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Johnson & Starley
COMBI
SERIES
Xtra High Efficiency
Combination
Boilers
INSTALLATION, MAINTENANCE &
SERVICING INSTRUCTIONS
Natural Gas G20:
RenoXtra 30CA - GC No: 47-416-05
RenoXtra 37C
Propane G31 Variant:
RenoXtra 30CP - GC No: 47-416-07
RenoXtra 37CP - GC No: 47-416-08
R E L I A B I L I T Y Y O U C A N T R U S T
www.johnsonandstarley.co.uk
- GC No: 47-416-06
Publication No. ZZ 1311-5 October 2009
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.
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Related Manuals for Johnson & Starley RenoXtra 30CA
Summary of Contents for Johnson & Starley RenoXtra 30CA
- Page 1 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 The Johnson &...
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Page 2: Table Of Contents
CONTENTS Features Brief Description Building Standards & Regulations Safety & Gas Information Preparation Technical Data Dimension & Positioning Heating System Fitting Flue Instructions Condensate Drain Electrical Functional Flow Diagram Wiring Diagram Commissioning Handing Over Servicing Defect Diagnosis Fault Finding Parts Replacement List of Spares Exploded Diagram Important Information... - Page 3 RENOXTRA FEATURES BRIEF DESCRIPTION CONTENTS CARTON 1 CONTENTS CARTON 2 CONTENTS CARTON 3 Wall Plate RenoXtra 30CA or RenoXtra 37C Boiler Gas Saver Side Panels Blending Valve, Shock Arrestor and Elbows Front Door Panel Control Module (including MMI, display and controls)
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Page 4: Building Standards & Regulations
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 •... -
Page 5: Preparation
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. -
Page 6: Technical Data
TECHNICAL DATA NATURAL GAS G20 LPG G31 RenoXtra 30CA 30CA 30CA 30CA MAXIMUM MINIMUM MAXIMUM MINIMUM RANGE RATING (kW) 30.0 37.1 30.0 37.1 OUTPUT -3.0 (Minus Three)** OFFSET (PASCAL) 9.3* 9.5* 8.4** 8.5** 10.2** 10.2** 9.4** 9.2** CASE OFF BURNER 9.5* 9.8* 8.6**... -
Page 7: Dimension & Positioning
DIMENSIONS & POSITIONING 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. -
Page 8: Heating System
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. 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. -
Page 9: Filling Loop
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... - Page 10 FIGURE 3 WATERFLOW SCHEMATIC DIAGRAM www.johnsonandstarley.co.uk...
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Page 11: Fitting
FITTING TEMPLATE Cold Feed 9.1.1 Using a plumb line (to make sure the unit is square) fix Pipe 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 Hot Feed the wall. -
Page 12: Flue Instructions
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. - Page 13 FIGURE 5 TERMINAL POSITIONS TABLE 7 TERMINAL POSITION MINIMUM DISTANCE Directly below an opening, air brick, opening window etc 300mm Above an opening, air brick, opening window, etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes. 75mm Below eaves.
- Page 14 10.8 TYPICAL FLUE CONFIGURATIONS HORIZONTAL FLUES VERTICAL FLUE HORIZONTAL REAR FLUE Vertical Appliance Adaptor Required Extension Lengths Standard flue kit comprising of: Vertical Terminal Turret Horizontal Terminal HORIZONTAL SIDE FLUE Can be fitted to the left or the right. Standard Flue Kit Turret Horizontal Terminal OFFSET EXTENDED HORIZONTAL REAR FLUE OFFSET VERTICAL FLUE Can be fitted to the left or the right.
- Page 15 PASCAL APPLICATION ITEM DESCRIPTION PARTS INCLUDED PART No. Turret Appliance Seal 60/80 Adaptor STANDARD FLUE KIT WHITE Inside Wall Cover Plate Horizontal 1000-0020070 Outside Wall Cover Plate 100mm Diameter Clamp 800mm Horizontal Terminal TURRET WHITE Turret Horizontal 1000-0020020 HORIZONTAL TERMINAL WHITE 800mm Horizontal Terminal Horizontal 1000-0019830...
- Page 16 10.9.7 Reference should be made to Tables 8. TABLE 8 FLUE PRESSURE DROPS Flue Pressure Drops for the RenoXtra 30CA & RenoXtra 37C RENOXTRA 30CA MAXIMUM FLUE RESISTANCE 82Pa RENOXTRA 37C MAXIMUM FLUE RESISTANCE 145Pa Flue Pressure Drop (Pascals)
- Page 17 10.10 INSTALLATION INSTRUCTION FOR ROOF OUTLETS PITCHED FLAT ROOF ROOF Pitched Roof Flat Roof Weather Weather Collar 20˚ to 50˚ RIDGE TERMINAL Ridge Terminal Ridge Terminal Flue Extensions Clamps Adjustable length Vertical Appliance Adaptor Telephone: 01604 762881...
- Page 18 10.12 INSTALL ATION OF THE STANDARD FLUE SYSTEMS The standard flue kit comprises of: IMPORTANT NOTE: ITEM DESCRIPTION Before carrying out this procedure Turret ensure seal has not been dislodged from top of heat exchanger. Appliance Seal 60/80 Adaptor With the appliance comes a wall template. EPDM Outside Wall Cover Plate (Label Ref: 1000-2217950-3) Inside wall cover Plate...
- Page 19 NO OUTSIDE ACCESS 155mm If no access is available from outside the building drill a 125mm diameter hole. 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;...
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Page 20: Condensate Drain
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. -
Page 21: Electrical
system must be through a common double pole isolation switched spur that has a 3mm separation on each pole and has a 3A rated fuse. It should be used for the heating system only and no other household components. A fused three pin plug and shuttered outlet may also be used provided they both comply with BS 1363. -
Page 22: Functional Flow Diagram
FUNCTIONAL FLOW DIAGRAM FIGURE 9 FUNCTIONAL FLOW CHART www.johnsonandstarley.co.uk... -
Page 23: Wiring Diagram
WIRING DIAGRAM REMOVE THIS LINK TO FIT THERMOSTAT MAINS DIVERTER SPARK FLAME DHW FLOW FLUE CH FLOW CH RETURN THERMISTOR SUPPLY VALVE ELECTRODE DETECTION TURBINE THERMISTOR THERMISTOR 230V~50Hz ELECTRODE or br CVBC y bk CLOCK PUMP (OPTIONAL) br b br or THERMISTOR MMI PCB MAINS... -
Page 24: Commissioning
15. COMMISSIONING 15.1 With all the pipe connections made, open the cold supply water valve NOTE and the CH flow and return valves at the base of the appliance. Open the manual vent at the top of the appliance and bleed, close the manual vent The gas valve is factory when all the air is removed and ensure that the autovent cap is open. -
Page 25: Servicing
16.5 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. 16.6 Explain how to control the temperature of the radiators and domestic hot water by use of the controls on the appliance. -
Page 26: Test Mode
TEST MODE To put the appliance in test mode, first press and whilst holding it, press the MODE button and hold both together until the display changes. (Possible 5 second time delay.) If the display shows EHIS press RESET. and try again. The flow and return temperatures are displayed along with the flame current value and the fan speed. -
Page 27: Defect Diagnosis
17.6 IGNITION AND DETECTION ELECTRODES Remove the plug cap from the top and the earth wire from the base of the spark electrode. Unscrew the two screws that retain the electrode in the cover plate and remove the assembly. Inspect and clean the electrode, removing any debris and oxidation. -
Page 28: Cbvc
DEFECT DIAGNOSIS SYMPTOM POSSIBLE CAUSE REMEDY Check all external controls (if fitted) Boiler will not run No call for heat to boiler control board Check settings on time clock Check settings of boiler controls Check flow from the appliance is correct Check cold water inlet filter No call for DHW to boiler control board. -
Page 29: Fault Finding
FAULT FINDING FLOW CHART FIGURE 11 FAULT FINDING FLOW CHART Telephone: 01604 762881... -
Page 30: Parts Replacement
20. PARTS REPLACEMENT 20.1 INITIAL DISASSEMBLY FIXING SCREWS X 2 per side 20.1.1 Remove the upper front case that is retained by a screw in the top of the appliance. 20.1.2 Remove the control facia by removing the plastic door unscrewing the two screws that hold the control module in place, rotate downward. -
Page 31: Primary Water Pressure Sensor
20.8 EXPANSION VESSEL Close the CH flow and return valves, ensuring the drain point on the flow valve is connected to the appliance side. Drain off the water from within the appliance using the drain valve. Remove the LH painted case side. Unscrew the flexible hose connection from the expansion vessel. -
Page 32: Ignition Electrode
20.14 PLATE HEAT EXCHANGER Close the mains inlet valve to the household, open a domestic hot water tap at the lowest point in the system and allow the pressure to dissipate. Close this tap again. Close the CH flow and return valves, ensuring the drain point on the flow valve is connected to the appliance side. - Page 33 20.19 FLUE TEMPERATURE SENSOR Carefully remove the two spade connectors from the sensor and unscrew the sensor from the plastic flue hood. Replace with a new component in reverse order, taking care not to over tighten! FLUE TEMPERATURE SENSOR 20.20 FAN Unscrew the gas joint at the top of the gas cock and remove the CVBC (red box) from the gas valve.
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Page 34: List Of Spares
14. LIST OF SPARES REFER TO THE EXPLODED DIAGRAM PART No. ITEM G.C. No. DESCRIPTION RENOXTRA 30CA RENOXTRA 37C R300-0501005 R380-0501005 Control Panel Assembly H23-609 1000-0301485 Pump H23-627 1000-0301615 Diverter Valve (Motorised Head) H23-610 1000-0019005 Expansion Vessel (with washer) H23-613... -
Page 35: Exploded Diagram
15. EXPLODED DIAGRAM Telephone: 01604 762881... -
Page 36: Important Information
18. IMPORTANT INFORMATION Fully complies with Part L of the Building Regulations by following the guidance in the British Standard BS 5864 and the Heating Compliance Guide For further information contact Johnson & Starley on Telephone 01604 762881 ADDITIONAL KITS AVAILABLE Mechanical Timer Part No. -
Page 37: Benchmark Checklist & Service Record
19. BENCHMARK CHECKLIST & SERVICE RECORD COMMISSIONING CHECKLIST & SERVICE RECORD This checklist should be filled out at each annual service Telephone: 01604 762881... - Page 40 Johnson & Starley Johnson & Starley are the leading UK & European manufacturers of a complete range of Domestic Warm Air Heaters. All the heaters suit both Replacement and Upgrade needs and are compliant with the new (2006) amendments to Part L of the Building Regulations. HOME COMFORT SOLUTIONS Company Details Website Address...
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