Supplied By www.heating spares.co Tel. 0161 620 6677
2
Contents
Design principles and operating sequence Page
1.1 Principle components 4
1.2 Mode of operation (at rest) 4
1.3 Mode of operation (heating) 4
1.4 Mode of operation (DHW) 4
1.5 Safety devices 4
Technical data Page
2.1 Central heating 5
2.2 Domestic hot water 5
2.3 Gas pressure 5
2.4 Expansion vessel 5
2.5 Dimensions 5
2.6 Clearances 5
2.7 Connections 5
2.8 Electrical 5
2.9 Flue details 5
2.10 Efficiency 5
2.11 Pump duty 6
2.12 Appliance 6
General requirements (UK) Page
3.1 Related documents 7
3.2 Location of appliance 7
3.3 Gas supply 7
3.4 Flue system 7
3.5 Air supply 7
3.6 Water circulation 7
3.6.1 Pipework 8
3.6.2 Automatic by-pass 8
3.6.3 Drain cocks 8
3.6.4 Air release points 8
3.6.5 Expansion vessel 8
3.6.6 Filling point 8
3.6.7 Low pressure sealed system 8
3.6.8 Frequent filling 8
3.7 Electrical supply 8
3.8 Showers 8
3.9 Mounting on a combustible surface 9
3.10 Timber framed building 9
3.11 Inhibitors 9
Installation Page
4.1 Delivery 10
4.2 Contents 10
4.3 Unpacking 10
4.4 Preparation for mounting the appliance 10
4.5 Fitting the flue 10
4.5.1 Concentric horizontal flue 10
4.5.2 Concentric vertical flue 11
4.6 Connecting the gas and water 12
4.6.1 Gas 12
4.6.2 Flow and return 12
4.6.3 Cold water inlet 12
4.6.4 Hot water outlet 12
4.6.5 Safety valve 12
4.6.6 Condense pipe 12
4.7 Electrical connections 13
4.7.1 Casing removal 13
4.7.2 Appliance terminal block 13
4.7.3 Connecting the mains (230V) input 13
Commissioning Page
5.1 Gas supply installation 14
5.2 The heating system 14
5.3 Initial filling of the system 14
5.4 Initial flushing 14
5.5 Filling the hot water system 14
5.6 Pre-operation checks 14
5.7 Initial lighting 14
5.7.1 Checking burner pressures 14
5.8 Final flushing of the heating system 14
5.8.1 Inhibitors 14
5.9 Setting the boiler operating temperature 14
5.9.1 Setting the DHW temperature 15
5.10 Setting the system design pressure 15
5.11 Regulating the hot water 15
5.11.1 Changing the flow restrictor 15
5.11.2 Regulating the central heating system 15
5.12 Final checks 15
5.13 Instructing the user 15
5.14 Technical assistance 15
Servicing instructions Page
6.1 General 16
6.2 Routine annual servicing 16
6.3 Replacement of components 16
6.4 Component removal procedure 16
6.5 Pump assembly 16
6.6 Safety valve 16
6.7 Automatic air release valve 16
6.8 Water pressure switch 17
6.9 Pressure gauge 17
6.10 Primary thermistor 17
6.11 High limit thermostat 17
6.12 PCB 17
6.13 Gas valve 17
6.14 Integral time switch 18
6.15 Electrode, burner thermostat, burner & injectors 18
6.16 Flue fan 18
6.17 Main heat exchanger 19
6.18 Air pressure switch 19
6.19 Flow restrictor 19
6.20 DHW flow switch 19
6.21 DHW heat exchanger 20
6.22 Valve actuator 20
6.23 Divertor valve cartridge 20
6.24 DHW thermistor 20
6.25 Automatic by-pass 20
6.26 DHW non-return valve 20
6.27 Expansion vessel 20
6.27.1 Expansion
vessel removal (with sufficient clearance above)
20
6.27.2 Expansion vessel removal
(with insufficient clearance above)
21
6.28.1 Latent heat collector 21
6.28.2 Dismantling the latent heat collector 21
6.29 Condense trap removal 21
Checks, adjustments and fault finding page
7.1 Checking appliance operation 22
7.2 Appliance mode of operation 22
7.2.1 Selector switch in the OFF position 22
7.2.2 Selector switch in the hot water only position 22
7.2.3 Selector switch in the heating & hot water position 22
7.2.4 Appliance functions 22
7.2.5 DHW mode 22
7.2.6 Heating mode 23
7.3 Checking & adjusting burner pressure 24
7.3.1 Setting the maximum burner pressure 24
7.3.2 Setting the minimum burner pressure 24
7.3.3 Setting the minimum CH output 24
7.4 Combustion analysis test 24
7.5 Checking the expansion vessel 25
7.6 External faults 25
7.6.1 Installation faults 25
7.7 Electrical checks 25
7.7.1 Earth continuity test 25
7.7.2 Short circuit check 25
7.7.3 Polarity check 25
7.7.4 Reversed polarity or supply fault 26
7.7.5 Resistance to earth check 26
7.8 Fault finding 26
7.8.1 Replacing the main PCB 26
7.9 Fault codes 26
7.10 Fault finding 27-32
Wiring diagrams Page
8.1 External wiring 33
8.2 Typical control applications 33
8.3 Room thermostat 33
8.4 Other controls 33
Functional diagram 34
L.P.G. instructions Page
10.1 Related documents 35
10.2 Technical data 35
10.3 Converting the appliance gas supply 35
10.4 Gas supply 35
10.5 Gas supply installation 35
10.6 Checking & adjusting burner pressure 35
10.6.1 Setting the maximum burner pressure 35
10.6.2 Setting the minimum burner pressure 35
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