanTec HR28C Boiler is certified as a heating 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. - Page 15 D, E FIGURE 10. FLUE TERMINAL POSITIONS TABLE 4 TERMINAL POSITION MIN DISTANCE Directly below an opening, air brick, opening window etc 300mm Above an opening, air brick, opening window, etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes.
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Page 16: Flue Terminal Positions
10.6 TYPE OF FLUE SYSTEMS 10.6.1 The standard concentric flue system 60/100mm (100mm diameter). 10.6.2 A Flexible flue kit (FFK-5) 60/100mm (100mm diameter). For further information contact the sales office at Johnson & Starley Ltd. Telephone 01604 762881. 10.6.3 The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air duct and the adjacent services. - Page 17 10.10 CONVENTIONAL 60/100mm FLUE ACCESSORY PARTS No’s TABLE 5. DESCRIPTION COLOUR APPLICATION PART No. White Horizontal 1000-0020070 60/100 Standard Horizontal Flue Kit Turret White Horizontal 1000-0020020 800mm Horizontal Terminal White Horizontal 1000-0019830 Vertical Appliance Adaptor White Vertical 1000-0018990 45° Elbow White Horizontal &...
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Page 18: Optional Roof Outlets
10.11 OPTIONAL ROOF OUTLETS FLAT ROOF PITCHED ROOF Pitched Flat Roof Roof Weather Weather Collar Collar 20˚ to 50˚ PITCHED ROOF PITCHED ROOF SIDE VIEW Ridge Terminal Adjustable length Ridge Terminal Flue Extensions Clamps Vertical Appliance Adaptor FIGURE 12. OPTIONAL ROOF OUTLETS 10.12 THE STANDARD HORIZONTAL FLUE SYSTEMS Clamp... - Page 19 10.13 INSTALLATION OF THE STANDARD FLUE SYSTEMS IMPORTANT NOTE: Before carrying out this procedure ensure seal has not 55mm been dislodged from top of the boiler. Using the template supplied with the boiler, determine the position of the flue. If access is available from outside drill a 105mm diameter hole. If no access is available refer to section 2.
- Page 20 CONDENSATE DRAIN 11.1 Where a new or replacement boiler is being installed, access to an internal “gravity discharge” termination should be one of the main factors considered when determining potential boiler locations, the NOTE:- Visible air break and trap condensate drainage pipe should be terminated as recommended. not required if there is a trap MINIMUM INTERNAL with a minimum condensate...
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Page 21: Electrical
ELECTRICAL WARNING: This appliance must be earthed. See paragraph 17.5. 12.1 DROP DOWN CONTROL PANEL: 12.2 ELECTRICAL CONNECTIONS 12.2.1 A mains supply of 230Vac ~ 50 Hz is required. 12.2.2 The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage. 12.2.3 Wiring external to the boiler MUST be in accordance with the current I.E.E. -
Page 22: Wiring Diagram
WIRING DIAGRAM FIGURE 22. WIRING DIAGRAM www.johnsonandstarley.co.uk... -
Page 23: Connections & Filling
CONNECTIONS & FILLING NOTES. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown. See Figure 25. Ensure each union is fitted with fibre seals provided. On the DHW inlet use the filter washer provided. DO NOT use a fibre seal. - Page 24 PRESSURE CABINET DRAIN GAUGE FILLING LOOP CONDENSATE DRAIN CH DRAIN POINT PRESSURE RELIEF VALVE DRAIN CH FLOW DHW INLET CH RETURN OUTLET SUPPLY ITEM DESCRIPTION ITEM DESCRIPTION CH - Central heating flow. Black handle CH - Central heating return. Black handle DHW - Domestic hot water outlet Filling loop isolation valves.
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Page 25: Initial Lighting
15.3 RESET PROCEDURE To reset boiler press the reset button ‘K4’ twice. Item Description CH - Central Heating + CH - Central Heating - Installer information Reset Summer/Winter mode DHW - Domestic Hot Water - DHW - Domestic Hot Water + 15.4 TEST MODE service... -
Page 26: Flushing The System & Water Circulation
IMPORTANT GENERAL CHECKS 15.9 DOMESTIC HOT WATER (DHW) MODE 15.9.1 Fully open all DHW taps in turn and ensure that water flows freely from them. 15.9.2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate. This is factory set to give a DHW temperature rise of approximately 35°C at the flow rate stated Section 5 Technical Data. -
Page 27: Handing Over
HANDING OVER 16.1 Hand the User Instructions to the householder and explain their responsibilities under the relevant national regulations. 16.2 This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have supervision or been given instruction concerning use of the appliance by a person responsible for their safety. -
Page 28: Flue Inspection & Checks
17.3.2 Clean the heat exchanger & condensate trap/siphon. 17.3.3 Check the main injector for blockage or damage. 17.3.4 Check that the flue terminal is unobstructed and that the flue system is sealed correctly. 17.3.5 After completing the servicing or exchange of components always test for gas tightness. 17.3.6 When work is complete the front panel MUST be correctly refitted, ensuring that a good seal is made. -
Page 29: Heat Exchanger
17.8 HEAT EXCHANGER Refer to paragraphs 17.5 to 17.7 17.8.1 Inspect the inside of the combustion chamber, with a soft brush remove any deposits that may have occurred. Flush with clean water. DO NOT use any chemicals. 17.8.2 Inspect the heat exchangers insulation at the front and back of the combustion chamber for any signs of damage. -
Page 30: Gas Valve
PARTS REPLACEMENT Before commencing with any part replacement the appliance should be isolated from the electrical 18.1 IMPORTANT: 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. - Page 31 18.7 DIVERTER VALVE ACTUATOR HEAD 18.7.1 Refer to paragraph 17.5 18.7.2 Remove the electrical connection. 18.7.3 Pull out the retaining clip and lift out the diverter head. 18.7.4 Fit new actuator head and refit in reverse order. 18.7.5 Check operation of the boiler. See Section 15. 18.8 CONDENSATE TRAP/SIPHON 18.8.1...
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Page 32: Pump
18.14 SAFETY PRESSURE RELIEF VALVE 18.14.1 Drain CH circuit. See paragraph 18.11. 18.14.2 Withdraw the clip securing the safety valve. 18.14.3 Undo the safety valve union connection. 18.14.4 Remove and refit new valve. 18.14.5 Refit in reverse order. 18.14.6 Refill boiler. See paragraph 14.5. 18.14.7 Check operation of boiler. -
Page 33: Expansion Vessel
d. Using either CH+ (K1) or CH - (K2) buttons select either 0 or 1. ‘0’ is for the fixed speed standard efficiency pump. ‘1’ is for the PWM High Efficiency pump. e. Press and release RESET (K4) button to return the display to P 27. Exit installer mode by pressing and releasing RESET again for ‘t 5’... - Page 34 FAULT FINDING FLOWCHARTS Should a fault occur, the boiler will shut down and these error codes will be displayed. Should a fault occur, the boiler will shut down and these error codes will be displayed. IGNITION LOCKOUT If the boiler is reset does the boiler ignite for Is the gas pressure available at the boiler Check the gas supply a short time and then extinguish?
- Page 35 FLAME CIRCUIT FAILURE Replace the PCB. VALVE FEED BACK ERROR Unplug the Gas Valve. Is there resistance between pins 114Ω. Replace Gas Valve. Replace Board. EEPROM LOCKOUT Replace the PCB. FLOW/RETURN SENSOR CALIBRATION CHECK Fill and vent the system and open all isolation Is the boiler &...
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Page 36: Water Pressure Sensor
OUTDOOR SENSOR ERROR service Is the outdoor sensor connected? Reset outside temperature compensation (P20) to 0 Is the resistance of the outside temperature sensor between 5 and 30 Replace sensor kohms? Replace board WATER PRESSURE TOO HIGH Is the water system pressure under 2.8bar? Release water from system. - Page 37 FLUE TEMPERATURE SENOR LOCKOUT Connect the wiring. Is the wiring securely connected to sensor? See graph Figure 51. Is the wiring secure to 9 way connector X5 on Interface PCB Secure connection. Replace the PCB NO DISPLAY Supply power to boiler. Is there 230VAC to the boiler at L &...
- Page 38 FLOW THERMISTOR FAULT Securely connect the wiring to the flow Thermistor. Is the wiring securely connected to the Flow thermistor? Disconnect the wiring from the Flow Thermistor. Check the resistance using a suitable multi-meter connected across the Fit new Thermistor. Thermistor’s terminal pins.
- Page 39 LIST OF SPARES ITEM DESCRIPTION PART No. G. C. No. PCB Assembly 1000-0526425 J21-296 Standard Pump Head 1000-0525565 J21-280 Pump Head Gasket 1000-1508930 J21-281 High Efficiency Pump Head 1000-0302415 Burner Arm Assembly 1000-0711815 J21-313 Burner Arm Fibre Seal Braid Gasket 1000-1509000 J21-236 Burner Door Seal...
- Page 40 Injector (4.75) 1000-0711135 J21-234 ‘O’ Ring 1000-2501860 J21-235 DHW Flow Turbine Sensor 1000-0526465 J21-262 Pressure Relief Valve 1000-0023235 J21-269 Washer 1000-3002060 J21-286 Auto Air Vent 1000-0023275 J21-271 CH Pressure Sensor 1000-0525555 J21-268 15mm ‘O’ Ring Clip Pressure Sensor Harness 1000-0526945 J21-278 DHW Temperature Sensor 1000-0302195...
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Page 41: Customer Service
Code Of Practice For the installation, commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on Standards of Work • Be competent and qualified to undertake the work both manufacturers and installers.* required. The purpose is to ensure that •... -
Page 42: Gas Boiler System Commissioning Checklist
GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. -
Page 43: Service Record
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. SERVICE 01 SERVICE 02 Date:... - Page 44 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 01604 767408 Johnson & Starley Dravo Division Industrial H&V Sales 01604 707022 sales@johnsonandstarley.co.uk www.dravo.co.uk Anniversary 1922 - 2012 In the interest of continuous development Johnson & Starley reserve the right to change specifications without prior notice.