Johnson & Starley HE25S Manual

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

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2
CONTENTS
Section Description Page
1. Important Information 3
2. Appliance Description 3
3. Fitting 8
4. Commissioning and Handover 19
5. Servicing Schedule 20
6. Fault Finding & Repair 22
7. Short Spare Parts List 29
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.
In order to demonstrate that that the installation
of this appliance complies with current Building
Regulations, you should complete and sign the
Benchmark log book.
Johnson & Starley Ltd, Rhosili Road, Brackmills, Northampton, NN4 7LZ
Tel: [phone] Fax: [phone] Sales Fax: [phone]
Johnson & Starley reserves the right to change specification without prior notice.

www.johnsonandstarley.co.uk 3
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.
Efficiency of Hot Water Boilers Directive 92/42/EEC
Gas Appliance Directive 90/396/EEC
Low Voltage Directive 93/68/EEC
Electromagnetic Compatibility Directive 92/31/EEC
No modifications to this appliance should be done unless they are fully approved by the manufacturer.
The installation of this appliance must be carried out by a competent person and must be in accordance with the cur-
rent rules in force at the time of installation, in the country of destination.
The manufacturers instructions supplied must not be taken as overriding any statutory requirements.
The weight of this appliance exceeds that recommended for a one-man lift. It will therefore be necessary to gain assis-
tance at times during the installation procedure.
GAS LEAKS. DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME. TURN OFF THE GAS
SUPPLY. VENTILATE THE AREA BY OPENING DOORS AND WINDOWS. CALL OUT YOUR LOCAL GAS SUPPLIER.
2. APPLIANCE DESCRIPTION
The appliance is a high efficiency system boiler that is designed to provide the user with both central heating and
domestic hot water. Its design is such that it is room sealed, taking combustion air from outside and expelling the
products of combustion to the outside again. The heat exchanger is constructed of stainless steel, which is corrosion
free.
Its fluing options ensure that the appliance can be installed in many locations within a building.
The appliance is controlled by fully featured microprocessor based electronics that monitor each of the operational pro-
cedures. An LCD display indicates the operational state of the appliance which illuminates for a short period when the
user control is operated. This starts with the full sequence automatic ignition and continues with monitoring the
demand requirements of either the central heating or the domestic hot water.
Should any fault occur the appliance will be shutdown to a safe condition with the fault code being displayed on the
LCD panel.
2.1 Appliance Safety Devices
Heating System Pressure Relief Valve
The appliance incorporates a pressure relief valve to protect the sealed water system from being over pressurised. The
discharge from this must be piped away to a safe place in accordance with the building regulations. Should there be a
discharge of water / steam from this device, the appliance should be switched off and a service engineer or the
installer called.
Frost Protection
The microprocessor based controls within the appliance monitor the water temperature in order to protect from freezing.
To ensure that this function is active the main switch on the appliance should be left on and the gas supply also left on.
This does not protect remote areas of the heating system, which should be protected by other means (e.g. an inde-
pendent frost thermostat that is linked back to the appliance).
Overheating Safety
There are a number of overheat safety devices on the appliance. Should any of these operate (see the fault codes table
in section 6.1) you should call a service engineer or the installer
Electrical Supply Failure
In the event of electrical voltage supply failure, the appliance will stop operating but remain in a safe condition. When
the electrical supply is resumed, the appliance will start from its safe off condition and continue to operate in the nor-
mal manor under the control of the system components. Should the appliance fail to resume, switch the appliance off
and then on again to allow the safety control to be reset. Normal operation should then continue.

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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
fitted expansion vessel, pressurised at 1 bar 73 litres
Electrical supply 230V
Electrical rating 145W
IP classification IP 20
External fuse rating 3 A
Expansion vessel capacity 8 litres
Expansion vessel initial charge pressure 1.0 bar
Heating system minimum pressure 0.7 bar
Ball valves are fitted in water and gas connections
For larger systems use an additional expansion vessel
2.2 Technical Data
Table 2-1
General Data
Nat Gas G20 LPG G31
Maximum Minimum Maximum Minimum
Offset (Pascal) -3.0 (Minus three)
Burner CO2 (%)
Case off 9.3 (+0.5) 8.4 (ref only) 10.2 (+0.5) 9.4 (ref only)
Case on 9.5 (+0.5) 8.6 (ref only) 10.4 (+0.5) 9.6 (ref only)
Table 2-2
Performance Data
Nat Gas G20 LPG G31
Maximum Minimum Maximum Minimum
CH Input Qm Net kW 25.5 7.14 25.5 7.29
Gross kW 28.3 7.92 28.3 7.92
Gas Consumption m3/h 2.6 0.74 1.06 0.30
CH Output P Non Condensing kW 25.0 7.0 25.0 7.0
Condensing kW 27.85 7.76 27.85 7.76
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION Class 5
Table 2-3
Performance Data (Central Heating)
Please Note:
Natural Gas (G20) consumption is calculated using gross CV of 38.7 MJ/m3 or 34.9 MJ/m3 net.
LPG (G31) consumption is calculated using gross CV of 95.6 MJ/m3 or 88.0 MJ/m3 net.

www.johnsonandstarley.co.uk 5
5mm 200mm
425mm
5mm
2.3 Dimensions and Clearances:
310mm
765mm
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. For the purpose of servicing, it is also recommended that the appliance be located with a minimum
gap of 200mm above any surface.
2.4 General Information
Appliance Classification
The appliance is certified as a type C13 C33 C53. As such it can only be installed with the flue components specified
within this document. The flue types are:
•Horizontal and vertical balanced flue using concentric ducts.
•Air entry and flue exit in zones of different pressure using twin (separate) flue and air ducts.
Gas Categories:
The appliance is certified as a CAT II 2H 3P appliance. This allows conversion between Natural gas (G20) and LPG
(G31). Their supply pressures are 20 mbar and 37 mbar respectively.
For natural gas to LPG conversion, kit number NG30 (complete with instructions) is available.
For LPG to natural gas conversion, kit number LPG30 (complete with instructions) is available.
Statutory Requirements:
The appliance must be installed in accordance with the current editions of:
•Building Standards (Scotland)(Consolidation) Regulations.
•Building Regulations
•Gas Safety (Installation and Use) Regulations (as amended)
•BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations
•BS 6891 Installation of Low Pressure Gas Pipework of up to 28 mm (R1) in domestic premises (2nd family gases).
•BS 5440 Pt.1 (Flues for Gas Appliances)
•BS 5440 Pt.2 (Air Supply for Gas Appliances)
•Model and Local Authority Byelaws
•BS 5546 Installation of Domestic Hot Water Supplies.
Gas Supply:
The gas installation must be completed in accordance with the relevant standards (BS 6891).
The supply must be capable of providing a steady inlet working pressure to the appliance of 20 mbar at a rate of 2.7
m3/h (Calculated with a Gas CV of 38.7MJ/m3)

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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 & return) to pass up the rear left hand side. These pipes are made
on site. Pre-fabricated pipes (kit number VPK30) are available direct from Johnson & Starley should they be required.
Additional Control Options:
Should an outside temperature compensation system be required, Opentherm kits are available direct from Johnson &
Starley. (Part No.1000-0019720)
2.5 Appliance Location:
The appliance is not suitable for external installation unless it is protected from the elements by a suitable enclosure.
The enclosure must provide the required clearances for installation, servicing and maintenance as well as the correct
level of ventilation. The selected position should allow for a suitable flue system to be installed.
When installed in a timber frame building guidance should be taken from the British Gas publication IGE/UP-7 (Guide
for Gas Installations in Timber Frame Housing).
BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to be
installed. An existing cupboard may require modification.
If the appliance is installed in a room containing a bath or shower it is important to locate the electrical switch in a
position where it cannot be touched by anyone using the bath or shower. The current IEE Wiring Regulations (BS
7671) for England and the electrical provision of the Building Regulations for Scotland gives details.
Room ventilation for the appliance is not necessary as the appliance draws its combustion air from outside of the
building and cupboard or compartment ventilation is not necessary providing that the minimum clearances are main-
tained. However, reference should be made to BS5440 Pt.2
2.6 Heating System Requirements:
This appliance incorporates all the necessary components to allow it to be connected to a sealed central heating sys-
tem. A typical system is shown at fig. 2.2 which incorporates radiators, an automatic by-pass valve and a drain facili-
ty that must be provided at the lowest point in the system to allow complete drain down. The installation should be
designed to operate with a flow temperature of up to 90 deg.C.
Expansion Vessel: The integral expansion vessel is pre-charged to a pressure of between 0.5 and 1.0 bar. This should
be checked before the water system is filled. Details below show the water system volume that is acceptable for this
vessel. If the system water volume is larger then an additional vessel must be fitted to the system. BS 5449 and BS
6798 give further details regarding expansion vessel sizing and sealed systems. See table 3-2 page 9
Pressure Gauge: The appliance has two components that monitor pressure. Firstly there is a mechanical pressure
gauge on the plumbing jig, this allows the heating system to be pre-plumbed and filled with a visual check on the
pressure. The second is an electronic device used by the microprocessor control to monitor the system pressure and
block the heat input, should there be a lack of pressure.
LCD Display: When the electrical supply is connected, the liquid crystal display indicates the system water pressure. This
pressure is also monitored by the microprocessor controls.
Pressure Relief Valve: The pressure relief valve protects the system from over pressurisation. It is set to be fully open
at 3 bar, however it will start to open at approximately 2.7 bar. It should not be used to flush the system.
Filling: Provision for filling the CH system must be made and three methods are shown in fig. 2.3 Connections to the
mains supply must not be permanent, even through a non-return valve. Fittings used for connection to potable water
must comply with the water supply (water fittings) regulations 1999 Section G24.1 and G24.2.
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 20oC
between flow and return. The maximum flow rate is 0.3 kg/s which through a 22mm pipe gives a velocity of 1.00
m/s. Therefore, the recommended minimum pipe size for the main carcass is 22mm.
Water Treatment: It is important that the system is cleansed and flushed thoroughly before the appliance is left to oper-
ate (as recommended in BS 7593) in order to maintain an efficiently operating heating system. Once the system has
been flushed, an inhibitor that is suitable for stainless steel heat exchangers should be added. Appropriate inhibitors are
available from both Sentinel and Fernox.
Note: Failure to carry out the above procedure will invalidate the guarantee!

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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
thermostat is fitted. There must be at least one radiator
installed with lock shield valves that should not be closed.
Further guidance can be obtained from the Domestic
Heating and Hot Water Guide to the building regulations and
GPG 302
NOTE: a differential pressure bypass valve MUST be
installed to maintain a minimum flow rate of 18 L/min
(20odifferential at maximum heat input).
2.7 Domestic Hot Water System Requirements:
Domestic hot water circuits and their components must be
in accordance with the relevant standards and water sup-
ply regulations. Further guidance and recommendations
can be found in the building regulations G17 to 24 and
R17 to 24.
Additional
Expansion Vessel
(if required)
BOILER
Drain
Point
Bypass
(if required)
Flow Control
Valve
Heating
Circuit
Fig.2-2
Heating System
Method 1 Method 2
Method 3
Supply
Hose
Unions
Hose Unions
Service
Valve
Service Valve
Heating System Heating
System
Heating
System
Service Valve
Service
Valve
Double Check
Valve System
Double Check
Valve System
Stop
Valve
Stop
Valve
Hose
Unions
Supply
Temp
Hose
Temp
Hose
Combined Check
Valve & Vacuum
Breaker
Supply
Stop
Valve
Overflow
Pressure
Reducing
Valve
Fig. 2.3
Filling Methods

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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.
Carton 1
With the carton upright, cut the tape securing the top of the
carton and open so that the contents can be removed. Care
should be taken not to damage the paper template which is
packed in a plastic protective sleeve.
Carton 2
With the carton on its back, cut the tape securing the top of the
carton and open so that the contents can be removed. Remove
and unpack the Installation Instructions, the side & front panels
and control module. The boiler can then be lifted from the carton.
3.2 Preparing the Wall:
Ensuring the wall is flat, unpack the wall template from its
protective sleeve and place it on the wall giving consideration
to: the flue position; water/gas connection positions and clear-
ances. Use the plumb line on the template to ensure it is
square! Mark the positions on the wall of the flue and the fix-
ing points. Using a 105 mm core drill make the hole through
the wall in the correct place. Installations that are made from
within the building only will require a 125 mm diameter hole
in order to fit the flue system. Using a 7mm bit, drill a total of
8 fixing holes (four of which MUST be at the top of the jig)
and insert the rawplugs. Remove the template.
3.3 Wall Fixing/Plumbing Jig:
The fixing jig is supplied in three parts and requires assem-
bly prior to fixing. Assemble the upper bracket; spine and
lower bracket as shown and using a light hammer, tap the 8
tags over so that they form a secure assembly.
Lift the wall fixing/plumbing jig up to the wall, ensuring it is
level and secure it with the screws provided.The gas and
water connections can now be made to the appropriate posi-
tions on the jig. Should the heating pipes be required to exit
vertically upwards, there is a kit available. It is acceptable to
fit pipes vertically upwards without the kit, provided that the
correct route is used. It is advisable to fit additional isolation
valves at the top of the appliance to allow complete removal
of the appliance and its wall plate. Once the heating system
and the domestic water connections are complete the system
can be filled, checked for soundness and flushed. See COM-
MISSIONING section.
3.4 Fitting the Appliance:
It is important to note that this appliance exceeds the recom-
mended weight for a one-man lift as detailed in the Manual
Handling Operations, 1992 Regulations. Lift the appliance
onto the wall jig and locate the unit on the two lugs on the
top of the wall jig. The boiler then drops into place and
needs no further fixing, notwithstanding that there is the
option to secure the boiler with a padlock should the need
arise. Ensure the gas and water connections are in correct
alignment. Connect the gas and water swivel nut joints (the
seals are captive inside the joints). The two remaining con-
nections must now be made. These are the condensate drain
and the pressure relief outlet.
Contents of Carton 1 Contents of Carton 2
•Upper Wall Bracket •Boiler
•Central Spine •Side & Front Panels
•Lower Wall Bracket
(Complete with Group
Set)
•Control Module (includ-
ing MMI, display and
controls)
•Paper Template •Installation & User
Instructions
•Rawplug/Screw Pack •Benchmark Book
•Guarantee Card
1
10
30
50
2
3
4
Upper Wall
Bracket
Central Spine
Tags
Lower Wall
Bracket
C.H.
Flow
C.H.
Return
Gas
Fig.3-1
Assembled Fixing Jig
Table.3-1

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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. Protection from freezing in cold weather conditions is also advisable.
Typical Condense Drain Arrangements:
Expansion Vessel Requirements
Vessel charge and initial system pressure bar 0.5 0.75 1.0 1.5
Total water content of system using 8 ltr (1.54 gal)
capacity expansion vessel supplied with appliance. ltr 95 84 73 50
For systems having a larger capacity multiply the total
system capacity in litres (gallons) by the factor to obtain
the total minimum expansion vessel capacity required
litres.
0.0833 0.09 0.109 0.156
Internal soil
and vent stack
Min. Dia. 22mm
No restriction on length
Invert
Boiler
Trap
75mm min.
4
50mm min.
Siphon (if not already
part of appliance)
Min. Dia. 22mm
No restriction
on length
Sink
(constitutes
air break) Boiler
Tra p
75mm min.
Siphon (if not already
part of appliance)
Min. Dia. 22mm
No restriction
on length
Sink
Boiler
Trap
75mm min.
Siphon (if not already
part of appliance)
Open end of pipe direct into gully
below ground but above water level
Min. Dia. 22mm Boiler
Open end of pipe
direct into gulley
below ground but
above water level
External length
of pipe 3m max. Siphon (if not already
part of appliance)
Table 3-2

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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. It is possible that boiling water and/or steam could be
discharged if the safety valve operates.
3.7 Preparing & Installing The Flue Components (100/60 Concentric):
With the appliance fitted to the wall and the gas and water connections complete.
Horizontal Flues:
Fit the turret to the appliance with the outlet in the correct direction. Measure the distance between the turret centre
line and the outside wall face where the terminal is to be fitted. Using fig. 3.2 assemble and if necessary cut the flue
to the correct length and ensure any seals are made correctly. If fitting from outside the building assemble the outer
wall-sealing disc onto the flue to its correct position. Insert the flue from outside. Fit the inner wall-sealing disc. Using
the clamp arrangement join the flue to the turret, ensuring all the seals are made correctly. The terminal must be
installed with the flue outlet at the top. Brackets are provided for extended flues to locate and fix the flue in position
should they be necessary.
Vertical Flues.
Flat roof: Measure the distance between the appliance top and the outer surface of the flat roof.
Pitched roo:f Measure the distance between the appliance top and the outer surface of the pitched roof at a point
that is central to the flue.Where necessary cut the flue to the correct length, ensuring that seals are
made correctly.
It is advisable to assemble the roof flashing onto the vertical terminal and inset this from outside the building.
Continue to assemble the remaining flue components and connect to the appliance using the vertical adaptor. Finally
make a good seal between the roof and the flashing piece. Brackets are provided to locate and fix the flue in position
should they be necessary.
R.H.Side
133
39.5
187.5
155
Wall
144
93.5
50.5
281
Use this distance to
calculate assembled
flue length
Overall Assembled
Flue Length
19
Fig. 3-2
Overall Assembled Flue Length = Measured Distance - 93.5mm + 155mm

11
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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.
Ensure that combustion products cannot enter the
building where the heater is installed or near to any
other building where doors or windows may be open.
Recommended terminal positions for both horizontal
and vertical flues are shown and flue components and
installation options are detailed on page 15.
For the installation of a vertical flue either a flat or
pitched roof with an angle of between 25° and 50°
should be used.
The British Gas publication "Guide for Gas Installations
in Timber Framed Housing DM2", or your local gas
region, MUST be consulted when installing the appli-
ance into a timber-framed building.
Where the lowest part of the flue terminal is located
less than 2 metres above the ground, a balcony or
above a flat roof across which there is access, the ter-
minal MUST be fitted with a guard (part No:1000-
0019710) which is available from Johnson & Starley.
The distance between the guard and the nearest part
of the terminal must not be less than 50 mm.
3.9 Flue Components & Fitting Options (100/60
Concentric Flue System):
The appliance is supplied with a standard flue kit that
includes a horizontal flue, complete with terminal, tur-
ret and fitting kit. Details of optional flue components
are also listed along with their resistance in Pascals in
order that flue length calculations can be made.
Horizontal and vertical concentric flues (60/100 diam-
eter) with balanced terminals and vertical and horizontal flues (twin 80 diameter) with the flue and air inlet terminals
terminating at least 500 mm apart may be installed on this appliance.
Note: If a twin duct system is to be used (type C5) then the air inlet and flue outlet must not be on the opposite sides
of the building.
Location Min Distance
ADirectly above or below a window or
other opening 300mm
BBelow gutters, soil pipes or drain
pipes. 75mm
CBelow eaves 200mm
DBelow balcony 200mm
EFrom vertical drain/soil pipes 150mm
FFrom internal or external corners. 300mm
GAbove ground or balcony level 300mm
HFrom a surface facing terminal 600mm
IFrom a terminal facing a terminal 1200mm
JVertically from a terminal on the
same wall. 1500mm
KHorizontally from a terminal on the
same wall. 300mm
Fig.3-4
Horizontal Terminal Positions
Location Min Distance
ADirectly below (or above) a window
or other opening. 300mm
BAbove roof level (to base of terminal). 300mm
CFrom adjacent wall to flue 300mm
DFrom internal corner to flue 400mm
EFrom facing terminal 1200mm
FBetween terminals 300mm
GBelow eaves or balcony 200mm
(NOT RECOMMENDED)
Fig. 3-3
Vertical Terminal Positions

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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.
The maximum length of flue permissible is calculated
using the component pressure drop and examples are
given on page15 which include the maximum lengths at
95% of input.
The minimum 60/100 concentric horizontal flue length
measured from the centre line of the turret to the outside
of the wall is 247mm.
The minimum vertical flue length is 1.14 m measured
from the top of the appliance case to the top of the termi-
nal.
The minimum combined 80 twin flue length is 600mm.
Longer flues may be fitted, however the input of the
appliance will be reduced accordingly.
Elbows may be fitted within the flue system with a corre-
sponding reduction in overall flue length based on the
component pressure drop.Reference should be made to
tables 3-3 to 3-5 on page 15.
Fig.3-5
Overall Assembled Flue Length = Measured Distance
+ 632mm
111
Roof Line
632
Use this measurement to calculate the overall flue length
Overall Assembled Flue Length
Adaptor

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Typical Concentric Flue Configurations
Fig.3-6
Horizontal Rear Flue
(Standard Flue Kit)
Fig.3-7
Raised Horizontal Flue
(Can also be LH or RH)
Standard Flue Kit
90oElbow
1m Extension
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
(may be offset to the rear, left or right)
Standard Flue Kit
500 mm Extension
90oElbow
Vertical Appliance Adaptor
Vertical Terminal
Fig.3-10
Offset Horizontal Rear Flue
(Can be offset to left or right)
Standard Flue Kit
90oElbow
1m Extension
Fig.3-11
Vertical Flue
1m Extension
500 mm Extension
Vertical Appliance Adaptor
Vertical Terminal

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14
Typical Twin Flue Configurations
Fig.3-15
Concentric to twin conversion
Fig.3-12
Horizontal Air & Flue Ducts
May be LH RH or as shown. Standard 90o
elbow
Fig.3-14
Raised Horizontal Air & Vertical Flue Outlet (offset)
Standard 90oand 45oelbows and standard vertical terminal
standard 90oelbow
Fig.3-13
Horizontal Air Duct & Vertical Flue Duct
Standard 90oelbow and standard vertical
terminal.
Full details of twin flue components can be found in publication ZZ1191

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60/100 Flue Components
Description Parts included Application Pt No Pascal
Std flue kit (horizontal terminal)
1 x Boiler connection elbow.
Horizontal 1000-0018920 45
1 x Appliance seal.
1 x 60/80 adaptor.
1 x 800 mm horizontal terminal.
1 x 100 mm diameter clamp.
2 x EPDM wall cover plate.
1000 mm straight extension
1 x 1000 mm straight extension.
Horizontal
Vertical 1000-0018940 5
1 x 100 mm diameter clamp.
2 x screws.
500 mm straight extension
1 x 500 mm straight extension.
Horizontal
Vertical 1000-0018950 2.5
1 x 100 mm diameter clamp.
2 x screws.
250 mm straight extension
1 x 250 mm straight extension.
Horizontal
Vertical 1000-0018960 1.25
1 x 100 mm diameter clamp.
2 x screws.
Vertical terminal 1140 mm
1 x vertical terminal assembly.
Vertical 1000-0018930 5
1 x support bracket
Vertical Appliance Adaptor 1 x Adaptor Vertical 1000-0018990 0
90° elbow 1 x Elbow Horizontal
Vertical 1000-0018980 10
45° elbow 1 x Elbow Horizontal
Vertical 1000-0018970 5
Flat Roof Weather Collar 1 x Aluminium circular flat roof seal Vertical 1000-0014900 N/A
Pitched Roof Weather Collar 1 x Plastic & lead pitched roof seal Vertical 1000-0014890 N/A
Fixing Bracket (5 Pack) 5 x clamps for 100 mm tube Horizontal
Vertical N/A
94
95
96
97
98
99
100
101
102
10 20 30 40 50 60 70 80 90 100 110 120 130
Flue Pressure Drop (Pascals)
Heat Input (%age)
Output in relation to flue resistance.
60/100 Concentric flue systems
Pa Direction
Overall
Assembled
Flue Length
mm
Heat
input
%
42 Horizontal 450 100
45 Horizontal 800 99
90 Horizontal 9800 95
5 Vertical 1140 101.5
42 Vertical 8540 100
90 Vertical 17740 95
Table.3-3
Table.3-5
Table.3-4

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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. It should be used for
the heating system only and no other household components.
A fused three pin plug and shuttered outlet may also be used
provided they both comply with BS 1363.
Important. This appliance must be earthed and it must be
wired in accordance with these instructions. In addition, it
must have a permanent electrical supply that is not inter-
rupted by a timing device or thermostat.
Fit the electrical supply cable as shown using the connection
plug provided. The cable must be at least 0.75 mm2, PVC
insulated to BS 6500 table 16.
If a frost ‘stat is required to protect remote parts of the heat-
ing system, this should be fitted as shown.
All cables entering/leaving the appliance MUST be
restrained by use of the cable clamps.
An external controller can be fitted, in which case reference
should be made to the appropriate diagram.
Optional System Controls: Controls are available for outside
temperature compensation and room temperature sensing.
These should be used to improve the heating system control.
They must be connected to the correct terminals as
described in their own instructions. A room thermostat
MUST NOT be used with these controls.
3.11 Fitting The Case & Control Module:
Remove the case components from their packaging. Fit the
LH and RH case panels to the appliance. Each panel hooks
over the two lugs at the top of the appliance and screws to
the base with the screws provided. Remove the controls door
from the module panel and slide the hinge pins inwards.
Offer the controls module up to the side case panels and
slide the hinge pins to locate into the case side panels. Fit
the support strap to the appliance LH side to support the
controls in the horizontal position. Connect the electrical con-
nections to the controls. Swing the controls up into their ver-
tical position and secure to the side case with the two
screws provided. Refit the controls door and fit the front
upper case and secure with the screw in the top of the boil-
er.
3.12 Electrical Testing:
Carry out electrical checks:
•Earth continuity and short circuit of cables
•Polarity of the mains supply
•Insulation resistance to earth
NL2L1
L3
Line
(Brown)
Neutral
(Blue)
Earth
(Green/Yellow)
Mains supply: fused at 3A 230V~50Hz
Link
Fig.3-16
Basic electrical connections
NL2L1L3
Line
(Brown)
Neutral
(Blue)
Mains supply
System
Controls
Optional Frost ‘stat
Fig.3-17
Electrical connections to system controls

www.johnsonandstarley.co.uk 17
Fig.3-18
Functional Flow Diagram
CH FLOW THERMISTOR CH RETURN THERMISTOR FLUE SENSOR
FLAME DETECTION ELECTRODE
IGNITION ELECTRODE
OTC OTC OPEN THERM
GAS VALVE
MAINS SWITCH
PUMP
FAN
SYSTEM PRESSURE SENSOR
MMI CVBC
pwm in from CVBC
tacho from CVBC
r r
g/y
g/y
g/y
g/y b
br
bk
bk b bk
y
r r
y b r
g/y
E
b
N
br
L
p p b
br
br
r
b
b
pk gy gy
b br b b r r
WIRE COLOUR CODE br - brown p - purple b - blue pk - pink bk - black y - yellow r - red g/y - green/yellow
gy - grey

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18
WIRE COLOUR CODE
black ------bk
blue -------b
brown -----br
pink --------pk
yellow------y
orange-----or
green/yellow ---g/y
purple------p
WIRE COLOUR CODE
black ------bk
blue -------b
brown -----br
pink --------pk
yellow------y
orange-----or
green/yellow ---g/y
purple------p
br
brybk
br
br br
bb
g/y g/y
r
rb
r
rb
bb
br br bpprb
or
bbr
b
b
ybr
b
b
g/ybk br or br b
br
L1 L2 NL3
PUMP
PC
CONNECTIONS
MAINS
SWITCH
FAN
PRESSURE
SENSOR
OPEN
THERM
OTC
MAINS
SUPPLY
230V~50Hz
SPARK
ELECTRODE
FLAME
DETECTION
ELECTRODE
FLUE
THERMISTOR
CH FLOW
THERMISTOR
CH RETURN
THERMISTOR
CVBC
gy
gy
g/y
br bbr or
rbkbk ybrbr
br
L
X1 X2 X3 X5 X4
NSL
bk
y
MMI PCB
pk
br
or br
bbor
br
REMOVE THIS
LINK TO FIT
EXTERNAL
CONTROLS
Fig.3-19
Illustrated Wiring Diagram

www.johnsonandstarley.co.uk 19
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.
Ensure that all isolating valves are open and that the system is pressurised to the correct level.
Having tested for gas soundness, purge air from the gas supply and turn on the gas service cock.
Ensure the domestic cold water system, all system radiators and the boiler, have been bled using the manual vent at
the top of the appliance.
Switch on the electricity supply to the appliance. Turn ON the ON/OFF switch on the boiler control panel and turn the
central heating (P1) control to minimum.
The LCD display will become active, whilst the microprocessor control completes a number of checks and sets the
appliance to a standby position.
The display will indicate the system pressure in the lower RH corner of the LCD panel and a numerical display in the
upper and lower LH side of the LCD panel.
Check that any external controls are calling for heat, and turn the CH temperature knob (P1) clockwise. The set point
temperature will be displayed on the LCD screen, set it to 60o. The fan will start and the ignition sequence will take
place. The display will indicate the burner is on as well as an indication of fan speed. A stylised flame will be dis-
played when the flame is established.
If ignition does not take place during the first ignition attempt, there will be a further 2 attempts. If the burner has still
not lit, a fault code will be displayed and this may be due to air being present in the gas supply. Pressing the reset
button will initiate a second sequence of ignition attempts.
When the boiler lights, allow the appliance to operate at low temperature and vent all the air from the boiler and sys-
tem. If necessary, re-pressurise the system to between 1.1 and 1.5 bar.
Turn OFF the appliance by turning the control knob (P1) to the OFF position.
When the above checks have been completed, a combustion performance test (as detailed in the SERVICING section)
can be carried out if required.
4.2 Handing over:
After completion of the commissioning procedure, the installer should hand the appliance over to the occupier of the
house by the following procedure:
•Hand the User Instructions (ZZ1187) to the occupier and explain their responsibilities in respect of current legisla-
tion and regulations, both national and local.
•Explain and demonstrate how to light and shut down the appliance.
•In order to gain the best possible fuel economy in relation to the heating and hot water requirements of the house-
hold, carefully explain the operation of the appliance and the use/adjustment of all the system controls.
•Advise on the precautions required to prevent damage to the appliance; the system and the building in the event
of the appliance being shut down in very cold weather.
•Explain how to control the temperature of the radiators by use of the controls on the appliance.

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20
•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.
•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.
•Point out the water pressure guage and explain what it indicates and that if the pressure falls over a period of time
when the system is cold, a water leak should be suspected and that a “competent person” should be contacted.
•Emphasise the importance of a regular service and that servicing of the appliance MUST only be carried out by a
“competent person” which in normal circumstances would be a CORGI registered engineer.
•As the installer you may wish to offer a service contract yourself, or alternatively you may wish to explain to the
occupier that they can take advantage of an extended warranty scheme offered by Johnson & Starley Ltd.
Reminder: following the commissioning and handover of the appliance, complete the Benchmark Log Book and
leave it with the occupier.
5. SERVICING SCHEDULE
To ensure that the appliance gives continued operation that is both safe and efficient, it is necessary to carry out regu-
lar service checks and whilst the period between servicing will depend on the installation condition and the demands
placed upon the appliance, it is recommended that the appliance be serviced annually.
NOTE: it is a statutory requirement that ALL work be carried out by a “competent person” which in normal circum-
stances would be a CORGI registered engineer.
5.1 Servicing Sequence:
•Light the boiler and carry out a pre-service check, noting any operational faults.
•Check the gas consumption.
•Put the appliance in test mode and connect a suitable gas analyser to the sampling point on the top of the boiler
or into the flue terminal if access is possible
(optional test).
For correct boiler operation, the CO/CO2content of
the flue gas should not be greater than 0.004 ratio.
Check that the gas input is at least 90% of the
nominal.
•Clean the main burner.
•Clean the heat exchanger.
•Check the condition of the combustion chamber
insulation. Any cracked or damaged pieces should
be replaced.
•Wherever possible, remove and clean the conden-
sate 'S' trap (refer to section 6.12) and check the
drain for blockage.
•Check that the flue terminal is unobstructed and that the flue system is sealed correctly.
Note. In order to carry out either servicing or replacement of components the boiler front panel and sealing panel must
be removed. (Refer to section 6.2)
WARNING. Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity sup-
ply to the appliance before servicing.
•After completing the servicing or exchange of components always test for gas soundness and carry out functional
checks as described above.
•When work is complete, the sealing panel MUST be correctly refitted, ensuring that a good seal is made.
WARNING: Do not operate the boiler if the sealing panel is not fitted!
•lf, for any reason, the condensate 'S' trap has been removed ensure the trap is refilled with water before reassembling.
•Complete the service section in the Benchmark log book.
Test Mode
To put the appliance in test mode, press both the MODE
and Tbuttons together for a minimum of 3 seconds.
“TEST” will be displayed in the LCD lower right hand cor-
ner and the flow and return temperatures will be displayed
along with the flame current value. The appliance will stay
in test mode for 30 minutes and the remaining time left in
test mode will be displayed. Whilst in test mode, the
appliance overrides all temperature setting and runs at
minimum rate. Pressing the Sbutton will cause the
appliance to run at maximum rate, whilst still overriding
all temperature settings. Press RESET to take the appli-
ance out of test mode.