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. ..................................................................................... 9
1.9
Gas Supply ................................................................................... 9
1.10 Water Circulation System ........................................................... 10
1.11
Boiler Controls ............................................................................ 10
1.12 Electrical Supply ......................................................................... 10
1.13 Condensate Drain ....................................................................... 10
1.14 Boiler Dimensions, Services & Clearances .................................11
1.15 System Requirements - Central Heating .................................... 12
1.16 System Balancing ....................................................................... 13
1.17 Water Treatment ......................................................................... 13
Section 2 - Installation .............................................................................. 14
2.1
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 ................................................................. 26
2.19 Installer Wiring ............................................................................ 26
2.20 InstalLer Wiring - Cont ................................................................ 27
2.21 Replacing Pre-Fitted Mains Cable .............................................. 28
2.22 External Electrical Controls ......................................................... 28
2.23 Wiring Diagram ........................................................................... 29
2.24 Commissioning and Testing ........................................................ 30
2.25 Initial Lighting .............................................................................. 31
2.26 The Display ................................................................................. 32
2.27 General Checks .......................................................................... 32
2.28 General Checks - Water Circulation .......................................... 33
2.29 Restart Procedure ....................................................................... 33
2.30 Accessing the Installer Mode ...................................................... 34
2.31 Handing Over.............................................................................. 34
Section 3 - Servicing ................................................................................. 35
3.1
Servicing Schedule ..................................................................... 35
3.2
Removal / Replacement of Components .................................... 36
3.3
Draining the Boiler ...................................................................... 36
3.4
Boiler Front Panel Removal / Replacement ................................ 36
3.5
Flue Manifold Removal/Replacement ......................................... 37
3.6
Burner Removal and Cleaning .................................................... 37
3.7
Fan and Venturi Assembly Removal and Cleaning ..................... 38
3.8
Cleaning the Heat Exchanger ..................................................... 39
3.9
Ignition / Detection Electrode Replacement / Inspection ............ 39
3.10 Cleaning the Condensate Trap ................................................... 40
3.11
Return Thermistor Replacement ................................................ 40
3.12 Burner Injector Replacement ...................................................... 40
3.13 Burner Replacement ................................................................... 41
3.14 Spark Generator Replacement ................................................... 41
3.15 Gas Control Valve Replacement ................................................. 41
3.17 Condensate Trap Replacement / Cleaning ................................. 42
3.16 Primary PCB Replacement ......................................................... 42
3.18 Pressure Gauge Replacement ................................................... 43
3.19 PRV Replacement ...................................................................... 43
3.20
Pump Automatic Air Vent Replacement ...................................... 44
3.21 CH Water Pressure Switch Replacement ................................... 44
3.22 Pump Head Replacement ........................................................... 45
3.23 Flow Thermistor Replacement .................................................... 45
3.24 Expansion Vessel Recharging & Replacement .......................... 46
3.25 Heat Engine Replacement .......................................................... 47
Section 4 - Fault Finding ........................................................................... 48
4.1
Fault Finding Main Menu ............................................................ 48
4.2
‘L 01’ - Overheat Lockout ............................................................ 49
4.3
‘L 02’ - Ignition Lockout ............................................................... 49
4.4
‘L 06’ - Flame On Before Gas Valve On ...................................... 50
4.5
‘F 01’ - Low Water Pressure ....................................................... 50
4.6
‘F 02 or FN or LN’ - Flame Loss.................................................. 50
4.7
‘F 03’ - Fan Fault ......................................................................... 51
4.8
F 04 or L 04’ - Flow Thermistor Fault ......................................... 51
4.9
‘F 05 or L 05’ - Return Thermistor Fault ..................................... 52
4.10 ‘F 06’ - Outside Sensor Fault ...................................................... 52
4.11
No CH Operation ........................................................................ 53
4.12 No Display .................................................................................. 54
4.13 No DHW Operation ..................................................................... 54
4.14 Flow/Return Differential Greater than 50°C ................................ 54
Section 5 - Spare Parts ............................................................................ 55
Section 6 - Benchmark to Commissioning ........................................... 56-64
CONTENTS
