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Table of Contents
Related Manuals for Johnson & Starley QuanTec 30C
Summary of Contents for Johnson & Starley QuanTec 30C
- Page 1 Publication No. ZZ 1432-2 September 2013 QUANTEC COMBI High Efficiency Combination Boiler INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS QuanTec 30C G.C. No. 47-416-12 QuanTec 24C G.C. No. 47-416-13 These instructions are to be left with the User www.johnsonandstarley.co.uk...
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Page 2: Table Of Contents
CONTENTS Features General Description Building Standards & Regulations Safety & Gas Information Technical Data Preparation & Positioning Dimension & Clearances Heating System Installation Instructions Flue Instructions Condensate Drain Electrical Wiring Diagram Connections & Filling Commissioning Handing Over Servicing & Maintenance Parts Replacements Fault Finding Flowcharts &... -
Page 3: Features
FEATURES Appliance Classification: The QuanTec Combi 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 Return Thermistor Sensor Combustion Fan Condensate Trap DHW Water Temperature Sensor Diverter Valve... -
Page 4: Building Standards & Regulations
BUILDING STANDARDS & REGULATIONS This appliance must be installed by a Gas Safe Registered Engineer in accordance with the current editions of: • Building Standards (Scotland) (Consolidation) Regulations • Building Regulations • Gas Safety (Installation and Use) Regulations (as amended) •... -
Page 5: Technical Data
GAS SUPPLY 4.3.1 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: Preparation & Positioning
TABLE 2. QUANTEC DATA PERFORMANCE DATA MAXIMUM MINIMUM MAXIMUM MINIMUM case off Burner CO² (%) case on ± 0.5 PERFORMANCE DATA FOR CENTRAL HEATING CH input Q Gross 18.87 4.88 26.6 Gas Consumption m³/h 1.75 0.45 2.47 0.48 Non condensing 16.76 4.83 23.4... - Page 7 6.1.9 BOILER CONTROL INTERLOCK: Central heating system controls should be installed to ensure the boiler 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.
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Page 8: 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 9: 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 10 FLOW THERMISTOR RETURN THERMISTOR DIVERTER VALVE PLATE TO PLATE HEAT EXCHANGER 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 CH RETURN DHW INLET FIGURE 6.
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Page 11: 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 12: 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. 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 13 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 sale office at Johnson & Starley Ltd. Telephone 01604 707000 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 14 10.8 PLUME TERMINAL OUTLETS 10.8.1 A flue duct outlet of an appliance should be at least 600mm from the boundary line when facing it and at least 300mm from the boundary line when running parallel to it. See Figure 11. NOTE: When the flow of products is at an angle to the boundary, the 600mm dimension may be measured in the direction of the flow, as long as the terminal is not less than 300mm from the boundary.
- Page 15 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 12. OPTIONAL ROOF OUTLETS 10.12 THE STANDARD HORIZONTAL FLUE SYSTEMS Clamp...
- Page 16 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 17: 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 18: 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. 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 19: Wiring Diagram
WIRING DIAGRAM FIGURE 22. WIRING DIAGRAM Sales/Spares 01604 707012 Replacement Help Line 01604 707011... -
Page 20: 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 21 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.
- Page 22 15.3 RESET PROCEDURE To reset boiler press the reset button ‘K4’. 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 15.4.1 To put the unit into test mode, press and hold K1 &...
- Page 23 15.5.3 Check that the drain cock is closed and that the CH and DHW isolating valves (A, E, and D) are OPEN. 15.5.4 Check that the electrical supply is OFF. 15.5.5 Check that the gas service cock is OPEN. (C) 15.5.6 Slacken the screw in the inlet pressure test point (H) and connect a gas pressure gauge via a flexible tube.
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Page 24: 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 25 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 26 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.
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Page 27: 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 28: Draining The Appliance
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... - Page 29 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 30 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. f. Exit installer mode by pressing and releasing RESET again for ‘t 5’ to flash followed by pressing and releasing ‘ ‘ (K5).
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Page 31: Fault Finding Flowcharts & Blocking Codes
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 boiler Check the gas supply a short time and then extinguish? inlet (>18mbar)? Check wiring connection from gas valve to... - Page 32 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 33 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 34 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 35 NO CH OPERATION BUT DHW WORKS OK Is the mode knob in the Winter position? Toggle to the Winter position. Switch the timer and room Are the timer and room thermostat switched on? thermostat on. Are the radiator valves open? Open the radiator valves.
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Page 36: List Of Spares
LIST OF SPARES ITEM PART No. DESCRIPTION 1000-0527055 PCB Assembly 1000-0527065 1000-0525565 Pump Head 1000-0525575 Diverter Head 1000-0025015 Diverter Cartridge 1000-0019005 Expansion Vessel 1000-0023235 Pressure Relief Valve 1000-0302195 DHW Temperature Sensor 1000-0301955 Plate Heat Exchanger 1000-0526515 DHW Flow Sensor 1000-0525555 CH Pressure Sensor www.johnsonandstarley.co.uk... - Page 37 1000.0711785 Ignition/Detection Electrode 24C 1000-0711815 Burner Assembly 30C 1000-0711835 1000-0526525 Flue Sensor 1000-0526415 Combustion Fan 1000-0710925 Gas Valve 1000-0711825 Venturi 1000-0710785 1000-0710935 Injector 1000-0711415 1000-0024525 Condensate Trap Sales/Spares 01604 707012 Replacement Help Line 01604 707011...
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Page 38: Benchmark Checklist And Service Record
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 Johnson & Starley Dravo Division Industrial H&V Rhosili Road, Brackmills, Northampton NN4 7LZ Sales 01604 707022 sales@johnsonandstarley.co.uk dravo@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk www.dravo.co.uk Reception 01604 762881 Sales/Spares 01604 707012 Service/Warm air upgrade 01604 762881 Warm air upgrade 01604 707011 Anniversary 1922 - 2012 In the interest of continuous development Johnson &...