
5Installation and Servicing
Section 1 - General.................................................................................6
1.1 Introduction...............................................................................8
1.2 Operation..................................................................................8
1.3 Safe Handling...........................................................................8
1.4 OptionalAccessories................................................................8
1.5 Safety........................................................................................9
1.6 Safe Handling of Substances...................................................9
1.7 Location of Boiler .....................................................................9
1.8 Air Supply...............................................................................10
1.9 Gas Supply.............................................................................10
1.10 Water Circulation System.......................................................10
1.11 Boiler Controls........................................................................10
1.12 Electrical Supply.....................................................................10
1.13 Condensate Drain...................................................................10
1.14 Boiler Dimensions, Services & Clearances............................11
1.15 System Requirements - Central Heating................................12
1.16 System Requirements - DHW.................................................13
1.18 Water Treatment.....................................................................13
1.17 System Balancing...................................................................13
Section 2 - Installation..........................................................................14
2.1 BoilerAssembly - Exploded View...........................................14
2.2 Unpacking...............................................................................15
2.3 Wall Mounting Template..........................................................16
2.4 Preparing the Wall..................................................................16
2.5 Fitting the Wall Mounting Plate...............................................16
2.6 Mounting the Boiler.................................................................16
2.7 Flues and Locations................................................................17
2.8 Flues and Locations - Cont.....................................................18
2.9 Horizontal Flue Positions .......................................................19
2.10 Vertical Flue Positions ...........................................................19
2.11 Flue System Dimensions .......................................................20
2.12 Fitting the Turret......................................................................20
2.13 Cutting the Flue......................................................................21
2.14 Assembling the Vertical Flue..................................................22
2.15 Condensate Drain...................................................................23
2.16 Condensate Drain - Cont’d.....................................................24
2.17 Connections & Filling..............................................................25
2.18 Connections & Filling Continued.............................................26
2.19 Electrical Connections............................................................27
2.20 Installer Wiring........................................................................27
2.21 External Wiring.......................................................................28
2.22 Wiring Diagram.......................................................................29
2.23 Replacing Pre-Fitted Mains Cable..........................................30
2.24 Commissioning and Testing....................................................30
2.25 Initial Lighting..........................................................................31
2.26 The Display.............................................................................32
2.27 General Checks......................................................................32
2.28 General Checks - Water Circulation.......................................33
2.29 Restart Procedure...................................................................33
2.30 Accessing the Installer Mode..................................................34
2.31 Handing Over..........................................................................34
Section 3 - Servicing.............................................................................35
3.1 Servicing Schedule.................................................................35
3.2 Removal / Replacement of Components................................36
3.3 Draining the Boiler..................................................................36
3.4 Boiler Front Panel Removal / Replacement............................37
3.5 Flue Manifold Removal/Replacement.....................................37
3.6 Fan and VenturiAssembly Removal and Cleaning.................38
3.7 Burner Removal and Cleaning................................................39
3.8 Cleaning the Heat Exchanger.................................................39
3.9 Ignition / Detection Electrode Replacement / Inspection........40
3.10 Cleaning the Condensate Trap...............................................40
3.11 DHW Filter & DHW Flow Regulator Cleaning/Replacement...41
3.12 Burner Injector Replacement..................................................41
3.13 Burner Replacement...............................................................41
3.14 Return Thermistor Replacement............................................42
3.15 Spark Generator Replacement...............................................42
3.16 Gas Control Valve Replacement.............................................43
3.17 Diverter Valve Actuator Replacement.....................................43
3.19 Condensate Trap Replacement / Cleaning.............................44
3.18 Primary PCB Replacement.....................................................44
3.20 DHW Flow Turbine Sensor Replacement...............................45
3.21 Pressure Gauge Replacement...............................................45
3.22 PRV Replacement..................................................................46
3.23 PumpAutomaticAir Vent Replacement..................................46
3.24 Replacement of DHW Thermistor...........................................47
3.25 DHW Plate Heat Exchanger Replacement.............................47
3.26 Diverter Valve Body Assembly Replacement..........................48
3.27 Pump Head Replacement.......................................................49
3.28 CH Water Pressure Switch Replacement...............................49
3.29 Flow Thermistor Replacement................................................50
3.30 Heat Engine Replacement......................................................51
3.31 Expansion Vessel Recharging & Replacement......................52
Section 4 - Fault Finding.......................................................................53
4.1 Fault Finding Main Menu........................................................53
4.2 ‘L01’ - Overheat Lockout........................................................54
4.3 ‘L02’ - Ignition Lockout...........................................................54
4.4 ‘L06’ - Flame On Before Gas Valve On..................................55
4.5 ‘F 01’- Low Water Pressure...................................................55
4.6 ‘F 02 - Flame Loss.................................................................55
4.7 ‘F 03’- Fan Fault.....................................................................56
4.8 F 04 or L04’ - FlowThermistor Fault .....................................56
4.9 ‘F 05 or L05’ - ReturnThermistor Fault .................................57
4.10 ‘F 06’- Outside Sensor Fault..................................................57
4.11 No CH Operation but DHW Works OK...................................58
4.12 No DHW but CH Works OK....................................................59
4.13 No Display..............................................................................60
4.14 ‘F0U’Flow/Return Differential Greater than 50°C ..................60
4.15 F 0C’DHW Thermistor Fault...................................................60
Section 5 - Spare Parts........................................................................61
Section 6 - Benchmark to Commissioning............................................62
CONTENTS