Ferroli optima 2001 VMF7 User manual

2001
WALLMOUNTED, ROOM SEALED,
FAN ASSISTED,
GAS CONDENSING COMBINATION BOILER
Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH
Sales: 0121/3523500 - Fax [phone]
ALL SPECIFICATIONS SUBJECT TO CHANGE
Phone numbers:
Installer
Service Engineer
Serial No.
Read these Instructions thoroughly
before using the appliance
FERROLI HELPLINE
FOR SERVICE INFORMATION OR
HELP TELEPHONE: [phone]
ALWAYS QUOTE YOUR SERIAL NUMBER
FOR IMMEDIATE ASSISTANCE
VMF7
INSTALLATION
INSTRUCTIONS
Appr. Nr. B95.01A CE 0063AQ2150
G.C. NO: 47-367-21

2001
2
page INDEX
3General Description
3Related Documents
4Technical Data
5Appliance Dimensions
6Boiler Flow Diagram
7Key of boiler flow diagram
8Installation Details
8Location of Boiler
8Air Supply
8Condensate
10 Flue System
10 Gas Supply
10 Water System
12 Central Heating Pump
12 Sizing of expansion vessel
13 Installation of Boiler
13 1. Unpacking
13 2. Mounting the Boiler Jig
on the Wall (rear flue)
13 3. Mounting the Boiler Jig
on the Wall (side flue)
14 Drilling template
15 4. Preparing the Flue Assembly
16 5. Connecting the Boiler
18 6. Fitting the Flue Assembly
18 7. Electrical Installation
19 External sensor
20 Setting of compensation curve
21 8. Commissioning & Testing
21 8.1 Filling the Central Heating System
21 8.2 FillingtheDomesticHotWaterSystem
21 8.3 Electricity Supply
21 8.4 The Gas Installation
22 8.5 To Light the Boiler
23 Burner pressure C.H. and D.H.W.
24 Gas pressure adjustment with Honeywell
VR 4605 NA 4003 valve
25 8.7 D.H.W. Burner Pressure
25 9. System operation
25 10. Handing Over to the User
26 General Wiring Diagram
27 Fast fault finding
28 General fault finding
29 Replacement of parts
30 Details GAS valve
30 Details combustion chamber
31 Details Burner
32 Honeywell gas valve
32 Printed circuit board (P.C.B.)
32 Thermostats
33 Temperature sensors
33 Pressure relief valve
33 Pump
34 Automatic air vent
35 Pressure gauge
35 C.H. selector switch
35 Time clock
36 Fault diagnostic/temperature control
36 Air pressure switch
37 C.H. expansion vessel
38 Exploded view gas line, combustion
chamber an draft diverter
39 Explodedviewheatexchanger+C.H.and
D.H.W. parts
40 Spare Parts List
41 Domestic Hot Water
Performance + Modureg
42 Special Installation Possibilities

2001
3
General Description
TheFerroli 2001 isa wall mounted, room sealed, fan assisted,condensing combination boiler for Central Heating (C.H.)
and domestic Hot Water (D.H.W.).
The boiler is of light weight construction with two heat exchangers providing Central Heating and Domestic Hot Water from an
integrally designed unit. The boiler contains its own expansion vessel for sealed systems. The wall mounting jig contains all the
isolating cocks for the water and gas supplies which can be fitted to the wall and provided with all the necessary gas and water
connections prior to the boiler being attached. The flue can either be left hand, right hand or rear. There are three flue lengths
available and they are 0.75 metres (for wall thickness up to 565 mm), 2 metres (for wall thickness up to 1815 mm) and 3 metres
(for wall thickness) up to 2815 mm these wall thicknesses assume a rear flue outlet. For side outlet the effective wall thickness for
each flue length is reduced by 91 mm plus the distance of the appliance from the side wall. The Central Heating and the Domestic
Hot Water temperature is controlled by the Honeywell Modureg valve in conjunction with the P.C.B. There is a limit thermostat on
the central heating circuit which operates at 88°C. There is also an overheat cut-off thermostat which will shut the boiler down
completely and this thermostat operates at 100°C. The boiler is fited with its own Central Heating pump. The pump is switched
ON/OFFbythetimeclock and/ora24Voltroomthermostat.Thepumpcircuitalsohasa6minuteover-runtime.ThereisaDomestic
Hot Water flow switch fitted and when there is a demand for Domestic Hot Water (flow of more than 0.5 gallon/minute, 2.5 litre/
minute)theCentral Heating pump is switched off making availablethemaximumoutputofthegasburnerforDomesticHotWater.
OntheP.C.B.themaximumoutputforCentralHeatingcanbeset.Thisdoesnotinfluencethemaximumoutputfordomestichotwater.
At the factory the central heating output is pre-set to maximum. The appliance is not suitable for external installation.
This appliance can also be installed using the Ferroli two pipe flue system providing flue lengths up to 20 m (see flue options
instructions).
Related Documents
This appliance must be installed strictly in accordance with these instructions:
The Gas Safety Regulations (Installations & Use) 1994.
The Local Building Regulations.
British Gas - "Guidance notes for the installation of domestic condensing boilers".
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1993 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 PART 1 FLUES
B.S. 5440 PART 2 AIR SUPPLY
B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 1989 GAS INSTALLTIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
Model Water Bye Laws.

2001
4
Technical data NATURAL GAS (G20)
Nominal heat input (gross caloric value) 26.6 kW
Nominal heat output 22.6 kW
Nominal heat output condensing (30-50°C) 24.2 kW
Minimum heat input (gross caloric value) 11.9 kW
Minimum heat output 9.7 kW
Minimum heat output condensing (30-50°C) 10.7 kW
Gas rate 2.53 m3S/h
Burner setting pressure 16 mbar (max.)
Minimum burner pressure 3.5 mbar (min.)
Main injector Ø 20 x 0.875 mm
Dimensions (o/all)
Height 1040 mm
Width 480 mm
Depth 360 mm
Weight (net) 65 kg
Weight (gross) 67 kg
Electricity supply: 230V - 50 Hz
Fuse rating:
Mains 3 Amp. (main fuse)
on P.C.B. in boiler F2 Amp (Fast)
Electrical input 150 Watt
Domestic Hot Water flow:
(35°C rise) 9.2 l/min.
Minimum Domestic Hot Water Flow 2.5 l/min.
Maximum domestic cold water
Inlet pressure: 10,0 bar
C.H. Safety valve pressure setting 3 bar
C.H. Expansion vessel capacity 7 litre
Min. heating circuit pressure 0,8 bar
Max. heating circuit pressure 3.0 bar
Boiler water capacity:
Heating 2.5 litre
Domestic hot water 0.8 litre
Pipe connections:
Gas 22 mm
Domestic cold water inlet 15 mm
Domestic cold water outlet 15 mm
Central heating flow 22 mm
Central heating return 22 mm
Pressure relief valve drain 15 mm
Condense drain pipe (rubber hose) 20 mm
Min. installation clearances. Sides:
Left hand 5* mm
Right hand 5* mm
Front 50** mm
(plus access for service)
Min. height from worktop to base 200 mm
* If using a side outlet flue then the minimum clearance on the flue outlet side of the appliance is increased to 75 mm (3 in.)
** Access to the front of the boiler must be available for maintenance (min. 600 mm)

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5
Appliance Dimensions
Fig. 1
Key
1. Electricity cable entry
2. Gas supply
3. Domestic Hot Water outlet
4. Domestic Cold Water inlet
5. Central Heating Pressure relief valve
6. Central Heating Flow outlet
7. Central Heating Return inlet
FRONT VIEW LEFT SIDE VIEW REAR VIEW
TOP VIEW
480
163
900
370
448
76
224
144
77.5507580505097.5
12 3 4 5 6 7
40
100
60
77
221

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6
Boiler Flow Diagram
Fig. 2

2001
7
Key
1. Fixing point
5. Room sealed compartment
7. Gas inlet
8. Domestic hot water outlet
9. Cold water inlet
10. Central heating flow outlet
11. Central heating return inlet
12. D.H.W. draining point
14. Central heating safety valve
16. Fan
19. Combustion - heat exchanging compartment
20. Burner assembly
21. Main injector
22. Burner
26. Combustion chamber insulation
27. Copper heat exchanger for C.H. + D.H.W.
28. Flue collector from heat exchanger
30. Flue/surplus air collector
31. Air pressure control damper
32. Central heating pump
33. C.H. waterway of the heat exchanger
34. C.H. flow temperature sensor
35. Air separator
36. Automatic air vent
37. Cold water inlet filter
39. Cold water flow limiter
41. D.H.W. waterway of the heat exchanger
42. D.H.W. temperature sensor
43. Air pressure switch
46. Operator gas valve
47. Modulating regulator (Modureg) gas valve
48. Burner pressure test point
49. Overheat cut-off thermostat
50. Central heating limit thermostat
51. Central heating frost thermostat
53. Heat exchanger venting point
56. Expansion vessel
58. Fan air outlet pressure test point
59. Flue outlet pressure test point
61. C.H. selector switch
62. Time clock
63. C.H. boiler thermostat
68. Control box with P.C.B.
71. Modulating balance tube
80. 230 V + 24 V roomstat terminal blocks
81. Ignition electrode
82. Flame sensing electrode
83. Automatic ignition control panel
84. 1. gas valve operator 230 V
85. 2. gas valve operator 230 V
86. Automatic control reset knob
100. Fault diagnostic/temperature control panel
101. P.C.B. (printed circuit board)
114. Water pressure switch
132. Flue deflector
136. Flowmeter
145. C.H. pressure gauges
154. Condense drain pipe
157. D.H.W. thermostat
158. Gas inlet pressure test point
161. Condensing heat exchanger
162. D.H.W. coil
172. Setting OTC curve
174. Fault dignostic/temperature control panel with outside
temperature compensation

2001
8
Installation Details
Gas Safety (Installation & Use) Regulations: 1994
In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance with the
above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E. Regulations
and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to prosecution;
it is in your interest and that of safety to ensure that the law is complied with.
Important - If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the
British Gas publication; Guide for Gas Installation inTimberFrameHousing:ReferenceDM2.Ifindoubtadvicemust
be sought from the Local Gas Region of British Gas Plc.
Location of Boiler
The installation of the 2001 must be on a suitable non-combustible load bearing wall which will provide an
adequate fixing for the boiler mounting bracket assembly. The location should be in an area where the water pipes will
not be subjected to frost conditions. In siting the combination boiler the following limitations must be observed:
The combination boiler may be installed in any room or internal space, although particular attention is drawn
to the requirements of the current, i.e. wiring regulations and in Scotland the electrical provisions of the building
regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space
containing a bath or shower.
Where a room sealed appliance is installed in a roomcontainingabathorshoweranyelectricalswitch orappliance
control utilising mains electricity, should be so situated that it cannot be touched by a person using the bath or shower.
Terminal Position
POSITION MINIMUM SPACING (fig. 3) mm
ADirectly below an openable window, air vent, or any other ventilation opening 300
BBelow gutters, soil pipes or drainpipes 75
CBelow Eaves 100
DBelow a Balcony 100
EFrom vertical drainpipes or soilpipes 75
FFrom internal or external corners 100
GAbove adjacent ground or balcony level 100
HFrom a surface facing the terminal 600
IFacing another terminal 1,200
JFrom opening (door/window) in carport into dwelling 1,200
KVertically from a terminal on the same wall 300
LHorizontally from a terminal on the same wall 300
NBelow carport 600
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when the distance
is less than 2 m from the outside floor.
Air Supply
The room in which the boiler is installed does not require a purpose provided vent. If the boiler is installed in a cupboard or
compartment, permanent air vent are required in the cupboard or compartment, one at high level one at low level, either direct
to the outside air to a room. Both high and low level air vents must communicate with the same space.
Minimum effective area requirements of compartment air vents (for cooling purposes only) (fig. 4).
Condensate
Theboilercondensateshould,ifpossible,bedischargedintothehouseholdinternaldrainingsystem,thatis,sinkorwashingmachine
drain. If this is not practicable, discharge can be external, into the household drainage system or a purpose designed soak away.
Shade condensate hose into a "U" prior to entering drainage system to form a water trap. See fig. 5.
Refer to British publication "Guidance notes for the installation of domestic condensing boilers" for further information.

2001
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Terminal Position Air supply
Minimum Clearance mm
NOTES
*If a side outlet flue is to be used, a clearance of 75 mm will be needed on the flue outlet side of the boiler.
** Access to the front of the boiler must be available for maintenance (min. 600 mm).
Fig. 5
Fig. 4
APPLIANCE
FLUE
SYSTEM
APPLIANCE
LOCATION
ROOM-SEALED AIR VENT AREAS
IN ROOM NIL
IN COMPARTMENT
OPEN TO ROOM
IN COMPARTMENT
OPEN TO OUTSIDE
HIGH LEVEL:
238 cm2(37 in.2)
LOW LEVEL:
238 cm2(37 in.2)
HIGH LEVEL:
119 cm2(18 in.2)
LOW LEVEL:
119 cm2(18 in.2)
Fig. 3
AIR VENT
AIR VENT
Condensate hose
Internal drainage
system fitted with
"U" bend

2001
10
Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
A standard flue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied (equivalent to wall
thicknesses of up to 565, 1815 and 2815 mm for rear flues and deduct 91 mm plus distance from side wall for side outlet flues).
It is absolutely essential, to ensure that products of combustion discharging from the terminal cannot re-enter the building, or
enter any adjacent building, through ventilators, windows, doors, natural air infiltration, or forced ventilation/air conditioning.
The flue must be installed with a fall of: 35 mm per metre (2°) towards the boiler, see fig. 12.
Gas Supply
If necessary the local Gas Region should be consulted, at the installation planning stage, in order to establish the availability of
an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the Local Gas Region.
A gas meter can only be connected by the Local Gas Region, or by a Local Gas Region's Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20 mbar MINIMUM.
Pipework from the meter to the combination boiler must be of an adequate size, minimum 22 mm.
The boiler requires 2.65 m3/h (93.6 ft3/h) of natural gas.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework must be
adequately supported. An isolating gas valve is provided and should be fitted on the manifold assembly.
Water System
Central Heating
It must be a sealed system. Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part. 2. Pipework
not forming part of the useful heating surface should be insulated to prevent any heat losses or possible freezing (i.e. in roof
spaces or ventilated underfloor spaces). Drain taps should be positioned at the lowest point of the system in accessible
locations to permit the whole system to be drained down. The drain taps should be in accordance with BS2879. Copper tubing
to BS2871, Part. 1 is recommended for water carrying pipework. Pipework in horizontal runs should have a gradient where
possible to facilitate the removal of air. It should be ensured that the boiler heat exchanger is not a natural point for collecting
air. A typical heating system with domestic hot water circuit is illustrated in fig. 6.
Important - A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min. The bypass should be fitted as
far as possible from the boiler if thermostatic radiator valves are fitted throughout.
Make up Water
Provision must be made for replacing water lost from sealed system. Reference should be made to BS6798, for methods of
filling and making up sealed systems. There must be no direct connection between the boiler's central heating system and the
mains water supply. The use of mains water to charge and pressurise the system directly, is conditional upon the Local Water
Byelaw. Again any such connection must be disconnected after use.
Domestic Hot Water
Always fit a water softener or descaler in «hard water areas». A 15 mm copper connection point on the boiler jig bracket for
attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply is 10 bar (145 P.S.I.). If the
cold mainssupplyexceeds5bar(72P.S.I.),awatergovernororpressurereducingvalvemustbefittedbytheinstallerintothemains
supply in an inconspicuous but accessible position preferable between 3 and 5 metres (10-16 ft) before the appliance.
Such a valve must be approved by the Water Research Council.
Attention - Is drawn to the Model Water Byelaws.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain water undertakings
will not accept their use above ground.

2001
11
Fig. 7
NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout.
Fig. 6
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply
Gas
Cold water
Additional expansion vessel C.H.
(if required)
Filling
point C.H.
Bypass
TEMPORARY FILLING LOOP
A temporary filling loop of the above type conforming to WRC
approval should be installed between the cold water mains and the
central heating system.

2001
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Built-in Central Heating Water Circulating Pump
The pump head available for circulating the water is given in fig. 8.
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grunfos Pump performance graph
Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.
If required an additional expansion vessel may be fitted to the central heating return inlet.
If the total volume of water in the system exceeds 40 litres an additional expansion vessel must be fitted to
the central heating return inlet.
Pump performance curve Grundfos UPS 25-60
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deductfromthevaluegiveninthetablethe7litrevesselsupplied.
Note
1. Fill C.H. installation to min. 1.5 bar.
2. Selectbypreferencetheexpansionvesselforincreased
system pressure of 2.0 bar
3. Expansion vessel must be fitted to Central Heating
Return Inlet
4. The standard 7 litres expansion vessel is charged to 1
bar
Fig. 9
SAFETY VALVE
SETTING (bar)
VESSEL CHARGE
PRESSURE (bar)
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
CONTENT of SYSTEM
3.0
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
LITRES
25 3.5 6.5 13.7 4.7 10.3 8.3
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 14.2 30.9 24.8
100 14.0 25.9 55.1 19.0 41.2 33.1
125 17.5 32.4 68.9 23.7 51.5 41.3
150 21.0 38.8 82.6 28.5 61.8 49.6
175 24.5 45.3 96.4 33.2 72.1 57.9
200 28.0 51.8 110.2 38.0 82.4 66.2
0.140 0.259 0.551 0.190 0.412 0.33
For syst. volumes other than
those given above, mult. the syst.
volume by the factor across

2001
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Installation
Note - To mount the boiler on the wall, a two person lift will be needed.
1.0 UNPACKING
The appliance is delivered in 2 cartons.
1.1 The large carton contains the boiler, and the Installation/Servicing and Users Instructions.
1.2 The second carton contains the mounting jig assembly, complete with isolating valves, the assembly fixing
screwsandwallplugs(x4),theboilermountingnutsandwashers(x2),drillingtemplate,flueassemblyandturret.
When thecartonsareunpackedexamineforanysignsof damageintransit.Allprotectiveplasticshouldbeleft inplace
until installation is complete.
2.0 FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
2.1 Select the boiler location carefully ensure that all requirements given in previous text are satisfied.
Fig. 10 will also give guidance to fixing dimensions.
2.2 Locate template on wall, mark the positions of the four jig bracket fixing holes and the flue opening.
2.3 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
2.4 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
2.5 Fit the top and bottom brackets using the four fixing screws provided (Ensure that all the service cocks are
in the OFF position). Operate valves several times to ensure they are free.
2.6 With the exception of the connection to the pressure relief valve, make all the water and gas connections
to the jig bracket valves. Fully tighten (fig. 11). Water connections can be made with compression or capillary
fittings.
3.0 FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
3.1 Select the boiler location carefully ensuring that all the requirements given in previous text are satisfied.
Fig. 10 will aso give guidance.
3.2 Locate the template on wall and mark the position of the four jig bracket fixing holes.
3.3 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
3.4 Fit the top and bottom brackets using the four fixing screws provided.
3.5 Extend a horizontal line from the centre of the rear flue outlet to the side wall.
3.6 Mark the centre line (vertically) for the flue assembly hole, and mark the centre of the hole.
3.7 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.

2001
14
Important Note - Always use two spanners to prevent twisting of soft copper pipework on the boiler.
Flush out the water system.
Note - The maximum inlet cold water pressure must not exceed 10 bar (145 P.S.I.) and a water governor or a pressure
reducing valve will be required if the pressure is in excess of 5 bar (72 P.S.I.).
Ensure all pipework is adequately supported.
Drilling template
Note - Min 91 for side flue outlet
Side flue outlet
Diam. min. 118 mm
Fixing stud
boiler
Upper bracket
Note - Min 75 for
side flue outlet
Rear flue outlet
Diam. min. 118 mm
2 Gas 22 mm 3 Domestic Hot Water outlet 15 mm 5 Outlet central heating safety valve 15 mm
4 Domestic Cold Water inlet 15 mm
6Central Heating flow outlet 22 mm
7Central Heating return inlet 22 mm
Important Note - Always use two spanners to prevent twisting of soft copper pipework.
Note - The central heating safety valve (5) should be piped 15 mm to discharge safely outside the property.
Fig. 10
1= Electrical cable entry
2= Gas supply
3= Domestic Hot Water outlet
4= Domestic Cold Water Inlet
5= Outlet Central Heating safety valve
6= Central Heating flow outlet
7= Central Heating return inlet
2 = 22 mm
3-4-5 = 15 mm
6-7 = 22 mm
Fig. 11
Boiler = 480 mm
Lower bracket
40

2001
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4.0 PREPARING THE FLUE ASSEMBLY
4.1 Rear Flue Outlet (fig. 12)
Important - The aluminium flue pipe must protrude into the outside grill by 2 in (50 mm), never cut it to the same length
as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 50 mm !).
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
4.1.1 Accurately measure the Wall thickness (P1)
4.1.2 Fromthe end opposite to the terminal,cut the plastic
air duct (dimension A1) to length (P1 + 105 mm).
Note - That the terminal is not included in A1.
4.1.3 Cut the metal flue duct to length (P1 + 155 mm)
(dimensions F1).
Note - Themetal flue pipe must be 50 mm (2 inches)
longer than the plastic air inlet pipe.
4.1.4 Drill a 3 mm hole 15 mm from the plain end of plastic
air duct.
4.1.5 Place flue components to one side to be used later.
4.2 Side Flue Outlet (fig. 13).
Important - The aluminium flue pipe must protrude
intotheoutsidegrillby2in(50mm),nevercutittothe
same length as the plastic air pipe.
Side Flue Outlet
Fig. 13
Rear flue Outlet
Fig. 12
Air sealing sleeve
Fixing screw Fixing
screw
F1 (Flue outlet)
A1 (Air intake)
Aluminiumfluepipelength=Plasticairinletpipelength
plus 50 mm (2") longer.
4.2.1 Accurately measure the Wall thickness (P2).
4.2.2 Accuratelymeasurethedistancefromthecentreofthestudfixingofthe
mounting jig assembly to the side wall (Q2).
4.2.3 Fromthe endoppositetotheterminal, cuttheplasticairduct (dimension
A2) to length (P2 + Q2 + 125 mm).
Note - That the terminal is not included in length A2.
4.2.4 Cut the metal flue duct to length (P2 + Q2 + 175 mm) (dimension F2).
Note - The metal flue pipe must be 50 mm (2 inches) longer than the
plastic air inlet pipe.
4.2.5 Drill a 3 mm hole 15 mm from the plain end of plastic air duct.
4.2.6 Place flue components to one side to be used later.
Make sure flue slopes 2°down towards the
boiler that is 35 mm fall per metre of flue length
K
K = 10 ÷60 mm

2001
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5.0 CONNECTING THE BOILER
5.1 Place the boiler on its back.
5.2 Remove the boiler base plate, four screws (fig. 16). Remove the plugs fitted to the boiler water connections.
Remove the bag of sealing washers from the boiler pipework. Remove the front panel by gripping on both
sides, slide up to disengage lugs and pull away.
5.3 Lift boiler as shown in fig. 15 onto the top studs and fit supplied nuts and washers hand tight.
5.4 Lift at bottom to engage the water and gas connections. Tighten central heating flow and return, and the
domestic hot water inlet and outlet, using appropriate sealing washers. Tighten the gas union.
5.5 Screw the pressure relief valve adaptor provided, through the jig bracketinto thevalve,using theremaining
washer (fig. 17).
5.6 Connect the pressure relief valve discharge pipe (15 mm) to the outside of the building, where possible over a
drain. The discharge must be such that it will not be hazardous to occupants or passers-by cause damage to
external electric components or wiring. The pipe should be directed towards the wall.
5.7 Connect the condensate hose to discharge into the internal household drainage system as shown in fig. 5.
Refer to British Gas Publication "Guidance notes for the Installation of Domestic Condensing Boilers" for further
information.
It must not discharge above an entrance or window, or any type of public access. The installer must consider
that the overflow could discharge boiling water.
Fig. 14
Fixing
screws
Flue sealing gasket
Air sealing gasket
TOP VIEW BOILER SIDE OUTLET

2001
17
Fixing points
Lift here Fig. 15
Fixing screws
Fig. 16 Fig. 17

2001
18
External controls: room stat or remote time
clock in the place of loop terminals 4 and 5.
Please note 24 V only, use only voltage free
contacts.
IMPORTANT
If 230 V is
connected to
terminals 4 or 5,
damage will be
caused to the
P.C.B.
Blue
Brown
Fig. 19
Fig. 18
6.0 FITTING THE FLUE ASSEMBLY
6.1 With Sufficient Clearance To Insert Assembly From Inside
6.1.1 Push the air duct seal onto the air duct at the cut end.
6.1.2 Insert the flue assembly into the wall ensuring a 2°slope back to the boiler.
6.1.3 Make good internal wall face.
6.1.4 Fully insert the flue assembly into the turret spigot. Insert the self tapping screw supplied. Fully tighten.
6.1.5 Secure the turret.
6.1.6 Slide the air duct seal over the joint.
6.1.7 Check the terminal relationship with the wall as shown in fig. 12.
6.1.8 Make good the outside wall face, re-weatherproof.
6.2 With insufficient Clearance To Insert Assembly From Inside
6.2.1 From outside, push flue duct, then the air duct through the wall.
6.2.2 Push the air duct seal over the air duct.
6.2.3 Fully insert the flue duct into the turret, then the air duct. Slide, back the seal and secure the air duct with the self
tapping screw provided.
6.2.4 Slide the seal over the joint and secure the turret.
6.2.5 Continue as detailed in 6.1.8 above.
7.0 ELECTRICAL INSTALLATION
Electrical installation must be carried out by a competent electrician. The appliance is to be connected to a 230 V ~ 50
Hz supply (see fig. 18). The supply fuse rating is 3A. The terminals are accessible after removing the white base plate
and single screw securing the terminal cover (see fig. 18).
7.1 Procedure
7.1.1 The supply cable must be no less than 0.75 mm (24x0.2 mm) to BS6500 table 16.
7.1.2 The earth conductor must be cut longer than the live and neutral (fig. 19).
Connect the Supply Cable to the terminal block marked 230 V ~ 50 Hz, L, N, the supply cable is to be connected as follows:
i) Connect the brown wire to the L (live) terminal).
ii) The blue wire to the N (neutral) terminal.
iii) The green/yellow wire to the (earth) terminal.
7.1.3 Securethe cable with thecableclamp.The supply cable canbe connected tothemainssupplyby the use ofanunswitched
shutteredsocket-outlet in conjunction with the 3A fused 3 pinplug both in accordance withBS 1363. This provides complete
isolation. Alternatively, a fused double pole switch having a contact separation of at least 3 mm, in all poles and provided
just for the boiler and its external controls can be used. A wiring diagram is provided on the appliance, attached to the
rearofthefrontpanel.Inaddition,thereis one in this manual (fig. 25). Attention is drawn to the requirements of the current
I.E.E. Regulation and in Scotland, the electrical provisions of the Building regulations.
7.2 Room Thermostat (fig. 18) (or remote time clock connection)
7.2.1 Please note that the room thermostat, clock switch connection is 24 V. To connect mains voltage to these terminals will
seriously damage the printed circuit board. The room thermostat and clock switch connector block is situated within the
connector box. Twin core cable should be used for this connection (terminals 4 and 5).
7.2.2 If using a remote 230 Volt time clock ensure that the motor and switch connections are totally separate in the clock and
that the switch connections are independent for the 24 Volt terminals (4 and 5) on the boiler.
Screw

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7.3 External compensation sensor (optional)
7.3.1 To be wired to terminals 7 and 8 on the appliance
connector box (see fig. 18), low voltage twin wire
can used.
7.3.2 External sensor location
The external sensor should be installed on the
North, North-West wall or on the one facing the
majority of the main living rooms in the building.
The sensor must never be exposed to the first
morning sunlight. It must never be subjected to
direct sunlight and should be protected if
necessary.
Innocasemaythesensorbemountednearwindows,
doors, ventilation openings, stacks or heat sources
which could alter its reading.
Fig. 19b
Fig. 19a

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7.4 Setting of compensation curve
The boiler can now be regulated to ensure the design critia of the system is matched to the outside tempera-
ture
7.4.1 Consult the outside compensation graph provided (fig. 19c)
7.4.2 Following the bottom ouside temperature line to find the outside temperature. The system is designed for.
7.4.3 Trace a line vertically until you reach the designed system flow temperature.
7.4.4 Read from the graph the number setting that the boiler is to be adjusted to. If the setting is between two
numers this can be set on the boiler, say between 2 and 3.
7.4.5 Remove the plastic cover of the outside compensation adjustment screw on the boiler facia panel (fig. 19d)
7.4.6 By use of a small screwdriver set the arrow on the adjustment screw to desired setting
MIN. MAX.
MIN.
C
MAX.
°
C
°
132654
42
5
3
1
Outside compensation
adjustment screw
Fig. 19c
Fig. 19d
20 15 10 5 0 -5 -10 -15 -20
90
80
70
60
50
40
30
20
2
3
4
1
5
Ouside temperature °C
Flow temperature °C
LEDS