Johnson & Starley Quantec 16RK User guide

www.johnsonandstarley.co.uk
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
QUANTEC
REGULAR
Kompact
ErP
High Efficiency Boiler
Quantec 16RK - G.C. No. 41-416-19
Quantec 24RK - G.C. No. 41-416-20
These instructions are to be left with the User
Publication No. ZZ 1463-5
September 2015

www.johnsonandstarley.co.uk
2
In the interest of continuous development Johnson and Starley reserve the right to change specication without prior notice.
Johnson and Starley prides itself on it’s ability to supply spare parts quickly and efciently.
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
LEAVE THESE INSTRUCTION WITH THE USER OR AT THE GAS METER AFTER INSTALLATION
The Benchmark Scheme
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that
customers are provided with the correct equipment for their needs, that it is installed, commissioned and
serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate
compliance with Building Regulations and should be provided to the customer for future reference.
Visit www.centralheating.co.uk for more information.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available
from the Heating and Hot water Industry Council who manage and promote the Scheme.
CONTENTS
The Benchmark Scheme 2
1 Features 3
2 General Description 3
3 Building Standards & Regulations 4
4 Safety & Gas Information 4
General Safety Information
Handling the Unit
Operating the Appliance
Electrical Supply
Gas Supply
5 Fiche ErP Technical Data 5
Technical Data
Performance Data
6 Preparation 8
Electrical Connections
Water Connections
Gas Connection
Condensate Drain
Boiler Control Interlock
Thermostaic Radiator Valves
Positioning
Timber Frame Buildings
Bathroom Installation
Compartment Installations
Room Ventilation
7 Dimension & Clearances 9
8 Heating System 10
Pipework Sizing
Water Treatment
Water Flow Schematic
9 Installation Instructions 12
Carton Contents
Wall Mounting Template
Fixing the Appliance
10 Flue Instructions 13
Flue Configuration
Diagram of Terminal Positions
Types of Flue Systems
Flue Terminal Positions
Plume Outlets
Flue Requirements & General Information
Conventional 60/100mm Flue Accessories Part No.s
Optional Roof Outlets
The Standard Horizontal Flue System
Installation of the Standard Horizontal Flue System
11 Condensate Drain 19
Use of a Condensate Pump to External Termination
External Termination
Unheated Internal Area’s
12 Electrical 20
Electrical Connections
Internal Wiring
Electrical Testing
13 Wiring Diagram 20
14 Connections & Filling 21
Gas Connection
Condensate Drain
15 Commissioning 21
Check Gas Installation
Air Purge Function
Reset Procedure
Test Mode
Initial Lighting
Cental Heating
Check the Operational Gas Inlet Pressure
CH Mode
Flushing the System & Water Circulation
Balance the System
Water Temperatures
16 Handing Over 23
Instructing the User
Loss of Water Pressure
17 Servicing & Maintenance 24
Service Schedule
Initial Inspection
Servicing Sequence
Flue Inspection & Checks
Gaining Access to the Boiler
Remove Front Door
Fan Removal
Burner Assembly Removal
Heat Exchanger
Condensate Trap
18 Parts Replacements 26
Part Replacements Without Draining the System
Burner Injector
Burner Assembly/Venturi
Flow & Return Thermistors Sensors
Ingnition/Dection Electrode
Gas Valve
Condensate Trap
PCB Assembly
19 Fault Finding Flowcharts & Blocking Codes 28
20 List of Spares 32
21 Benchmark Checklist and Service Record 33
Code of Practice
Commissioning Checklist
Service Record

3
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
1. FEATURES
Appliance Classification:
The QuanTec Regular Kompact has been
tested and CE certified by B.S.I Ltd for
use with NATURAL Gas G20.
2. GENERAL DESCRIPTION
2.1 The QuanTec Regular Kompact appliance is a high efficiency boiler, designed to provide central heating and
hot water via and indirect hot water cylinder. It’s design is room sealed, taking combustion air from outside and
expelling the products of combustion back to the outside.
Standard features include full sequence automatic spark ignition, low water content stainless steel heat exchanger.
• Boiler output is fully modulating with a range of 16RK is 4.83 to 18.48kW and 24RK is 4.58 to 25.6kW
The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when
operating, and performance of key components to aid commissioning and fault finding.
FEATURES
1 Flue Sensor
2 View Port
3 Ignition/Detection Electrode
4 Flow Thermistor sensors
5 Condensate Trap
6
PCB Assembly & Electrical
Connections (inside control panel)
7 Gas Valve
8 Fan
9 Burner Injector
10 Venturi
11 Heat Exchanger
12 Control Panel
13 LED Display
FIGURE 1. QUANTEC REGULAR KOMPACT FEATURES
2
3
5
1
4
6
9
8
12 13
11
7
10

www.johnsonandstarley.co.uk
4
3. 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: [phone] IN ACCORDANCE WITH
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION).
FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
3.1 INSTALLATION REGULATIONS
• Building Standards (Scotland) (Consolidation) Regulations
• Building Regulation Part L
• Gas Safety (Installation and Use) Regulations (as amended)
• The Water Fittings Regulations or Water by-laws in Scotland
• Building Regulation (Northern Ireland)
• Model and Local Authority Byelaws
• Health & Safety Document No. 635.
• The Electricity at Work Regulations, 1989.
• Institute of Electrical Engineers (I.E.E) Wiring Regulations
• EU Regulation No 811/2013 and No. 812/2013 suppliment Directive 2013/20/EU
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.
• Efciency of Hot Water Boilers Directive 92/42/EEC
• Gas Appliance Directive 2009/142/EC
• Low Voltage Directive 2006/95/EEC
• Electromagnetic Compatibility Directive 93/68/EEC
3.2 BUILDING STANDARDS AND REGULATIONS
Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.
BS 5440:1 Flues (for gas appliances of rated input not exceeding 70 kW).
BS 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW).
BS EN 12828 Heating Systems in buildings: Design for water based heating systems.
BS EN 12831 Heating Systems in buildings: Method for calculation of the design heat load.
BS EN 14336 Heating Systems in buildings: Installation and commissioning of water based heating systems.
BS 5546 Installation of gas hot water supplies for domestic purposes (2nd Family Gases)
BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW.
BS 6891 Installation of Low Pressure Gas Pipework of up to 28 mm (R1) in domestic premises (2nd family gases).
IMPORTANT: This appliance is CE certificated for safety and performance. It is important that no modifications are made to
this appliance, unless fully approved in writing by Johnson & Starley Ltd. If in doubt please ring Johnson & Starley Ltd on
Telephone [phone].
4. SAFETY & GAS INFORMATION
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION
4.1 GENERAL SAFETY INFORMATION
4.1.1 An LPG unit should not be intalled in a room or internal space below ground level unless one side of the sides of
the building is open to the ground.
4.1.2 Only use QuanTec original spare parts on this appliance. Failure to do so will invalidate the guarantee.
4.1.3 No artifically softened water must not be used to fill the central heating system.
4.1.4 The system can be damaged by debris entering the heat exchanger and reduce efficiency. It is reccommended
that the boiler is flushed, follow these guidelines as this will protect the boiler and prolong its life.
4.1.5 It is important that the system is flushed thoroughly before the appliance is left to operate (as recommended in BS
7593) in order to maintain an efficiently operating heating system. For replacement installations, the system MUST
be flushed with the old boiler in situ, in order to prevent the QuanTec becoming a trap for system debris. Once the
system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added. Appropriate
inhibitors are available, for example Sentinel, Fernox and Salamader. We also recommend a Magnetic & Non
Magnetic Filtration system is fitted between the last radiator and the boiler.
4.1.6 Failure to carry out the above procedure will invalidate the guarantee!

5
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
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 THE NATIONAL GAS EMERGENCY SERVICE ON
0800 111999
4.2 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. Care MUST be taken when handling the appliance
to prevent injury. We advise the engineer to wear suitable P.P.E.
4.2.3 Once the appliance has been fired beware that certain parts will be hot to the touch.
4.2.4 Do not install flues during rain, high winds or in severe weather conditions.
4.2.5 The manufacturers instructions supplied must not be taken as overriding any statutory requirements.
4.3 OPERATING THE APPLIANCE
4.3.1 This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have supervision or been given instruction
concerning use of the appliance by a person responsible for their safety.
4.3.2 Children should be supervised to ensure they do not play with the appliance.
4.4 ELECTRICAL SUPPLY
4.4.1 Ensure the mains supply voltage, frequency, number of phases and power rating comply with details on
the rating label.
4.4.2 All wiring must be in accordance with the appropriate standards. The equipment must be supplied with a double
pole isolator switch and for new heating systems, and where practical replacement installations, the isolator shall
be situated adjacent to the appliance.
4.4.3 Ensure safety regulations and practices are adhered to when installing and using this appliance.
4.5 GAS SUPPY
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. When operating pressures are found to
be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and
safe operation.
4.3.2 Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that a mini-
mum permitted operating pressure of 18mb will be delivered to the inlet of the appliance. (Reference BS 6400-1
Clause 6.2 Pressure Absorption).
4.3.3 The external gas cock could further reduce the operating pressure when measured at its test point. The pressure
drop is relative to the heat input to the boiler (kW), see Figure 2.
IMPORTANT: Installation pipes must be fitted in accordance with BS 6891. In IE refer to IS.813.
FIGURE 2. GAS COCK PRESSURE DROP
3
2.5
2
1.5
1
0.5
0
PRESSURE DROP (mbar)
0.0 0.5 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0
HEAT INPUT TO BOILER (kW)

www.johnsonandstarley.co.uk
6
TABLE 1. ErP TECHNICAL DATA 16RK 24RK
PRODUCT DATA SYMBOL VALUE VALUE UNIT
Condensing boiler - Yes Yes -
Low temperature boiler - No No -
B11 Boiler - No No -
Cogeneration space heater - No No -
Combination Heater - No No -
Rated heat output Prated 16 23 kW
Seasonal space heating energy efficiency ŊS94 94 %
Energy efficiency class A
USEFUL HEAT OUTPUT
At rated heat output and high temperature regime P416.3 23.4 kW
At 30% of rated heat output and low temperature regime P15.5 7.8 kW
USEFUL EFFICIENCY
At rated heat output and high temperature regime Ŋ488.8 87.9 %
At 30% of rated heat output and low temperature regime Ŋ198.8 99.1 %
AUXILLARY ELECTRICITY CONSUMPTION
At full load elmax 0.025 0.068 kW
At part load elmin 0.013 0.048 kW
In standby mode PSB 0.007 0.007 kW
OTHER ITEMS
Standby heat loss PSB 0.099 0.099 kW
Ignition burner power consumption Pign 0 0 kW
Sound power level indoors L
WA
46 46 dB
5. TECHNICAL DATA
EU Regulations No. 811/2013 and No. 812/2013 supplementing Directive 2010/30/EU.
1. High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at
heater output.
2. Low temperature means for condensing boiler 30°C, for low temperature boilers 37°C and for other heaters
50°C return temperature (at heater).

7
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
TABLE 2. TECHNICAL DATA 16RK 24RK
Maximum weight lift 38kg
Gas supply
2H - G20 - 20mbar
Gas connection 15mm copper
Injector size 4.20mm 4.75mm
Heating flow and return 22mm copper
Flue terminal diameter 100mm (4”)
Condense drain 21.5mm plastic overflow pipe
Electrical supply 230V ~ 50Hz
Electrical rating 100W
External fuse rating 3A
* Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery
** In areas of low water pressure the DHW restrictor can be removed
16RK 24RK
TABEL 3. PERFORMANCE DATA
MAXIMUM MINIMUM MAXIMUM MINIMUM
Burner CO² (%)
case off 9.3 8.4 9.4 8.5
case on 9.5 8.6 9.6 8.7
± 0.5
PERFORMANCE DATA FOR CENTRAL HEATING
CH input Q
Net kW 17 4.4 24 4.7
Gross kW 18.9 4.88 26.6 5.21
Gas Consumption
m³/h 1.75 0.45 2.48 0.48
CH Output
Non condensing kW 16.76 4.83 23.4 4.58
Condensing kW 18.48 4.83 25.6 5.17
Seasonal Efciancy*
SEDBUK 2005 A
SEDBUK 2009 89.1 89.6
NOx Classication
CLASS 5 17mg/kWh CLASS 5 34mg/kWh
Central Heating set point temperature range
20 - 82°C

www.johnsonandstarley.co.uk
8
6. PREPARATION & POSITIONING
6.1 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.
6.1.4 Water treatment - see paragraph 8.3.
6.1.5 GAS CONNECTIONS: Make sure the gas connections are in place.
6.1.6 Give consideration to the flue position. Pluming will occur at the terminal so terminal positions where this
could cause a nuisance should be avoided. See section 10.
6.1.7 Give consideration to the overall height.
6.1.8 CONDENSE DRAIN: This drain must be connected to a drainage point on site. All pipework and fittings in
the condensate drainage system MUST be made of plastic - no other materials may be used.
IMPORTANT: Any external runs must be in accordance with BS 6798. The drain outlet on the boiler is
sized for standard 21.5mm (¾”) overflow pipe.
6.1.9 BOILER CONTROL INTERLOCK: Central heating systems 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 THERMOSTAIC RADIATOR VALVES: Heating systems utilising full thermostatic radiator valve control of
temperature in individual rooms should also be fitted with a room thermostat controlling the temperature
in a space served by radiators not fitted with such a valve. The 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 should be achieved using a room thermostat, whilst other rooms are individually controlled by
thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all radiators,
or two port valves, then a bypass circuit must be fitted with an automatic bypass valve to ensure minimum
flow is maintained.
6.2 POSITIONING
6.2.1 The boiler must be installed on a flat and vertical internal wall, capable of adequately supporting the
weight of the boiler and any ancillary equipment.
6.2.2 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.
6.2.3 The boiler may be installed in any room or internal space, although particular attention is drawn to the
requirements of the current IEE (BS 7671) Wiring Regulations and the electrical provisions of the building
regulations applicable in Scotland, with respect to the installation of the boiler in a room or internal space
containing a bath or shower. For IE reference should be made to the current ETCI rules for electrical
installations and I.S. 813.
6.2.4 TIMBER FRAME BUILDINGS: When installed in a timber frame building guidance should be taken from
the gas industry 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.
FIGURE 3. BATHROOM ZONES
6.2.5 BATHROOM INSTALLATIONS
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. The appliance
must be installed beyond Zone 2, as
detailed in BS 7671. A compartment
used to enclose the boiler should be
designed and constructed specially for
this purpose.

9
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
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:
• BS 6798 (No cupboard ventilation is required - see ‘Air Supply’ for details).
• The position selected for installation MUST allow adequate space for servicing in front of the boiler.
• For the minimum clearances required for safety and subsequent service, see the wall mounting template
and section 7. In addition, sufficient space may be required to allow lifting access to the wall mounting
bracket.
6.3 ROOM VENTILATION: It is not necessary as the appliance draws it’s combustion air from outside of the building
and cupboard or compartment ventilation is not necessary providing that the minimum clearances are maintained.
However, reference should be made to BS 5440 Pt. 2
7. DIMENSIONS & CLEARANCES
7.1 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. For the purpose of servicing, it is also recommended that the
appliance be located with a minimum gap of 200mm above any surface.
*Note: A minimum 400mm dimension is a desired workable clearance for servicing.
7.1.2 The boiler connections are made on the boiler connection tails.
7.1.3 The minimum clearances must be maintained for operation and servicing.
7.1.4 Additional space will be required for installation, depending upon site conditions.
7.2 CLEARANCES
7.2.1 Bottom clearance after installation can be reduced to 5mm. This must be obtained with an easily removable
panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance
required for servicing.
7.2.2 The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm
overall clearance is still required, with the cupboard door open, to allow for servicing.
370
647
40 40
306
110
184
127.20
38
19
FIGURE 4. QUANTEC REGULAR KOMPACT DIMENSIONS
370mm
400mm*
FIGURE 5.
FLUE CLEARANCES KITCHEN LAYOUT - TOP VIEW

www.johnsonandstarley.co.uk
10
8. HEATING SYSTEM
8.1 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.
8.2 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
20˚C between flow and return. The maximum flow rates are 0.3 kg/s which, through a 22mm pipe, gives velocities
of 1.00 m/s. Therefore, the recommended minimum pipe size for the main carcass is 22mm.
8.3 WATER TREATMENT: It is important that the system is flushed thoroughly before the appliance is left to operate
(as recommended in BS 7593) in order to maintain an efficiently operating heating system and in accordance with
the Benchmark Guidance Notes on Water Treatnment in Central Heating Systems.
8.3.1 For replacement installations, the system MUST be flushed with the old boiler in situ, in order to prevent
the boiler becoming a trap for system debris. Once the system has been flushed, an inhibitor (suitable for
stainless steel heat exchangers) should be added.
8.3.2 Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. Failure to carry out the
above procedure will invalidate the guarantee!
NOTE: Water supplied from a water softener MUST NOT be used unless a specially formulated corrosion inhibitor
is added (see BS 6798)
FIGURE 6. QUANTEC REGULAR KOMPACT HEATING SYSTEM
150mm
max
15mm (min)
15mm (min)
22mm (min)
450mm (min)
1000mm (min)
QUANTEC
REGULAR
KOMPACT
VENT FEED &
EXPANSION
COLD FEED
CYLINDER
HEATING
BY-PASS
PUMP
2000mm (min)