
7
Installation and Servicing
CONTENTS
1 GENERAL.................................................................. 10
1.1 Introduction ................................................................ 10
1.2 Operation ................................................................... 10
1.3 Safe Handling............................................................. 10
1.4 Optional Extra Kits ..................................................... 10
1.5 Safety ......................................................................... 11
1.6 Safe Handling Of Substances .................................... 11
1.7 Location Of Boiler ...................................................... 11
1.8 Gas Supply................................................................. 12
1.9 Flue Installation .......................................................... 12
1.10 Air Supply................................................................... 13
1.11 Water Circulation System........................................... 13
1.12 Boiler Control Interlocks ............................................. 13
1.13 Electrical Supply......................................................... 13
1.14 Condensate Drain .................................................... 13
1.15 Boiler Dimensions, Services & Clearances................ 14
1.16 System Requirements - Central Heating.................... 15
1.17 System Balancing ...................................................... 16
1.18 Water Treatment......................................................... 16
2 INSTALLATION ......................................................... 17
2.1 Boiler Assembly - Exploded View............................... 17
2.2 Unpacking .................................................................. 18
2.3 Unpacking Cont’d....................................................... 19
2.4 Front Panel Removal ................................................. 19
2.5 Wall Mounting Template ............................................. 20
2.6 Preparing The Wall..................................................... 20
2.7 Fitting The Wall Mounting Plate ................................. 20
2.8 Mounting The Boiler ................................................... 20
2.9 Determining The Flue Length
And Flue Packs Required ......................................... 21
2.10 Determining The Flue Length
And Flue Packs Required, Cont’d ............................. 22
2.11 Cutting & Setting The Flue Length ............................. 23
2.12 Installing The Flue...................................................... 24
2.13 Fitting The Optional Roof Flue Kit (Flat Or Pitched)... 25
2.14 Roof Flue Kit Contents / Options................................ 25
2.15 Flue Terminal Position................................................ 26
2.16 Assembling The Roof Flue Kit.................................... 27
2.17 Condensate Drain ...................................................... 28
2.18 Connections & Filling ................................................. 30
2.19 Electrical Connections................................................ 31
2.20 Internal ...................................................................... 31
2.21 External Electrical Connections ................................. 31
2.22 Wiring Diagram .......................................................... 32
2.23 Commissioning And Testing ....................................... 33
2.24 Initial Lighting ............................................................. 34
2.25 General Checks ......................................................... 35
2.26 Restart Procedure ...................................................... 36
2.27 Handing Over ............................................................. 36
3 SERVICING ............................................................... 37
3.1 Servicing .................................................................... 37
3.2 Boiler Upper & Lower Front Panel Removal /
Replacement .............................................................. 38
3.3 Fan And Venturi Assembly Removal And Cleaning.... 38
3.4 Burner Removal And Cleaning................................... 39
3.5 Cleaning The Condensate Trap/Siphon .................... 39
3.6 Cleaning The Heat Exchanger ................................... 40
3.7 Reassembly ............................................................... 40
3.8 Replacement Of Components.................................... 41
3.9 Fan Replacement....................................................... 41
3.10 Burner Injector Replacement ..................................... 42
3.11 Burner Replacement .................................................. 42
3.12 Ignition Electrode / Ionisation Detection Probe
Replacement .............................................................. 43
3.13 Spark Generator Replacement .................................. 44
3.14 Gas Control Valve Replacement ................................ 44
3.15 Diverter Valve Actuator Replacement ........................ 45
3.16 Condensate Trap/Siphon Replacement ..................... 45
3.17 Main PCB Replacement............................................. 46
3.18 Replacing The Mechanical Timer............................... 47
3.19 Draining The Boiler .................................................... 47
3.20 DHW Flow Turbine Sensor Replacement .................. 48
3.21 Pressure Gauge Replacement................................... 48
3.22 Safety Relief Valve Replacement .............................. 49
3.23 Pump Automatic Air Vent Replacement ..................... 49
3.24 Diverter Valve Body Assembly Replacement ............. 50
3.25 DHW Plate Heat Exchanger Replacement ................ 50
3.26 Pump Head Replacement .......................................... 50
3.27 CH Water Pressure Switch Replacement .................. 51
3.28 DHW Filter & DHW Flow Regulator
Cleaning/Replacement............................................... 51
3.29 Flow Thermistor ........................................................ 52
3.30 Return Thermistor Replacement Replacement.......... 52
3.31 Heat Engine Renewal ................................................ 53
3.32 Expansion Vessel Recharging & Replacement.......... 54
3.33 Boiler Sealing Panel Seal Replacement .................... 54
4 FAULT FINDING ........................................................ 55
4.1 Fault Finding Chart Main Menu.................................. 55
4.2 ‘L1’ - Flow Temperature Overheat Lockout ................ 56
4.3 ‘L2’ - Ignition Lockout ................................................. 56
4.4 ‘LC’ - 5 Resets Within 15 Mins ................................... 57
4.5 ‘L6’ - False Flame Lockout ........................................ 57
4.6 ‘F1’ - Low Water Pressure.......................................... 57
4.7 ‘F2 Or Fn Or Ln’ - Flame Loss.................................... 58
4.8 ‘F3’ - Fan Fault ........................................................... 58
4.9 ‘L4 Or F4’ - Flow Thermistor Fault.............................. 59
4.10 ‘L5 Or F5’ - Return Thermistor Fault .......................... 59
4.11 F6 - Outside Sensor Fault .......................................... 60
4.12 F7 - Low Mains Voltage.............................................. 60
4.13 F8/L8 - Lockout Due To Parameter Fault ................... 60
4.14 F9/L9 - PCB Fault ...................................................... 60
4.15 No CH Operation But HW Works OK......................... 61
4.16 No HW But CH On ..................................................... 62
4.17 No Display.................................................................. 62
5 SPARE PARTS .......................................................... 63
6 FLUE & INTEGRITY CHECKS.................................. 69