
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............................................................................................8
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 Balancing.......................................................................13
1.17 Water Treatment......................................................................... 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 - Continued................................................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 - Continued...................................................24
2.17 Connections & Filling..................................................................25
2.18 Electrical Connections................................................................25
2.19 Installer Wiring............................................................................26
2.20 Installer Wiring Continued...........................................................27
2.21 ReplacingPre-ttedMainsCable ...............................................27
2.22 Electrical Controls....................................................................... 27
2.23 Wiring Diagram...........................................................................28
2.24 Commissioning and Testing........................................................29
2.25 Initial Lighting.............................................................................. 30
2.26 User Interface Commissioning....................................................31
2.27 Changing Boiler Operating Mode ..............................................31
2.28 Menu Operation..........................................................................32
2.29 Maximum and Minimum Rates...................................................32
2.30 General Checks..........................................................................33
2.31 Restart Procedure.......................................................................34
2.32 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 External System Filter Cleaning Guide....................................... 41
3.12 Burner Injector Replacement......................................................41
3.13 Burner Replacement................................................................... 41
3.14 Return Thermistor Replacement.................................................41
3.15 Spark Generator Replacement...................................................42
3.16 Gas Control Valve Replacement.................................................42
3.17 Condensate Trap Replacement / Cleaning.................................42
3.18 Pressure Gauge Replacement...................................................43
3.19 PRV Replacement......................................................................43
3.20 Primary PCB Replacement......................................................... 44
3.21 PumpAutomaticAir Vent Replacement ..................................... 45
3.22 Pump Head Replacement...........................................................45
3.23 CH Water Pressure Switch Replacement...................................46
3.24 Flow Thermistor Replacement....................................................46
3.25 Expansion Vessel Recharging & Replacement..........................47
3.26 Heat Engine Replacement.......................................................... 48
Section 4 - Fault Finding...........................................................................49
4.1 Main Menu, Fault Help................................................................49
4.2 Overheat Lockout.......................................................................49
4.3 Ignition Lockout........................................................................... 50
4.4 Flame On Before Gas Valve On.................................................50
4.5 Low Water Pressure...................................................................50
4.6 Flame Loss.................................................................................51
4.7 Fan Fault..................................................................................... 51
4.8 Flow Thermistor Fault ................................................................52
4.9 Return Thermistor Fault .............................................................52
4.10 Outside Sensor Fault..................................................................53
4.11 No CH Operation........................................................................53
4.12 No DHW Operation..................................................................... 54
4.13 No Display..................................................................................54
Section 5 - Spare Parts............................................................................55
Section 6 - Benchmark & Commissioning................................................ 56
CONTENTS