
5Installation and Servicing
Section 1 - General...............................................................................6
1.1 Introduction.............................................................................8
1.2 Operation................................................................................8
1.3 Safe Handling .........................................................................8
1.4 Optional Accessories ..............................................................8
1.5 Safety......................................................................................8
1.6 Safe Handling of Substances .................................................9
1.7 Location of Boiler ...................................................................9
1.8 Air Supply ...............................................................................9
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 Open Vent System Requirements ........................................12
1.16 Schematic Pipework and System Balancing ........................12
1.17 Low Head and Large Systems with Extensive Pipe Runs - .....
Open Vent.............................................................................13
1.18 Sealed
System Requirements ..............................................13
1.19 Sealed System Requirements - Cont. ..................................14
1.20 System Balancing.................................................................15
1.21 Water Treatment...................................................................15
Section 2 - Installation ........................................................................16
2.1 Boiler Assembly - Exploded View .........................................16
2.2 Unpacking.............................................................................17
2.3 Wall Mounting Template........................................................18
2.4 Preparing the Wall ................................................................18
2.5 Fitting the Wall Mounting Plate .............................................18
2.6 Mounting the Boiler ..............................................................18
2.7 Flues and Locations..............................................................19
2.8 Flues and Locations - Cont...................................................20
2.9 Horizontal Flue Positions .....................................................21
2.10 Vertical Flue Positions .........................................................21
2.11 Flue System Dimensions .....................................................22
2.12 Fitting the Turret....................................................................22
2.13 Cutting the Flue ....................................................................23
2.14 Assembling the Vertical Flue ................................................24
2.15 Rear Flue Outlet Kit (55/80) Assembly - ...................................
Exploded View......................................................................25
2.16 Terminal Wall Seal Assembly / Positioning...........................25
2.17 Setting the rear ue length - ....................................................
Wall Thickness of 115 mm to 442 mm .................................25
2.18 Fitting the Wall Plate / Rear Flue Terminal Assembly ...........26
2.19 Mounting the Boiler - Rear Flue Outlet Kit (55/80)................26
2.20 Condensate Drain.................................................................27
2.21 Condensate Drain - Cont’d ...................................................28
2.22 Connections..........................................................................29
2.23 Electrical Connections ..........................................................29
2.24 Installer Wiring......................................................................29
2.25 Installer Wiring - Continued ..................................................30
2.26 Installer Wiring - Cont ...........................................................31
2.27 Pump Overrun - Install..........................................................31
2.28 Wiring Diagram.....................................................................32
2.29 Commissioning and Testing..................................................33
2.30 Initial Lighting........................................................................34
2.31 The Display...........................................................................35
2.32 General Checks....................................................................35
2.33 General Checks Cont. - Water Circulation............................36
2.34 Restart Procedure.................................................................36
2.35 Accessing the Installer Mode................................................37
2.36 Handing Over........................................................................37
Section 3 - Servicing...........................................................................38
3.1 Servicing Schedule...............................................................38
3.2 Removal / Replacement of Components..............................39
3.3 Draining the Boiler ................................................................39
3.4 Boiler Front Panel Removal / Replacement..........................40
3.5 Flue Manifold Removal/Replacement...................................40
3.6 Fan and Venturi Assembly Removal and Cleaning...............41
3.7 Burner Removal and Cleaning..............................................42
3.8 Cleaning the Heat Exchanger...............................................42
3.9 Ignition / Detection Electrode Replacement / Inspection ......43
3.10 Cleaning the Condensate Trap.............................................43
3.11 Flow & Return Thermistor Replacement...............................44
3.12 Burner Injector Replacement................................................44
3.13 Burner Replacement.............................................................44
3.14 Spark Generator Replacement.............................................45
3.15 Gas Control Valve Replacement...........................................45
3.16 Condensate Trap Replacement / Cleaning...........................46
3.17 Flow Switch Replacement ....................................................46
3.18 Primary PCB Replacement...................................................46
3.19 Heat Engine Replacement....................................................47
Section 4 - Fault Finding.....................................................................48
4.1 Fault Finding Main Menu ......................................................48
4.2 ‘L 01’ - Overheat Lockout......................................................49
4.3 ‘L 02’ - IGNITION Lockout.....................................................49
4.4 ‘L 06’ - Flame On Before Gas Valve On................................50
4.5 ‘F 02 or FN or LN’ - Flame Loss............................................50
4.6 ‘F 03’ - Fan Fault...................................................................51
4.8 Flow/Return Reversed..........................................................51
4.7 F 04 or L 04’ - Flow Thermistor Fault ...................................51
4.9 ‘F 05 or L 05’ - Return Thermistor Fault ...............................52
4.10 ‘F 06’ - Outside Sensor Fault ................................................52
4.11 No CH Operation ..................................................................53
4.12 No Display ............................................................................54
4.13 No DHW Operation...............................................................54
4.14 Flow/Return Differential Greater than 50°C..........................54
Section 5 - Spare Parts ......................................................................55
Section 6 - Benchmark & Commissioning ..........................................56
CONTENTS