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H E A T I N G
QUANTEC COMBI
High Efficiency
Combination
Boiler
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
QuanTec 30C
ErP
QuanTec 24C
ErP
These instructions are to be left with the User
H O T W A T E R
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G.C. No. 47-416-12
G.C. No. 47-416-13
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V E N T I L A T I O N
ErP
www.johnsonandstarley.co.uk
Publication No. ZZ 1432-6
September 2015
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Summary of Contents for Quantec 30C
- Page 1 V E N T I L A T I O N Publication No. ZZ 1432-6 September 2015 QUANTEC COMBI High Efficiency Combination Boiler INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS QuanTec 30C G.C. No. 47-416-12 G.C. No. 47-416-13 QuanTec 24C These instructions are to be left with the User www.johnsonandstarley.co.uk...
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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
Variable CH and DHW temperature controls are fitted on the user control. • Central heating (CH) output is fully modulating with a range of 30C is 4.58 to 25.6kW, and 24C is 4.83 to 18.48kW • Instant domestic hot water (DHW) output is also fully modulating with a maximum of 30C is 30.3kW, and 24C is 24.8kW... -
Page 4: Building Standards & Regulations
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 QuanTec becoming a trap for system debris. Once the system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added. Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. -
Page 5: Handling The Unit
It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS 6891. Whilst the principle of the 1:1 gas valve ensures the QuanTec range is able to deliver it’s full output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant. - Page 6 TECHNICAL DATA EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU. TABLE 1. ErP TECHNICAL DATA 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 Maximum weight lift 37kg 38kg Gas supply 2H - G20 - 20mbar Gas connection 15mm copper Injector size 4.2mm 4.75mm 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: Preparation
MAXIMUM MINIMUM MAXIMUM MINIMUM TABLE 3. PERFORMANCE DATA case off case on Burner CO² (%) ± 0.5 PERFORMANCE DATA FOR CENTRAL HEATING CH input Q Gross 18.87 4.88 26.6 m³/h 1.75 0.45 2.47 0.48 Gas Consumption Non condensing 16.76 4.83 23.4 4.58 CH Output... -
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
The boiler connections are made on the boiler connection tails. 7.1.3 The minimum clearances must be maintained for operation and servicing. 7.1.4 Additional space will be required for installation, depending upon site conditions. FIGURE 4. QUANTEC COMBI DIMENSIONS CLEARANCES 7.2.1 Bottom clearance after installation reduced to 5mm. -
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
DHW COLD INLET FILTER DHW FLOW AUTOMATIC RESTRICTOR THERMISTOR AIR VENT PRESSURE SWITCH PRESSURE DHW FLOW RELIEF SENSOR VALVE PUMP DRAIN FILLING LOOP CH FLOW DHW OUTLET GAS INLET DHW INLET CH RETURN FIGURE 6. QUANTEC COMBI WATER FLOW SCHEMATIC www.johnsonandstarley.co.uk... -
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... -
Page 14: Flue Instructions
FLUE INSTRUCTIONS 10.1 The QuanTec Combi 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. - 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
FLUE REQUIREMENTS & GENERAL INFORMATION 10.9.1 Horizontal and vertical concentric flues (60/100mm diameter) with balanced terminals may be installed on all the QuanTec appliances. 10.9.2 If an extended horizontal flue is being used it must have a continuous fall back towards the appliance of 3°... - 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.
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Page 20: Condensate Drain
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... -
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
15.4.2 Using K1 and K2 to select the required setting. 15.4.3 To reset press “K4” button twice. FIGURE 26. QUANTEC COMBI LED DISPLAY 15.5 INITIAL LIGHTING 15.5.1 Check that the system has been filled and the boiler is not air-locked. Ensure the automatic air vent cap is open. -
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. Explain and demonstrate the lighting and shutting down procedures. 16.3 The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption. -
Page 28: Flue Inspection & Checks
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. 17.3.7 Check the gas consumption. -
Page 29: Heat Exchanger
DHW FILTER & DIVERTER PLATE HEAT GAS VALVE PUMP HEAD FLOW REGULATOR VALVE EXCHANGER (at the rear) (in front of plate heat exchanger) FIGURE 35. QUANTEC INTERNAL COMPONENTS FIGURE 35 QUANTEC INTERNAL COMPONENTS Sales/Spares & Replacement Help Line 01604 762881... - Page 30 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. 19.7.5 Check operation of the boiler. See Section 15. 18.8 CONDENSATE TRAP/SIPHON 18.8.1...
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Page 32: Automatic Air Vent 12
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 &...
- Page 36 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.
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Page 37: 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 38 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 39 LIST OF SPARES ITEM DESCRIPTION MODEL PART No. G. C. No. J21-369 1000-0527055 PCB Assembly J21-370 1000-0527065 Standard Pump Head 1000-0525565 J21-280 Pump Head Gasket 1000-1508935 J21-281 PWM High Efficiency Pump Head 1000-0302415 1000-0711815 J21-313 Burner Arm Assembly 1000-0711835 J21-311 Burner Arm Fibre Seal Braid Gasket 1000-1509000 J21-236...
- Page 40 1000-0711755 J21-359 Injector (4.75) 1000-0711135 J21-318 ‘O’ Ring 1000-2501860 J21-235 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 J21-267 Flow/Return Temperature Sensor...
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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.
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