5
Installation and Servicing
Section 1 - General ..................................................................................... 6
1.1 Introduction ................................................................................... 8
1.2 Operation ...................................................................................... 8
1.3
Safe Handling ............................................................................... 8
1.4
Optional Accessories .................................................................... 8
1.5 Safety............................................................................................ 8
1.6
Safe Handling of Substances ....................................................... 9
1.7
Location of Boiler ......................................................................... 9
1.8
Air Supply. ................................................................................... 10
1.9
Gas Supply ................................................................................. 10
1.10 Water Circulation System ........................................................... 10
1.11
Boiler Controls ............................................................................ 10
1.12 Electrical Supply ......................................................................... 10
1.13 Condensate Drain ....................................................................... 10
1.14 Boiler Dimensions, Services & Clearances .................................11
1.15 System Requirements - Central Heating .................................... 12
1.16 System Balancing ....................................................................... 13
1.17 Water Treatment ......................................................................... 13
Section 2 - Installation .............................................................................. 14
2.1
Boiler Assembly - Exploded View ............................................... 14
2.2 Unpacking ................................................................................... 15
2.3
Wall Mounting Template.............................................................. 16
2.4
Preparing the Wall ...................................................................... 16
2.5
Fitting the Wall Mounting Plate ................................................... 16
2.6
Mounting the Boiler ..................................................................... 16
2.7
Flues and Locations.................................................................... 17
2.8
Flues and Locations - Continued ................................................ 18
2.9
Horizontal Flue Positions ........................................................... 19
2.10 Vertical Flue Positions ............................................................... 19
2.11
Flue System Dimensions ........................................................... 20
2.12 Fitting the Turret.......................................................................... 20
2.13 Cutting the Flue .......................................................................... 21
2.14 Assembling the Vertical Flue ...................................................... 22
2.15 Condensate Drain ....................................................................... 23
2.16 Condensate Drain - Continued ................................................... 24
2.17 Connections & Filling .................................................................. 25
2.18 Electrical Connections ................................................................ 25
2.19 Installer Wiring ............................................................................ 26
2.20 Installer Wiring Continued ........................................................... 27
2.21 Replacing Pre-fitted Mains Cable
............................................... 27
2.22 Electrical Controls ....................................................................... 27
2.23 Wiring Diagram ........................................................................... 28
2.24 Commissioning and Testing ........................................................ 29
2.25 Initial Lighting .............................................................................. 30
2.26 User Interface Commissioning .................................................... 31
2.27 Changing Boiler Operating Mode .............................................. 31
2.28 Menu Operation .......................................................................... 32
2.29 Maximum and Minimum Rates ................................................... 32
2.30 General Checks .......................................................................... 33
2.31 Restart Procedure ....................................................................... 34
2.32 Handing Over.............................................................................. 34
Section 3 - Servicing ................................................................................. 35
3.1
Servicing Schedule ..................................................................... 35
3.2
Removal / Replacement of Components .................................... 36
3.3
Draining the Boiler ...................................................................... 36
3.4
Boiler Front Panel Removal / Replacement ................................ 37
3.5
Flue Manifold Removal/Replacement ......................................... 37
3.6
Fan and Venturi Assembly Removal and Cleaning ..................... 38
3.7
Burner Removal and Cleaning .................................................... 39
3.8
Cleaning the Heat Exchanger ..................................................... 39
3.9
Ignition / Detection Electrode Replacement / Inspection ............ 40
3.10 Cleaning the Condensate Trap ................................................... 40
3.11
External System Filter Cleaning Guide ....................................... 41
3.12 Burner Injector Replacement ...................................................... 41
3.13 Burner Replacement ................................................................... 41
3.14 Return Thermistor Replacement ................................................. 41
3.15 Spark Generator Replacement ................................................... 42
3.16 Gas Control Valve Replacement ................................................. 42
3.17 Condensate Trap Replacement / Cleaning ................................. 42
3.18 Pressure Gauge Replacement ................................................... 43
3.19 PRV Replacement ...................................................................... 43
3.20 Primary PCB Replacement ......................................................... 44
3.21
Pump Automatic Air Vent Replacement ..................................... 45
3.22 Pump Head Replacement ........................................................... 45
3.23 CH Water Pressure Switch Replacement ................................... 46
3.24 Flow Thermistor Replacement .................................................... 46
3.25 Expansion Vessel Recharging & Replacement .......................... 47
3.26 Heat Engine Replacement .......................................................... 48
Section 4 - Fault Finding ........................................................................... 49
4.1
Main Menu, Fault Help ................................................................ 49
4.2
Overheat Lockout ....................................................................... 49
4.3
Ignition Lockout........................................................................... 50
4.4
Flame On Before Gas Valve On ................................................. 50
4.5
Low Water Pressure ................................................................... 50
4.6
Flame Loss ................................................................................. 51
4.7
Fan Fault..................................................................................... 51
4.8
Flow Thermistor Fault ................................................................ 52
4.9
Return Thermistor Fault ............................................................. 52
4.10 Outside Sensor Fault .................................................................. 53
4.11
No CH Operation ........................................................................ 53
4.12 No DHW Operation ..................................................................... 54
4.13 No Display .................................................................................. 54
Section 5 - Spare Parts ............................................................................ 55
Section 6 - Benchmark & Commissioning ................................................ 56
CONTENTS
