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Johnson & Starley Reno HE25S Installation Maintenance And Service Manual

High efficiency system boiler
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Johnson & Starley
Publication ZZ1186/1
Product Identification No: 87B 074
Reno
High Efficiency System Boiler
Model: HE25S
GC No: 41-416-02
Installation, Maintenance and Service Instructions
BS EN ISO 9001 : 2000
Tel: 01604 762 881
www.johnsonandstarley.co.uk

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Summary of Contents for Johnson & Starley Reno HE25S

  • Page 1 Johnson & Starley Publication ZZ1186/1 Product Identification No: 87B 074 Reno High Efficiency System Boiler Model: HE25S GC No: 41-416-02 Installation, Maintenance and Service Instructions BS EN ISO 9001 : 2000 Tel: 01604 762 881 www.johnsonandstarley.co.uk...

  • Page 2: Table Of Contents

    CONTENTS Section Description Page Important Information Appliance Description Fitting Commissioning and Handover Servicing Schedule Fault Finding & Repair Short Spare Parts List BENCHMARK LOG BOOK 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.

  • Page 3: Important Information

    1. IMPORTANT INFORMATION IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, (i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULA- TIONS (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.
  • Page 4 2.2 Technical Data Maximum Lift Weight Total Weight (installed) 42.5 Kg 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 73 litres fitted expansion vessel, pressurised at 1 bar Electrical supply...
  • Page 5 2.3 Dimensions and Clearances: 425mm 765mm 310mm 200mm Work Surface Fig. 2-1 Minimum 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, similarly a minimum gap of 5mm should be left.
  • Page 6 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 &...
  • Page 7 Controls: As a minimum it is recommended that a 2 chan- nel 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 BOILER thermostat is fitted.

  • Page 8: Fitting

    3. FITTING 3.1 Unpacking the Appliance: The appliance is supplied packaged in two cartons which are strapped together and need separation prior to unpacking. The first carton contains the wall template and jig, the second contains the boiler and controls. Caution: this appliance exceeds the recommended weight for a one-man lift as detailed in the Manual Handling Operations, 1992 Regulations.
  • Page 9 3.5 Condensate Drain: The condensate drain utilises plastic 3/4 inch push fit or adhesive overflow pipes and fittings. It should be piped to drain, preferably within the building, maintaining a 2.5° fall away from the appliance. If the drain is routed to outside it should be to a drain or soak away.
  • Page 10 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.
  • Page 11 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 projec- tions especially under a balcony or near to a drainpipe.
  • Page 12 If an extended horizontal flue is being used (any flue length longer than the standard kit) it must have a con- tinuous 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.
  • Page 13 Typical Concentric Flue Configurations Fig.3-7 Raised Horizontal Flue (Can also be LH or RH) Standard Flue Kit Fig.3-6 Elbow Horizontal Rear Flue 1m Extension (Standard Flue Kit) Vertical Appliance Adaptor Fig.3-8 Horizontal Side Flue (Can be left or right) Standard Flue Kit 500 mm Extension Fig.3-9 Offset Vertical Flue...
  • Page 14 Typical Twin Flue Configurations Full details of twin flue components can be found in publication ZZ1191 Fig.3-12 Horizontal Air & Flue Ducts Fig.3-14 May be LH RH or as shown. Standard 90 Raised Horizontal Air & Vertical Flue Outlet (offset) elbow Standard 90 and 45...
  • Page 15 60/100 Concentric flue systems Overall Heat Assembled Direction input Flue Length 42 Horizontal 45 Horizontal 90 Horizontal 9800 Vertical 1140 101.5 Vertical 8540 Vertical 17740 Output in relation to flue resistance. 90 100 110 120 130 Flue Pressure Drop (Pascals) Table.3-4 Table.3-3 60/100 Flue Components...
  • Page 16 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 connec- tions to the heating system must be through a common dou- ble pole isolation switched spur that has a 3 mm separation on each pole and has a 3A rated fuse.
  • Page 17 Fig.3-18 Functional Flow Diagram www.johnsonandstarley.co.uk...

  • Page 18: Illustrated Wiring Diagram

    REMOVE THIS LINK TO FIT EXTERNAL CONTROLS MAINS SPARK FLAME FLUE CH FLOW CH RETURN SUPPLY THERMISTOR ELECTRODE DETECTION THERMISTOR THERMISTOR 230V~50Hz ELECTRODE or br CVBC y bk PUMP br b br or MMI PCB MAINS SWITCH r bk bk y b r b r CONNECTIONS N SL br b...

  • Page 19: Commissioning And Handover

    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.

  • Page 20: Servicing Schedule

    • 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 circum- stances would be a CORGI registered engineer.
  • Page 21 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.

  • Page 22: Fault Finding & Repair

    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 oxi- dation.
  • Page 23 6.1 Fault Codes Code Fault Reason Action Check all external controls if fitted. No call for heat to boiler control Boiler will not run Check settings of the time clock. board Check settings of boiler controls Check gas supply and gas cock Flame lockout after several If burner lights check flame sensor and wiring Flame not detected...
  • Page 24 Replacement of Parts 6.2 Initial Disassembly Front case retaining screw 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.
  • Page 25 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.
  • Page 26 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.
  • Page 27 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.
  • Page 28 6.18 Fan Unscrew the gas joint at the top of the gas cock and remove the CVBC (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.

  • Page 29: Short Spare Parts List

    7 SHORT SPARE PARTS LIST Item Part No GC No Description 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 (with nut & olive) 5 1000-0522595 H23-613 Water Temperature Sensors 6 1000-0019045 H23-614 CH Pressure Sensor, Clip &...
  • Page 30 Notes www.johnsonandstarley.co.uk...
  • Page 31 Notes www.johnsonandstarley.co.uk...
  • Page 32 Johnson & Starley Tel: 01604 762 881 www.johnsonandstarley.co.uk www.johnsonandstarley.co.uk...