Main System 28 Eco, Installation & Service Instructions Manual

Page 1: ...g UK Ltd 2011 Installation Service Instructions System Eco Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Supplied by HeatingS...

Page 2: ...he Scheme Visit www centralheating co uk for more information 0086 ISO 9001 FM 00866 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notificat...

Page 3: ...ust ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegist...

Page 4: ...s in force Read the instructions fully before installing or using the appliance In GB this must be carried out by a competent person as stated in the Gas Safety Installation Use Regulations Definition...

Page 5: ...ructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straigh...

Page 6: ...stem Details 12 7 0 Site Requirements 14 8 0 Flue Options 18 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning 33 12 0 Completion 35 13 0 Servicing 36 14 0 Changing Components 38 15 0...

Page 7: ...c plate It is visible when the case front panel is removed and the control box hinged down Fig 1 1a 6 The boiler model name and serial number are also shown on the information label on the back of the...

Page 8: ...ondensate Trap 13 Heat Exchanger Air Vent 14 Electrode Assembly 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch 18 Central Heating Temperature Control 19 Calibration Control...

Page 9: ...3 minute delay occurs before the burner relights automatically anti cycling The pump continues to run during this period 3 When the demand is satisfied the burner is extinguished and the pump continu...

Page 10: ...flue Below Casing 200 mm Min Front 450 mm Min For Servicing Front 5 mm Min In Operation L H Side 5 mm Min R H Side 5 mm Min In Operation Heat Input CH Net Max Min 24 model kW 26 06 7 82 28 model kW 2...

Page 11: ...ube 100mm D C B A G F H H Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Condensate Drain 127 mm Dimensions A 780mm B 345mm C 450mm D 116mm Min F 1...

Page 12: ...hich should be used following the inhibitor manufacturer s instructions Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362...

Page 13: ...the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres 18 24 155 litres 27 For greater system capacities an additional expansion...

Page 14: ...In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If...

Page 15: ...3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation...

Page 16: ...ould be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possibl...

Page 17: ...th the diagram below Opening Window or Door 150mm MIN IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 150mm from any opening windows or doors see Section 9 0 Fig...

Page 18: ...ith the standard horizontal telescopic flue kit is not included in any equivalent length calculations NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be secure...

Page 19: ...e supports are available as accessories The total equivalent length for this example is 6 5 metres 1m extension 135 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m AIR DUCT No of fittings pipes Sub...

Page 20: ...stem 80mm diameter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 Y Flue H...

Page 21: ...n the boiler adaptor making sure that it is pushed down as far as possible 2 Ensure that the air flue ducts are connected correctly and that they are adequately supported at least once every metre usi...

Page 22: ...NT If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prio...

Page 23: ...addition of extensions the length of either or both the 60 100 concentric and 60 exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The...

Page 24: ...OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that 2 metres of concentric flue and 4 metres of...

Page 25: ...ntric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and an...

Page 26: ...mm as shown in two positions directly opposite each other Fig 36 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw m...

Page 27: ...of the centre of the flue hole rear exit For side flue exit mark as shown Fig 40 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum dia...

Page 28: ...pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing...

Page 29: ...t 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 48 4 To dimension X add 50mm This dimension to be...

Page 30: ...embly Fig 51 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It...

Page 31: ...ler adaptor 16 Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct Fig 53 17 Engage the extension into the adaptor up to this position Fig 54 Once the inst...

Page 32: ...UST be suitable for 230V switching 6 Remove the link between terminals 1 2 The switched output from the external control must be connected to terminal 1 Fig 57 7 Ensure that the external control input...

Page 33: ...screw on the automatic air vent on the pump body Fig 59 7 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 8 Pressurise the syst...

Page 34: ...ler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 62a is in accordance with B S 6798 B S 6891 7 Ensure that this inle...

Page 35: ...appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recor...

Page 36: ...nts of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which co...

Page 37: ...racket on the boiler top panel Remove the pipe Fig 73 9 Undo the five retaining nuts and washers and remove the fan gas air inlet and burner assembly Figs 74 10 Carefully clean any debris from the hea...

Page 38: ...gniter feed plug and the electrode leads noting their positions 2 Undo the nuts and screws securing the igniter to the boiler top panel Remove the igniter 3 Fit the new igniter and reassemble in rever...

Page 39: ...ace the gasket if necessary 6 Remove the four nuts and separate the fan from the gas air inlet Note the position of the orifice plate and examine the gasket replacing if necessary Fig 79 7 Fit the new...

Page 40: ...nd gasket examine the insulation and heat exchanger gasket replacing if necessary 7 Reassemble in reverse order 14 6 Insulation Fig 80 1 Undo the nut on the gas pipe at the gas air inlet and the gas v...

Page 41: ...boiler primary circuit 2 Disconnect the two wires from the sensor 3 Unscrew the sensor from the hydraulic outlet assembly examine the sealing washer and replace if necessary 4 Reassemble in reverse or...

Page 42: ...peed must be set to 3 Fig 86 4 Reassemble in reverse order 14 13 Pump Complete Fig 87 1 Drain the boiler primary circuit 2 Undo the two screws securing the body to the pipe and manifold and draw the p...

Page 43: ...eassemble in reverse order 14 17 Pressure Relief Valve Fig 90 1 Drain the boiler primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw suffici...

Page 44: ...reverse order ensuring that the temperature controllers are reset to their previous positions 14 19 Selector Switch Figs 91 92 1 Note the setting of the selector switch knob and carefully pull it off...

Page 45: ...or is fitted NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Throttle adjustment screw until it is flush with the valve body then turn the screw 4...

Page 46: ...ck fully anticlockwise Fig 95 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 96 97 5 Turn the left hand knob fully clockwise As the...

Page 47: ...Central Heating NTC Sensor Fan GasValve Overheat Stat Pump X400 X401 g g b b r r b b b br bk g b br g y b br b br br b b b br br br b b br r bk r bk Water Pressure Switch Spark Generator Ignition Elec...

Page 48: ...No A Fan 5121447 B Electrode Assembly 5130293 C Gas Valve 5122149 D Burner 5130292 E Water Pressure Switch 5114748 F Pump 248042 G NTC Sensor 5114725 H Overheat Thermostat 5114729 J NTC Sensor 5130291...

Page 49: ...33 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty or incorrect components E110 shows overheat of the primary water E119 is displayed when the primary...

Page 50: ...flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section H Operation sequence successful If the error 110 is still flashing Go to section I Fan runs at correct speed YES...

Page 51: ...stem 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or fau...

Page 52: ...heck and correct the connection of the tube between the venturi and gas valve 1 2 Check and correct if necessary 1 The mechanical set of the gas valve CO2 values see instruction 2 Flame sensing electr...

Page 53: ...ly cable YES Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 YES Replace fan Temperature sensors faulty Cold resistance approximately 10k 25 C CH sensor resistance reduces with inc...

Page 54: ...statutory rights If yes and if required by the manufacturer has a water scale reducer been fitted CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s...

Page 55: ...me Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Regis...

Page 56: ...oducts which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request MAIN A Trading Division o...