
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......................................................................................9
1.9 Gas Supply...................................................................................9
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.................................................................26
2.19 Installer Wiring............................................................................26
2.20 InstalLer Wiring - Cont................................................................27
2.21 Replacing Pre-Fitted Mains Cable..............................................28
2.22 External Electrical Controls.........................................................28
2.23 Wiring Diagram...........................................................................29
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................................ 36
3.5 Flue Manifold Removal/Replacement......................................... 37
3.6 Burner Removal and Cleaning....................................................37
3.7 Fan and VenturiAssembly Removal and Cleaning..................... 38
3.8 Cleaning the Heat Exchanger..................................................... 39
3.9 Ignition / Detection Electrode Replacement / Inspection............39
3.10 Cleaning the Condensate Trap................................................... 40
3.11 Return Thermistor Replacement................................................ 40
3.12 Burner Injector Replacement......................................................40
3.13 Burner Replacement................................................................... 41
3.14 Spark Generator Replacement...................................................41
3.15 Gas Control Valve Replacement.................................................41
3.17 Condensate Trap Replacement / Cleaning................................. 42
3.16 Primary PCB Replacement......................................................... 42
3.18 Pressure Gauge Replacement................................................... 43
3.19 PRV Replacement......................................................................43
3.20 PumpAutomaticAir Vent Replacement...................................... 44
3.21 CH Water Pressure Switch Replacement................................... 44
3.22 Pump Head Replacement...........................................................45
3.23 Flow Thermistor Replacement....................................................45
3.24 Expansion Vessel Recharging & Replacement.......................... 46
3.25 Heat Engine Replacement.......................................................... 47
Section 4 - Fault Finding...........................................................................48
4.1 Fault Finding Main Menu............................................................48
4.2 ‘L01’ - Overheat Lockout............................................................ 49
4.3 ‘L02’ - Ignition Lockout...............................................................49
4.4 ‘L06’ - Flame On Before Gas Valve On...................................... 50
4.5 ‘F 01’- Low Water Pressure....................................................... 50
4.6 ‘F 02 or FN or LN’- Flame Loss.................................................. 50
4.7 ‘F 03’- Fan Fault......................................................................... 51
4.8 F 04 or L04’ - Flow Thermistor Fault .........................................51
4.9 ‘F 05 or L05’ - 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 to Commissioning...........................................56-64
CONTENTS