Table of Contents
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1
GENERAL ....................................................................... 8
1.1
Introduction ....................................................................10
1.2
Operation .......................................................................10
1.3
Safe Handling .................................................................10
1.4
Optional Extra Kits .........................................................10
1.5
Safety .............................................................................11
1.6
Safe Handling Of Substances ........................................11
1.7
Location Of Boiler ..........................................................11
1.8
Gas Supply .....................................................................12
1.9
Flue Installation ..............................................................12
1.10
Terminal ..........................................................................13
1.11
Air Supply .......................................................................13
1.12
Water Circulation System ...............................................13
1.13
Boiler Control Interlocks .................................................13
1.14
Electrical Supply .............................................................13
1.15
Condensate Drain ........................................................13
1.16
Boiler Dimensions, Services & Clearances ....................14
1.17
System Requirements ...................................................15
1.18
System Balancing ..........................................................16
1.19
Water Treatment.............................................................16
2
INSTALLATION ............................................................ 17
2.1
Boiler Assembly - Exploded View ...................................17
2.2
Unpacking ......................................................................18
2.3
Unpacking Cont'd ...........................................................19
2.4
Front Panel Removal .....................................................19
2.5
Wall Mounting Template .................................................20
2.6
Preparing The Wall .........................................................20
2.7
Fitting The Wall Mounting Plate .....................................20
2.8
Mounting The Boiler .......................................................20
2.9
2.10
Cutting & Setting The Flue Length .................................23
2.11
Installing The Flue ..........................................................24
2.12
2.13
Flue Terminal Position ....................................................26
2.14
Assembling The Roof Flue Kit ........................................27
2.15
Condensate Drain ..........................................................28
2.16
Connections & Filling .....................................................30
2.17
Electrical Connections ....................................................31
2.18
Installer Wiring ...............................................................31
2.19
External Wiring ...............................................................32
2.20
Wiring Diagram ..............................................................33
2.21
Commissioning and Testing ...........................................34
2.22
Initial Lighting .................................................................35
2.23
General Checks .............................................................36
2.24
Restart Procedure ..........................................................37
2.25
Accessing The Installer Mode ........................................37
2.26
Handing Over .................................................................38
Installation and Servicing
CONTENTS
3
SERVICING .................................................................. 39
3.1
Servicing Schedule ........................................................39
3.2
Boiler Front Panel Removal / Replacement ...................40
3.3
3.4
Burner Removal And Cleaning .......................................41
3.5
Cleaning The Condensate Trap/Siphon ........................41
3.6
Cleaning The Heat Exchanger .......................................42
3.7
Reassembly ...................................................................42
3.8
Replacement Of Components ........................................43
3.9
Fan Replacement ...........................................................43
3.10
Burner Injector Replacement .........................................44
3.11
Burner Replacement ......................................................44
3.12
Return Thermistor Replacement ...................................45
3.13
Ignition Electrode Replacement .....................................45
3.14
Flame Detection Electrode Replacement .......................46
3.15
Spark Generator Replacement ......................................46
3.16
Gas Control Valve Replacement ....................................46
3.17
Diverter Valve Actuator Replacement ............................47
3.18
Condensate Trap/Siphon Replacement .........................47
3.19
PCB Replacement ..........................................................48
3.20
DHW Flow Turbine Sensor Replacement ......................48
3.21
Replacing The Mechanical Timer ...................................49
3.22
Draining The Boiler ........................................................49
3.23
Pressure Gauge Replacement .......................................50
3.24
Safety Relief Valve Renewal ..........................................50
3.25
Pump Automatic Air Vent Replacement .........................51
3.26
Diverter Valve Body Assembly Replacement .................51
3.27
DHW Plate Heat Exchanger Replacement ....................52
3.28
Pump Head Replacement ..............................................52
3.29
CH Water Pressure Switch Replacement ......................52
3.30
3.31
Flow Thermistor Replacement .......................................53
3.32
Heat Engine Replacement .............................................54
3.33
Expansion Vessel Recharging & Replacement ..............55
4
FAULT FINDING ........................................................... 55
4.1
Fault Finding Chart Main Menu ......................................56
4.2
'L1' - Flow Temperature Overheat Lockout ....................57
4.3
'L2' - Ignition Lockout .....................................................57
4.4
'L6' - False Flame Lockout ............................................58
4.5
'F1' - Low Water Pressure ..............................................58
4.6
'F2 or Fn or Ln' - Flame Loss .........................................58
4.7
'F3' - Fan Fault ...............................................................59
4.8
'F4 or L4' - Flow Thermistor Fault ..................................59
4.9
'F5 or L5' - Return Thermistor Fault ...............................59
4.10
'F6' - Outside Sensor Fault.............................................60
4.11
No CH Operation But HW Works Ok .............................60
4.12
No HW But CH On .........................................................61
4.13
No Display ......................................................................61
5
SPARE PARTS ............................................................. 62
6
BENCHMARK & COMMISSIONING ............................64
7
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