Ideal Heating LOGIC+ COMBI C35 Installation & Servicing Download

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Installation and Servicing

CONTENTS

1 GENERAL .................................................................... 8

1.1

Introduction

.................................................................. 8

1.2

Operation

..................................................................... 8

1.3

Safe Handling

............................................................... 8

1.4

Optional Extra Kits

....................................................... 8

1.5 Safety ........................................................................... 9

1.6

Safe Handling Of Substances

...................................... 9

1.7

Location Of Boiler

........................................................ 9

1.8

Gas Supply

................................................................... 9

1.9

Flue Installation

.......................................................... 10

1.10 Terminal

...................................................................... 11

1.11 Air Supply

................................................................... 11

1.12 Water Circulation System

........................................... 11

1.13 Boiler Control Interlocks

............................................. 11

1.14 Electrical Supply

......................................................... 11

1.15 Condensate Drain

..................................................... 11

1.16 Boiler Dimensions, Services &

Clearances - Internal

.................................................. 12

1.17 Boiler Dimensions, Services &

Clearances - External

................................................. 13

1.18 System Requirements - Central Heating

.................... 14

1.19 System Balancing

...................................................... 15

1.20 Water Treatment

......................................................... 15

2 INSTALLATION ......................................................... 16

2.1

Internal Boiler Assembly - Exploded View

.................. 16

2.2

External Boiler Assembly - Exploded View

................ 17

2.3

Unpacking - Internal Boiler

......................................... 18

2.4

Unpacking - External Boiler

........................................ 18

2.5

Front Panel Removal

................................................. 19

2.6

Wall Mounting Template

............................................. 19

2.7

Preparing The Wall

..................................................... 19

2.8

Fitting The Wall Mounting Bracket - Internal Boiler

.... 20

2.9

Mounting The Boiler - Internal

.................................... 20

2.10 Fitting The Wall Mounting Bracket - External Boiler

... 20

2.11 Mounting The Boiler - External

................................... 21

2.12 Attaching Weather Shield

.......................................... 22

2.13 Determining The Flue Length And

Flue Packs Required

................................................. 23

2.14 Cutting & Setting The Flue Length

............................. 24

2.15 Installing The Flue (Internal Boiler)

............................ 24

2.16 Fitting The Optional Roof Flue Kit

.............................. 25

2.17 Assembling The Roof Flue Kit

.................................... 26

2.18 Condensate Drain

...................................................... 27

2.19 Connections & Filling

................................................. 28

2.20 Electrical Connections

................................................ 29

2.21 Installer Wiring

........................................................... 29

2.22 Replacing Pre-Fitted Mains Cable

............................. 30

2.23 Wiring Diagram

.......................................................... 31

2.24 Commissioning And Testing

....................................... 32

2.25 Initial Lighting

............................................................. 33

2.26 The Display

................................................................ 34

2.27 General Checks

......................................................... 38

2.28 Restart Procedure

...................................................... 39

2.29 Handing Over

............................................................. 39

3 SERVICING ............................................................... 40

3.1

Servicing Schedule

.................................................... 40

3.2

Boiler Front Panel Removal / Replacement

............... 41

3.3

Weather Shield Removal / Replacement

................... 41

3.4

Fan And Venturi Assembly Removal And Cleaning

.... 42

3.5

Burner Removal And Cleaning

................................... 43

3.6

Cleaning The Condensate Trap/Siphon

..................... 43

3.7

Cleaning The Heat Exchanger

................................... 44

3.8

Reassembly

............................................................... 44

3.9

Replacement Of Components

.................................... 45

3.10 Fan Replacement

....................................................... 45

3.11 Burner Injector Replacement

..................................... 46

3.12 Burner Replacement

.................................................. 46

3.13 Return Thermistor Replacement

................................ 47

3.14 Ignition Electrode Replacement

................................. 47

3.15 Flame Detection Electrode Replacement

................... 48

3.16 Spark Generator Replacement

.................................. 48

3.17 Gas Control Valve Replacement

................................ 48

3.18 Diverter Valve Actuator Replacement

........................ 49

3.19 Condensate Trap / Siphon Replacement

................... 49

3.20 PCB Replacement

...................................................... 50

3.21 DHW Flow Turbine Sensor Replacement

.................. 51

3.22 Draining The Boiler

.................................................... 51

3.23 Pressure Gauge Replacement

................................... 51

3.24 Safety Relief Valve Replacement

............................... 52

3.25 Pump Automatic Air Vent Replacement

..................... 52

3.26 DHW Filter & DHW Flow Regulator

Cleaning / Replacement

............................................. 52

3.27 Diverter Valve Body Assembly Replacement

............. 53

3.28 DHW Plate Heat Exch. Replacement

......................... 53

3.29 Pump Head Replacement

.......................................... 53

3.30 CH Water Pressure Switch Replacement

.................. 54

3.31 Flow Thermistor Replacement

................................... 54

3.32 Heat Engine Replacement

......................................... 55

3.33 Expansion Vessel Recharging & Replacement

.......... 56

FAULT FINDING ........................................................ 57

4.1

Fault Finding Chart Main Menu

.................................. 57

4.2

Overheat Lockout

....................................................... 59

4.3

Ignition Lockout

.......................................................... 59

4.4

Flame On Before Gas Valve On

................................. 60

4.5

Low Water Pressure

................................................... 60

4.6

Flame Loss

................................................................. 60

4.7

Fan Fault

.................................................................... 61

4.8

Flow Thermistor Fault

............................................... 61

4.9

Return Thermistor Fault

............................................. 61

4.10 Outside Sensor Fault

................................................. 62

4.11 No CH Operation But DHW Works OK

...................... 63

4.12 No HW But CH On

..................................................... 64

4.13 No Display

.................................................................. 64

SPARE PARTS .......................................................... 65

COMMISSIONING & SERVICING ............................ 67

Summary of Contents for LOGIC+ COMBI C35

Page 1: ...hat you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Hunt Heating November 2020 UIN 225325 A03 INSTALLATION SERVICING LOGIC COMBI C35 H E A T I N G ...

Page 2: ...2 Installation and Servicing ...

Page 3: ...PLEASE RING THE HUNT HEATING INSTALLER HELPLINE 1300 00 1800 NOTE BOILER RESTART PROCEDURE Press the RESTART button The boiler will repeat the ignition sequence if a heat demand is present NOTES FOR THE INSTALLER Relevant Installation changes implemented in this book from Mod Level A01 Aug 20 to A02 Nov 20 Table 1 General Data Updated figures ...

Page 4: ...2 27 General Checks 38 2 28 Restart Procedure 39 2 29 Handing Over 39 3 SERVICING 40 3 1 Servicing Schedule 40 3 2 Boiler Front Panel Removal Replacement 41 3 3 Weather Shield Removal Replacement 41 3 4 Fan And Venturi Assembly Removal And Cleaning 42 3 5 Burner Removal And Cleaning 43 3 6 Cleaning The Condensate Trap Siphon 43 3 7 Cleaning The Heat Exchanger 44 3 8 Reassembly 44 3 9 Replacement O...

Page 5: ...ic Hot Water Inlet Pressure kPa 130 Minimum DHW Inlet Pressure to operate at 60kPa system pressure 50kPa Electrical Supply 230 V 50 Hz Power Consumption W 114 Fuse Rating External 3A Internal T4A HRC L250V Water Content Central Heating litre 1 2 Domestic Hot Water litre 0 5 Packaged Weight Internal Boiler kg 34 2 Packaged Weight External Boiler kg 50 0 Maximum Installation Weight Internal Boiler k...

Page 6: ... which in this case are concentric The fan is up stream of the combustion chamber The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Boiler 35 Min Max Boiler Input Q Net CV kW Gross CV kW 7 1 24 3 7 9 27 0 Boiler output non condensing Mean 70 C kW 7 1 24 2 B...

Page 7: ...re n a Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer 15 Hot water mode Heat input to be calculated Max operating burner pressure n a Max operating water pressure measure record Cold water inlet temp measure record Hot water outlet temp measure record Water flow rate at max setting measure record For condensing...

Page 8: ...y occurs if the PREHEAT button is pressed and the display reads HOT WATER PREHEAT ON When there is a demand for CH the heating system is supplied at the selected temperature of between 30o C and 80o C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw off of 14 5 l min at 35ºC temperature rise The ...

Page 9: ...ANCES ARE UNSUITABLE FOR USE AS A POOL HEATER 1 6 SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture 1 7 LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler bracket supplied with the unit must be used as standard but...

Page 10: ...above a balcony or other surface 300 300 c From a return wall or external corner 500 300 d From a gas meter M see Note 3 1 000 1 000 e From an electricity meter or fuse box P see Note 3 500 500 f From a drain pipe or soil pipe 150 75 g Horizontally from any building structure or obstruction facing a terminal 500 500 h From any other flue terminal cowl or combustion air intake 500 300 j Horizontall...

Page 11: ...bypass valve to ensure a flow of water should all valves be in the closed position 1 14 ELECTRICAL SUPPLY WARNING Electrical safety of the appliance is reached only when it is correctly connected to an efficient earthing system as specified by current safety standards Attention Hunt Heating declines any responsibility for damage or physical injury caused by failure to connect the boiler to an effi...

Page 12: ...o Section 2 19 The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Bottom ...

Page 13: ... INLET DHW INLET CH RETURN PRV 902 425 312 450 625 100 100 100 150 1 17 BOILER DIMENSIONS SERVICES CLEARANCES EXTERNAL The boiler connections are made on the boiler connection tails Refer to Section 2 19 The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions all dimensions in mm ...

Page 14: ...ing After installation of an Autofill valve and required backflow prevention the system may be filled by the following method i Thoroughly flush out the whole system with cold water ii Fill and vent the system until the pressure gauge registers 150kPa and examine for leaks iii Check the operation of the safety valve by raising the water pressure until the valve lifts This should occur within 30kPa...

Page 15: ...ystem any unsuitable additives MUST be removed by thorough cleansing 3 In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted 4 Under no circumstances should the boiler be fired before the system has been thoroughly flushed For further information contact Hunt Heating SYSTEM REQUIREMENTS CONT Domestic Hot Water 1 The DHW...

Page 16: ...pe Gas Injector 211 Injector Assy 214 Venturi 215 Fan 217 Burner 218 Gasket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Condensate Internal 229 Siphon Trap 231 Condensate Outlet Connection 302 PCB 304 Control Thermistor Return 306 Electrode Ignition 307 Electrode Detection 308 Ignitor Unit 309 Thermistor Flow 313 Ignition Lead 32...

Page 17: ...et 240 Flue Terminal 241 Flue Terminal Seal 242 External Flue Terminal Aperture Seal 501 Internal Boiler Accessory Pack 501 External Boiler Accessory Pack 520 Wall Mounting Bracket Assembly 521 Wall Mounting Bracket Seal Kit 522 Front Removable Panel 523 Securing Bracket Kit 524 Front Panel Assembly 605 PRV Compression Coupler 240 522 241 242 523 524 239 521 520 605 501 501 ...

Page 18: ...r D Wall Mounting Plate E Installation User Instructions F Wall Mounting Template located on internal protective packaging Pack Contents A Boiler B Hardware Pack includes flue installation instructions PRV Compression Coupler other fixings C Wall Mounting Template D Weather Shield E Wall Mounting Bracket C A D F E B A B C D E Unpack and check the contents Unpack and check the contents ...

Page 19: ...IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic plu...

Page 20: ...top slot and the mounting bracket is level esp9496 Example of fixing 2 9 MOUNTING THE BOILER INTERNAL 2 10 FITTING THE WALL MOUNTING BRACKET EXTERNAL BOILER 1 Align the template on the wall ensuring adequate clearances are met as defined in Section 1 and level and mark the 6 holes 2 Drill the 6 holes with the appropriate masonry drill size required for the masonry plugs used 3 Insert all 6 masonry...

Page 21: ...gs are rmoved from both the CH and DHW connections before mounting the boiler Note Boiler may contain residual water 3 Lift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs Note Install service connections at this point 1 3 Ensure the flue turret is perpendicular to the front of the boiler ...

Page 22: ...rifice 3 Fit external black flue seal ensuring the inside of the outer lip is in contact with the terminal lip 4 Apply water to the flue turret seals and place the flue through the orifice ensuring full insertion and the external seal is flush to the case 5 Attach the two securing tabs on the bottom of the appliance with the screws provided 6 Fit the front removable panel and secure with the retai...

Page 23: ...copic Flue B Pack 600mm long contains Flue turret telescopic flue incorporating a terminal and rubber wall seals Telescopic Flue B Pack 1000mm long B Pack contains Flue turret telescopic flue incorporating a terminal and rubber wall seals Note If B packs are used on their own then they MUST be fitted horizontally as the flue inside is designed to slope 1 5 degrees When extensions are used the flue...

Page 24: ...of outer flue Pull apart flue until desired length is achieved ENSURE THE STOP MARK IS NOT VISIBLE IF IT IS THE FLUE IS TOO SHORT AND SHOULD NOT BE USED 3 Check that both flue seams are at the top and the outlet terminal is uppermost 4 Drill a 3 5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue as shown Take care not to pierce the inner plastic f...

Page 25: ...pliance using securing screw 6 Ensure all sample points are accessible and all sample plugs and caps are fitted Retaining screw Clamp Lugs Sample points Flue Outlet C A A Duct Assembly B Flue Turret C Turret Clamp D Seal Flue Outlet D B Note A flat or pitched roof flashing plate not supplied is required before proceeding with the installation of this kit This kit is suitable for both flat and pitc...

Page 26: ...the instructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw 5 Push extension duct if required supplied separately into verti...

Page 27: ...ough the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External unheated pipework should be kept to a minimum and insulated with Class O waterproof pipe insulation g All installations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams BS6798 h Pipework must be installed so that...

Page 28: ... is correctly located 2 Fit the DHW outlet pipe tail to DHW outlet connection ensuring the seal is correctly located 3 Fit the filling assembly between the DHW inlet valve and the CH return valve GAS CONNECTION IMPORTANT The gas service cock is sealed with a non metallic fibre washer which must not be overheated when making capillary connections Refer to Section 1 16 1 17 for details of the positi...

Page 29: ...s pre fitted with a mains cable and plug This must be connected to a permanent live supply and NOT switched by thermostats programmers If the supply cord is damaged it must be replaced by the manufacturer service agent or similarly qualified persons in order to avoid hazard Accessing the installer wiring 1 Isolate the mains supply from the boiler 2 Remove the front panel Refer to section 3 2 3 Swi...

Page 30: ...s connector and release the cable from strain relief 5 Unscrew the L N E connections remove wires from connector 6 Remove the mains cable by pulling back through the grommet 7 Route the replacement through the grommet and re fit in reverse order 8 Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown 9 Swing the contro...

Page 31: ...IVE X3 PUMP GND X9 X8 OWC OWC OPENTHERM OPENTHERM OPENTHERM 5V CHIP COM BUS TX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE IONISATION 2 2 FLOW DHW DHW X7 1 3 2 1 1 1 2 3 4 5 2 WPS SIGNAL WPS GND FLUE FLUE RETURN RETURN 1 3 2 1 black grey red green blue brown green yellow orange pink violet yellow bk gy r g b br g y o p v y KEY 4 8 7 6 5...

Page 32: ...actory for operation on the gas type defined on the appliance data plate DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE Se...

Page 33: ...he burner is established 10 If the boiler does not light then after 5 attempts the boiler will lock out and display Ignition Lockout Restart the boiler Refer to Section 2 28 The boiler will repeat its ignition sequence If restart occurs 5 times within 15 minutes then Too Many Restarts will be shown When the burner is established a screen similar to the following will be shown DOMESTIC HOT WATER 11...

Page 34: ...d Domestic hot water operation without call for CH Domestic hot water operation with call for CH Central Heating Operaton Preheat operation Boiler frost protection Service required Display Functions Settings Changed DHW temperature knob moved CH temperature knob moved CH temperature knob moved with outside sensor connected Pre Heat If preheat is switched on then the boiler will periodically fire t...

Page 35: ... Exit to return to normal operation Fault History To view the Fault History of the boiler press Menu and the following screen will be displayed Press Next until the following screen is displayed Press Enter and a screen similar to the following will be displayed Press More to see more faults Press Exit to return to normal operation Fault Help This feature provides a list of potential corrective ac...

Page 36: ...displayed Press Enter and a screen similar to the following will be displayed Press Change until the desired temperature is displayed Press Exit to return to normal operation Service Mode Minimum Rate This feature will run the burner at minimum rate Note that a CH demand has to already be present for this feature to be active To activate the feature press Menu and the folloiwng screen will be disp...

Page 37: ...he slope press Menu and the following screen will be displayed Press Next until the following screen is displayed Press Enter and the following screen will be displayed Press Change until the desired setting is displayed Note The slope is active for settings between 5 and 40 Default is 17 Press Exit to return to normal operation Diverter Valve Mid Position To move the diverter valve to the mid pos...

Page 38: ... from them The display should show 2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of approximately 35o C at the flow rate stated on page 8 under operation 3 Reduce the DHW draw off rate to about 3 l min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 65o C 4 C...

Page 39: ...ities under the relevant national regulations 2 Explain and demonstrate the lighting and shutting down procedures 3 The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption Advise the User of the precauti...

Page 40: ...e checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance Note In order to carry out either servicing or replacement of components the boiler front panel must be removed Refer to Section 3 2 PRELIMINARY INSPECTION 1 Light the b...

Page 41: ...l until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel 5 Re tighten the two retaining screws view from bottom of boiler view from top of boiler 3 3 1 1 2 IMPORTANT The Weather Shield must only be removed by the service engineer 1 Unscrew the front removable panel using the securing knob 2 Turn the boiler off and isolate the power 3 Remove th...

Page 42: ...clip from the gas control valve outlet and ease the pipe upwards Rotate and then ease down to remove 3 Remove the extended nut on the fan mounting bracket 4 Lift off fan and venturi assembly 5 Undo the two M4 screws and release the nozzle assembly 6 Inspect the injector for blockage or damage 7 Inspect fan outlet sealing gasket and replace if necessary 1 2 3 5 Injector ...

Page 43: ... IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may be on the ceramic with a SOFT brush 7 Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 3 6 CLEANING THE CONDENSATE TRAP SIPHON 1 3 2 2 4 4 5 1 Pull...

Page 44: ...that the ignition and detection gaps are correct Refer to Sections 3 14 3 15 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of water 2 Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below 3 Refit the fan venturi assembly en...

Page 45: ... drain the boiler Refer to Section 3 22 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 10 FAN REPLACEMENT 1 Refer to Section 3 9 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas control valve outlet 4 Remove the extended nut retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti cloc...

Page 46: ...ble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check that the boiler operates in both DHW CH modes 4 3 3 3 12 BURNER REPLACEMENT 5 5 6 1 See Section 3 9 2 Refer to Section 3 5 3 Undo the two screws and remove the sump cover 4 Lift the manifold to clear the bottom sealing gasket and remove manifold 5 Remove the 2 front fixing screws and ...

Page 47: ...sions as shown 8 Reassemble in reverse order 9 Check that the boiler operates in both DHW CH modes 3 14 IGNITION ELECTRODE REPLACEMENT 1 Refer to Section 3 9 2 Unclip the return thermistor from the return pipe and withdraw it from the boiler 3 Disconnect the electrical lead from the thermistor 4 Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the t...

Page 48: ...m the electrode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check that the boiler operates in both DHW CH modes 3 17 GAS CONTROL VALVE REPLACEMENT 1 Refer to Section 3 9 2 Unplug the electrical lead connection from the gas control valve 3 Remove the outlet gas va...

Page 49: ... DHW and CH modes 3 18 DIVERTER VALVE ACTUATOR REPLACEMENT 3 3 19 CONDENSATE TRAP SIPHON REPLACEMENT Refer to Section 3 9 To remove the motor 1 Remove the condensate trap siphon Refer to Section 3 6 2 Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator 3 Disconnect the electrical plug from the motor 4 Fit the new motor ensuring the arm is correctly engaged in th...

Page 50: ...order 9 Turn power on display shows Installer Turn all dials to mimimum position Menu Turn all dials to minimum position and the following screen will be shown Installer Initialise spare PCB Yes Press Yes and the following screen will be shown Installer Switch mains off After 5s switch mains on Switch mains off After 5s switch mains on The following screen will be shown Select Boiler Model 1 4 Com...

Page 51: ... both DHW CH modes CENTRAL HEATING CIRCUIT 1 Refer to Section 3 9 2 Close all the CH water isolating valves on the boiler inlet 3 To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point 4 After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate by re...

Page 52: ...cess area by disconnecting the 22mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe Refer to Section 3 27 5 The automatic air vent head is retained in the pump body with a bayonet connection The air vent head and float assembly is removed by turning the head anti clockwise viewed from above and pulling upwards 6 Reassemble in reverse order Ensure the air vent h...

Page 53: ...ody assembly 1 Refer to Section 3 9 2 Drain the boiler Refer to Section 3 22 3 Remove the condensate trap siphon Refer to Section 3 19 4 Remove the electrical plug Refer to Section 3 20 5 Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor Refer to Section 3 18 6 Remove the return thermistor electrical connection Refer to Section 3 13 7 Remove the ...

Page 54: ...efill the boiler Refer to Section 2 19 8 Check that the boiler operates in both DHW CH modes 3 30 CH WATER PRESSURE SWITCH REPLACEMENT 4 3 3 31 FLOW THERMISTOR REPLACEMENT 1 Refer to Section 3 9 2 Drain the boiler Refer to Section 3 22 3 Pull off the two electrical connections 4 Using a suitable tool pull out the metal retaining clip 5 Carefully withdraw the pressure switch 6 Fit the new pressure ...

Page 55: ...ted to correctly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer to Section 3 19 19 Refill the boiler and check for leaks Refer to Section 2 19 20 Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve 21 Check that the boiler operates in both DHW CH modes 1 Refer to Section 3 9 2 Drain the boiler Refer to Section ...

Page 56: ...ler CH circuit Refer to Section 3 22 8 Remove the retaining clip on the vessel water connection pipe and remove the pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing bracket located on the top of the boiler and remove Note the position of the bracket on the vessel 10 Remove the expansion vessel 11 Fit the new expansion vessel 12 Reassemble in reverse order ensuring the...

Page 57: ... Work Restart Boiler Restart Menu Overheat Lockout 4 4 Restart Boiler If Fault Persists Contact Installer Restart Menu Ignition Lockout 2 2 Check Other Gas Appliances Work Restart Boiler Restart Menu Too Many Restarts Contact Installer Restart Menu Flame On Before Gas On Contact Installer Restart Menu Flame Loss Contact Installer Menu Fan Fault Contact Installer Restart Menu Flow Thermistor Fault ...

Page 58: ...vider Menu High Mains Voltage Contact Electricity Provider Menu Flow Return Reversed Contact Installer Menu Room Stat Fault Check Room Stat Batteries Menu No CH operation but DHW operates OK No DHW operation but CH operates OK No Display Follow instructions in Section 3 19 Replace PCB Low Mains Voltage Contact Electricity Provider Contact Electricity Provider Check Return Thermistor Check Room Sta...

Page 59: ...k gas supply and rectify fault NO YES Is approx 24Vdc supply available at the Gas Valve YES Check spark generator and associated harness for continuity and visual condition Refer to Section 3 15 Are these functioning correctly YES Check ignition electrode and associated harness for continuity visual condition and position Refer to Section 3 14 Are these functioning correctly Check siphon and conde...

Page 60: ...re available at the Boiler Inlet Check the detection electrode and associated harness for continuity visual condition and position Refer to Section 3 15 Check if condensate pipe is blocked Check if flue is blocked Replace as necessary NO Check gas supply and rectify fault NO YES Is 24Vdc supply available at the Gas Valve while the flame is on YES Check spark generator and associated harness for co...

Page 61: ...0 300 Ohms At 60 o C expect 2 400 2 600 Ohms At 85 o C expect 1 000 1 100 Ohms Is the Thermistor value correct YES Is there continuity between the PCB and the Thermistor YES Replace PCB Fit a new Thermistor NO Check and replace wiring as necessary NO Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected across the Thermistor s terminal pins At 25...

Page 62: ...pect 31 000 35 000 Ohms At 15 o C expect 15 000 16 500 Ohms At 30 o C expect 7 700 8 500 Ohms Is the Outside Sensor value correct YES YES Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB Replace PCB Fit a new Outside Sensor NO Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected at bot...

Page 63: ...ion YES NO Move the mode knob to the Winter position Are the Timer and the Room Thermostat switched on YES NO Switch the Timer and Room Thermostat On Are the Radiator Valves Open YES NO Open the Radiator Valves Is there 230Vac at A YES NO There is no Voltage from the Timer Room Stat This is not boiler fault Ensure Voltage is supplied to boiler by rectifying external wiring Replace the Divertor Val...

Page 64: ...W OK NO Change diverter Valve motor NO Adjust flow rates to achieve 35º temp rise and check filter is not blocked with debris NO Reconnect wiring or replace wiring harness if no continuity NO Re engage diverter head and secure clip to wateset NO Replace PCB Is the wiring connected between PCB and DHW sensor Remove the turbine and check for debris in the turbine filter Replace turbine if necessary ...

Page 65: ...es parts information and details of approved parts distributors are available from Hunt Heating Our Parts team are also available to help with your spare parts enquiries on 1300 00 1800 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Boiler Serial Number IMPORTANT NOTE Propane Boilers After installatio...

Page 66: ...66 Installation and Servicing INTENTIONALLY LEFT BLANK ...

Page 67: ...existing Fitted Not required What type of scale reducer softener has been fitted Brand Product Water meter fitted Yes No If yes DHW expansion vessel pre existing Fitted Not required Pressure reducing valve pre existing Fitted Not required DOMESTIC HOT WATER MODE Measure and record Gas rate m3 hr or ft3 hr Dynamic gas inlet pressure at maximum rate kPa Cold water inlet temperature C Hot water has b...

Page 68: ...ot have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO Where possible has a flue integrity check been undertaken in accordance with manufacturers instructions and readings...

Page 69: ...ot have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO Where possible has a flue integrity check been undertaken in accordance with manufacturers instructions and readings...

Page 70: ...he installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed Prior to its use the ECGA should have been maintained and calibrated as sp...

Page 71: ...xed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Turn off appliance and call Hunt Heating Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance ...

Page 72: ...iveways Boulevarde Keysborough Victoria 3195 Tel 1300 00 1800 or 61 0 3 9798 5111 Fax 61 0 3 9798 5133 Email enquiries huntheat com au Website www huntheat com au Hunt Heating Technical Helpline 1300 00 1800 Hunt Heating pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice H E A T I N G ...

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