Johnson & Starley Reno HE16H User guide

Johnson & Starley Publication ZZ1189-13 June 2010
Product Identification No: 87B 074
The Johnson & Starley Reno
range has an energy rating A on
a scale of A to G.
For more information see
www.boilers.org.uk
This is a certification mark.
www.johnsonandstarley.co.uk
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Installation, Maintenance & Service Instructions
RELIABILITY YOU CAN TRUST
HEAT ONLY
Natural Gas G20:
HE16H - GC No: 41-416-07
from Serial No. 78000294
HE25H - GC No: 41-416-03
from Serial No. 70001122
HE31H - GC No: 41-416-06
from Serial No. 75000194
Propane G31 Variants:
HE16HP - GC No: 41-416-11
from Serial No. 79000105
HE25HP - GC No: 41-416-13
from Serial No. 73000115
HE31HP - GC No: 41-416-10
from Serial No. 85000109

-www.johnsonandstarley.co.uk
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 28
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.
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.
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 Hotwater Industry Council who manage and promote the
Scheme. Visit www.centralheating.co.uk for more information.
Johnson & Starley Ltd, Rhosili Road, Brackmills, Northampton, NN4 7LZ
Tel: [phone] Fax: [phone] Sales Fax: [phone]
www.johnsonandstarley.co.uk
Johnson & Starley reserves the right to change specification without prior notice.

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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 ACCORDANCE
WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (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.
It should be noted that this appliance may contain sharp edges. In order to prevent injury, care MUST be taken when
handing the appliance! We advise the engineer to wear suitable P.P.E.
A two year manufacturers warranty applies to this appliance.
GAS LEAKS. DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPLY. VENTI-
LATE THE AREA BY OPENING DOORS AND WINDOWS. CALL THE NATIONAL GAS EMERGENCY SERVICE ON 0800 111 999.
2. APPLIANCE DESCRIPTION
The appliance is a high efficiency 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.
Flueing options ensure that the appliance can be installed in many locations within a building and a schematic dia-
gram (2-2) shows the water flow through the boiler.
The appliance is controlled by fully featured microprocessor based electronics that monitor each of the operational pro-
cedures. An LED display indicates the operational state of the appliance which starts with the full sequence automatic
ignition and continues with monitoring the demand requirements.
Should any fault occur the appliance will be shutdown to a safe condition with the fault code being displayed on the
LED panel.
2.1 Appliance Safety Devices
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 manner under the control of the system components. Should the appliance fail to resume, turn the temp.control to
the RESET position until the fault clears. Normal operation should then continue.

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4
HE16H HE25H HE31H
Maximum Lift Weight 27.0Kg 27.0Kg 28.0 Kg
Gas Connection 15 mm copper
Heating flow and return 22 mm copper
Condensate Drain 3/4 inch plastic overflow pipe
Electrical supply 230V
Electrical rating 95W
IP classification IP 40
External fuse rating 3 A
Heating system minimum head 3 metre
2.2 Technical Data
Table 2-1
General Data
Table 2-2
Performance Data (Central Heating)
Nat Gas G20
Maximum Minimum
CH Input Qm
16H 25H 31H 16H 25H 31H
Net kW 16.3 25.5 30.7 3.81 7.14 9.18
Gross kW 18.1 28.3 34.0 4.23 7.92 10.1
Gas Consumption m3/h 1.7 2.6 3.16 0.40 0.74 0.85
CH Output P
Non Condensing kW 16.0 25.0 30.0 4.08 7.0 9.0
Condensing kW 17.8 27.85 32.6 3.75 7.76 9.8
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION Class 5
CENTRAL HEATING SET POINT TEMP RANGE 20-82oC
LPG G31
Maximum Minimum
CH Input Qm
16H 25H 31H 16H 25H 31H
Net kW 16.3 26.06 30.7 3.81 7.29 9.18
Gross kW 17.7 28.3 33.3 4.14 7.92 9.97
Gas Consumption m3/h 0.67 1.06 1.25 0.16 0.30 0.38
CH Output P
Non Condensing kW 16.0 25.0 30.0 3.75 7.0 9.0
Condensing kW 17.2 27.85 32.6 4.02 7.76 9.8
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION Class 5
CENTRAL HEATING SET POINT TEMP RANGE 20-82oC

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Table 2-3
Performance Data
Nat Gas G20 LPG G31
16H 25H 31H 16H 25H 31H 16H 25H 31H 16H 25H 31H
Maximum Minimum Maximum Minimum
Burner
CO2 (%)
Case off 9.5* 9.3* 9.5* 8.5** 8.4** 8.5** 10.1* 10.2* 10.2* 9.2** 9.4** 9.2**
Case on 9.8* 9.5* 9.8* 8.8 ** 8.6** 8.8** 10.3* 10.4* 10.5* 9.4** 9.6** 9.5**
*= +0.5 ** = Ref Only
Offset (Pascal) -3.0 (Minus three)**
Please Note:
Natural Gas (G20) consumption is calculated using gross CV of 38.7 MJ/m3or 34.9 MJ/m3net.
LPG (G31) consumption is calculated using gross CV of 95.6 MJ/m3or 88.0 MJ/m3net.
2.3 Dimensions and 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, again a minimum gap of 5mm
should be left.
*NOTE - These are recommended clearances when servicing the appliance.
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.
5mm 200mm*
370mm
5mm
310mm
647mm
Work Surface
Fig. 2-1
Minimum Clearances
400mm*
min 180mm
* Note: 200mm dimension is a desired workable clearance but can be reduced.

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6
Cylinder
150mm max
15mm (min) by-pass
15mm (min)
cold feed
22mm (min)
vent feed & expansion
Boiler
Heating
Min 450mm
Pump
1000mm min
Fig.2-2
Heating System
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 28mm (R1) in domestic prem-
ises (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 accor-
dance 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)
The installation must be tested for gas tightness
using suitable methods. The pipework should also be
purged of air in accordance with the above standard.
Flow
Return

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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 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.
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 BS 5440 Pt.2
2.6 Heating System Requirements:
A typical system is shown at fig. 2.2 which incorporates radiators, an automatic by-pass valve and a drain facility 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 90oC.
Pump
The pump should be fitted on the flow side of the boiler and have isolating valves each side to allow removal without
draining the system. A variable duty pump should be set to give a temperature difference of no greater than 20oC
between flow and return with the thermostat set at maximum (around 82oC) and a flow rate as shown in table 2.4.
Reference should also be made to 2.4 for the pressure loss of the boiler and consideration MUST be given to the fact
that high resistance microbore systems may require a higher duty pump.
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 0.19 kg/s (HE16H) 0.3 kg/s (HE25H) and 0.38 kg/s (HE31H)
which through a 22mm pipe gives a velocity of 0.75 m/z (HE16H) 1.00 m/s. (HE25H) and 1.25 m/s (HE31H)
Therefore, the recommended minimum pipe size for the main carcass is 22mm..
Sealed Water Systems: The installation must comply with the appropriate requirements of the current issue of
BS 4814, BS 5449, BS 6759, BS 6798 and BS 7074 part 1 and 2. See table 2-5 below.
Water Treatment: It is important that the system is flushed thoroughly before the appliance is left to operate (as rec-
ommended 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 Reno 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 and Fernox.
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)
Controls: As a minimum it is recommended that a 2 channel timer and room thermostat is installed to control the appli-
ance. Thermostatic radiator valves may be fitted to the system but must not be fitted in the room where the room thermo-
stat is fitted. There must be at least one radiator installed with lock shield valves that should not be closed. Further guid-
ance 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 the following minimum flow rates:
12 L/min - HE16H
18 L/min - HE25H
23 L/min - HE31H
(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 supply
regulations. Further guidance and recommendations can be found in the building regulations G17 to 24 and R17 to 24.

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8
3. FITTING
3.1 Unpacking the Appliance:
The appliance is supplied packaged in a single carton
which contains the wall fixing plate, template, boiler and
controls.
Caution: this appliance exceeds the recommended weight
for a one-man lift as detailed in the Manual Handling
Operations, 1992 Regulations.
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 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 clearances. Use the plumb line on the template to ensure it is
square! Mark the positions on the wall of the flue and the fixing 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 5 fixing holes and insert the rawplugs. Remove the
template.
Table 2-5
Contents of Carton
•Wall Fixing Plate •Installation
Instructions (inc.
Benchmark Logbook)
& User Guide
•Paper Template
•Rawplug/Screw Pack •Guarantee Card
•Boiler Assembly
Table.3-1
Safety valve setting (bar) 3.0
Vessel charge and initial system pressure (bar) 0.5 1.0 1.5
Total water content of system (litres) Vessel Volume
25 2.1 2.7 3.9
50 4.2 5.4 7.8
75 6.3 8.2 11.7
100 8.3 10.9 15.6
125 10.4 13.6 19.5
150 12.5 16.3 23.4
0.5
1.0
0
1.5
2.0
2.5
3.0
3.5
0 5 10 15 20 25
Flow Rate l/m
Water Pressure Loss (meters head of water)
Table 2-4
Pressure Loss
16H
25H
31H

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NOTE:
*External runs exceeding 3 metres the discharge pipe
should be increased to 32mm diameter for complete
peace of mind.
3.3 Wall Fixing Plate:
Place the wall fixing plate on the wall, ensuring it is level
and secure it with the screws provided. It is advisable to
fit additional isolation valves at the top of the appliances
to allow complete removal of the appliance. Once the
heating system 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
recommended weight for a one-man lift as detailed in
the Manual Handling Operations, 1992 Regulations.
Remove the finger guard from the bottom of the boiler
(secured with 2 fixing screws), lift the appliance onto the
wall fixing plate and locate the unit on the two lugs on
the top of the fixing plate. The boiler then drops into
place and is secured with a single fixing screw at the
bottom of the boiler. (see fig.3-1(b)) The finger guard can
now be re-fitted to the bottom of the appliance.
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.
Protection from freezing in cold weather conditions is
also advisable.
Typical Condense Drain Arrangements:
Fig.3-1 (a)
Fixing Plate
Fig 3-1(b)
Boiler fixing point
Fixing point
NB the boiler has a built in condense trap and it MUST be noted that fitting an additional trap to the configurations
shown above, may have an edverse effect on the evacuation of condensate from the boiler.
Internal soil
& vent stack
Invert
Sink (Constitutes
air break)
450mm min
Min dia 21.5mm no
restriction on length
Min dia 21.5mm no
restriction on length
Min dia 21.5mm no
restriction on length External length of
pipe 3m max.
(See Note *)
Min dia 21.5mm
Sink
Open end of pipe straight
into gully below ground but
above water level
Open end of pipe
straight into gully
below ground but
above water level
Boiler
Boiler Boiler
Boiler

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
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10
204
166
3.6 Preparing & Installing The Flue Components (100/60 Concentric):
With the appliance fitted to the wall and the gas and water connections complete.
IMPORTANT NOTE: Before carrying out procedure ensure seal has not been dislodged from top of heat exchanger.
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 roof: 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.
FOR FULL DETAILS OF FLUE COMPONENTS, PLEASE REFER TO ZZ1191
Fig. 3-2
Overall Assembled Flue Length = Measured Distance - 93.5mm + 155mm

11
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3-5 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 0.7m from the top of the appliance case to the top of the terminal.
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 corresponding reduction in overall flue length based on the compo-
nent pressure drop.Reference should be made to tables 3-3 to 3-5)
It is reccommended the terminals are not sited within 2 m of an opening in an adjacent building or within 2m of the
boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e’g dischargin over a walkway
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 projections 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 verti-
cal flues are shown and flue components and installation
options are also detailed.
For the installation of a vertical flue either a flat or pitched
roof with an angle of between 25° and 50° should be used.
Gas industry publication: "Guide for Gas Installations in Timber
Framed Housing DM2", or your local gas region, MUST be con-
sulted when installing the appliance into a timber-framed build-
ing.
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 terminal 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 (60/100 Concentric
Flue System):
The appliance can be purchased with a standard flue kit that
includes: horizontal terminal; turret and fitting kit. Details of
optional flue components are listed in table 3-5 along with
their resistance in Pascals in order that flue length calculations
can be made.
Horizontal and vertical concentric flues (60/100 diameter)
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.
If an extended horizontal flue is being used (any flue length
longer than the standard kit) it must have a continuous fall
back towards the appliance of 2.5°. This ensures that conden-
sate 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 in table
Fig.3-5
Overall Assembled Flue
Length
=
Measured Distance +
632mm
Overall assembled flue length
Use this measurement to calculate flue length

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3.10 Plume Terminal Outlets
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 Fig 3.4a)
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.
It is reccommended the terminals are not sited within 2 m of an opening in an adjacent building or within 2m of the
boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e.g discharging over a walkway
or patio.
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 ter-
minal). 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
Fig.3-4a
Plume Terminal Outlet Dimensions
1. Boundary 2. Terminal 3. Building 4. Adjacent 5. Window

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Typical Concentric Flue Configurations
Fig.3-7
Horizontal Rear Flue
(Standard Flue Kit)
Fig.3-9
Horizontal Side Flue
(Can be left or right)
Standard Flue Kit
500 mm Extension
Fig.3-8
Offset Vertical Flue
(may be offset to the rear, left or right)
Turret
500 mm Extension
90oElbow
Vertical Terminal
Fig.3-10
Vertical Flue
1m Extension
500 mm Extension
Vertical Appliance Adaptor
Vertical Terminal
Fig. 3.6
Standard Horizontal Flue Kit
Horizontal Terminal
Turret
Sealing Rings
Clamp

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14
Typical Twin to Concentric Flue Configurations
Fig.3-13
Offset Twin to Vertical Concentric Terminal
Twin pipe adaptor
80mm x 500mm extensions (2 off)
80mm x 45oelbows (4 off)
80mm x 1000mm extension (2 off)
Twin to concentric adaptor
60/100mm vertical terminal
Fig.3-11
Offset Horizontal Rear Flue
(Can be offset to left or right)
Standard Flue Kit
90oElbow
1m Extension
Fig.3-12
Raised Horizontal Flue
(Can also be LH or RH)
Horizontal Terminal
90oElbow
1m Extension
Vertical Appliance Adaptor
Fig.3-14
Offset Twin to Horizontal Concentric Terminal
Twin pipe adaptor
80mm x 500mm extensions (4 off)
80mm x 90oelbows (2 off)
Twin to concentric adaptor
60/100mm horizontal terminal

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Description Parts included Application Pt No Pascal
Std flue kit (horizontal terminal)
1 x Turret.
Horizontal 1000-0020070 45
1 x Appliance seal.
1 x 60/80 adaptor.
2 x EPDM wall cover plate.
1 x 100 mm diameter clamp.
1 x 800 mm horizontal terminal.
Turret 1 x Turret. Horizontal 1000-0020020 40
Horizontal Terminal 1 x 800 mm horizontal terminal. Horizontal 1000-0019830 5
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 1000-0020060 N/A
Pitched Roof Collar (Black) 1 x Plastic & lead pitched roof seal Vertical 1000-0020030 N/A
Pitched Roof Collar (Terracotta) 1 x Plastic & lead pitched roof seal Vertical 1000-0020040 N/A
Fixing Bracket Clamp for 100 mm tube Horizontal
Vertical 1000-0020050 N/A
PRESSURE DROP EXAMPLE
Turret + Horizontal Terminal = 45 Pa
500mm Extension = 2.5 Pa
90 Elbow = 10 Pa
100m Extension = 5 Pa
90 Elbow = 10 Pa
TOTAL = 72.5 Pa
Table.3-2
Table.3-4
(60/100 Flue Components)
94
95
96
97
98
99
100
101
102
10 20 30 40 50 60 70 80 90 100 11 0 120 130 140 150 160 170 180
Flue Pressure Drop (Pascals)
Heat Input (%age)
HE16H & 25H HE31H
HE16H & HE25H MAXIMUM FLUE RESISTANCE 95Pa HE31H MAXIMUM FLUE RESISTANCE 160Pa

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16
3.9 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
connections to the heating system must be through a com-
mon double 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 house-
hold 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 connec-
tion 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
heating 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: Opentherm protocol controls
are available for outside temperature compensation and
room temperature sensing and can be used to improve
the heating system control. They must be connected to
the correct terminals as described in their own instruc-
tions. A room thermostat MUST NOT be used with these
controls
3.12 Electrical Testing:
Carry out electrical checks:
•Earth continuity and short circuit of cables
•Polarity of the mains supply
•Insulation resistance to earth
L3 NL2L1
MAINS SUPPLY
230V~50Hz
FUSED AT 3A
SYSTEM
CONTROLS
PUMPL
OUT
SWITCHED
LINE IN
LN
}
Fig.3-16
Basic electrical connections

www.johnsonandstarley.co.uk 17
Fig.3-18
Functional Flow Diagram

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18
Fig.3-19
Illustrated Wiring Diagram

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4 COMMISSIONING AND HANDOVER
4.1 Commissioning the Appliance:
With all the pipe connections made, ensure that the system is filled, vented
and having tested for gas tightness, purge air from the gas supply and turn on
the gas service cock.
Switch on the electricity supply to the appliance, turn ON the ON/OFF switch
on the boiler control panel and turn the temperature control to minimum.
The LED display will become active, whilst the microprocessor control completes a number of checks and sets the
appliance to a standby position.
Check that any external controls are calling for heat, and turn the temperature control fully clockwise. The fan will
start and the ignition sequence will take place. The display will indicate the burner is on.
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. Turn the temperature
control to the “RESET” position and leave until the fault code clears and the boiler will initiate a fresh 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 system.
Turn OFF the appliance by turning the temperature control to the minimum position.
When the above checks have been completed, a combustion performance test (as detailed in the SERVICING section)
can be carried out if required.
After the combustion test, set the temperature control so that the boiler gives a flow temperature of between 60oC and
80oC.
When the boiler reaches its temp. set point, the anti-cycle feature introduces a 180 second delay between cycles
NOTE
The gas valve is
factory preset and
must not be adjusted.
A replacement valve
must only be supplied
by Johnson & Starley
Ltd.

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20
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 (ZZ1190) 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, in the event of a fault, the appliance will display a fault code, emphasising that if a fault is indicated
they should should note the fault code, turn off the appliance and contact a “competent person” which in normal
circumstances would be a Gas Safe 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 programmer to the occupier.
•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 Gas Safe 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 regular service checks and whilst the period
between servicing will depend on the installation condi-
tion 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
circumstances would be a Gas Safe registered engi-
neer.
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 suit-
able flue 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 0.008 ratio.
Check that the gas input is at least 90% of the
nominal. * See test mode inputs.
•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 condensate
'S' trap (refer to section 6.6) and check the drain for
blockage.
•Check that the flue terminal is unobstructed and
that the flue system is sealed correctly.
Test Mode
To put the appliance in test mode, remove the fixing screw
and drop down the electronics panel so that access can be
gained to the PCB. The supplied jumper (parked) should
be used to jump the two pins marked X7.
Test mode is indicated by the power light flashing. Max
and min test mode can be selected by max and min on
boiler stat.
Whilst in test mode, the appliance overrides all tempera-
ture setting and the temp control allows you to scroll
between maximum and minmum rates, whilst still overrid-
ing all temperature settings*.To take the boiler out of test
mode, remove the jumper and put it back into its parked
position.
When in max test mode the unit will run at 100% fan
speed. This will give an input of-
*On smaller heating systems, running at maximum output MIGHT cause the
boiler to go into lockout. Allow the heating system to cool and turn the temp.
control to RESET until the lockout clears.
Jumper
16H 25H 31H
INPUT NET Kw 16.3 30.6 38.0
GROSS Kw 18.1 34.0 42.1