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Summary of Contents for Johnson & Starley Quantec 16RK
- Page 1 Publication No. ZZ 1463-5 September 2015 QUANTEC REGULAR Kompact High Efficiency Boiler INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS Quantec 16RK G.C. No. 41-416-19 Quantec 24RK G.C. No. 41-416-20 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 Electrical Connections Features Internal Wiring Electrical Testing General Description 13 Wiring Diagram Building Standards & Regulations 14 Connections & Filling Safety & Gas Information Gas Connection General Safety Information Condensate Drain Handling the Unit 15 Commissioning Operating the Appliance Electrical Supply... -
Page 3: Features
FEATURES Appliance Classification: The QuanTec Regular Kompact has been tested and CE certified by B.S.I Ltd for use with NATURAL Gas G20. FEATURES Flue Sensor View Port Ignition/Detection Electrode Flow Thermistor sensors Condensate Trap PCB Assembly & Electrical Connections (inside control panel) Gas Valve Burner Injector Venturi... -
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 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 16RK 24RK PRODUCT DATA SYMBOL VALUE VALUE UNIT Condensing boiler Low temperature boiler B11 Boiler Cogeneration space heater Combination Heater Rated heat output rated Ŋ...
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Page 7: Technical Data
TABLE 2. TECHNICAL DATA 16RK 24RK Maximum weight lift 38kg Gas supply 2H - G20 - 20mbar Gas connection 15mm copper Injector size 4.20mm 4.75mm Heating flow and return 22mm copper Flue terminal diameter 100mm (4”) Condense drain 21.5mm plastic overflow pipe Electrical supply 230V ~ 50Hz Electrical rating... -
Page 8: Preparation
PREPARATION & POSITIONING PREPARATION 6.1.1 ELECTIRCAL CONNECTIONS: Make sure all the electrical cables are in place. 6.1.2 WATER CONNECTIONS: Important. A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping. 6.1.3 The central heating system should be in accordance with BS 6798 and for smallbore and microbore systems, BS 5449. -
Page 9: Dimension & Clearances
COMPARTMENT INSTALLATIONS: An existing cupboard or compartment may be used, provided that 6.2.6 it is modified for the purpose. In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to conform to the following: •... -
Page 10: 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. 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... - Page 11 FLOW THERMISTOR RETURN THERMISTOR CH FLOW GAS INLET CH RETURN FIGURE 7. QUANTEC REGULAR KOMPACT WATER FLOW SCHEMATIC Sales/Spares 01604 707012 Replacement Help Line 01604 707011...
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Page 12: Installation Instructions
INSTALLATION INSTRUCTIONS GAS VALVE PACK CARTON CONTENT Quantec Regular Kompact Appliance Group Set Components Pack Gas Valve Pack Accessory Pack ACCESSORIES PACK Copper connection pack Wall Mounting Plate Wall Mounting Template Installation & Users Instructions INSTRUCTIONS WALL BRACKET FIGURE 8. CARTON CONTENTS WALL MOUNTING TEMPLATE Use a plumb line to make sure the unit is square. -
Page 13: Flue Instructions
FLUE INSTRUCTIONS 10.1 The QuanTec Regular Kompact 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 14 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.
- Page 15 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 16 TABLE 5. DESCRIPTION COLOUR APPLICATION PART No. 60/100 Standard Horizontal Flue Kit White Horizontal 1000-0020070 Turret White Horizontal 1000-0020020 800mm Horizontal Terminal White Horizontal 1000-0019830 Vertical Appliance Adaptor White Vertical 1000-0018990 45° Elbow White Horizontal & Vertical 1000-0018980 90° Elbow White Horizontal &...
- Page 17 10.11 OPTIONAL ROOF OUTLETS FLAT ROOF PITCHED ROOF Pitched Roof Flat Roof Weather Collar Weather Collar 20˚ to 50˚ PITCHED ROOF PITCHED ROOF SIDE VIEW Ridge Terminal Adjustable length Ridge Terminal Flue Extensions Clamps Vertical Appliance Adaptor FIGURE 13. OPTIONAL ROOF OUTLETS 10.12 THE STANDARD HORIZONTAL FLUE SYSTEMS Clamp...
- Page 18 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 19: 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 20 ELECTRICAL WARNING: This appliance must be earthed. 12.1 ELECTRICAL CONNECTIONS 12.1.1 A mains supply of 230Vac ~ 50 Hz is required. 12.1.2 The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage. 12.1.3 Wiring external to the boiler MUST be in accordance with the current I.E.E.
- Page 21 CONNECTIONS 14.1 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer, CABINET DRAIN which must not be overheated when making capillary connections. See Figure 24 for details of the position of the gas connection. 14.1.1 For additional information of the Gas Supply see paragraph 4.3.
- Page 22 15.4 TEST MODE 15.4.1 To put the unit into test mode, press and hold K1 & K2 for 5 seconds. service 15.4.2 Using K1 and K2 to select the required setting. 15.4.3 To reset press ‘K4’ button twice. 15.5 INITIAL LIGHTING FIGURE 28.
- Page 23 Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator. These valves should now be left as set. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20°C temperature drop at each radiator.
- Page 24 SERVICING & MAINTENANCE 17.1 SERVICING SCHEDULE NOTE: it is a statutory requirement that ALL work is carried out by a “competent person” which in normal circumstances would be a GAS SAFE registered engineer. 17.1.1 For the very latest copy of literature for servicing & maintenance instructions, visit our website www. johnsonandstarley.co.uk, where you can download the information.
- Page 25 GAINING ACCESS TO THE BOILER 17.5 REMOVE THE FRONT DOOR 17.5.1 Remove the two screws of the base and lift the front cover off. 17.5.2 Remove the four screws securing the control panel. Swing the control panel down. See figure 29. 17.5.3 Refit in reverse order.
- Page 26 FLUE BURNER ARM TEMPERATURE FIXING NUTS SENSOR VIEW PORT HEAT EXCHANGER IGNITION & FLAME DETECTION ELECTRODE BURNER BURNER VENTURI FIXING NUTS BURNER INJECTOR FLOW & RETURN THERMISTOR SENSORS CONDENSATE TRAP GAS VALVE CASE DRAIN POINT FIGURE 33. QUANTEC REGULAR KOMPACT INTERNAL COMPONENTS PARTS REPLACEMENT 18.1 IMPORTANT:...
- Page 27 18.3 BURNER ASSEMBLY/VENTURI 18.3.1 Refer to paragraph 17.5 18.3.2 Remove the burner assembly. See paragraph 17.7. 18.3.3 To replace the venturi, remove the 4 screws and replace with new. 18.3.4 Inspect the ignition/detection electrode and check the electrode gaps. 18.3.5 Replace with new burner assembly.
- Page 28 FAULT FINDING FLOWCHARTS 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 boler inlet Check the gas supply a short time and then extingush? (>18mbar)?
- Page 29 FAN FAULT Does the wiring from the fan to the PCB have secure connections at both Rectify wiring & connections ends and has not deteriorated? Does the wiring have continuity? Is there 230Vac at the Blue Brown connections to the 3 way connection on Replace the PCB.
- Page 30 RETURN THERMISTOR FAULT Remove the return thermistor from the CH return pipe and disconnect the Fit a new Thermistor. wires. Check the resistance using a suitable multi-meter connected across the thermistor’s terminal pins. Is the thermistor valve correct? Is the wiring securely connected to the low voltage 9 way connector X5 on Check and replace wiring as necessary.
- Page 31 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 32 LIST OF SPARES ITEM DESCRIPTION MODEL PART No. G. C. No. 1000-0527075 16RK J21-328 PCB Assembly 1000-0527085 24RK J21-327 16RK 1000-0711815 J21-312 Burner Arm Assembly 24RK 1000-0711835 J21-311 Burner Arm Fibre Seal Braid Gasket 1000-1509000 J21-236 Burner Door Seal 1000-1509860 J21-237 Venturi Gasket 1000-1508630...
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Page 33: 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 both manufacturers and installers.* • Be competent and qualified to undertake the work required. The purpose is to ensure that •... -
Page 34: 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 35: 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 36 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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