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Johnson & Starley HE16S Installation, Maintenance & User Instructions
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Johnson & Starley HE16S Installation, Maintenance & User Instructions

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Johnson & Starley
H H i i g g h h E E f f f f i i c c i i e e n n c c y y S S y y s s t t e e m m B B o o i i l l e e r r s s
Installation, Maintenance & Service Instructions
Natural Gas G20:
HE16S - GC No: 41-416-05
from Serial No. 76000247
HE25S - GC No: 41-416-02
from Serial No. 69000778
HE31S - GC No: 41-416-04
from Serial No. 77000182
R E L I A B I L I T Y
Y O U
www.johnsonandstarley.co.uk
SYSTEM SERIES
C A N
T R U S T
Publication ZZ1186-13 June 2010
Product Identification No: 87B 074
Propane G31 Variants:
HE16SP - GC No: 41-416-09
from Serial No. 82000102
HE25SP - GC No: 41-416-12
from Serial No. 72000112
HE31SP - GC No: 41-416-08
from Serial No. 84000101
The Johnson & Starley Reno
range has an energy rating A on
For more information see
This is a certification mark.
a scale of A to G.
www.boilers.org.uk

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Summary of Contents for Johnson & Starley HE16S

  • Page 1 H H i i g g h h E E f f f f i i c c i i e e n n c c y y S S y y s s t t e e m m B B o o i i l l e e r r s s Installation, Maintenance & Service Instructions Propane G31 Variants: Natural Gas G20: HE16SP - GC No: 41-416-09 HE16S - GC No: 41-416-05 from Serial No. 82000102 from Serial No. 76000247 HE25SP - GC No: 41-416-12 HE25S - GC No: 41-416-02 from Serial No.

  • 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 THE BENCHMARK SCHEME 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. GAS SAFE REGISTERED INSTALLERS. GAS SAFE MEMBERSHIP ENQUIRIES - 0800 408 5500 ) IN ACCOR- DANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
  • Page 4 2.2 Technical Data HE25S HE16S HE31S Maximum Lift Weight 33.0 Kg 33.0 Kg 34.0 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 fitted...
  • Page 5 Nat Gas G20 Maximum Minimum CH Input Q 16.3 25.5 30.7 3.81 7.14 9.18 Gross 18.1 28.3 34.0 4.23 7.92 10.1 Gas Consumption 3.16 0.40 0.74 0.85 Non Condensing 16.0 25.0 30.0 4.08 CH Output P Condensing 17.8 27.85 32.6 3.75 7.76 SEASONAL EFFICIENCY (SEDBUK)
  • Page 6 The supply must be capable of providing a steady inlet working pressure to the appliance of 20 mbar at a rate of 1.7 /h (HE16S) 2.7 (HE 25S) and 3.16 m /h (HE31S) (Calculated with a Gas CV of 38.7MJ/m...
  • Page 7 1.5 m/s and it should be noted that the appliance is designed to operate with a temperature differential of 20 between flow and return. The maximum flow rate is 0.19 kg/s (HE16S) 0.3 kg/s (HE25S) and 0.38 kg/s (HE31S) which through a 22mm pipe gives a velocity of 0.75 m/z (HE16S) 1.00 m/s. (HE25S) and 1.25 m/s (HE31S) Therefore, the recommended minimum pipe size for the main carcass is 22mm.
  • Page 8 GPG 302 NOTE: a differential pressure bypass valve MUST be installed to maintain the following minimum flow rates: Additional Expansion Vessel 12 L/min - HE16S (if required) 18 L/min - HE25S 23 L/min - HE31S differential at maximum heat input).
  • Page 9 Fig 2-4 Schematic Diagram (Waterflow) www.johnsonandstarley.co.uk...

  • Page 10: Fitting

    3. FITTING 3.1 Unpacking the Appliance: CARTON CONTENTS The appliance is supplied packaged complete in one carton • • Paper Template System Boiler Caution: this appliance exceeds the recommended weight • • Wall Plate Rawplug/Screw Pack for a one-man lift as detailed in the Manual Handling Operations, 1992 Regulations.
  • Page 11 3.5 Condensate Drain: The condensate drain utilises plastic 21.5mm push fit or adhesive overflow pipes and fittings. It should be piped to drain, preferably within the building, maintaining a 44mm in 1m fall away from the appliance. If the drain is routed to outside it should be to a drain or soak away.
  • Page 12 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 13 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 ter- minal close to projections especially under a balcony or near to a drainpipe.
  • Page 14 Location Min Distance Directly below (or above) a 300mm window or other opening. Above roof level (to base of ter- 300mm minal). From adjacent wall to flue 300mm From internal corner to flue 400mm From facing terminal 1200mm Between terminals 300mm Fig.
  • Page 15 Typical Concentric Flue Configurations Turret Horizontal Terminal Clamp Sealing Rings Fig. 3.6 Standard Horizontal Flue Kit Fig. 3-7 Horizontal Rear Flue (Standard Flue Kit) Fig. 3.8 Vertical Flue (may be offset to the rear, left or right) Turret 500 mm Extension Elbow Vertical Terminal Fig.
  • Page 16 Fig.3-11 Offset Horizontal Rear Flue (Can be offset to left or right) Standard Flue Kit Fig.3-12 Elbow Raised Horizontal Flue 1m Extension (Can also be LH or RH) Horizontal Terminal Elbow 1m Extension Typical Twin to Concentric Flue Configurations Vertical Appliance Adaptor Fig.3-13 Offset Twin to Vertical Concentric Terminal Fig.3-14...
  • Page 17 Table.3-3 PRESSURE DROP EXAMPLE HE16S & HE25S MAXIMUM FLUE RESISTANCE 95Pa HE31S MAXIMUM FLUE RESISTANCE 160Pa Turret + Horizontal Terminal = 45 Pa 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 500mm Extension = 2.5 Pa...
  • Page 18 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 19 Fig.3-18 Functional Flow Diagram www.johnsonandstarley.co.uk...
  • Page 20 Fig.3-19 Illustrated Wiring Diagram www.johnsonandstarley.co.uk...

  • Page 21: 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 NOTE and the CH flow and return valves at the base of the appliance. Open the manual vent at The gas valve is the top of the appliance and bleed, close the manual vent when all the air is removed.

  • Page 22: Servicing Schedule

    • Explain and demonstrate the function/operation of time/temperature controls and thermostatic radiator valves, emphasising the economic use of the appliance. • If a programmer has been fitted, hand the user instructions that were supplied with the progammer to the occupier. •...
  • Page 23 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 24: 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 25 6.1 Fault Codes Code Fault Reason Action Check all external controls (if fitted) Boiler will not run No call for heat to boiler control board Check settings on time clock Check settings of boiler controls Check gas supply and gas cock If burner lights, check flame sensor and wiring to control Flame lockout after several attempts Flame not detected...
  • Page 26 Is there Check connections symbols show Replace MMI a mains supply between MMI & boiler on the to boiler? MMI? Establish power supply Is there Refer to table a fault of fault codes code? Set a call for CH on Check for a Is radiator Is there a...
  • Page 27 Error History Mode The MMI stores the last 8 error codes and these can be viewed by putting the appliance into error history mode. To do this, press the MODE button and “EHIS” will be displayed on the LCD display. The number in the top right hand-corner is the error index (1 being the most recent) and the number in the bottom right hand corner is the error code that applies to that index number.
  • Page 28 6.7 Expansion Vessel 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, remove the LH painted case side and unscrew the flexible hose connection from the expansion vessel.
  • Page 29 Fixing screw 6.12 Condensate Siphon (Where Fitted) Place a bowl under the cap on the condensate siphon and remove the cap in order to drain the siphon. Pull the condense pipe from the top of the siphon and remove the fixing screw retaining the support bracket.
  • Page 30 6.16 Main Ignition/Control PCB (ESYS Grey/Red Housing on Gas Valve) Unplug the multi pin plug connections from the top of the control and remove the spark detection wires.Unscrew the single retaining screw and slide the housing off the gas valve electrical connections. Replace with a new component in reverse order.
  • Page 31 NOTES: www.johnsonandstarley.co.uk...

  • Page 32: Short Spare Parts List

    7 SHORT SPARE PARTS LIST www.johnsonandstarley.co.uk...
  • Page 33 Burner and Small Seal 1000-0523405 Main Ignition/Control PCB (ESYS) 1000-0709875 Gas Valve & Venturi Assy (inc fan gasket, pipe gasket & screws (4)) HE16S (as HE25S with the following variations) R160-0510005 Control Panel (complete) 1000-0709805 Burner and Small Seal 1000-0523415...
  • Page 36 Johnson & Starley Johnson & Starley are the leading UK & European manufacturers of a complete range of Domestic Warm Air Heaters. All the heaters suit both Replacement and Upgrade needs and are compliant with the new (2006) amendments to Part L of the Building Regulations.

This manual is also suitable for:

He25sHe31sHe16spHe25spHe31sp