Ferroli optima 801 User manual

801
WALLMOUNTED, ROOM SEALED,
FAN ASSISTED, GAS COMBINATION BOILER
Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH
Tel.: [phone] - 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
INSTALLATION
INSTRUCTIONS
Appr. Nr. B94.02A CE 0063AQ2150
04/98
G.C. NO: 47-267-17

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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
10 Flue System
10 Gas Supply
10 Water System
12 Central Heating Pump
12 Sizing of expansion vessel
13 Installation of Boiler
13 Unpacking
13 Mounting the Boiler Jig
on the Wall (rear flue)
13 Mounting the Boiler Jig
on the Wall (side flue)
14 Drilling template
15 Preparing the Flue Assembly
15 Connecting the Boiler
18 Fitting the Flue Assembly
18 Electrical Installation
19 Commissioning & Testing
19 Filling the Central Heating System
19 Filling the Domestic Hot Water System
19 Electricity Supply
19 The Gas Installation
20 To Light the Boiler
21 To Range Rate the Boiler C.H.
22 Gas pressure adjustment with Honeywell
VR 4600 N 4002 valve
23 D.H.W. Burner Pressure
23 System operation
23 Handing Over to the User
24 Time clock
26 Spare Parts List
27 Domestic Hot Water
Performance + Modureg
28 General Wiring Diagram
29 Fast Fault Finding
30 Special Installation Possibilities

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General Description
TheFerroli 801isawallmounted,roomsealed,fanassisted,combinationboilerforCentralHeating
(C.H.) and domestic Hot Water (D.H.W.).
The boiler is of light weight construction and the heat exchanger provides Central Heating and Domestic
HotWaterfromanintegrallydesignedunit.Theboilercontainsitsownexpansionvesselforsealedsystems.
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 wallthickness upto 565mm), 2metres (forwall thicknessup to1815 mm)and 3metres (for wall
thickness)upto2815mm.Thesewallthicknessesassumearearflueoutlet.Forsideoutlettheeffectivewall
thicknessfor eachflue lengthis reducedby 91mm plusthe distanceof theappliance fromthe sidewall. The
Central Heating and the Domestic Hot Water temperature is controlled by the Honeywell Modureg valve
in conjunction with the P.C.B. The boiler is fitted with its own Central Heating pump. The pump is switched
ON/OFF by the time clock and/or a 24 Volt room thermostat. The pump circuit also has a 6 minute over-run
time. There is a Domestic Hot Water flow switch fitted and when there is a demand for Domestic Hot
Water the Central Heating pump is switched off making available the maximum output of the gas burner
forDomesticHotWater.OntheP.C.B.theoutputforCentralHeatingcanbeset.However,thisisnotrequired
forthe majority ofinstallations as theboiler will automaticallyadjust its outputto the systemdemand-AUTO-
MISERcontrol.Thisdoesnotinfluencethemaximumoutputfordomestichotwater.Atthefactorythecentral
heating output is pre-set to maximum. The appliance is not suitable for external installation.
Related Documents
This appliance must be installed strictly in accordance with these instructions:
The Gas Safety Regulations (Installations & Use) 1994.
The Local Building Regulations.
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 INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4841 1990 SPECIFICATION FOR EXPANSIONE VESSALS
Model Water Bye Laws.

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Technical Data G20 G31
Nominal Heat Input D.H.W. & C.H. (gross) 28.6 kW 26.0 kW
Minimum Heat Input D.H.W. & C.H. (gross) 12.8 kW 12.5 kW
Nominal Heat Input D.H.W. & C.H. (net) 25.8 kW 25.8 kW
Minimum Heat Input D.H.W. & C.H. (net) 11.5 kW 11.5 kW
Nominal Heat Output D.H.W. & C.H. 23.3 kW 23.3 kW
Minimum Heat Output D.H.W. & C.H. 9.7 kW 9.7 kW
Maximum Gas Rate 2.72 m3/h 2.66 m3/h
Maximum Burner Pressure 14.5 mbar 36.0 mbar
Minimum Burner Pressure 2.7 mbar 7.9 mbar
Injector Marking (Main Burners) 210
Injector Size (4 off) 2.10 mm
Dimensions (overall):
Height 1020 mm
Width 480 mm
Depth 360 mm
Weight (nett) 51 kg
Weight (gross) 53 kg
Electricity supply: 230 V ~ 50 Hz
External fuse 3 A
Internal fuses on P.C.B. F2A to BS4265 - (2 Amp. Fast)
Electrical Input 150 W
Central Heating:
Max. Flow Temperature 85°C
Temperature Rise Across Boiler 20°C
Domestic Hot Water Flow:
30°C Rise 11.1 litres/min.
32°C Rise 10.4 litres/min.
35°C Rise 9.5 litres/min.
40°C Rise 8.3 litres/min.
Minimum Domestic Hot Water Flow 2.5 litres/min.
Maximum Domestic Cold Water Inlet pressure 10 bar
Minimum Heating Circuit Pressure 0.8 bar
Maximum Heating Circuit Pressure 3.0 bar
Low water pressure switch 0.4 bar
Boiler Water Capacity: Heating 2.0 litres
Domestic Hot Water 0.5 litres
Connections:
Gas 22 mm
Domestic Hot Water Outlet 15 mm
Domestic Cold Water Inlet 15 mm
Pressure Relief Valve Drain 15 mm
Central Heating Flow 22 mm
Central Heating Return 22 mm
Minimum Installation Clearances:
Sides -Left hand 5 mm
Right hand 5 mm
Front 50 mm*
Minimum Clearance below 200 mm
Minimum Clearance above 100 mm
NOTES
* Access to the front of the boiler must be
available for maintenance (min. 600 mm)

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Appliance Dimensions
Fig. 1
FRONT VIEW LEFT SIDE VIEW REAR VIEW
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
8. Air intake for two pipe flue systems
8 - TOP VIEW
480
900
370
77.5507580505097.5
12 3 4 5 6 7
40
85
242 235
60
100
Øi92
Øi82
120
242
126.5
235
160
157
480

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Boiler Flow Diagram
Fig. 2

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Key
1Fixing point
5Room sealed compartment
6Control panel
7Gas inlet
8Domestic hot water outlet
9Cold 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
29 Internal flue exit
30 Flue/surplus air collector
31 Air pressure control damper
32 Central heating pump
34 C.H. flow temperature sensor
35 Air separator
36 Automatic air vent
37 Cold water inlet filter
39 Cold water flow limiter
40 Domestic hot water expansion vessel (optional)
41 D.H.W. waterway of the heat exchanger
42 D.H.W. temperature sensor
43 Air pressure switch
44 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 (if fitted)
63 C.H. boiler thermostat
68 Control box with P.C.B.
71 Modulating balance tube
80 240 V + 24 V roomstat terminal blocks
81 Ignition electrode
82 Flame sensing electrode
83 Automatic ignition control panel
84 1. gas valve operator 240V
85 2. gas valve operator 240V
86 Automatic control reset knob
87 Venturi test point
90 Flue outlet pressure test point
91 Air pressure test point
100 Fault diagnostic/temperature control panel
101 P.C.B. (printed circuit board)
114 Low water pressure switch
136 Flowmeter
145 C.H. pressure gauges
157 D.H.W. thermostat
158 Gas inlet pressure test point

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Installation Details
Gas Safety (Installation & Use) Regulations: 1994
Intheinterestofsafety,itisthelawthatallgasappliancesareinstalledbyacompetentpersoninaccordance
with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current
I.E.E. Regulations and the byelawsof the Local WaterUndertaking.FailuretocomplywiththeRegulations
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 buiding it should be fitted in accordance
with the British Gas publication; Guide for Gas Installation in Timber Frame Housing: Reference DM2.
If in doubt advice must be sought from the Local Gas Region of British Gas Plc.
Location of Boiler
The installation of the 801 must be on a suitable non-combustible load bearing wall which will
provideanadequatefixingfortheboilermountingbracketassembly.Thelocationshouldbeinanareawhere
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 thecurrent,i.e.wiringregulationsandinScotlandtheelectricalprovisions
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 room containing abath or shower any electrical switch
or appliance 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
AQuinnel Barrat and Quinnel guard (part.No.C2) should be screwed to thewallcentrally over the terminal,
when the distance is less than 2 m from the outside floor.
Air Supply
Theroom,cupboardorcompartmentinwhichtheboilerisinstalleddoesnotrequireapurposeprovidedvent.

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Terminal Position
Fig. 5
Fig. 3
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).

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Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
Astandardfluelengthof0.75metresisprovided.Alternativelengthsoftwoorthreemetrescanbesupplied(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,orenteranyadjacentbuilding,throughventilators,windows,doors,naturalairinfiltration,orforcedventilation/
air conditioning.
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.
The boiler requires 2.75 m3/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.Pipeworknot forming part of the useful heating surface shouldbeinsulatedtopreventanyheatlossesorpossible
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
accordancewithBS2879.Coppertubingto 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
theboilerheatexchangerisnota naturalpointforcollectingair. Atypicalheatingsystemwith domestichotwatercircuit
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 mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing valve must
be fitted by the installer into the mains 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.

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Fig. 7
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
NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted
throughout.

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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 15-50
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 7 litre
vessel supplied.
Note
1. Fill C.H. installation to min. 1.5 bar.
2. Select by preference the expansion vessel for
increased system pressure of 2.0 bar
3. ExpansionvesselmustbefittedtoCentralHeating
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

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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 screws and wall plugs (x4), the boiler mounting nuts and washers (x2), drilling template, flue
assembly and flue bend.
When the cartons are unpacked examine for any signs of damage in transit. All protective plastic should be
left in place 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 mounting jig assembly using the four fixingscrewsprovided(Ensurethatalltheservicecocks
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 (before the gas inlet to the boiler there must be at least 100 mm of
straight before any bends).
3.0 FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
3.1 Selecttheboilerlocationcarefullyensuringthatalltherequirementsgiveninprevioustextaresatisfied.
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 mounting jig assembly 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.

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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
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
Side flue outlet
Diam. min. 118 mm
Fixing stud
boiler
Upper bracket
Rear flue outlet
Diam. min. 118 mm
Boiler = 480 mm
Lower bracket

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4.0 PREPARING THE FLUE ASSEMBLY
4.1 Rear Flue Outlet (fig. 12)
Important - The aluminium fluepipemust protrude intotheoutside grill by 60mm, never cut itto the
same length as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 70 mm !).
Aluminium flue pipe length = Plastic air inlet pipe length plus 70 mm longer.
4.1.1 AccuratelymeasuretheWallthickness(P1)
4.1.2 From the end opposite to the terminal, cut
theplasticairduct(dimensionA1)tolength
(P1 + 192 mm).
Note-ThattheterminalisnotincludedinA1.
4.1.3 Cut the aluminium flue duct to length (P1 +
262 mm) (dimensions F1).
Note - The aluminium flue pipe must be 70
mm 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.
Side Flue Outlet
Fig. 13
4.2 Side Flue Outlet (fig. 13).
Important- Thealuminium fluepipemustprotrudeinto the
outsidegrillby60mm,nevercutittothesamelengthasthe
plastic air pipe.
Aluminiumfluepipelength=Plasticairinletpipelength
plus 70 mm longer.
4.2.1 Accurately measure the Wall thickness (P2).
4.2.2 Accuratelymeasurethedistancefromthecentreofthestud
fixing of the mounting jig assembly to the side wall (Q2).
4.2.3 Fromtheendoppositetotheterminal,cuttheplasticairduct
(dimension A2) to length (P2 + Q2 + 180 mm).
Note - That the terminal is not included in length A2.
4.2.4 Cut the aluminium flue duct to length (P2 + Q2 + 250 mm)
(dimension F2).
Note - Thealuminium fluepipe must be70 mmlonger than
the plastic air inlet pipe.
4.2.5 Drilla3mmhole15mmfromtheplainendofplasticairduct.
4.2.6 Place flue components to one side to be used later.
Rear flue Outlet
Fig. 12
Fixing
screw
F1 (Flue outlet)
A1 (Air intake)
K = 10 mm min.
60 mm max.
Fixing
screw

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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, sliding up and lifting away from the main boiler.
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,
andthe domestichot waterinlet andoutlet,using appropriatesealing washers.Tighten thegas union.
5.5 Screw the pressure relief valve adaptor provided, through the jig bracketintothevalve,using the
remaining washer (fig. 17).
5.6 Connectthepressurereliefvalvedischargepipe(15mm)totheoutsideofthebuilding,wherepossible
overadrain.Thedischargemustbesuchthatitwillnotbehazardoustooccupantsorpassers-bycause
damage to external electric components or wiring. The pipe should be directed towards the wall.
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
TOP VIEW BOILER SIDE OUTLET

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

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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 240 V is
connected to
terminals 4 or 5,
damage will be
caused to the
P.C.B.
Fixing screw
Screw
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 Insert the flue assembly into the wall.
6.1.2 Insert the flue bend in the top plate of the boiler
6.1.3 Secure the flue bend.
6.1.4 Fully insert the flue assembly into the boiler flue bend. Insert the self tapping screw supplied. Fully tighten.
6.1.5 Check the terminal relationship with the wall as shown in fig. 12.
6.1.6 Make good internal wall face.
6.1.7 Make good the outside wall face, re-weatherproof.
6.2 With insufficient Clearance To Insert Assembly From Inside
6.2.1 Insert the flue bend in the top plate of the boiler
6.2.2 Secure the flue bend.
6.2.3 From outside, push flue duct, then the air duct through the wall.
6.2.4 Fully insert the flue duct into the flue bend, then the air duct. Securetheair duct with the self tapping screw
provided.
6.2.5 Continue as detailed in 6.1.5 above.
7.0 ELECTRICAL INSTALLATION
Electrical installation must be carried out by a competent electrician. The appliance is to be connected to a
240 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 Theearthconductormustbecutlongerthantheliveandneutral(fig.19).ConnecttheSupplyCabletotheterminal
block marked 240 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 Secure the cable with the cable clamp. The supply cable can be connected to the mains supply by the use of
an unswitched shuttered socket-outlet in conjunction with the 3A fused 3 pin plug both in accordance with BS
1363. This provides complete isolation. Alternatively, a fused double pole switch having a contact separation
ofatleast3mm,inallpolesandprovidedjustfortheboileranditsexternalcontrolscanbeused.A wiring diagram
is provided on the appliance, attached to the rear of the front panel. In addition, there is 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 Pleasenotethattheroomthermostat,clockswitchconnectionis24V.Toconnectmainsvoltagetotheseterminals
willseriouslydamagetheprintedcircuitboard.The room thermostat and clock switch connectorblockissituated
within the connector box. Twin core cable should be used for this connection (terminals 4 and 5).
7.2.2 If using a remote 240 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.

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8.0 COMMISSIONING AND TESTING
8.1 Filling the Central Heating System
Fig. 20
Burner pressure
test point Automatic air vent Vent cap
Heat exchanger vent
Pump
C.H. pressure relief valve
D.H.W. expansion
vessel (optional)
Gas inlet pressure
test point D.H.W. drain point
pressure gauge
Removethe topfront panelbygrippingbothsidesandliftingforwardawayfrommainboilerassembly.
Loosen the cap of the automatic air vent (fig. 20) and leave it loose.
Open the central heating flow and return cocks (fig. 11).
Gradually fill the system as detailed in Make up Water.
Whilefilling,venttheheatexchangeratventingpointbylooseningcap(fig.20)andventeachradiator.
Tighten cap on heat exchanger air vent.
Ensuretheworkingpressure,whenfilled,isbetween1to1.5baronthepressuregauge(seetechnical
data).
Check the system for leaks.
Flush system in accordance with BS 7593.
8.2 Filling the Domestic Hot Water System
Close all hot water draw off points. Open main cold water stop cock and ensure the cold water inlet
cock is open at the boiler jig bracket (fig. 11). Slowly open each hot tap in turn until clean water, free
from air pockets, is seen.
Check system for leaks.
8.3 Electricity Supply
Carry out preliminary checks (i.e. earth continuity, polarily short circuit and resistance to earth
using a suitable multimeter).
8.4 The Gas Installation
The whole of the gas installation including the meter, should be inspected and tested for soundness,
and purged in accordance with the recommendations of BS6891-1988.
Low water pressure switch

801
20
fig. 21
8.5 To Light the Boiler (fig. 21)
a. Open controls panel door.
b. Switch on electricity supply.
c. Adjust room thermostat and all external controls to «ON». Check operation of pump.
d. Turnthe boiler thermostatto maximum. Fanwillrun (A waitingtime of max3minutes before fanwill
run is possible!), and main burner will light.
e. Temporarily turn off by switching off electricity supply.
Important Note: If the burner stops for C.H. only after a waiting time of 3 minutes will the boiler light again!
P
+
-
P
AUTO
R
OVERRIDE
12:31
x
x
4
AUTO
Flame viewing
opening
C.H. pressure
gauge
C.H. boiler
thermostat
Fault diagnostic lights Domestic hot water thermostat
Time clock (if fitted)
Flame
failure
reset knob
C.H./D.H.W. selector switch