Myson Apollo 30Si User guide

lWYSOnr
HEATIh'G
4UC3r24
-01
for.
the
Apollo
30Si,40Siand
50Si
wallmounted
gas
boilers
G.C.ApplianceNo's.
Apollo
30Si 41494 37
Apollo40Si 41494
38
Apollo
50Si 41494
39
IMPORTANT
FOR
USEWITHNATURAL
GASONLY.
Read
these
instructions
thoroughly
beforeworking
ontheboiler.
Leave
these
instructions
adjacenttothe
gas
meter.

Section
I
2
3
4
5
6
7
8
9
l0
ll
t2
t3
l4
l5
l6
t7
l8
19
20
2r
22
23
u
LISTOFCONTENTS
Subject Page
Introduction 3
Technical
data 3
Creneral
requirements 4
Delivery 4
Gas
supply 4
Electricity
supply 4
Air supply 4
Fluesyslem 4
Boilerlocation 5
Importantinstallationnoles 5
Boilerdimensions
and
position
of waterand
gas
connections 6
Watersystemschematics 6
Sealed
systemrequirements 7
Instnllation
procedure 8
Commissioning 12
Boilercontrols 13
Finalassemblyand handing
overthe
instqllation 13
Annual
servicing 14
Lightinginstructions 15
Replacement
ofparts 15
Wiring diagrams 20
Fault
finding
guide 23
Explodedview U
Short
list spare
parts 25
If youhave
anyreason !o compliainof anyshortage
of componentslistedin Figs5 or 6, supplyalist of theitem(s)
concerned,
boilermodel,
yourname,
addressandanyinformationwhichmayhelpusavoidfurthererror.
Addressfor return:
Spare
Adminisration ldanager
CurzonComponents
Ltd.
Earlsway
TeamValley TradingEstate
Gateshead,
TyneandWear
NEII OSA
Page 2

1. INTRODUCTION
Thesefanned
draught
room-sealedwallmounted
borlersare
foruseonnatural
gas
only, andare suitableforrear orside
exitflue.
The
Apolloboilersarenmge rated
atthe
followingoutputs:
Apollo
30
Si: 4.4
to8.8
kW (15
000to30000
Btu/h)
Apollo40Si: 8.8toll.7 kW(30 000to40000
Btu/h)
Apollo50Si: I1.7to 14.7
kW(40
000
to50000
Btu/h)
All models
are
factory
s€ttothe
maximumoutpuL
Theboilers
are
designed
foruseonlyonfully pumped open
vented
or sealed
watcr
systems
withanindirecthotwater cylinder.
THEYMUSTNOTBECONNECTED
TO A DIRECTCYLINDER.
2. TECHNICALDATA
For
boilermodelsee
lightinginstruction
label
insidethebottomcoverorthe
data
plate
onthe
inner
case.Forserial
No.seetagon
thebottomof tle innercase
justabove
thecontrolbox(visible
afterremovingthebottom
cover).
Boiler Aoollo 30Si Aoollo
40
Si Apollo 50Si
Burner
type &ay A82,1013Mo.
Furiqas179500-018 bray AEzz+ucr+M
Furigas 175-50G032 Eray482401
4Mor
Furioas175-500-017
Burnerinjector Bray16/800 Bray2811000 Bray16/1400
Pilot
injector Honeywell4500-41
08-005
marked
56/
424
Pilotflame 35to
40
mmlong
Spark
gap 3.0to
4.0
mm
lgnition lntermittent
oilot
Weight
(empty) 27 .3kg(60
lb)
Liftingweight
(installing) 21.8kg
(48
lb)
water
content 0.36
litre
(0.08
gal) 0.€ lire(0.1 gal) 0.50lite
(0.11
gal)
Max.
flow
temperature g20c
Design
temperature
rise goc
Maximum
static
head 30.5
m
(100
ft)
Minimum
static
head 150mm
(6
in)
abovethe
highest
point
in
thesystem
' Headloss 0.38m
(15
in) 0.54
m
QlYzinl 0.71
m
(28
in)
Height 711mm
(28
in)
width 340
mm
(13%
in)
Depth 300
mm
(113/
in)
Clearance
required
for
ServrCrng
I Too 50mm/2in't
I Bottom 90
mm
(3'r'z
in)
, Fronl | 3fn mm r113,.Inl
I Sides | 5
mm
p'.In)
Flue
terminalsize 100 mm
dia.x65
mm
deep
(4
in
dia.
x2'/z
tn
d*9\
Water
connections Compression fittings
toaccept
22mm
coppertubeto
852871
Gasconnection RpV"
' Headloss
given
is
applicableonly
whentheflow
through
the
boiler
is
690
litreVh(2.5
gal/min)
for
the
Apollo
30Si,
910
litres/h
(3.3
gal/min)
for
the
Apollo
40
Si
and
1146litres/h
(4.2
gal/min)
for
the
Apollo
50
Si.
NOMINAL
BOILER
RATINGS
Boiler OuFut Input Burner
setting
pressure
kw Btu/h kw Btu/h mbar inwo
Apollo
30Si 4.4 15
000
8.8 30000 5.8 19
600
11.0 37500 4.1 't.6
14.9 6.0
Apollo
40
Si 8.8 30000
11.7 40
000 11.4 39000
14.7 50000 10.0 4.4
16.5 6.6
Apollo50
Si 11.7 40
000
14.7 50000 14.9 50900
18.3 62500 9.0 3.6
12.2 4.9
Page
3

3. GENERAL
REQUIREMENTS
The
boiler
mustbeinstalledinaccordance
with:
TheGas
Safety
(lnstallation
andUse)
Regulations1984
andthecurrent
issue
of:
theBuildingRegulations,BuildingStandards
(Scotland)
Regulations,Local Building
Regulauons,
ModelandlocalWater
UnderukingByelawsandIEE
WiringRegulations.
Detailedrecommendations
are
stated
inthefollowingBritish
Standards:
85689l:1988,B56798:1987,
855!16:1990,BS5440:l:1990,
8S5440:2:1989
and
B55449:1:1977
.
Note:
Gas
Safety
(Installation
andUse)
Regulations198^l:
Itis
the
law
thatall
gas
appliances
are
installed
bycompetent
persons,
in
accordance
with
theabove
regulations.
Failure
to
install
applnnces
conectlycouldlead
to
prosecution.
Itisinyour
own
interest,
and
that
ofsafetytoensure
that
'Jre
law
is
comnlied
wit}t.
4. DELIYERY
The
unit
is
delivered
intwo
packagcs(
I)the
cased
boilerand
(2)
the
fludterminal
assemblytypeA,B,C,DorEas required.
In
additiona
965mm
(38
in)fiuc extcnsion
isavarlable.
Undernocircumstancesshouldmore
than
two
extension
kits
beused.
A plug-in
progr:rmmer
kitis
alsoavailableto
fit inside
theboilercasing.This
programmer
simplifies
wiring
and
is
suiuble
for
use
with
all
externalcontrolsystems
shown
inthe system
wiring
diagramssupplied
withtheboiler.
A lit from
tie insidekit isavailable
which
enables
the
flue/terminal
assemblyto
be
fitted
frominside
thebuilding.
A Vertexflue kit isavailable which
allowstheboiler!o
be
connecrcdto
avertical
flue
system.
Apump
andby-pass
kitis
available
which
posiitions
the
pump
in
a
readily
accessible
position,
includes
a
built
in
by-pass
which
does
not
rcquireadjusungand
allowsthe
combinedcold
feed
and
vent
tobeconnecteddirectlytothe
boiler.
Thekit includes
anouter
casc
extension
whichincreases
the
boiler
heieht
to861
mm.
5. GAS SUPPLY
Thenatural
gas
requirements
areas
follows:
Apollo30Si:
l.l m3/h(37ft3lh) Apollo40Si:l.4m3lh(51ft3/h) Apollo50Si:1.8
mt/h(62ft3/h)
The
meter
and
supply
pipes
must
becapableofdelivering
this
quantity
ofgas
inaddition
to
the
demand
from
anyother
appliances
in
thc
house.
Thc
complete
installation
mustbe
tested
for
gas
soundnessand
purged
as
describedin 85689l.
6. ELECTRICITYSUPPLY
210V
- 50FIz
via
a
fused
double
pole
switch
with
a
contactseparationofat least
3
mminboth
poles
or
preferably
a
fused
3
pinplug
and
shutteredsocketoutlet
(both
complying
withthe requircments
ofBSl363)
adjacent
tothe
boiler.
Fuse
the
supply
at
3A.Theminimumrequirement
forthe
power
supply
cable
is
that
it should
be
a
PVC
sheathed
flexible
cordat
least
0.75
mm2
(24
x0.2 mm)
(code
designationHO5
VV-ForHO5 VVH2-F)
as
specifiedintable16
of 856500:1984.
All wiring
externalto
the
boiler
shall
comply
with
the
latestIEEWiring
Regulations,
andanylocal
regulations
which
apply.
The
appliance
must
beearthed.
Inthe
evenl.ofan
electrical
fault
after
inslallation
ofthe appliance,
preliminary
elecnicalsystemschecksmust
becarriedouti.e.
Earth
Continuity,Short
Circuit,
Polanty
anC
ResisLancc
to
Eanh.
7. AIRSUPPLY
The
roominwhich
the
boiler
isinsnlled
docs
not
rcquire
a
purposeprovided
air
vent.
If theboiler isinstalledin
acupboardor
compartment,
permanent
air
vents
are
requiredin
0recupboardorcompartrncnt,
oneathigh
level
andoneat
lowlevel,
eitherdircct
totheoutsideairortoaroorn.Bothhighlevel
and
lowlevel
airvents must
communicate
with
the
sameroom
ormust
beon
the
same
walltooutsideair.Boththehighlevel
andlowlevelvent
musteachhave
a
free
area
asstated
below.Thefrec
areaofeach
vent
may
be
halved
if the
ventilation
isprovided
directlyfrom
outside.
Apollo
30Si: 99cm2
(
15
inz) Apollo40 Si: 133 cm2
(20
inz) Apollo
50
Si: I 65cm2
(25
in2)
If the
boiler
isinsulledina
cupboardorcompartment
with
adoor,allow
at
least
100mm
clearancebetween
the
front
ofthe
boiler
andthedoor
for
air
movemenL
E.
FLUESYSTEM
Five
telescopic
flue/terminal
asscmblies
are
availableand
afixedlength, 965mm
(38
in),
extension
kil
Theflue
lengths
are:
SizpA: 123
- 175mm
(43A
-7n)
Siire
B: 17l
-275mm(GA-lUAin)
SizrC: 274
- 478mm
(|Glr
- l8%in)
Siz.cD: 362
-652mm
(l4t/e
-251/tin)
Sze
E: 582
- lW2 mm
(23
-43
in)
Unless
otherwise
specified
theCsize flue/terminalwill be
supplied
with
theboiler.
Thefollowing
method
shouldbe
used
todeterminethe
required
flue/terminalassembly.
RearflueA=C+83mm(3%in) Side flue
A
=
B+
C+ 127
mm
(5
in)
WhereA =requiredflue
length,B= insidewall
to
side
ofboilerandC= finished wall
thickness.
If A isgreater
than
1092
mm
(43
in)oneortwo
extension
kits
maybe
used.
Note:Themaximum
allowable
fluelengthis3022
mm
(119
in).
Poge 4

9. BOILER
LOCATION
Theboiler
isnotsuitable
forexternal
installation.
The
boiler
musrbe
mountedonaflatwallwhich
issufficiently robust
totakethe
weightof theboiler.
The
boiler
is
suitable
forinstallationtoa
combustible
walle.g.
woo<l
cladding,
provided
thattheairlfluetube
assembly
isnotcloser
than
25mm
(l in)
to
combustible
material.
A metalsleeveshouldbc
installed
to
surroundtheairlt'luetube
assemblyto
provide
a
25mm
(l in)
annular
space.
Further
guidance
isgiven
inBS5440:l:1990,sub-clauses3.3and
4.2.5.
If rheboiler istobe
installedinatimber
framedbuilding
itshould befitted
inaccordancewiththeBritishGas
publication
-"Cuide
for
Gas
Installation
inTimber
FramedHousing"
reference
DM2.If indoubt advicc
must
besought
from
the
local
region
ofBritish
GasorfromMyson
Heating.
Theboiler
may
be
installed
in any room,although
particular
attention
isdrawntothc
rcquirements
of thecurrent
IEEWiring
Regulationsand,
in
Scotland,
theelectrical
provisions
ofthe
Building
Standards
applicable
in
Scotland
withrespect
to
the
installation
of thetroiler
in aroom
containing
abath
orshower.
Wherearoom-sealedappliance
isinstalledin
a
roomcontainingabath
orshower,any
electricalswitchorappliancecontrol,utilising
mains
electricity
shouldbesosituated
that
it cannotbetouched byaperson using
thebathorshower.
Where
the
installation
ofthe
boiler
will be inanunusual
position,
special
procedures
maybe
necessary
and
856798
and
855546
give
detailed
guidance
onthisaspecl
Acupboard
orcompartment
usedto
enclosetheboiler
must
bedesigned
andconstructed
specifically
for
this
pupose.
Anexisting
cupboard
or compargnent
maybeused
provided
thatit is modifiedfor thepurpose.
Details
of essential
features
of cupboard/
compartment
design
including
airing
cupboard
installationsare
given
in856798and
B55546
andshouldbecomplied
with.
The
boiler
requires
onlytheclearances
stated
inthetechnicaldata,
page
3,after
installation.If it isfelt
that
extraspace
isrequired
forinstallationanyadjacent
kitchenunitsor fitmentsmayhavetobe
removed.
The
boiler
must
be
installedsothatthe
flue
terminal
is
exposedto
theexternalair.
It isimportantthatthe
position
oftheterminal
allowsthe
free
passage
ofairacross
it atallttmes.
Theminimumacceptable
spacings
from
the
terminaltoobstructions,corners
and
ventilation
openingsare
specificd
in
the
following
table:
Termlnal
posltlon Minimumspacing
Directly
belowanopenable
window,
airventoranyother
ventilationopening 300mm
(12
in)
Below
gutters,
soil
pipes
ordrain
pipes 75mm
(3
rn)
Beloweaves
orabalcony 200mm
(8
in;
Aboveadjacent
ground
orbalcony
level 300
mm
(12
in)
Fromverticalsoil
pipes
ordrain
pipes 75mm (3
in)
Frominlernalor
externalcorn€rs 25mm
(1
in)
Fromasurlace
lacinothelerminal 600mm
(24
in)
From
alerminal
lacingtheterminal 1200mm
(48
in)
Vertically
lromaterminal
onthesame
wall 1500mm
(60
in)
Horizontally
tromalerminalon
lhesamewall 300mm
(12
in)
Adjac€nt
toanop€ning
window 150
mm
(6
in)
From
anopening
inacar
pod
i.e.door
orwindowintothe
house 1200mm
(48
in)
*Ifrhererminal
isfitted
within
850
mm
(34
in)
ofa
plastic
or
paintedgutter/pipe
or
450mm
(18
in)
of
painted
eaves,
analuminium
shieldofar
least750
mm
(30
in)inlength
shouldbe
fittedtotheundersideof the
gutter/pipe
orpainted
surface.
** If theterminal
isfiaed
less
than
2m
(6.6
ft)above abalcony,above
ground
or
abovea
flatroof
to
which
people
havc
access
then
asuitable
terminal
guard
must
be
provided
and
fitted.
A type
Kl protective
guard
isavailble
fromTowerFlue
Components
Ltd.at:
ValeRise,Tonbridge,KentTN9 1TB,Tcl:0732
35
r555.
The
guard
mustbesecurely
fittedtothe
wall
andcentrally
locatedoverthe
flue
terminal.
Refer
tothe
manufacturers
instrucLions.
I().IMPORTANT
INSTALLATION
NOTES
l. TheApolloistobeused
onlyonfullypumped systems,
and
with anindirect
cylinder.
2. {Jnly
high
head
pumpsproducing
atleast
3.35
m(ll f0 head ataflowrate of690
litres/h
(25gaVmin)
forthe Apollo
30Si,910litreJh
(33gaVmin)
forthe Apollo40
Sior 1146litresih
(4.2
gaVmin)
forthe Apollo50Si
must
beused.
3. Connect
the
pump
in the
flowpipe asshovrn
inthe water
systemschematics.
4. Mainselectricity
andthe
pump
must
alwaysbeconnectedtotheboilertoallowthe
pump
overrunto
function.
5. It isimportantthatthe
polarity
ofthe
mains
supply
is
correctandthattheboiler
is
adequatelyearthed.
6. Foropen
vented
systems
acombined
or closecoupled
feed
andventmust beconnectedassho*r in the
watersystem
schematics.
7. Asystem by-pass
is
essential.
Theby-passshould
beof15mm
pipe
and
must
be
asshort
as
possible
acrossthe
22mmflow
and
returnpipes andat
least1.5maway
from
theboiler.Install
theby-passasshown
inthe water
systemschematics
and
adjustasdescribed
in thecommissioning
instructions.
8. Tbe
systemwiring
mustbecompleted
inaccordance with
thediagramssupplied
with
theboiler.
9. When commissioning,
thesystem
mustbe
vented
andthe
pump
running
beforethemainburner islit.
Page5

10.The
systemmust
be
flushed
twice;
initiallycoldwith thepumpremoved
andall valves open,
andthen
afterthefirst
heating.
11.
Where
the
Apollo
replaces
anolder
boilerin anexisting
system,
make
surethecylinderisindirect.
12.In areaswith hardor aggressivewet€rwerecommend
thatFernoxCP3
inhibitorshouldbe
used.Seecommissioning
instructionsfor detailsof use.
13.
Theinner
casc
oftheboiler shouldnotberemoved
duringinstallation.
T1.BOILERDIMENSIONS
ANDPOSITION
OF
WATER
ANDGAS
CONNECTIONS
Refer
toF,g. 1.
Overall
caseddimensions:
Height: 7ll mm
Width: 340
mm
Depth: 300
mm
Clearances
requiredfor servicin
g:
Top: 50
mm
Bottom: 90mm
Front 300mm
Sides: 5mm
See
section9for installation
clearances.
Water connections:
Compression
fittingsaresupplied
for flow andreturn
connections
toaccept22mmcoppertubing
toBS287l.
12.
WATER
SYSTEM
SCHEMATICS
22nn 22mm
Relurn. zJo -^ Flow
. 145 - Fig.I -bE-
a. Fully
pumped
openvented
systemwith combined
cold
feed
and
vent
-s€e
Fig.2.
The
combinedcoldfeed
and
vent
must
rise
fromtheboiler.
Somewater
authorities
require
astopcock
inthe
coldfeed, in which
caseaseparatevent
must
be
connectedas
shown.
b. Lengthof wetanddry ventsfor close
coupled
coldfeed
-see
Fig.3.
The
distance
betweenthe
coldfeed
and
vent
connection
tothe systemmust
not
be
more
than
150
mm.The
point
ofconnection
of
these
pipes
shouldbeas
closetotheboiler
as
practicable.
IAlternative
vent
i arrangement
It
I coldfeedisvalved
Optronal
Zone
Valves
Optrona
.3 pos
t
on
va
ve
See8S5449
clause
24 l
Fig.2
The
by-pass
balancing
valve
should
be
ofatypethatisnon-adjustable
bythehouseholder
andmusrhave
ar
least1.5
mof22mm
pipe
each
sidebetweenit andthe
boiler.
Always
ensurethat
the
pump
has
sufficient
statichead.
Checkthe
pump
manufacturers
minimum
head.
The
flow through
theboilermustnotbe
allowed
ao
fall below690litreVh(2.5 ga[min)fortheApouo30
Si,
910litres/h
(3.3
gaVmin)
forthe Apollo
40
Sior l146litres/h
(4.2
gaVmin)
fortheApollo
50Siwhile
rheburner
isalight
Ensurethat
the
pump
isaccessible
for servicing.
Isolating
valves
must
be
positioned
ascloserorhe
pump
as
possible.
Fitone
ormore
drainingtaps
(BS2879)
toenable
the
water
system
tobe
fully drained.
A - length
of dry venl
B - length
ol waterfilled
vent
C - 150 mD min
T2CDmm
I
Fig. 3
HEATII{G
LOAD VENT
LENGTH
Bu,n A
(mm) (mm)
5C000
40 000
3C000
20 000
.0 000
4n
3(n
z&
140
50
330
m
m
no
no
Page6

13.SEALEDSYSTEM
REQUTREMENTS
Refer
to Frg.4.
a. Theinstallationmust comply
withthe
requirements
of856798 and
BS5449:1.
Maximum
water
temperature
is82oCt 3oC.
b. A safety
valve
settooperat€at3bar
(45
lbf/in2)
shallbe
fittedinthe flowpipe
close!othe
boiler.
Theremust
not
be
any
valves
between
the
safety
valve
andtheboiler.
Thevalve should
be
positioned
onadischarge pipefitted[oprcvent
any
discharge
creating
ahazard
tooccupantsorcausedamage!oelectricalcomponentsand
wiring.
c. A pressuregauge coveringatleast the
range0 m4bar
(0!o60lbf6nz;
shallbe
fittedin thesystem.
d. A diaphragm
type
expansion
vessel,
toBS48
14,
shall
be
connected
atapoint
inthereturn
pipe
close
tothe boiler.
Thevessel
must
bechosentro
suit
the
volume
ofwaterinthesystemandthe charge
pressure
must
notbeless
thanthe
static
head
atthe
point
ofconnection.Further detailscanbeobtainedfrom"Materialand
Installation
Specification
forDomestic
Central
Heating
and
HotWater"published
byBritish Gasand
BS7074:1.
Sizingtable:
Airor NiEogen cfiargeprsssure
(bar) 0.5 1.0
Pre-pressurisation
pressure(bar) None 1.0 None 1.5
Expansionvesselvolume
(lifes) Ax0.07 Ax0.120 Ax
0.088 Ax0.160
A
=
System
volume
(litres)
e. Thehotwater cylindershall
eitherbethe
indirect
coil type
oracylinderfittedwithanimmersion calorifier.
f. Waterlost
fromthe
systemshallbe
replaced
fromamake-up
vessel
and
non-returnvalve,
mountedhigher
thanthetop
ofthe
systemonthe
return
side
of thecylinderorradiators.
Where
accesstoamake-up
vessel
would
bedifficult,make-up canbe
provided
bypre-pressurisation
of thesyste.
g. The
systemmaybefilledfromthemains
via
a
Lemporaryhose
connection
from
adraw-offtap
supplied
from
aservice
pipe
under
mains
pressure,provided
that
this
procedure
is
accepuble
tothe localwater
authority.Thefollowing
fittingsshouldform
a
perrnanentpart
of fre systemand
fittedin theorderstated:
i) astop valve
complying
totle requiremenLs ofBSl0l0:2.
iD atestcock.
iii) an anti-vacuumvalve
ofatyp€approvedbytheNarional
Water
Council.
iv) anon-returnvalve
of anapproved
type.
h. Fill thesystemuntil
the
pressuregauge
registers1.5
bar
(22lbflinz).
Examineforleaks
and
rectify
whcre
neccssary.
Refer
tothe commissioning
instructions,light
the
boilerand
allowthe
systern
toreach ilsmaximumworking
temperature.
Examineforleaks
thenturnoff the boiler.Drainthe
system
whileit isstill hot.Refill, vent
andadjust
the
coldfill pressure to
therequired
value.
The
by-pass
balancingvalve
musthave
at ieast1
5rnof 22mm pipe
eachside
betweenitand
theboiler.
Exoansron
Vessel Optional
Zone
Valve
Optronal
3-position
valve
Fig.4
l5mm
Pressure Balancrng
Gauge -
valve
Page 7

templatesupplied
withtheboiler.
The
overall
size
ofthetemplate
isthe size
oftheboiler
plus
the
minimum
side,topandbottom
clearances.
2. When
youhave
decidedonthe
position
of theboiler
tape
the
template
tothewall,ensuringit islevel
andthecorrect
way
up.
3. Makesure thatthe
position
of theflueterminal
will meet
therequirements
given
in section
9.
4. Markthe
position
of theholefor theflue.
5. Remove thetemplate
(donot
discard
i0 and cuttheI 15mm@th in)diameterholein thewall for the flue/terminal
assembly.
6. Repositionthetemplateonthe
wall,mark,
drill and
plug
the
hvefixingholes
toaccept
215"lg. No.12woodscrews.
7. Makeanote of the
finishedwallthickness, this
isveryimportant
and
isrequiredforsection 14.5when
adjusting
thelengthof
the
flue/terminal
assembly.
8. Remove thetemplateand
position
the
wallmounting
plate
cenrallyoverthehole
inthewall,ensuring
it isleveland
the
right
way
up(studs atthebottom).Secrrrethe
mounting
plate
o thewallwith four21h"lg.No.12woodscrews
(not
supplied).
14.3
Securetheboiler
tothe
wall(rearflue).
Note:The
inner
case
doesnot
need
toberemovedduring
installatron
L Lift the boilerinto
position
and
locate
the
two
holes
inthetop
ofthechassisover
fte studs
onthe
wall
mounting
plate.
Secure
theboiler
tothe
wallmounting
plate
withtwoM6nuts
supplied
with
theboiler.
14.INSTALLATION PROCEDUR.E
14.1Unpacktheboiler
- see
Fig.5.
Note:Donotstandthe boileronitsendas
it will damage
the
gas
valve.
l. Carefullyunpack
theboiler.
Donot
discardthe
packing
untilall
the
items
are
found.
2. Carefullyslideoff the bottom
cover
fromthe boiler.
3. Removetheoutercaseby slackeningthe
botlomfixing screw
and
firmly pullingthe
case
off the
fixing pins.
4. Keeptheoutercase,bottomcoverandinfrll panels
in a safe
place
soas
nottodamagethem beforefitting.
IF REAR EXIT FLUE IS TO BE USED CONTINUE ON
TO SECTION l42.IFSIDEEXITFLT.IE ISTO BEUSED
PROCEED TO SECTION 14A.
14.2Preparethe
wall(rearflue).
L Decideuponthe
position
of the
boiler
usingthe
wallmounting
2. Secure the
bottom
ofthe
boiler
tothe
wallwildl.
a2th" lg.No.l2
woodscrew
(notsupplied)
via theholepreviously
drilledand
plugged.
3. Remove the
fluediverter fromthe
topof theboilertaking
care
nottodamage
the
gasket
4. Connectthe
system
flowand return
pipes
tothetop
compression
unions
(see
watersystem
schematics,section
l2).
5. Refitthefluediverterfacingtotherear.
14.4Unpackthe
flue/terminalassembly
-see
Fig.6.
Carefully
unpack
theflue/terminal
assembly.
Do notdiscard
the
packing
untilallthe
items
are
found.
14.5Adjustthe lengthofthe
flue/terminal
assembly
-see
Fig.
7
(rear
flue).
l. Using themeasurement
notedinsection 14.2
adjustthe
length
of
the
flue/terminal
assemblyso
that
it is:
83mm(3V in)+ finishedwall thickness,
fromthe
back
of the
terminalflange!othe
end
ofthe OUTERair
tubeas
shown
inFig.
1
Note:
Ensure
that
the
seams
inthe
outer
airtubesare
inline.
2. Drillthrough
the
three
pilot
holes,
shown
inFig.7,with
a
2.8
mmdrill and securethetwo nrbesogetherusingthethree
No.8x l0lg. screws suppliedwiththeflue/terminal
assembly.
Note:When
drillingthroughtheouterairtube
take
care
not
todamagethe
innerfluetube
withthe
drill.
3. Seal
thecentre
joint with thetape
supplied
with theflue/
terminal
assembly.
t!
mountrng
plate
T??TTT??
No 8 x 12 19 scraaa 8 off
6@
M6 nuts 2off
Flnd these
parlsin the pack.
Fis.5
cover
Clamping
ring2 off
gggg
M4 ' 1619
screws
4 off llll
AAAg
No.8 x 1" lg
sranress
screws 4 of{
I roll oi sealing tape
o
'O'ring
Outer seaftng
plate
AAJ
No8' lOlg
screws
3 of{
Flnd there parts in lhe pack.
Fig.6
Outer
wall
plate
Flue./lerminalass€mbl!
Seal
this
loint
wtth tape
supplied
Keeoseams
Finished
wallthickness
Inlrne
* 83
mm(3%
in)
---
Prlot
notes
t3off)
F+
Fig. 7
Page I

14.6
Fitthe
flue/terminal
ess€mbly
-s€eFig.t (rearflue).
Note:
If the
wallistobe made
good
upo the terminal,
the
outerwallplate
need
notbeused.
1. Fit theouter wallplate overthe flue/terminal
assembly.
2. Fit the'O' ring in position
overtheouter air tube
against
theflared
section.
3. Fromoutside
thebuildinginserttheflue/terminal assemblyinto the
wall.Ensure
thatthe
slotsin the end
of theterminalare
vertical.
4. Push
the
flue/terminal
assemblylowardstheboiler
and
engage
thetube
intothe fluediverter
ontopof the boiler,
ensuringthatthe
innerflue
tubeslides
INTO the inner
tube
of the
diverterandtheouter
airtube
slides
intothe
diverter. Fig.
t
Fig.9
,!?' '.u.r'r€
Fig.I0
Check
thatthe'O' ringisontheboiler'sideof theflaredsection.
Pushfully home
untiltheflared endof theouler
tube
isincontactwith the fluediverter.
14.7
Connect
thefluetotheboiler
-seeFig.
9(rearflue).
l. Fitthetwo halves
ofthe
clamping
ring
overtheair
tube
asshowninFig.
9.
Ensure
thatthe
flatsideisagainstthe
wallmounting
plate,
and
the
recessed
sideagainst
theflaredpartof theair tube.
2. Securetheclamping ring
tothe
fluediverter
usingthe
fourM4screws
supplied
(use
the
threaded
holesin theclamping ring).
3. Tighten thescrewstoseal
the
flueassembly.
4. Proceed
losection14.14.
14.E
Preparethewall-seeFig.10
(side
flue).
l. Decideupon
the
position
oftheboiler
using
thewallmounting
template
supplied
with theboiler.Theoverallsizeof thetemplateis sizeof theboilerplusthe
minimumside,
topand
bottom
clearances.
Note
that
the
maximum
distance
(using
thelongestflue/terminal
assemblyand
two965mm
(38
in)flue
extensions)from
the
side
ofthewhite
casetotheOUTSIDE
ofthe
wallis2895
mm
(114
in).
2. Tape
the
wall mounting
templatetothe
wall,ensuringit islevel
andthecorrect
way
up.
3. Continue thered
line,
on
thetemplate,
horizontally
across
the
walluntil
itreaches
the
side
wall.
4. Tape
the
sidefluetemplate,
supplied
with
theboiler,
tothesidewallso
that
it is
inLhecornerandthat
theline
just
drawn
lines
up
with
the
red
line
on
thetemplate.
5. Makesurethat
the
posirion
ofthe
flue
terminal
nill meet
tie requiremcns
given
insection
9.
6. Mark the
positions
of the
fourwallmounring
plate
fixingscre
*s andthelo*er
fixingscrew.
7. Drillandplugthefivefixingholes!oaccept2th"
lg.No.l2
*mdscre*s.
\{ark
r}r
position
oftheholeinthe
side
wallforthe flue/terminal
assembly.
8. Cutthe ll5 mm (4rhin)diameterholein theside wall for rhe
flueAcrmrnal
assembly.
9. Makeanote
oftle finished
wallthickness
andthe
distance
from
theside
*all to
the
side
ofthewhitecase
as
shownon
thetemplate.These
measurements
are
ver)'
important
andare
requiredinsection 14.10when
adjustingthe
length
of tlre flue/termrnal
asse
mbly.
10.
Removethe
templates
and
place
thewallmounting
plate
inposition
ontlrewall
ensuringrrrsle
vel
andthe
rightway
up
(studs
atthe
botrom).
Secure
themounting
plate
!o
thewallwithfour21h"lg.No.l2woodscre*
s
(
nor
supplied).
14.9
Securetheboilertothe
wall(side flue).
Note:The inner
casedoes
notneed
toberemoved duringinsnllation.
I. Lift theboilerinto
position
and
locate
thewo holes inthetop
offte chassisoverthe
studsonthe
wall
mounting
plate.
Secure
the
boilertothe
wall mounting
plate
with nvoM6 nuts
suppliedwith the
boiler.
2. Secure
thebouom
ofthe boilerto
the
wallwith
a2l5" lg.No.12woodscrew
(not
supplied)
i'ia
rlrehole
previously
drilled
and
plugged.
3. Removethefluediverter fromthe topof theboiler
takingcare
nottodamage
the
gaskcr-
4. Connect
the
system
flowand return
pipes
tothe
topcompression
unions
(se€
water
systemschematics,
sectionl2).
5. Refitthe fluediverter facing
leftorrightasdetermined
bythefluedirection.
6. Unpack theflue/terminal
assemblyasdescribedin section 14.4.
Page 9

14.10Adjustthelength
ofthe
flue/terminal
assembly
-see
Fig.11
(side
flue).
l. Usingthem@surementsnotedin section 14.8,
adjustthe
lengthof the
flue/terminalassemblyso
that
it is:
127mm
(5in)+A + B,fromtheback
of theterminalflange
totheend of the OUTER
airtubeasshown
in Fig. Il.
WhereA isthe
finishedwallthicknessand B isthedistance
between
thesidewall andthesideof the
white
case.
Note:
Ensurethattheseams
inthe
outerairtubesare
inline.
2. Drill throughthethree
pilotholes,
shown
inFig. I l, witha
2.8
mm
drilland
securethe
two
tubes
togetherusingthethree
No.8x l0lg. screwssup'plied with
the
fluelterminal
assernbly.
Note:
Whendrillingthroughtheouterairtubetakecarenot
todamageiheinner fluetube
with thedrill.
3. Sealthecenre
jointwiththetape
supplied
with
theflue/terminal
assembly.
l4.ll Flue
extension
-see
Fig.12
(side
flue).
Theflue
extension
kitallowsthestandard flue/terminal
assembly
tobe extendedby965
mm(38in).
A maximum
of twoflueextension maybeused,
if required.
l. If theflueextensionkit isused,connectthe
plain
endofthe
extensionto theswagedend
of thesondard flue/terminal
assembly.Ensure
thatthe
innerflue
tubeof
thestandafiflue/
terminal
fis INSIDEthe
innerfluetubeoftheextensionand
theouteraL tubefits OVERtheair tubeof theextension.
Pushfullyhome.
Note:
Ensurethattheseams
intheouter
airtubes
are
inline.
Seal
this
loint
with tapesupplied..
Extension Keeps
seamsin line Standard
flueltermrnal
assemblv
Fig. 12
2. Drill threeequally
spaced
holes
usinga2.8
mmdrill inthe
position
shown
inFig. 12,
through
boththestandard
fluelterminal
andtheextensiontubesleeve.Serurethetwo
&bes
togetherusing
thethree
No.8x l0lg. screws
suppliedwiththeflueextension.
Note:
Whendrillingthroughtheouterairtubetakecare
not
to
damage
the
inner
flue
tube
withtlredrill.
3. Sealthe
lrints withthetape
supplied
withthe
flueextension.
4. AdjusttheOVERALL length
asdescribed
insection 14.10.
Secureand
seal
the
joins.
14.12
Fittheflue/terminal
pssembly-s€€
Fig.13
(side
flue).
Note:
If the wall istobemade
good
upto the
terminal,tlreouter
wall
plate
neednotbeus€d.
l. Fit theouter wallplate
overthe
flue/terminal
assembly.
2. Fitthe
'O' ringinposition
over
theouterairtube
against
theflared
section.
3. From outsidethebuilding
insert
the
flue/terminal
assembly
into
the
wall.Ensure
that
theslos in theendof theterminal
are
vertical.
4. Pushtheflue/terminalassemblytowardsthe
boilerandengagethe
tube
into
theflue
diverter
ontopofthe
boiler,
ensuring
thatthe
inner
fluetube
slidesINTOthe inner
tube
ofthe
diverter
andtheouter
air
tubeslides
intothe diverter.
Checkthatthe
'O' ringisonthe
boilersideof theflaredsection.
Push
fully home
untilthe
flared
endof the
outertube
isincontact with thefluediverter.
14.13
Connect
the
fluetotheboiler
- see
Fig.14
(side
flue).
l. FitthetwohalvesoftheclampingringovertheairtubeasshowninFig.14.Ensure
thatthe
flatside
isfacing
away
fromthe
boiler,andthe
recessed
side
isagainstthe
flared
part
of theairtube.
2. Securetheclamping ring
to
theflue
diverterusingthe
fourM4screwssupplied
(use
thethreaded
holes
in theclampingring).
3. Tighten thescrews
toseal theflueassembly.
4. Make
good
the
gap
onthe
inside
wallaroundthe fluetube.
Fig.14
Sealthrs;oint
wrlh tape
supplied , Pilor holes (3 off)
Keep seams rn lrne
+--
Finished wall thickness +8+ 127mm (5 tn)
Fig.11
Page
I0

14.14
Fittheoutersealing
plate
-see
Fig.15.
l. Make
good
theoutside
wallaroundthe flueduct
Note:Theoutersealing
plate
neednotbeused
if the wallismade
good
up
tothe
terminal.
2. Place
theoutersealing
plate
over
the
terminaland
markthe
position
of the
four
fixingholes.
3. Removethe
sealing
plate
anddrilland
plug
the
fixingholes,
suitablefor I"lg.No.8
woodscrews.
Note:Theterminal
should
be
covered
beforedrilling
loprevent
debris
enteringthe
terminal.
4. Removeany covering
from the terminal.
Position
the sealing
plateover the
terminal
andsecuretothe
wallwithfourI"lg.No.8screws
(supplied
withthe flue/
terminal
assembly).
14.15
Connect
the
gas
supply
-see
Fig.
16.
Connecta 15
mm
gas
supplytothe
service
cock.
Donotturn the
gas
supplyonatthis stage.
Fig.l5
lr
Fis. I7
14.16
Connect
the
power
supply
cabh- see
Fig.17.
Note:A permanent liveand the
pump
must
beconnectedtothe boiler.
l. Removethe
screw
securingthe
frontof the wiringcentreandcarefully lower
iL
2. Slackentwoscrews inthecableclampbelowthe
wiring
centre.
Feedthe
power
supplycableunderthe
clampand
connect
the
wires,
browntoL andbluetoN onthe
terminal
blockand
green
and
yellowtotheearthingscrew (f ).
3. Keep
thewiringcentre
intheopen
position,
take
up
excess
slack
inthe
power
supplycablebetweentheterminalblockandthe
cableclamp,
then
tighten
the
cableclampscrews.
Checkthat
the
wiring
centre
will openand
close
freely
wiihoutsraining
the
power
supplycable.
Note:
When
connecting
the
power
supplycable,ensurethatthe
lengthofthe earthwireissuch,
that
if the
po*,er
supply
cable
slips
outof the cableclamp
the
liveand neutralwiresbecometautbeforethe
earthwire.
4. The
pump
lead
andany
externalcontrols
wiringshouldbe
passed
throughoneorbothofthe
bushes,
provided
at
the
rear
ofthe
wiringcentre,and
connected
totheterminalblock.See
wiringdiagram
page
20.
5. If aprogrammer
isnotfitted,
removelinkHWtoONandconnectaswitched livetoterminalON.
Do
notswitch
ontheelectricity
supplyat this stage.
14.17Remove
theinnercase
inreadinessfor commissioning.
l. Withthe
wiring
centreopenslideout
thefacia
panel
on
the
side
oftheconnolbox.
2. Unscrew
thefour
innercase
fixing
screws,twoatthetop,
one
abovethe
gas
valve
andone
tothe
left
ofthc
* inng
centre,and
removethe
inner
case.
3. If the
programmer
kit is
not
tobe
fitted
closethe
wiring
centreandsecure
in
position
withthe
fixing
scre*.Do
not
replacethe
facia
panel
atthisstage.
14.18
Fit the
programmer
kit.
1. Withthe
wiring
centre
lowered,
engage
the
programmer
fixinginto
theslot
intheconrolborand
push
fullyhome.
2. Connect the
programmer
6-pin
plug
tothe6-pinsocketon
the
wiring
centre,
push
fullyhome
untilthe
latch
engages.
3. Closethe
wiring
centre
and
secure
inposition with
the
fixing
screw.
14.19Completethe
installation.
l. Thoroughly
flushthe
whole
system
witlr
cold
waterwithout
the
pump
inposirion. Ensure
allvalves areopen.
2. Withthe
pump
fitted,fill, vent
andcheck
forwater
soundness,
rectifying
where
necessary.
I6
F
Page
II

15.COMMISSIONING
Seesection
16
for boilercontrols.
1. Testfor gas soundness
andpurgethesupply
a. Withtheboilerservicecockclosed
(the
cock
isclosed
when
theoperatingslotisvertical),
pressure
test
the
gas
supplyand
inlet
pipework
connection
o the
boilerservicecock forsoundness
in accordance with85689l.
b. Removethe
screw
securingthe
gas
valve
coverand
lift off the cover.
c. Loosenthe
gas
inlet
pressure
test
point
screwonenrrn.
Ensure
the
gas
supply
isonandopentheboilerservicecockto
purge
inaccordance with 85689l. Retightenthetest
pointscrewandtest
forgas
soundness.
2. Checkthe
ignition
sequence
Withthe
gas
supply
isolated
check
theignitionsequenceasfollows:
a. Setthe
programme
switch
toCONT,if aprogrammer
isfittedand check
thatall systemcontrolsarecalling
for heat
b. Switch
ontheelectricitysupplyandset
theboiler
thermostatswitch
!oHIGH.
The
automatic
ignitionsequence
will start. The
fan
will start
and
aftera
purge
period
ofabout
l0 seconds
a
clickwill beheard
indicating
thatthe
start
gas
solenoid
has
opened,
theignition
sparks
will also
be
heard.The
ignition
sparks
continue
untilthe
pilotislit. Asthe
gas
supplyisnot
yet
turned
on
the
ignition
sparks
will continue untileithertheelectricitysupply
isswitchedoff orthe boiler
thermoslatswitch
issettoO.
c. Set theboilerthermostatswitch
toOtoterminatethe
ignition
sequence.
3. Checkthe
pilotflameand
test
the
pilot
supplyfor gas soundness
a. Ensurethat theboilerthermostat
switchisset!oO.
b. Removethetwoscrewssecuring
the
pilotshield
and
lift off the
shield.
c. Disconnectand
isolate
one
of the
leads
(black
orwhite)
fromthe main
gas
solenoidonthe
gas
valve.
d. Setthe boiler
thermostat
switchtoHIGH.The unitwill gothrough
theignitionsequencebutonlythe
pilot will light-
e.Checkthatthepilotflame(35to40mmlong)envelopstheelecrodeandextendsl0mmpastit.Adjustifnecessary(clockwise
toreducetheflame).
Note:The
pilotthrottleisfactoryset
fully open.
f. Testthe
pilotsupplyconnections
at
the
gas
valve
and
pilotassembly
forgas soundness
usingasuitableleakdetecting
fluid.
g. Set
theboilerthermostatswitch
toOand reconnect
tlte
main
gas
solenoid
lead.
h. Replacethe
pilot shield
and
secure
with twoscrews.
4. Test
the
main
burner
supply
for gas
soundness
a. Applyasuitrble
leakdetectingfluidtothe main
burner
manifold
jointat
thechassis
and
the
gas
valve
andchassis
connections
of the
gas
valve
manifold.
b. Setthe boiler
thermostat
switch
toHIGH.The
unit
will go
through
the
automaticignitionsequence
andthe
pilot
will light.
Asecond orsoafter the
pilotislit themain
gas
solenoid
will open
and
tlre
main
burnerwill light.Test
the
burner
andmanifold
connections
forgas soundness.
5. Checkthe
main
burner
setting
pressure
Afterthe main
burner
has
been
alight
for l0 minutes:
a. Setthe boilerthermostatswitchtoO.Remove theburnersetting
pressure
test
pointscrew
onthe
gas
valvemanifold
and
connect
apressuregauge.
b. Setthe boiler
thermostatswitch
toHIGHandif necessary
adjust
the
burnersening
pressure
togive theheat
input
required.
Turntheadjustingscrew
clockwisetodecreasethe
seuing
pressure.
Note:The
boiler
isfactory
settothemaximum input SeeTechnical
Data,
page
3,fortheboilerratingsand
setting
pressures.
c. Settheboilerthermostatswitch
toO,disconnectthe
pressuregauge
and
replace
the
pressure
test
point
screw.Setthe
boiler
thermostat
switchtoHIGH tolightthe mainburner
and
testforgas
soundnessaroundthe
pressure
test
point
screw
using
a
suitable
leak
detecting
fluid. Setthe
boiler
thermostatswirch
!oOtoturntheboileroff.
d. Check that
the
arrowonfte data
plate
(positioned
onthefrontof theinner
qrse
atthebottom
righthand
corner)
isagainst
thecorrectboiler
rating.
Note:The
pilotburner
istumed
off everytimethe
main
burnerisoff.Theignition
sequenceisautomatically activatedwhen
the
boiler
thermostatrequiresheaL
6. Replace the
gas
valve
cover
Replace
the
gas
valve
cover,
ensuringthatthe
cable
clampislocatedcorrectlyin thecover,andsecure withitsscrew.
7. Replace
theinner case
a. If aprogrammer
isfiued
open
thewiringcentre,disconnectthe
programmer
plug
andsocket
and
slide
tle programmer out
of thecontrolbox.
b. Ensurethatthe
inner
caseseal
isintact
around
the
boilerchassis
and
replace
the
inner
case,
s€cure
withfour
screws.Tighten
sufficientlytoformaseal.
c. If aprogrammer
isfittedreplrce
andreconnect
the
programmer
then
replace
thewiringcentre.
If aprogrammer isnotfitted
openrhe
wiringcenEe, replrce
the
facia
panel
then
replace
the
winngcentre.
Page
12

t. Final
water
system
checkandadditionof inhibitor
a.When thesystem
has
beentested,
ensuretheboiler
is
off Soiler
thermostat
switch
se
ttoO),drainthe
waterwhileit isstill
hotin order
tocomplete
theflushing
process.
b. When an
inhibitorisaddedtothe system,
FernoxManufacturingCo.Ltd.recommend Fernox
CP3
foruse withcoppertube
boilers
and
this
shouldbeused
inaccordance
withtheir instructions.Where
the
boilerisused
onan
oldsystem,
special
care
isrequired.Thesystemshouldbedrainedand
flushed
out,ensuringthatallradiators
are
drained.
Whenfilling add
the
correct
quantity
of
CP3
forthesystem
volume.
Asa
guide
a3
radiator
system
will onaverage
require
about2%
pints,
a6
radiator
system
4Vtpinsand
a9radiattr
systemabout6%
pints.
c. Afterthe
system
has
been
filled,vent
and
make
afinalcheck
for watersoundness.
9. By-passvalve
adjustment
a. Fullyclosethe
by-pass
valve
and
then
open
it one full turn. Lighttheboilerwith the heating
circuitonlyinoperationand
balancetle system using
pump
and
radiator
valves
togive anl loCtemperature
drop
acrossthe
individual
radiators.
b. Adjustthe
by-pass
valve
as
necessary
togive atemperature
riseof9oCacross
the
boilerflowandreturn,i.e.measuredbefore
the
by-pass.
16.BOILER CONTROLS
(inner
case,
gas
valve
coverand
facia
panel
removed)
RefertoFig.18.
bas
/
servrce
cock
Pilot
burner
Prlot
throtlle
Inlet
pressure Burnerselting Eurnersetttng Boiler
lest
point pressure pressure Thermostat
adlustlngscrew test
polnt sw{tch
Fis.18
17.FINAL ASSEMBLYANDHANDING OVERTHE INSTALLATION
l Beforefitting the out€rcase,the
inhll panel(s) must
be
fitted
tothe side
of the
case.
If rearexitfluehas
beenused,
fit thetwo
panels,
if sideexitfluehasbeen
used
fit oneofthe
panels
tothesideoppositethe flue.Tofit an
infill panel,place it inposition
in thecasesideand s@urewith fourof theN0.8x 12
lg.screwssupplied withtheboiler.
2. Lift the outercas€
into
position
over
the
boiler
and
push
backtoengagethe
fixingpins
on
thechassisside
into
the
case.
Secure
thecase
inposition byretighteningthebottom
fixing screw.
3. If a
programmer
isfitted,setthe
clock
totheconecttime
(do
notrotate
thedialanti-clockwise)andthe
programme
andselector
switchestotherequiredsettings.SeeUser
instructions.
4. Hand
theUser
instructionstotheuserand
instructin the safe
operationof theboilerandcontrols.
5. Advise
theUser of the
precautions
necessary
toprevent
damagetothesystemandtothebuilding in tle event of thesystem
rem
ain
in
gi
noperativeduring frost
condi
l.ions.
6. AdvisetheUserthatforcontinuedefficientandsafeoperationoftheboileritisimportantthatadequateservicingiscarriedout
atleast onceayear
byaqualified serviceengineeror the
local
Gas
Region.
7. Leave apermanent
cardauachedtotheboiler
giving:
a. Nameand addressof installer.
b. Date of installation.
c. A wiring diagram
ofthe circuit-
Page
13

IIt. {\\T AL SER\-ICTNG
Ti r.oSUreconrinued efficientoperation
of theappliance, it isrecommendedthat
it ischeckedand
cleanedas
necessary
atregular
rrrt!-n
als.
The
frequency
of servicing
will dependuponthe
particular
Instellstisn
conditionsand
usage
but
ingeneral
once
per
year
shouldbe
adequate.
It isthe lawthatanyservice workmust
becarriedoutbyacompetent
person
such
as
British
GasorotherCorgi
registered
personnel.
Thefollowingaspectsof theboilerand
installation
shouldbeexamined,and
rectified
as
nec€ssary.
l. Run
theboilerandchecktheoperationof itscontrols,observetheflame
picture
andensurethattheboilerresponds
toany
switches
and
programmer.
2. Checkthe installation
of the
flueterminal
andensure
it isnotobstructed.
If it isnecessary
todismantletheboilerthe
followingchecksshouldbemade.
L Remove
thecombustion
fan
andensure
thatit iscleanand free
of debris.Checkthe
impellorforfreedom
of rotation.
2. Removethe
combustionchamber
frontandcheckif theburnerorheatexchangerrequires
cleaning.
3. Examinethemain
injector
orificeandensure
it isclearandundamaged.
4. If asufficientlylarge
pilot flame
cannotbeachieved
examine
the
pilotinjectororificetoensure
it isclearandundamaged.
5. Whenrefitting the
inner
casecheckthatthe
sealisin good
conditionandensurethat
it compresses
satisfrctorily.
Oncompletionof theserviceruntheboilerandensurethatit operates
satisfactorily.
The
boilerdata
plate
ispositioned
onthe
inner
caseatthebottom
righthand
corner.
WARNING: Before
commencing
worksettheboilerthermostat
switchtoO.Allow theboilertocooland
isolate
theelectricity
supply.Slideoff thebottomcoverandturnoff the
gas
supply
atthe
gas
service
cock.
IMPORTANT: Always
test
forgas
soundnessaftercompletinganyservicingofgas
carryingcomponentsandcarry
out
functional
checksofcontrols.
18.1
Dismantling
-see
Fig.19.
I. Slacken thescrewsecuring
thebottomoftheoutercaseand
pulloffthe
case.
Place
thecasesafelyasidetoavoid
possible
damage.
2. Remove theonescrew,
above
the
boilertherrnostatswitch,securingthe
wiringcentreand lower
the
wiringcentre.
3. If a
programmer
isfitted,
unplugthe
programmerplug
from
the
wiring
centreand
slide
outthe
programmer.
If aprogrammer isnotfitted,
slideoutthe
facia
panel.
4. Unscrewthefour
inner
case
fixingscrews,
twoatthetop,oneabovethe
gas
valve
andoneo the
leftofthe wiringcentre,and remove
the
inner
case.
5. Disconnect tle two
wiresfrom
the
fanmotor,
the
polarity
ofthese
wires
isnotimportanl
6. Remove thethreehex.hd.screws
and
washers
securingthefanmotor
assemblyto
thefanhousing
andcarefully
withdraw
the
motor
complete
withimpellorfromthe fanhousing.
7, Removethetwohex.hd.
screwssecuring
the
fluehood
coverand
remove
the
cover.
8. Slackenthe
two
nuts
securing
thefluehood
tothecombusrion
chamber.
9. Remove the
four
screwsand
wing
nut
secunngOrecombustion
chamber
front
cover
and
withdraw
the
cover.
10.
Undothesecuringnutand
remove
theelectrode,seeFig.19,from
the
pilot
assembly.
Remove
the
grommet
onthe
elecEode
leadfromthe
burner
air
guide.
Il. Remove
thescrewsecunngthe
gasvalve
cover
and
lift offthecover.
12.
Removetheclampingbracket
* hich
retains
the
pilot
supply
andelectrode
lead
atthebottomlefthand
corner
ofthechassis.
13.
Undothetubing
nuts
and
disconnect
the
pilot
supply,
see
Fig.19,from
boththe
pilot
assemblyand
gas
valve.
14.
Carefully
remove
and
reuinthe pilot
injector,
see
Fig.19.
15.From
underneaththebaseof thechassis
remove
thetwopoziscrewssecuringthe
burner
manifold.
16.
Carefully
move
the
pilot
supplytoonesideandlift outtheburnerassembly.Take
care
not
tolose
theburner
flange
'O' ring.
17.
Covertheexposed
gasway
inthebaseof thechassis.
lE.2
Cleaningtheboiler.
L Brush the
heat
exchanger
from
aboveand
belowusingasuitablebrush.Brush
backto
frontNOTsideways.Remove
any
fallen
deposits
fromtheboilerbase.
2. Examinethefanimpellorand
carefullyclean
if necessary.
3. Turntheburnerupsidedownandtap
gently
toremove anydebris.
4. Cleanthe
pilotburnerandspark
electrode
withafinewirebrushif necessary.
5. Unscrewthe
injectorfrom
theburner
manifold,
cleanbyblowingthroughorwashing.DoNOTcleartheinjectorwith
a
pin
or
wire.
Cleanthe
pilot
injectorinasimilarmanner.
Tocleanorreplace
the
pilot filter in the
gas
valve
refer
tosection20.Il.
3.Oto
4.omm
Fig.19
Page14

18.3Reassemble
the
boiler.
L Replace
theburner
injector
usingasmallamountof
jointing
compound.
Note:The
40Siinjr:ctor
usesasealingwasher.
2. Remove the
protective
covering
fromthe
gas
wayinthebaseof thechassis.
3. Checkthatthe
'O' ringisin position
in the
burner
flange.
4. Replace
the
burner
assembly
and
secure
withtwoscrews
previously
removed.
5. Replacethe
pilotinjector
and
reconnect
the
pilotsupply
tothe
pilotassembly
and
gas
valve.
6. Replace thespark
electrode.
Ensure
thatthe
grommet
ontheelecrode
leadishtted
tothebumerairguide. Checkthatthespark
gap
is3.0to
4.0mm,
see
Fig.19.
7. Replace theclampingbracket
-bottom
lefthand
cornerofthe chassis.
Enswethat
the
pilotsupplyandelectrode
lead
are
behind
theclamp.
8. Replace thecombustionchamber
front
ensuringthat
the
burnerstud
locatesinthe
bracket.Secure
withfourscrews
and
onewing
nuL
9. Fully tightenthe
nuts
securingthe
fluehood.
10.Replacethefluehood
cover
andsecurc
withtwoscrews
previously
removed.
Il. Replace
the
fanmotor
and
impellor
assemblyand
reconnect
the
fanwires
(the
polarity
of the wires
isnotimportant).
12.lf aprogrammer is fitted,
temporarily
reconnectit tothe wiringcentre.
13.
Refertothecommissioninginstructions,sectionl5.Lightthepilotandchecktheflame,testthepilotandmainburnersupplies
forgas
soundness,checkthe
main
burnersetting
pressure
and
replace
the
gas
valve
cover
and
inner
case.
14.Lift the outJer
case
into
position
over
theboi-lerand
push
back
toengagethe
fixingpins
on
thechassisside
into
the
case.
Secure
inposition
byretighteningthe
bottom
fixingscrew.
15.If a
programmer
isfitted,
setthe
clock
tothecorrecttime
(do
not
rotate
the
dialanti-clockwise)
and
the
programme
and
selector
switchestotheir
previous
sett"ings.
16.Replace
thebottomcover.
19.LIGHTING INSTRUCTIONS
Seesection
16for boilercontrols.
Withthe
gas
supplyon,electricity
supply
off and the
boiler
thermostatswitchsettoO:
l Turn
onthe
gas
and
electricity
suppliestotheboiler.
2. Setthe
programme
switchtoCONT,if aprogrammer isfitted
andcheckthatall system
controlsarecalling
for heat.
3. Set
the
boilerthermostatswitchtoHIGH. Theautomatic
ignition
sequence
will start.
Thefanwill start
andaftera
purge
period
ofabout
l0 secondsa
clickwill be
heard
indicating
that
thestart
gas
solenoid
has
opened,the
ignition
sparks
will alsobeheard.
The
pilot
will lightandafterasecond
orsc' the
main
gas
solenoid
will open
andthe
main
burner
will light.
Note:The
pilot
burner
isturnedoffeverytimethe main
burner
is
off.
Theignition
sequenceisautomatically
activatedwhen
the
boiler
thermostatrequires
heat
4. If aprogrammer isfitted,
ensurethatthe
clock
isset
tothe
correct
time
(do
not
rotate
thedial
anti-clockwise)
and
that
the
programme
andselcctor
s*'itches
are
s€t
totheir
previous
scttings.
20.REPLACEIIIENT
OFPARTS
WARNING: Before commencing
*ork set theboilerthermostatswitchto
O.Allowtheboilertocool
and
isolate
theelectricity
supply.Slide
off the bottom
coverand
turnoffthe
gas
supply
at
the
gas
service
cock.
IMPORTANT:Al*a; stestfor
gas
soundnessaftercompleting
any
exchange
ofgas carrying
componentsandcarryout
functional
checksofcontrols.
20.1Toreplace
the
spark
electrode
-see
Fig.
19.
l. Remove freouterand
inner
casesasdescribed
insection 18.1,
paras
I o 4.
2. Disconnect
tlreelectrode
leadfrom
the
ignition
circuitboard.
Seesection
20.6.
3. Withdra* tlre electrode
leadthroughthe
circuit
board
mounting
boxandtheclampingbracket
(bouom
lefthand
corner
ofthe
chassis).
4. Undo thesecuring
nut
and
remove
theelectrode
from
the
pilot
assembly.
5. Insert anew electrodeand
securewithnut. Passthe
elecrode
lead
behindtheclampingbracket
(bottom
lefthand
cornerofthe
chassis),
through
thesideof the circuitboardmounting boxandconnect
it tothe
circuitboard.
Ensure
thatthe
large
grommet
isfittedtothe burner
airguide andthesmall
grommet
isfittedin thesideof the
circuit
board
mountingbox.
6. Replaceany
winngconnectorsremovedfromthe
circuitboard and
replace
the
circuitboardmounting
plate.
7. Remove thetwoscrewssecuringthe
pilot
shield.
Liftoffthe
pilot
shield
andcheckthatthe
spark
gap
is
3.0to
4.0mm
as
shown
in
Fig.
19.
8. Replace the
pilot
shield
and
secure
with
two
screws.
9. Replace the
inner
case,
programmer
orfacia
panel
,wiring
centre
andoutercase.
10.Refer
tothelightrng
instructions,
section
19.Light
theboiler
and
replace
the
bottom
cover.
Page15

l0.l Toreplecethe
pilotinjector
- see
Fig.19.
I R-,.mov€the
outer
and
inner
casesasdescribed
insection
18.1,
paras
I to4.
l. Removethescrewsecuring
the
gas
valvecover
and
lift off thecover.
3. Remove
theclampingbracket
whichrecains
the
pilotsupplyandelectrode
lead
atthebotmmleft hand cornerof thechassis.
4. Undothetubing nuts
anddisconnect
the
pilotsupply,
see
Fig. 19,fromboth
the
pilotassemblyand
gas
valve.
5. Removethe
pilot injectorfromthe pilotassembly,
seeFig. 19.
6. Fitanewinjecor and
reconnect
the
pilot supply.
7. Replace the
clamping
bracket
-bottom
lefthand
cornerofthechassis.
Ensurethatthe
pilotsupply
andelectrode
lead
are
behind
theclamp.
8. Refer to
the
commissioning
instructions,
section
15.Light
the
pilot
and
checkthe
flame,
testthe
pilot
supply
for
gas
soundness,
replace
the
gas
valve
cover,inner
case,
programmer
orfacia
panel
and
wiring
centre.
9. Replacetheoutercase.
10.Refer
tothe
lightinginstructions,
section
19.
Lightthe
boiler
and
replace
thebottom
cover.
20.3Toreplace the
pilotburner-see
Fig.l9.
l. Removetheouter
and
inner
casesasdescribed
insection
18.1,
paras
I o 4.
2. Remove
thescrewsecuringthe
gas
valve
cover
and
lift off thecover.
3. Remove theclampingbracketwhich
retains
the
pilotsupplyandelecrodelead
atthebottomleft hand corner
of thechassis.
4. Undothesecuring nutandremovetheelecrode fromthe
pilotassembly.
5. Undothetubing
nuts
anddisconnect
the
pilotsupply,see
Fig.19,
fromboththe
pilotassemblyand gas
valve.
6. Removethe
pilot injector
fromthe
pilotassembly,see
Fig. 19.
7. Remove the
twoscrews
securingthe
pilot shieldand
lift off the
pilot shield.
8. Removetheremainingscrew securingthe
pilotburnerand
remove
the
pilotburner.
9. Fitanew
pilotburnerandsecure
withtwoscrews.Replace
tlre
pilotinjector, pilotsupply
andspark
electrode.
Checkthatthe
spark
gap
is3.0
to
4.0mm
as
showninFig.19.
10.Removethe
uppermost
screw
securingthe
pilotburnerand
replace
the
pilot shield
securing
it with twoscrews.
Il. Replacethe
clampingbracket
-boaom
lefthand corner
ofthe chassis.
Ensure
thatthe
pilotsupplyandelectrode
lead
arebehind
theclamp.
12.Refer
tothe commissioning
instructions,
section
15.
Lightthe
pilotandcheck
theflame,testthe
pilotsupply
forgas
soundness,
replace
the
gas
valve
cover,inner
case,
programmer
or facia
panel
and
wiringcentre.
13.
Replace
the
outer
case.
14.Refer
tothelightinginsrucdons,section19.Light theboiler
andreplace
thebottom
cover.
20.4Toreplace
theburner.
Note:
The
burnerfittedmaybeeitherFurigas
(silver)
or Bray(blue)
either
may
be
usedasareplacement for theother.
L Remove
theouter
andinner
casesasdescribed
insection
18.1,
paras
I to 4.
2. Removethe
burner
as
described
insection 18.1,
paras
8to17,
3. Removethe
pilotassemblyand
main
bumer
injector
and
fit tothe
new
burner.Useasmall
amountofjointing
compound
on
the
burner
injector.Note:The40Siinjector
usesasealingwasher.
4. Usinganew'O' ringin theburner manifoldflangefit tlreburnerand reassemble
asdescribedin section18.3,
paras
2to9.
5. Ifaprogrammerisfitted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginstructions,section l5.Light
the
pilotand
check
the
flame,
testthe
pilotandmainburnersupplies
forgas
soundness
and
replace
gas
valve
cover,inner
case,
prognrmmer
orfacia
panelandwiringcentre.
6. Replacethe outer
caseand
bottom
cover.
20.5Toreplace
the'Hi' or 'Lo' thermostats.
Three
thermostatsare
mountedontherighthand
(flow)
pipe
fromthe heat
exchanger.
The'Hi' thermostat ismarked
with
brown
paint,
the
'Lo' thermostat
withwhite
paint
and
the
overheat
cut-offdevice
with grey
paint.
I. Removethe
outerand
innercasesas
described
insection
18.
I,paras I o 4.
2. Disconnect
thetwowiresfromthethermostal
3. Unscrewthe
fixingscrewsand remove
the
thermostal
4. Ensure
thatthe
mounting
plate
isclean, fit thenew
thermostat
andsecureinposition.
5. Reconnect thetwowires.The
polarity
ofthese wiresisnotimportant.Ensure
that
thetwogrey
* irt's go
tothe overheatcut-off
device,
a
brownand
yellow
wire
tothe
'Hi' thermostatandawhite
and
yellowwire
tothe
'Lo' the
rmostat.
See
wiringdiagram
page
20.
6. Replace
the
inner
qrse,
programmer
orfacia
panel
,wiringcentre and
outer
case.
7
. Refer tothe
lightinginstructions,
section19.
Light
theboilerandallowit toheat
up.Check
rharthe
'Hi' thermostatswitches
the
boiler
offandon
when
theboilerthermostatswitch
issettoHIGH.SettheboilerthermosrarswitchtoLOW andcheckthat
the'Lo' thermostat switchesthe
boiler
off andon.
8. Replace
thebottom
cover.
Page16

20.6
Toreplace
the
ignition
circuitboard
'seeFig.
20.
Theignition
circuit boardispositionedon theside
of thewiring centre
behind
the
facia
panel
or programmer.
l. Remove
thescrew
securing
thefrontof thewiring centre
and
lowerthe
wiringcentre.
2. If aprogrammer
is fitted,unplug
theprogrammer
plugfromthewiring
centre
and
slide
outthe
programmer.
If a
programmer
isnot
fitted,slide
out
the
facia
panel.
3. Fromunderneath
the
ignition
circuit
board
mounting
plate
slacken
the
one
screw
securing
itatthe
back.
Remove
tftetwoscrews
securing
itat the
front
and
carefully
lowerthe
mounting
plate
withdrawing
it fonvards
slightly
to
disengage
the
rear
fixing.
4. Disconnect
the
wiringconnector
fromthe
front,
the
elecnode
lead
and
the
twowiringconnectors
fromthe
rearof thecircuitboard,
see
Fig' 20'
5. Carefully
removethe
circuit
board
fromthe
mounting
pillan and
replace
withanew
one.
Reassemble
inreverseorder.
6.
7. Refertothe
lightinginstructions,
section
19.Lightthe
boilerand
replace
thebottom
cover.
20,7
Toreplace
the
gas
valve
'see
Fig.2l.
Ensure
thatthe
gas
suPPlY
is
off.
l. Remove
theouter
andinnercases
asdescribed
in section
18.1,
paras
I to
4.
2. Removethescrew
securing
the
gasvalvecoverand
lift off
the
cover.
3. Disconnect
thepush-on
terminals
andunscrew
tle earth
terminal
fromthe
gasvalve.
(The
polarity
of these
wiresis
not
importantbut
the
redandblue
wires
must
go
o the
inlet
(pilot)solenoid and
thewhite
and
blrck wiresto the
outlet
(main)
solenoid).
See
wiringdiagram,
page20.
4. Remove
tlre
ignition
circuit
board
mounting
plate
asdescribed
in section
20.6.
5.
6.
7.
8.
9.
10.
Mounting
plate
oox
Fan,
pressure
Fig.20
@@
Fig.21
Remove
theone
screw
securing
the
mountingplatebox
to
the -
side
ofthe
wiring
centre
anO
wittrOraw
ne box.
Thescrew
is
accessible
from
beneath
thebox.
Note:When
refittingthebox
make
sure
that
the
'tag;
atthe
rearoftheboxislocated
inthe
cut
out
on
the
side
ofthe
wiringcentre
before
replacing
the
fixingscrew'
Remove
the
clamping
bracket
whichretains
the
pilot
supply
andelectrode
lead
at
the
bottom
lefthandcorner
ofthe
chassis.
Disconnect
the
pilor
supply
from
both
the
gasvalve
and
pilot
assembly.
Takecare
nottolose
the
pilotinjector,
see
Fig.l9'
Remove
the
eight
3 mmsocketscrews
securing
the
gasvalve
(fourtothe
service
cock
and
fourtotheburner
manifold)'
Withdraw
the
gasvalveanddiscard
the
'O' rings
inthe service
cock
and
burner
manifold
flanges.
Using
new
,O'rings
in
the
service
cockand
burner
manifold
flanges
(both
'O'ringsare
thesame
size)
reassemble
the
new
valve
tothe
boiler
inreverse
order.
Ensurethat
the
pilot
supply
andelectrode
lead
are
behind
theclamp
in
the
bottom
left
hand
corner
ofthe
chassis.
Donot
replacethe
gasvalvecover
at
thisstage.
ll. Ifaprogrammerisf,itted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginstruclions,section
l5.Light
ttre
pitoi
anO
check
theflame,iestthepilotsupply
connections
and
gasvalveinletandoutletconnections
forgas
soundness,check
the
burner
setring
pressure,replacethe
gas
valve
cover,
inner
case,
programmer
or facia
paneland
wiringcentre.
12.Replace
the
outer
caseand
bottom
cover.
20.E
Toreplace
theburnerinjector.
l. Remove
the
outerand
innercases
asdescribed
insection
18.1,
parasI to
4.
2. Remove
theburnerassembly
asdescribed
insection
18.1,
paras
8toU'
3. Unscrew
tlre
injector
fromthe
manifold.
4. Screw
inareplacement
injector
using
asmall
amount
ofjointing
compound.
Note:The
40Siinlcctoruse
sasealing
washer.
5. Replace
the
burnerassembly
asdescribed
insection
18.3,
paras2 to9'
6. Ifaprogrammerisfitted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginsfictions,sectionl5.Light
the
boiler,
testthe
pilot
and
main
burnersupplies
forgas soundness
and
replacethe
gasvalve
cover,
inner
case,
progfammer
orfacia
panel
and
wiring
centre.
7. Replace
the
outercaseand
botlom
cover'
Page
17

20.9
Toreplace
agas
valve
solenoid
-see
Fig.22.
l. Remove
the
screw
securing
the
gas
valve
coverand
lift off the
cover.
2. Disconnectthe
push-on
terminalsandunscrew
the
earth
terminal
from
the
gas
valve.
(fhe polarity
of thesewiresisnotimportant
butthered
andbluewires
must
go
totheinlet
(pilot)solenoid
andthewhite
andblackwires
tothe
outlet
(main)
solenoid).
Seewiringdiagram,
page20.
3. Carefully
prise
outthe
retaining
clipfrombehindthesolenoid
and
lift off the
solenoidanditsmounting
bracket,
seeFig.22.
4. Position
the
new
solenoid
into
themounting
bracketand
reassemble
inreverse
order.
5. Refer
tothe
lighting
instructions,
section
19.Lighttheboiler
andreplace
the
bottom
cover.
20.10
Toreplace
the
pump
oyerrun
thermostat
-seeFig.
23.
The
pump
overrun
thermostatis
situatedattbe bottomrighthand
cornerofthe
chassis
above
thewiring centre.
l. Remove
the
outerand
inner
cases
as
describedin section
18.1,
I to4.
2. Remove
the
ignition
controlboxas
described
in section20.6.
3. Remove
the
one
screw
securingthe
pump
overrunthermostatmounting
bracketsituated
next
tothe wiring
centreunderneath
tlrechassis.
Carefullywithdraw
the
bracket
complete
withthermostaL
4. Disconnect
thethreewiresand
remove
the
two screws
securingthethermostat
to the
brackeL
5. Fit the new
thermostat
tothemounting
bracket
andsecurewithtwoscrews.
6. Connect
thethreewires
tothe
thermostat,
see
Fig.23 andreassemble
inreverse
order.
7. Refer
n thelightinginstructions,
section19.Light theboilerand
replace
thebottom
cover.
8. Allow theboilertoheat
up
fully then
switchit off atthe
programmer
orextemal
conrrolsand
check
thatthe
pump
continues
ro
runfor5to15minutes.
20.11Toreplace
thepilotfilter -seeFig.24.
Note:It isextremelyunlikely
thatthe
pilot
filter*ill become
blocked.If the pilot
injector
and
pilot
supplyare
clear
and
the
filteris
stillsuspect
proceed
as
follows:
Ensure
thatthe
gas
supply
is
off.
l. Remove
the
gas
valve
asdescribedinsection20.7.
2. Remove
the
fivescrewssecuring
the
rear
cover
plate
and
carefully
remove
it,seeFig.
24.Discard
the
gasker
3. Carefully remove
ttre
pilot filter,seeFig.24 andreplacewithanewone.
4. Replace
the
rear
cover
usinganewgasket
andsecure
by evenly
tighteningthefive
screws.
5. Replace
the
gas
valve
inreverse
order
to
section20.7,
butdo
not
replace
the
gas
valve
coverorthe
inner
and
outercases.
6. Turn onthe
gas
supply
andtestthe
servibecocktogas
valvejointforgas
soundness
using
asuitable
leak
detecting
fluid.
7. Refer
tothe
commissioning
instructions,
section15.Light
the
pilot
andcheck
treflame and
rcsrric pilot
supply
connections
forgas
soundness.
8. If aprogrammer
is fittedtemporarilyreconnectit tothewiringce
nrre.
9. Apply
a
suitableleak
detectingfluid
around
the
gas
valve
rearco','er
and$c'
lasvalve
outlet
connection.Refer
to
the
lighting
instructions,
section
l9 andlightthemain
burner.
Test
the
gasvalve
rL-ar
cover
andoutletconneclion
for
gas
soundness.
10.
Refer
tothecommissioninginstructions,
sectionl5 and replace
the
gasvalve
cover,
innercase,
prcgrammer
orfacia
panet
and
wiring
centre.
11.Replacetheoutercase
and
bottomcover.
20.l2To replace
theprogrammer(if fitted).
L Removethe
screw
securing
the
front
of the
wiringcenuc
and
carefully
lower
iL
2. Unplugthe
programmer
plug
from
the
wiring
centre.
3. Slideoutthe
programmer
fromthecontrol
box.
4. Slidethe
new
progmmmer
inlothe
controlbox,and
push
fully home.
5. Connect
the
programmer
plugtothe
wiringcentre,
closethe
wiringcenreand
securein posiuon
withthefixing screw.
6. Refermthe
lighting
instructions,section
19.Light
theboiler
andcheck
thecontrols.
7. Set the
programmer
clocko thecorrecttime
and
the
switchestotheir
previous
settings.
8. Replace thebottom
cover.
Page I8
Mounting
bracket
Fig.22
Brown
lead
(3)
Yellow
lead
(2) overrun
thermostat
Fig.23
I-ig.24

20.13
Toreplace
theairflow
pressure
switch.
The
air flowpressure
switch
is
situatedatthetopright hand
cornerofthechassistothe right ofthefan.
l. Removetheouter
andinner
casesas
described
insection
18.1,
paras
I to 4.
2. Carefully disconnectthe
flexible
tube
from
the
pressure
switchand
disconnect
thethree
wires
,notingtheir
position.
3. Removethe
twoscrewssecuringthe
pressure
switch
mountirig
brackettothe
fluehood.Note:There
aretwofibrewashers
on
these
screwstoinsulate the
pressure
switchfromthe
fluehood.
4. Using
a
new
pressure
switch
(supplied
withmountingbracket)securethemounting
brackettothe
fluehood.Ensure
thatthetwo
fibrewashers areused.
5. Reconnectthe
wires
tothe
pressure
switch.
See
wiring
diagram
page
20.
6. Reconnectthe
flexible
tubeand
reassemble
inreverseordcr.
7
. Referto the
lightinginstructions,section
19.Light
theboiler
andcheck
thatthe
pressure
switch
allows
the
mainburnertolight.
8. Replace thebottomcover.
2A,MToreplacethe
fan
motorand
impellor
assembly.
l. Remove
theouter
case,
inner
case
and
thefan
motor
and
impellor
assemblyas
describedinsection I8.1
,
paras
I to6.
2. Reassembleinreverseordcrusingthe
newassembly.
3. Refertothe
lightinginstructions,section19.Light
theboilerandcheckthatthe
fan
switchesonandoff
as
themain
burnercycles
onandoffrespectrvely.
4. Replace
thebottomcover.
20.15
Toreplace
thecombustionchamber
insulation.
l. Removetheouterand
innc'rcases
as
described
insection18.1,
paras
I to
4.
2. Removethebumerasdcscribed
in
section18.1,
paras
8to17.
3. Removethetwonurssccuring
the
fluehoodto
thecombustionchamberanddisengagethetie
rods.
4. Remove
the
fourscrc*s
(two
eachside)
securing
thecombustionchamber
fothe chassis.Carefully
lower
thecombustion
chamber
toclear
the
heat
exchanger
and
remove.
5. Slide
out$e frontrnsulation
panel
andcarefully
replace
with
anew one.
6. Slide
out
the
tuo side
panels
and
remove
the
rear
panel
bypulling forwards
atthetopthen
lifting
out
7. Fitane*'
panel,
lower
edge
firstand
push
back
into
position.
Slide
intwonew
side
panels.
8. Reassemblein
reverse
order.
Ensure
thatthe
pilot
supplyandelectrode
lead
are
behindtheclamp
at
thebottom
lefthand
corner
ofthechassrs.
9. Ifaprogrammerisfitted,temporarilyreconnectittotlewiringcentre.Refertothecommissioninginstructions,sectionl5.Light
theboiler,
test
the
pilot
and
main
burner
suppliesfor
gas
soundnessand
replace
the
gas
valve
cover,
inner
case,
progmmmer
10.or
facia
panel
and
wiring
centre.mcover.
10.Replacetheouter
case
and
bottom
cover.
20.16
Toreplacetheheat
exchanger.
Ensurethatthesystem
is
drained.
Take
care
when
removing
the
heatexchanger
as
even
with
the
system
drained
therewill
stillbe
waterin
theheatexchanger
anditsconnecting
pipes.
L Removetheouterand
inner
cases
as
describedinsection
18.I
,paras
I to
4.
2. Removetheburnerasdescribedinsection18.1,
paras
8to17.
3. Remove
the
two
nutssecuring
thefluehood
ulthe
combustionchamber
anddisengagethetierods.
4. Remove thefourscrews
(two
eachside)securing
ftecombustionchamber.Carefullylower
thecombustionchamber
to
clear
the
heatexchanger
and
remove.
5. Undo
the
littings
securing
the
inlet
and
outlet
pipes
totheheatexchanger
and
carefully
lower
the
heat
exchangerro
disengage
it fromthe
pipes.
6. Reassemble
inreverseorderusing
a
new
heat
exchanger.Ensure
thatthe
pilot
supply
andelectrodeleadare
behrndrhe
clamp
at
the
bouomleft
hand
cornerofthechassis.
7. Fill and
vent
thesystem.
8. Ifaprogrammerisfitted,temporarilyreconnectittothewiringcenue.Refertothecommissioninginstructions,secLron
l5.Light
tle boiler,testthe
pilot
and
main
burnersuppliesfor
gas
soundness
and
replace
the
gas
valve
cover,innercase,
programmer
orfacia
panel
and
wiring
centre.
9. Replace
the
ourcr
caseandbottom
cover.
Page
19

21.
WIRING DIAGRAMS
a. Illustratedwiring diagram
withApollo
programmer.
FanMotor
v
c0t0uR
c00E
b- blue
bk- black
br - brown
g- green
gy
- grey
0- orange
ilOTE:
pk
- pink
p- purple
Y
- violet
r-red
w - white
y - yellow
g/y- green
and
yellow
M",^,
{
Boiler
Terminal
Block
6-waySocket
forApollo
Programmer
> '( ,,',{" L't
'Hi Thermostat br
Overheat gY
cut ofl devtce
'Lo'Thermostat
lf the Apollo
prog,ammer
isnot
litted,remove
linkHWlo 0t{ andconnecla
swilchedlive
toterminal
0l{.
BemovelinkHWto Oil when
fittingerternalcontrols.lf anApollo
programmer
is
finedterminal
CHOFF
islive
whenHOT
WATER
isselected.
gv
Pumpoverrun
Thermostat
jarthrng Screw
Pumn
{L
Earthin
Stud High
o
Low
3-way
Switch
Apollo
Programmer 6-w plug I
I
I
I
I
I
I
J
I >LVV
Ir
b,-,i
t
l'
4
f..u'l ( lc
Once
Twice
Cont
lr*
I ott
I Hw&cH
L-
3-way
Switch
MNI
+ lgnition i
' Crrcu,t F
? Board F
NH
L HL
Suppressor
Page20
| $t.a *l -- i . -c l, L-\vL
3-r/aySwrtch Clock