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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 1434-8
Feb 2017
QUANTEC SYSTEM
ErP
High Efficiency Boiler
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
Quantec 24S
ErP
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G.C. No. 41-416-16
These instructions are to be left with the User
www.johnsonandstarley.co.uk
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Summary of Contents for Johnson & Starley Quantec SYSTEM 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 1434-8 Feb 2017 QUANTEC SYSTEM High Efficiency Boiler 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, Electrical & Gas Information General Safety Information 13 Wiring Diagram Handling the unit Operating the Appliance... -
Page 3: Features
FEATURES Appliance Classification: The QuanTec System has been tested and CE certified by B.S.I Ltd for use with NATURAL Gas G20. FEATURES Rain Trap Flue Sensor View Port Heat Exchanger Ignition/Detection Electrode Flow Thermistor Sensor Condensate Trap Condensate Pipe Control Panel Gas Valve Pump CH Water Pressure Sensor... -
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 PRODUCT DATA SYMBOL VALUE UNIT Condensing boiler Low temperature boiler B11 Boiler Cogeneration space heater Combination Heater Rated heat output rated Ŋ 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 48kg Gas supply 2H - G20 - 20mbar Gas connection 15mm copper Injector size 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”) Condense drain... -
Page 8: Water Connections
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: Dimensions And Clearances
6.2.6 COMPARTMENT INSTALLATIONS: An existing cupboard or compartment may be used, provided that 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. NOTE: a. - Page 11 FLOW THERMISTOR RETURN THERMISTOR PRESSURE SWITCH PRESSURE RELIEF VALVE PUMP GAS INLET CH FLOW CH RETURN FIGURE 6. QUANTEC SYSTEM 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 System Appliance Group Set Components Pack Gas Valve Pack RETURN VALVE PACK Return Valve Pack Flow Valve Pack Accessory Pack Copper connection pack FLOW VALVE PACK Wall Mounting Plate Wall Mounting Template WALL BRACKET Installation &... -
Page 13: Flue Instructions
FLUE INSTRUCTIONS 10.1 The QuanTec System 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 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 15: 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 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 1000-0018970 90° Elbow White Horizontal &...
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Page 17: Optional Roof Outlets
10.11 OPTIONAL ROOF OUTLETS FLAT ROOF PITCHED ROOF FLAT ROOF WEATHER COLLAR PITCHED ROOF WEATHER 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 The standard horizontal flue kit comprises of:... - Page 18 10.13 INSTALLATION OF THE STANDARD FLUE SYSTEMS IMPORTANT NOTE: Before carrying out this procedure ensure seal has not been dislodged from top of the boiler. 55mm 10.13.1 Using the template supplied with the boiler, determine the position of the flue. 10.13.2 If access is available from outside drill a 105mm diameter hole.
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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 condensate drainage pipe should be terminated as recommended below. -
Page 20: Electrical
ELECTRICAL WARNING: This appliance must be earthed. 12.1 DROP DOWN CONTROL PANEL: See paragraph 17.5. 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. 12.2.3 Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS 7671) Wiring Regulations and any local regulations. -
Page 21: Wiring Diagram
WIRING DIAGRAM & SCHEMATIC 3 4 5 6 7 8 FIGURE 22. QUANTEC SYSTEM WIRING DIAGRAM Sales/Spares 01604 707012 Replacement Help Line 01604 707011... -
Page 22: 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. Do not subject any of the isolating valves to heat as the seals may be damaged. 14.1 WATER CONNECTIONS CH 14.1.1... -
Page 23: Reset Procedure
PRESSURE CABINET DRAIN GAUGE ITEM DESCRIPTION Central heating flow. Black handle Gas Valve. Yellow handle Central heating return. Black handle Gas valve test point CH DRAIN POINT PRESSURE CONDENSATE RELIEF DRAIN VALVE CH RETURN CH FLOW SUPPLY DRAIN VALVE OPEN WHEN IN LINE WITH FLOW FIGURE 25. -
Page 24: Initial Lighting
15.4 TEST MODE 15.4.1 To put the unit into test mode, press and hold K1 & K2 for 5 seconds. 15.4.2 Using K1 and K2 to select the required setting. 15.4.3 To reset boiler press the reset button ‘K4’ twice. 15.5 INITIAL LIGHTING 15.5.1... -
Page 25: Water Temperatures
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. Adjust the room thermostat and programmer to normal settings. 15.8.3 Check the condensate drain for leaks and check that it is discharging correctly. 15.8.4 Finally, set the controls to the User’s requirements. -
Page 26: Servicing And Maintenance
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 27: Gaining Access To The Boiler
GAINING ACCESS TO THE BOILER 17.5 LOWER FLIP PANEL & CONTROL PANEL 17.5.1 Lower the flip door and remove the 2 screws cover plugs and unscrew the 2 screws. See figure 30. Drop down and move the control panel assembly. See figure 29. 17.5.2. - Page 28 RAIN TRAP FLUE FLUE TEMPERATURE ADAPTER SENSOR DRAIN PIPE VIEW PORT HEAT EXCHANGER EXPANSION VESSEL IGNITION & FLAME DETECTION ELECTRODE BURNER VENTURI BURNER FLOW INJECTOR THERMISTOR SENSOR PRESSURE RELIEF VALVE (at the rear) AUTOMATIC AIR VENT CONDENSATE TRAP (at the rear) CH WATER PRESSURE SENSOR...
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Page 29: Parts Replacements
PARTS REPLACEMENT 18.1 IMPORTANT: Before commencing with any part replacement the appliance should be isolated from the electrical 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 30: Pcb Assembly
18.7 CONDENSATE TRAP/SIPHON 18.7.1 Refer to paragraph 17.5 and 17.9 18.7.2 Replace and refit in reverse order. 18.8 PCB ASSEMBLY 18.8.1 Refer to paragraph 17.5 18.8.2 Remove the 4 screws retaining the control box cover. 18.8.3 Unplug all lead connections to the PCB assembly 18.8.4 Remove 4 PCB fixing screws, remove PCB and fit new. -
Page 31: Flue Sensor
18.13.7 Refit in reverse order. 18.13.8 Refill the boiler. Refer to paragraph 14.5 18.13.9 Check operation of the boiler. See Section 15. 18.13.10 If you have replace a standard pump with a new HE pump, as follows a. Remove blanking cover from K6 & K7 buttons. b. -
Page 32: Ignition Lockout
FAULT FINDING & BLOCKING CODE 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 boiler Check the gas supply a short time and then extinguish? inlet (>18mbar)? - Page 33 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.
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Page 34: Blocking Codes
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 35: Low Water Pressure
LOW WATER PRESSURE Is the boiler & CH system filled with water and all isolation valves open. Fill and vent the system and open all isolation (check pressure gauge is between 1 & 1.5bar)? valves, check as supply, then reset boiler. Are connections on water pressure sensor secure? Re-fit connections. -
Page 36: List Of Spares
LIST OF SPARES ITEM DESCRIPTION PART No. G. C. No. PCB Assembly 1000-0527025 J21-356 Standard Pump Head 1000-0024665 Includes 3 Pump Head Gasket 1000-1508935 J21-281 High Efficiency Pump Head 1000-0302415 Includes 3 - 6 Pump Head Gasket 1000-1508930 J21-281 Pump Lead 1000-0530220 Pump Lead 1000-0530200... -
Page 37: Code Of Practice
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 38: 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 39: 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 40 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 01604 767408 Anniversary 1922 - 2012 In the interest of continuous developement Johnson & Starley reserve the right to change specifications without prior notice.
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