Johnson & Starley RenoXtra 30CA User guide

Johnson & Starley
®
RELIABILITY YOU CAN TRUST
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.
Publication No. ZZ 1311-5 October 2009
Product Identification No: 87B 074
COMBI
SERIES
Xtra High Efficiency
Combination
Boilers
INSTALLATION, MAINTENANCE &
SERVICING INSTRUCTIONS
Natural Gas G20:
RenoXtra 30CA - GC No: 47-416-05
RenoXtra 37C - GC No: 47-416-06
Propane G31 Variant:
RenoXtra 30CP - GC No: 47-416-07
RenoXtra 37CP - GC No: 47-416-08
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CONTENTS
1. Features 3
2. Brief Description 3
3. Building Standards & Regulations 4
4. Safety & Gas Information 4
5. Preparation 5
6. Technical Data 5
7. Dimension & Positioning 7
8. Heating System 8
9. Fitting 11
10. Flue Instructions 12
11. Condensate Drain 20
12. Electrical 21
13. Functional Flow Diagram 22
14. Wiring Diagram 23
15. Commissioning 24
16. Handing Over 24
17. Servicing 25
18. Defect Diagnosis 27
19. Fault Finding 29
20. Parts Replacement 30
21. List of Spares 34
22. Exploded Diagram 35
23. Important Information 36
24. Benchmark Checklist & Service Record 37
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.
PLEASE READ THESE INSTRUCTIONS CAREFULLY
BEFORE STARTING INSTALLATION
LEAVE THESE INSTRUCTION WITH THE USER OR
AT THE GAS METER AFTER INSTALLATION
In the interest of continuous development Johnson and Starley reserve the right to change
specification without prior notice Johnson and Starley prides itself on it’s ability to supply spare
parts quickly and efficiently.
If your service engineer indicates a problem in obtaining a spare part, advise him to contact
Johnson and Starley Spares Department.
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1. FEATURES
Appliance Classification.
This appliance is tested and certified by G.L.
Industrial Services UK Ltd for use of type C13, C33,
C53. natural gas.
FEATURES
1 Warm Water Return
2 Cold Water supply
3 Flue Turret
4 Gas Saver Unit
5 Expansion Vessel
6 Ignition Electrode
7 Fan/Venturi Assembly
8 Electrical Connection Harness
9 Trap Assembly
10 Shock Arrester
11 Blending Valve
12 Pump
13 Pressure Transducer
14 CBVC
15 Detector Electrode
16 Gas/Air Duct
17 Heat Exchanger
2. BRIEF DESCRIPTION
2.1 The RenoXtra appliance is a high efficiency combination boiler that is
designed to provide the use with both central heating and domestic
hot water on demand. 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.
2.2 The appliance is controlled by fully featured microprocessor based
electronics that monitor each of the operational procedures. 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.
2.3 Whilst the appliance is in pre-heat mode it maintains a limited
temperature in the heat exchanger in order to quickly satisfy any
domestic hot water demand. Should any fault occur the appliance will
be shutdown to a safe condition with the fault code being displayed on
the LCD panel.
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CONTENTS CARTON 1 CONTENTS CARTON 2 CONTENTS CARTON 3
1 Wall Plate 1 RenoXtra 30CA or RenoXtra 37C Boiler 1 Gas Saver
2 Side Panels 2 Blending Valve, Shock Arrestor and Elbows
3 Front Door Panel 3 Control Module (including MMI, display and controls)
4 Paper Template 4 Wall Jig
5 Raw plug/Screw Pack 5 Installation Instructions (inc. Benchmark Logbook)
Table 1
6 Users Instructions
7 Guarantee Card
FIGURE 1
RENOXTRA FEATURES

3. BUILDING STANDARDS & REGULATIONS
This 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
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 made, unless they are fully
approved by the manufacturer.
The manufacturers instructions supplied must not be taken as overriding any
statutory requirements.
A two year manufacturers warranty applies to this appliance.
It is important that the system is flushed thoroughly before the applianceIt 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
RenoXtra 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.
Failure to carry out the above procedure will invalidate the
guarantee!
IMPORTANT: STATUTE LAW DEFINES THAT ALL GAS
APPLIANCES MUST BE INSTALLED BY COMPETENT
PERSONS, (i.e. GAS SAFE REGISTERED INSTALLERS) IN
ACCORDANCE WITH THE GAS SAFETY (INSTALLATION
AND USE) REGULATIONS (CURRENT EDITION). FAILURE
TO COMPLY WITH THESE REGULATIONS MAY LEAD TO
PROSECUTION.
4. SAFETY & GAS INFORMATION
4.1 SAFETY INFORMATION
4.1.1 Ensure the mains supply voltage, frequency, number of phases and
power rating comply with details on the rating label.
4.1.2 All wiring must be in accordance with the appropriate standards. The
equipment must be supplied with a double pole isolator switch.
4.1.3 Ensure safety regulations and practices are adhered to when installing
and using this equipment
4.1.4 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 installation procedure.
4.1.5 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.
4.1.6 Once the appliance has been fired beware that certain parts will be hot
to the touch.
4.1.7 Do not install flues during rain, high winds or in severe weather
conditions.
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4.2 GAS INFORMATION
4.2.1 Gas Categories
a. 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.
b. For Natural gas to LPG conversion kit number: NG30 (complete with
instructions) is available.
c. For LPG to natural gas conversion kit number LPG30 (complete with
instructions) is available.
4.2.2 Gas Supply
a. The gas installation must be completed in accordance with the
relevant standards (BS 6891).
b. The supply must be capable of providing a steady inlet working
pressure to the appliance of 20 mbar at a rate of 3.2 m³/h
(RenoXtra 30CA) or 3.92 m³/h (RenoXtra 37C) (Calculated with a
Gas CV of 38.7 MJ/m³)
c. The installation must be tested for gas tightness using suitable
methods. The Pipework should also be purged of air in
accordance with the IG Publication Standard.
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
5. PREPARATION
5.1 Make sure all the electrical cables are in place.
5.2 Water connections.
5.3 Gas connections are in place.
5.4 The wall surface where boiler is being fixed is smooth and flat.
5.5 Giving consideration to the flue position.
5.6 Give consideration to the overall height.
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RenoXtra 30CA RenoXtra 37C
Maximum Lift Weight 34.45 kg 36.5 kg
Gas Connection 15 mm copper
Domestic hot water 15 mm copper
Heating flow and return 22 mm copper
Safety valve discharge 15 mm copper
Condensate Drain 21.5mm 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 40
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
DHW max. inlet pressure 5 bar
Minimum inlet pressure for maximum DHW flow rate 1.0 bar
Minimum inlet pressure for appliance to operate 0.2 bar
Maximum DHW flow rate at 35° rise 12.3 l/m 15.9 l/m
Minimum domestic hot water flow rate 2.2 l/m
Maximum flow temperature. 63°C
DHW Specific Rate 14.3 l/min 18.6 l/m
Ball valves are fitted in water and gas connections
For larger systems use an additional expansion vessel
TABLE 2
GENERAL DATA

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.
RenoXtra
NATURAL GAS G20 LPG G31
30CA 37C 30CA 37C 30CA 37C 30CA 37C
MAXIMUM MINIMUM MAXIMUM MINIMUM
CH
INPUT Q
NET kW 25.5 30.7 7.14 9.18 26.06 30.7 7.29 9.18
GROSS kW 28.3 34.0 7.92 10.1 28.3 33.3 7.92 9.97
GAS CONSUMPTION m³/h 2.6 3.16 0.74 0.85 1.06 1.25 0.30 0.38
CH
OUTPUT
NON
CONDENSING
kW 24.8 30.0 6.95 9.0 25.0 30.0 7.0 9.0
CONDENSING kW 27.85 32.6 7.76 9.8 27.85 32.6 7.76 9.8
SEASONAL EFFICIENCY (SEDBUK) ‘A’
NOX CLASSIFICATION CLASS 5
CENTRAL HEATING SETPOINT TEMPERATURE RANGE 20 - 82˚C
TABLE 4
PERFORMANCE DATA (CENTRAL HEATING)
RenoXtra
NATURAL GAS G20 LPG G31
30CA 37C 30CA 37C 30CA 37C 30CA 37C
MAXIMUM MINIMUM MAXIMUM MINIMUM
DHW
INPUT Q
NET kW 30.6 38.0 7.14 9.18 31.3 38.0 7.29 9.18
GROSS kW 34.0 42.1 7.92 10.19 34.0 41.3 7.92 9.97
GAS CONSUMPTION m³/h 3.2 3.92 0.74 0.95 1.28 1.56 0.30 0.34
DHW OUTPUT kW 30.0 37.1 7.0 9.0 30.0 37.1 7.0 9.0
TABLE 5
PERFORMANCE DATA (DOMESTIC HOT WATER)
RenoXtra
NATURAL GAS G20 LPG G31
30CA 37C 30CA 37C 30CA 37C 30CA 37C
MAXIMUM MINIMUM MAXIMUM MINIMUM
RANGE RATING (kW)
OUTPUT 30.0 37.1 7.0 9.0 30.0 37.1 7.0 9.0
OFFSET (PASCAL) -3.0 (Minus Three)**
BURNER
CO2(%)
CASE OFF 9.3* 9.5* 8.4** 8.5** 10.2** 10.2** 9.4** 9.2**
CASE ON 9.5* 9.8* 8.6** 8.8** 10.4** 10.5** 9.6** 9.5**
* =
+ 0.5 ** = Ref Only
MAXIMUM
GAS RATE m³/h 3.2 3.92 0.74 0.95 1.28 1.56 0.30 0.34
TABLE 3
PERFORMANCE DATA
6. TECHNICAL DATA
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7. DIMENSIONS & POSITIONING
7.1 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. For the purpose of servicing, it is also recommended that the
appliance be located with a minimum gap of 200mm above any surface.
7.2 APPLIANCE LOCATION
7.2.1 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.
7.2.2 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).
7.2.3 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.
7.2.4 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.
7.2.5 Room ventilation for the appliances
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
maintained. However, reference
should be made to BS 5440 Pt. 2.
RenoXtra
NATURAL GAS G20 LPG G31
30CA 37C 30CA 37C 30CA 37C 30CA 37C
MAXIMUM MINIMUM MAXIMUM MINIMUM
RANGE RATING (kW)
OUTPUT 30.0 37.1 7.0 9.0 30.0 37.1 7.0 9.0
OFFSET (PASCAL) -3.0 (Minus Three)**
BURNER
CO2(%)
CASE OFF 9.3* 9.5* 8.4** 8.5** 10.2** 10.2** 9.4** 9.2**
CASE ON 9.5* 9.8* 8.6** 8.8** 10.4** 10.5** 9.6** 9.5**
* =
+ 0.5 ** = Ref Only
MAXIMUM
GAS RATE m³/h 3.2 3.92 0.74 0.95 1.28 1.56 0.30 0.34
TABLE 3
PERFORMANCE DATA
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FIGURE 2
MINIMUM CLEARANCE
KITCHEN FRONT VIEW
*Note: 200mm dimension is a desired
workable clearance but can be reduced
KITCHEN TOP VIEW
*
** Note: 400mm dimension is a
desired workable clearance
for servicing
**

8. HEATING SYSTEM
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.
8.1 This appliance incorporates all the necessary components to allow it
to be connected to a sealed central heating system. Figure 3 shows a
typical system incorporating 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 domestic cold inlet and hot outlet are
also shown and Figure 4 shows the water flow through the boiler. The
installation should be designed to operate with a flow temperature of up to
90˚C.
8.2 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 6.
8.3 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.
8.4 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.
8.5 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. Using no less than 15Using 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.
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8
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 litres
(1.45 gals) capacity expansion vessel supplied with
appliance
L 95 84 73 50
For system having a larger capacity multiply the total
system capacity in litres by the factor to obtain the total
minimum expansion vessel capacity required litres
0.0833 0.09 0.109 0.156
TABLE 6
Expansion Vessel Requirement

8.6 FILLING LOOP
The plumbing jig incorporates a filling loop that temporarily connects
the DHW supply to the CH system. This is used to fill the CH system on
installation and whenever the water pressure has been removed for system
modifications, etc. The filling loop complies with the water supply (water
fittings) regulations 1999 Section G24.1 and G24.2. After filling the system
the hose should be disconnected and stored in a safe place for future use.
A blanking kit (part No: 1000-0020810) is available where it is necessary to
remove the filling loop at one end only.
8.7 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 (HE30CA) and 0.38
kg/s (HE37C) which, through a 22mm pipe, gives velocities of 1.00 m/s
(HE30CA) and 1.25 m/s (HE37C). Therefore, the recommended minimum
pipe size for the main carcass is 22mm.
8.8 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. 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, 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)
8.9 CONTROLS
As a minimum, a time clock and room thermostat must be installed to
control the appliance. Thermostatic radiator valves may be fitted to the
system, however they 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 (RenoXtra 30CA) or 23 l/min (RenoXtra 37C)
(20˚ differential at maximum heat input).
8.10 DOMESTIC HOT WATER SYSTEM REQUIREMENTS
8.10.1 Domestic hot water circuits and their components, must be
in accordance with the relevant standards and water supply
regulations. Further guidance/recommendations can be found in
building regulations G17 to 24 and R17 to 24.
8.10.2 The maximum domestic cold water supply pressure allowable
for this appliance is 5 bar. If the supply pressure exceeds this,
a pressure-reducing valve must be installed in the supply to the
appliance.
8.10.3 If the water to the property is “hard”, more than 200ppm of salts,
then a scale inhibitor should be fitted. Such products are available
from Salamander.
NOTE: The system must not be filled with ‘softened’ water.
The cold water filling position should be before any softening
product.
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FIGURE 3
WATERFLOW SCHEMATIC DIAGRAM

9. FITTING
9.1 TEMPLATE
9.1.1 Using a plumb line (to make sure the unit is square) fix
the template to the wall. Mark the positions of the flue
and the 8 fixing points.
9.1.2 Using a 105 mm core drill make the hole through
the wall. Installations that are made from within the
building only will require a 125 mm diameter hole in
order to fit the flue system.
9.1.3 Using a 7mm bit, drill a total of 4 fixing holes at the top
of the wall plate and a minimum of 2 at the bottom.
Insert the Rawlplugs. Remove the template.
9.2 WALL PLATE ADAPTOR
The wall plate adaptor comes already fitted with the 2 downpipes
attached by clips on the back. Figure 4a
9.2.1 Fix the wall plate to the wall ensuring it is level, with the
screws provided.
9.2.2 Fit the blending valve between the DHW cold inlet
and lower end of pre-heat pipe connect the the outlet
blending valve to the cold water inlet connection on
the RenoXtra. Fit the shock arrestor to the lower end of
the cold feed connection. See Figure 4b.
9.3 FITTING THE APPLIANCE
Caution: this appliance exceeds the recommended weight for
a one-man lift as detailed in the Manual Handling Operations,
1992 Regulations.
It should be noted that this appliance could contain sharp edges and
care MUST be taken when handling.
9.3.1 Lift the appliance onto the wall plate adaptor and
locate the unit on the two lugs on the wall plate. Figure
4c
9.3.2 The boiler then drops into place and needs no further
fixing.
9.3.3 Ensure the gasket is in place and sit the gas saver
unit on top of the appliance. The spigot on the bottom
of the gas saver should slot easily into the heat
exchanger on the appliance. Remove boiler inner
panel to check engaged. These will make a seal once
aligned. Line up the screw holes on the front and
top rear and fix together using the screws and nuts
provided. Figure 4d & 4e
9.3.4 Connect the blending valve outlet to DHW inlet on the
boiler. Figure 4b
9.3.5 Connect the 2 pipes in the wall plate to the gas saver
using 15mm compression elbows. Figure 4g.
9.3.6 Prime gas saver unit by pouring 6 litres of water into
the top of the gas saver before connecting the flue.
9.3.7 Fit side panels, front door and MMI panel.
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FIGURE 4
FITTING THE WALL PLATE & APPLIANCE
a.
b.
e.
c.
d.
Gasket
f.
Top Rear
Fixing
Front
Fixing
Cold Feed
Pipe
Hot Feed
Pipe
g.

10. FLUE INSTRUCTIONS
FOR A DETAILED INFORMATION MANUAL ABOUT THE FLUE SYSTEMS AVAILABLE
PLEASE REFER TO OUR RENO, CONCENTRIC & TWIN FLUE INSTALLATION INSTRUCTION
PUBLICATION No. ZZ1191.
10.1 The Reno Combi Boiler is certified as a heating boiler with corresponding flue systems
according to EU Directive 90/396/EEC on gas-fired devices. These installation instructions
are covered by this certification and are referred to in the design approval test certificate.
10.2 The installation of the boiler and flue system must be in accordance with the Gas Safety
(Installation and Use) Regulations 1998 and the Building Regulations. If no specific
instructions are given, reference should be made to the relevant codes of practice.
THESE RELEVANT STANDARDS SHOULD BE FOLLOWED
BS 5440:1 Flues and ventilation for gas appliances of rated heating input not
exceeding 70kW (net) : Flues
BS 5440:2 Flues and ventilation for gas appliances of rated heating input not
exceeding 70kW (net) : Air Supply
Ensure all legislation, regulations and directives mentioned are observed.
10.3 Two types of flue systems are available for the Reno Boiler Range. The standard
concentric flue system 60/100 (100mm diameter) and the concentric twin flue system
80mm which allows for longer flue duct lengths to be achieved.
10.4 The air/flue duct operates at very low temperatures therefore no clearance is necessary
between the air duct and the adjacent services.
10.5 Ensure while installation work is being carried out that no debris such as swarf, filings or
fragments of mortar are allowed to remain in the air/flue duct.
10.6 TYPE OF FLUE SYSTEMS
10.6.1 The standard concentric flue system 60/100 (100mm diameter)
10.6.2 The air/flue duct operates at very low temperatures therefore no clearance is
necessary between the air duct and the adjacent services.
10.7 FLUE TERMINAL POSITIONS
10.7.1 The following information provides the general requirements for siting flue
terminals. As part of the recommendation given in BS 1550 Part 1. For IE
recommendations, see the current issue of I.S. 813 “Domestic Gas Installations.”
Also publication a “Guide for Gas Installations in Timber Framed Housing
DM2” or consult your local gas region, MUST be consulted when installing the
appliance into a timber-framed building.
NOTE: Due to the nature of the boiler, water vapour will discharge from the flue. This
should be taken into account when siting the flue
10.7.2 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.
10.7.3 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.
10.7.4 Recommended terminal positions for both horizontal and vertical flues are shown
and flue components and installation options are also detailed.
10.7.5 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.
10.7.6 The Flue MUST NOT be installed under a car port.
10.8 PLUME TERMINAL OUTLETS
10.8.1 A flue duct outlet of an appliance should be at least 600mm from the boundary
line when facing it and at least 300mm from the boundary line when running
parallel to it. (see Fig 6)
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.
10.8.2 It is recommended 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.
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TABLE 7 TERMINAL POSITION MINIMUM DISTANCE
A Directly below an opening, air brick, opening window etc 300mm
B Above an opening, air brick, opening window, etc. 300mm
C Horizontally to an opening, air brick, opening window etc. 300mm
D Below gutters, soil pipes or drain pipes. 75mm
E Below eaves. 200mm
F Below balconies. 200mm
G From a vertical drain pipe or soil pipe. 150mm
H From an internal or external corner. Greater than 450mm protrusion. 300mm
I Above ground, roof or balcony level. 300mm
J From a surface facing the terminal. 600mm
K From a terminal facing the terminal. 1,200mm
M Vertically from a terminal on the same wall. 1,500mm
N Horizontally from a terminal on the same wall. 300mm
Q Above intersection with roof. 530mm
P From a vertical structure on the roof 300mm
R From the terminal to the boundary 300mm
FIGURE 5
TERMINAL POSITIONS
FIGURE 6
PLUME TERMINAL OUTLET DIMENSIONS

10.8 TYPICAL FLUE CONFIGURATIONS
HORIZONTAL REAR FLUE
Standard flue kit comprising of:
Turret
Horizontal Terminal
HORIZONTAL SIDE FLUE
Can be fitted to the left or the right.
Standard Flue Kit
Turret
Horizontal Terminal
EXTENDED HORIZONTAL REAR FLUE
Can be fitted to the left or the right.
Vertical Appliance Adaptor
Horizontal Terminal
90˚ Elbow
Required Extension Length
OFFSET EXTENDED HORIZONTAL REAR FLUE
Can be fitted to the left or the right.
Standard Flue Kit +
90˚ Elbow
Required Extension Length
OFFSET VERTICAL FLUE
Can be fitted to the left or the right.
Turret
Vertical Terminal
90˚ Elbow
Required Extension Lengths
VERTICAL FLUE
Vertical Appliance Adaptor
Required Extension Lengths
Vertical Terminal
HORIZONTAL FLUES
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ITEM DESCRIPTION QTY PARTS INCLUDED APPLICATION PART No. PASCAL
30C 37C
1STANDARD FLUE KIT WHITE
1Turret
Horizontal 1000-0020070 45 60
1Appliance Seal
160/80 Adaptor
1Inside Wall Cover Plate
1Outside Wall Cover Plate
1100mm Diameter Clamp
1800mm Horizontal Terminal
1a TURRET WHITE 1Turret Horizontal 1000-0020020 40 45
1b HORIZONTAL TERMINAL WHITE 1800mm Horizontal Terminal Horizontal 1000-0019830 5 15
2VERTICAL APPLIANCE ADAPTOR WHITE 1Adaptor Vertical 1000-00018990 0 0
345˚ ELBOW WHITE 1Elbow
Horizontal + Vertical 1000-00018980 5 12.5
4* 90˚ ELBOW WHITE 1Elbow
Horizontal + Vertical 1000-00018980 10 75
5250mm STRAIGHT EXTENSION WHITE
1 250mm Straight Extension
Horizontal + Vertical 1000-0018960 1.25 41 100mm Diameter Clamp
2 Screws
6500mm STRAIGHT EXTENSION WHITE
1 500mm Straight Extension
Horizontal + Vertical 1000-0018950 2.5 7.51 100mm Diameter Clamp
2 Screws
71000mm STRAIGHT EXTENSION WHITE
1 1000mm Straight Extension
Horizontal + Vertical 1000-0018940 5 151 100mm Diameter Clamp
2 Screws
8FLAT ROOF WEATHER COLLAR 1 Aluminium Circular Flat Roof Seal Vertical 1000-0020060 n/a n/a
9PITCHED ROOF COLLAR BLACK 1 Plastic & Lead Pitched Roof Seal Vertical 1000-0020030 n/a n/a
10 RIDGE TERMINAL 1Condensing Concentric Ridge
Terminal 1000-0021030 5 10
11 WALL FIXING BRACKET 100mm 1 Clamp for 100mm tube
Horizontal + Vertical 1000-0020050 n/a n/a
12 1140mm VERTICAL TERMINAL
1 Vertical Terminal Assembly
Vertical 1000-00018930 5 10
1 Support Bracket
PLUME MANAGEMENT SYSTEM
17 PLUME MANAGEMENT KIT
(BLACK) 60mm 1
Horizontal + Vertical 1000-00200730 21 53
18 1000mm EXTENSION FLUE 60mm 1
Horizontal + Vertical 1000-0020740 3 8
19 90˚ ELBOW BLACK 60mm 1
Horizontal + Vertical 1000-0020680 6 15
20 45˚ ELBOW (BLACK) 60mm 2
Horizontal + Vertical 1000-0020670 3 8
21 WALL FIXING BRACKET 60mm 1
Horizontal + Vertical 100-0020770 n/a n/a
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TABLE 7
60/100 FLUE COMPONENTS

10.9 FLUE REQUIREMENTS & GENERAL INFORMATION
10.9.1 Horizontal and vertical concentric flues (60/100mm diameter) with balanced
terminals may be installed on all the Reno appliance’s.
10.9.2 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 3°
(52mm) per meter. This ensures that condensate runs back into the appliance
from the flue system for safe discharge via the condensate waste pipe.
Reference should be made to Table 7 for relevant part numbers.
10.9.3 The maximum length of flue permissible is calculated by using the component
pressure drop (Examples are given in Figure 8 which include the maximum
lengths at 95% of input.)
10.9.4 The minimum vertical flue length is 0.7m from the top of the appliance case to
the top of the terminal.
10.9.5 Longer flues may be fitted, however the input of the appliance will be reduced
accordingly.
10.9.6 Elbows may be fitted within the flue system with a corresponding reduction in
overall flue length based on the component pressure drop.
10.9.7 Reference should be made to Tables 8.
Heat Input (%)
106
104
102
100
99
98
97
96
95
94
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Flue Pressure Drop (Pascals)
Flue Pressure Drops for the RenoXtra 30CA & RenoXtra 37C
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TABLE 8
FLUE PRESSURE DROPS
FLUE 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
RENOXTRA 30CA MAXIMUM FLUE RESISTANCE 82Pa RENOXTRA 37C MAXIMUM FLUE RESISTANCE 145Pa

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500mm
Pitched
Roof
Weather
500mm
1140mm
Flat Roof
Weather
Collar
20˚ to 50˚
RIDGE TERMINAL
Ridge
Terminal
Ridge
Terminal
Clamps
Flue Extensions
Vertical
Appliance
Adaptor
Adjustable
length
10.10 INSTALLATION INSTRUCTION FOR ROOF OUTLETS
PITCHED
ROOF
FLAT ROOF

10.12 INSTALLATION OF THE STANDARD FLUE SYSTEMS
The standard flue kit comprises of:
ITEM DESCRIPTION QTY
1 Turret 1
2 Appliance Seal 1
3 60/80 Adaptor 1
4 EPDM Outside Wall Cover Plate 1
5 Inside wall cover Plate 1
6 100mm Diameter Clamp 1
7 800mm Horizontal Terminal 1
Horizontal Terminal
Turret
IMPORTANT NOTE:
Before carrying out this procedure
ensure seal has not been dislodged
from top of heat exchanger.
With the appliance comes a wall template.
(Label Ref: 1000-2217950-3)
1. INSTALLATION INSTRUCTIONS
1.1 Using the template supplied with the boiler,
determine the position of the flue.
1.2 If access is available from outside drill a
105mm diameter hole.
If no access is available refer to section 2.
1.3 Mount the jig and the boiler on the wall
as detailed in the boiler installation
instructions.
1.4 Fit the appliance seal to the underside of
the turret and fix the turret to the top of
the boiler using the 4 screws supplied,
ensuring that the heat exchanger flue seal
and 60/80 adaptor is in place.
1.5 Take a measurement from the outside of
the wall to the edge of the turret dimension
“X” Fig. 1.
1.6 Mark this dimension onto the horizontal
terminal as shown in Fig. 2.
1.7 Cut the flue to the desired length making
sure the ends are square and free from
burrs.
NOTE:
To ease the assembly of the flue
components,
apply suitable silicone lubricant to
the male plastic end. (Any other type of lubricant
may corrode the gasket.)
1.8 Place flue clamp over turret rim.
1.9 From the outside of the building, push the
terminal through the wall and locate the
male plastic end of the terminal into the
female end of the turret.
1.10 Place clamp equally over the turret and
terminal ends and tighten the 2 screws.
1.11 Fit the rubber-finishing ring over the
outside of the flue, pushing it flush to the
wall. The rib on the inside of the ring will
locate in-between the locating pips on the
end of the terminal.
Clamp
HORIZONTAL REAR FLUE
HORIZONTAL SIDE FLUE
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Horizontal Terminal
Turret
Clamp

Fig. 1
Fig. 2
X
155mm
x
155mm
Horizontal Terminal
2. NO OUTSIDE ACCESS
2.1 If no access is available from outside
the building drill a 125mm diameter
hole.
2.2 Mount the jig and the boiler on
the wall as detailed in the boiler
installation manual.
2.3. a. For a rear flue measure the wall
thickness and add;
40mm for a standard rear flue
90mm for a rear flue if the
standoff bracket is used.
b. For a side flue measure the
distance from the outside wall to
the side of the boiler and add;
Length shown in Fig. 3.
This dimension is known as
dimension “X”.
2.4 Mark this dimension on to the turret
as in Fig. 2.
2.5 Cut the flue to the desired length
making sure the ends are square and
free from burrs.
NOTE:
To ease the assembly of the flue
components,
apply suitable silicone
lubricant to the male plastic end. (Any other
type of lubricant may corrode the gasket.)
2.6 Fit the rubber-finishing ring over
the outside of the flue. The rib on
the inside of the ring will locate in-
between the locating pips on the end
of the terminal.
2.7 Push the terminal through the hole in
the wall.
2.8 Fit the appliance seal to the
underside of the turret and fix the
turret to the top of the boiler using
the 4 screws supplied, ensuring that
the heat exchanger flue seal and
80/60 reducer is in place.
2.9 Place flue clamp over turret rim
2.10 Pull back the terminal through the
wall locating the male plastic end of
the terminal into the female end of
the turret.
2.11 Place the clamp equally over the
turret and terminal and tighten the 2
screws.
Fig. 3
Distance to outside wall
TURRET FLUE LENGTH =
Centre of boiler to outside wall + XXXmm
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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 adverse effect on the evacuation of condensate from the
boiler.
12. ELECTRICAL
12.1 Electrical Connections
12.1.1 External wiring must be correctly earthed, polarised and in
accordance with BS 7671 (current edition).
12.1.2 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
11. CONDENSATE DRAIN
11.1 The condensate drain utilizes 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.
NOTE: * External runs exceeding 3 metres the discharge pipe should be
increased to 32mm diameter for complete peace of mind.
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FIGURE 7
TYPICAL CONDENSATE DRAIN ARRANGEMENTS
FIGURE 7bFIGURE 78a
FIGURE 7c FIGURE 7d