Page 1: ... 47 311 14 BOILER OUTPUT Automatic Modulating Control To Domestic Hot Water Minimum 9 2 kW 31 400 Btu h Maximum 23 0 kW 78 500 Btu h To Central Heating Minimum 9 2 kW 31 400 Btu h Maximum 23 0 kW 78 500 Btu h IMPORTANT THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER ...
Page 2: ...low thermal capacity Gas to Water heat exchanger AWater to Water heat exchanger to provide domestic hot water Fully modulating controls in the central heating and domestic hot water modes of operation An expansion vessel pressure gauge and pressure relief valve Aby pass for the central heating system Temperature safety cut out controls Awater flow regulator 2 9 Electrical Page 9 10 Installation Pa...
Page 3: ...and cold taps and mixing valves used in the system must be suitable for operating at a mains pressure of up to 10 bar Thermostatically controlled or pressure equalising shower valves will guard against the flow of water at too high a temperature Hot and cold mains fed water can be supplied direct to an over rim flushing bidet subject to local Water Company require ments With all mains fed systems ...
Page 4: ... FITTING 15 mm Compression GAS INLET FITTING Rcl 2 PRESSURE RELIEF VALVE DISCHARGE FITTING 15 mm Compression OVERALL HEIGHT including flue elbow 11 00 mm 143 3 in CASING HEIGHT 900 mm 35 4 in CASING WIDTH 450 mm 17 7 in CASING DEPTH 360 mm 14 2 in WEIGHT including water 47 6 kg 105lb INSTALLATION WEIGHT 45 6 kg 1 00 lb PACKAGED WEIGHT 48 5 kg 1 07 lb TABLE 5 SPECIFICATIONS PRIMARY WATER CAPACITY 2...
Page 5: ...eft hand side Smm Smm and for servicing See Fig 2 4 7 The appliance can be installed in a cupboard used for airing clothes provided that the requirements of BS 6798 and BS 5440 2 are strictly followed 4 8 The airing space must be separated from the boiler space by a perforated non combustible partition Expanded metal or rigid wire mesh are acceptable provided that the major dimension is less than ...
Page 6: ...nal and fixed to the wall using plated screws 5 6 In certain weather conditions a terminal may steam and sit ing where this could cause a nuisance should be avoided 5 7 Take care to ensure that combustion products do not enter ventilated roof voids MINIMUM SITING DIMENSIONS FOR POSITIONING THE BALANCED FLUE TERMINAL TERMINAL POSITION A directly below an openable window or MIN DISTANCE other openin...
Page 7: ...nts the room from outside High Level 260 em 130cm 40 in 20 in Low Level 260 em 130 em 40 in 20in 6 5 Refer to BS 6798 and BS 5440 2 for additional information 7 7 The filling point must be at low level See Figs 5 and 6 7 8 Water loss must be replaced See Fig 6 The connection should be made in the central heating return as close to the appliance as possible See Figs 5 and 6 7 9 The make up vessel m...
Page 8: ...Heating return Auto air vent Fill point Heating return 300 mm 12 in min above the highest point of the system 8 9 Hot and cold taps and mixing valves used with this appliance must be suitable for operating at a pressure of up to 10 bar 1 50 lblin 8 1 0 No anti syphonage arrangements are necessary except for some loose head showers See also Section 8 1 0 following 8 11 Thermostatically controlled o...
Page 9: ...itted externally to the appliance 9 10 SAFETY CHECK After installation or in the event of an electrical fault the electrical system shall be checked for short circuits fuse failure incorrect polarity of connections earth con tinuity and resistance to earth Fig 7 Wiring Diagram Control panel and facia All components shown viewed from front of ippliance r T r I Indicator Ughts I Operating Switch I I...
Page 10: ...and yellow bk black or orange I 1 r red w white y yellow g grey v violet pk pink br bl I r__L_____________ 1 I _L ___ L T 1 I I I I I I I I l Central Spark Electrode w l _ _ I I I I 1 I I I Pump Overrun Thermostat I _____ _j I I I I I 1 I I I I I I I I _____ I 1 Heating r Sensor 1 1 br gy bl D G I I I I Gas Valve 1 c c c c y y 2 0 Modulating Solenoid Domestic Hot Uf l Water Sensor r r E H c J I I ...
Page 11: ...OARD 1 I IGNITION ljj 1 BOARD I I I I L I IaECTRONICS I I FUSE F2 5 315mA SLOW XJIPIN l ELECTRONICS I 3 I PI r White CENTRAL HEATING SENSOR DOMESTIC HOTWATER SENSOR I I I I I brown CNSIPIN Fll rCN2 PIN L31 brown TEMPERATURE CONTROl POTENTIOMETER I I I I I ISAFETY I v I I CIRCUITS I _____ _j I I L ___ _ I N N N Fig 9 Functional flow diagram PUMP N r N I ng 10 Room thermostat l connections I I Remov...
Page 12: ...tions 4 and 5 The distance from the bottom of the mounting plate to the top of the appliance asing is 106mm Hold the appliance mounting plate to the wall Check that the plate is horizontal See Fig 12 Mark the position of the fixing holes and the position of the flue hole centre line onto the wall Draw a horizontal line along the bottom of the mounting plate Rear Flue Mark a vertical line through t...
Page 13: ...See Fig 16 Air duct length L 73 mm Flue duct length L 128 mm Do not cut the drilled end of either duct Assemble the air and flue ducts to the terminal Drill through the holes in the terminal into the air duct and fix using the screws provided See Fig 18 Join the extension ducts to the standard ducts as indicated in Fig 19 applying a smear of silicone sealant to the end of the flue duct Drill and s...
Page 14: ...lding the facia panel in place and carefully lower the facia See Fig 23 Unplug the Operating Switch from terminal X1 0 on the main driver board See Fig 7 Unscrew the four screws holding the switch plate and remove the complete Operating Switch assem bly Fit the programmer and tighten the four screws Plug the programmer into terminal X1 0 on the main driver board Lower the control box as described ...
Page 15: ...to flue duct fixing screws Appliance casing Fig 19 Flue assembly using the extension ducts Fig 20 Flue elbow Access to the flue fixing holes __Flue duct length L 128 mm rearllue __________________ _ 1 L 225 mm side llue Air duct fixing screws Standard flue duct Standard air duct Air duct length L 73 mm rear flue L 170 mm side llue 1 L Applimce casing ____ 15 Fig 21 Terminal assembly for internal f...
Page 16: ...at or leave operating continuously with the room thermostat set at 6 C or drain the appliance and system Fig 22 Duct and terminal assembly for internal fitting of the flue Air duct Rubber sealing gasket Fig 24 Electrical cable exits from control box IGNITION BOARD Fig 23 Appliance casing and control equipment fixings r Inner casing cover fixing screws 4 J c Control box fixing screws 2 Upper facia ...
Page 17: ...ed can accommodate a system val ume of about 83 litres Refer to BS 7074 Part 1 If the system volume is in excess of that accommodated by the expansion vessel fitted to the appliance then an extra vessel must be fitted as close as possible to the central heating return connection of the appliance Any extra vessel fitted must be pressurised to the same figure as the il tegrc l vessel if the expcmsi0...
Page 18: ...e electrode will continue Carefully open the gas service cock and observe the burner religh and follow the normal sequence of op raUon 18 Minimum pressure adjuster Maximum pressure adjuster Nole Cloclwise to increase and antl clocl wise to decrease the pressure Modulating solenoid Pressure compensating connection at rear Electrical connections modulator Yellow yellow Set the Operating Switch or Pr...
Page 19: ...system controls to the user s requirements 12 6 If an external programmer has been fitted which has a pro grammable domestic hot water facility then it is suggested that this be set to Continuous or the equivalent 13 3 DISMANTLE THE APPLIANCE To carry out a full and comprehensive service of the appliance remove the following parts to gain access to the components which need to be checked or servic...
Page 20: ... fixings upper assembly 77 f B t Fan assembly ixing screws 3 Flue hood 0 010 0 0 Inner casing Combustion chamber cover fixing screws 4 Combustion chamber cover 0 0 0 0 Fig 30 Pilot burner assembly Sparl electrode Pilot injector 0 20 ...
Page 21: ...p on the Water to Water heat exchanger and open the tap about one turn See Fig 36 Close the drain tap when the flow has stopped Some water will remain in the expansion vessel pump divert Jr valve il d Gas to Water heat e changer arJd t xt a care m sl bE takf 1whe11 removing th Jse ompnnents 21 Pilot burner assembly chamber Do not distort any of the blades Combustion Chamber Insulation Examine and ...
Page 22: ...the rear M4 screw securing the thermostat to its mounting plate on the Gas to Water heat exchanger Remove the front screw and thermostat Fig 33 Air flow pressure switch 22 Fit the replacement thermostat ensuring a layer of heat sink compound is between the faces 7 Combustion Chamber Insulation See Fig 35 Check that the electricity supply to the appliance is turned off Drain the central heating cir...
Page 23: ...Appliance components lower assembly Water divcrter valve micro switchjlssembly 1 H Mains cold inlet filter t 11 fir Sealing plate Expansion vessel connection Expansion vessel Side insulalion pad Expansion vessel support bracket Water to Water heat exchanger Domestic hot water sensor Drain point Gas inlet union 23 ...
Page 24: ... the lead to the modulating solenoid After completing the adjustments check the minimum and max imum pressures and re adjust as necessary It should not be necessary to alter the central heating paten tiometer setting when the gas control is replaced and the mini mum and maximum burner pressures are set 14 Central Heating Sensor See Fig 36 Check that the electricity supply to the appliance is turne...
Page 25: ...e electricity supply to the appliance is turned off Drain the central heating and domestic hot water circuits as described in Sections 14 3 a and b Hang the control box assem bly in the servicing position as described in Section 13 3 d Remove the micro switch assembly as described in Section 14 4 20 Undo all the water connections to the valve and remove from the appliance Fit the replacement valve...
Page 26: ...ture Control Potentiometer See Fig 41 Check that the electricity supply to the appliance is turned off 26 Lower the facia as described in Section 13 3 c Pull the knob off the spindle Unscrew the locknut and remove the potentiometer from the facia paneL Remove the Molex plug from terminal X1 on the main driver board Fit the replacement potentiometer in the reverse order 26 Main Driver Board See Fig...
Page 27: ...27 ...
Page 28: ... 006161 1 SSA6161 1 57 379 216 Diverter Valve Inter Albion D2040 1 ZAGAS166 97 379 556 Driver Board Pektron ASS PRO 358 1 ZAGAS094 98 378 132 Ignition Board Honeywell S458 B1002 Pactrol415000 1 ZAGAS096 31 378 029 Overheat Thermostat Ranco LM7 P5050 1 ZAMA 133 17 378 028 Fan Assembly Sifan 1 SSA6072 9 100 379 560 Air Pressure Switch Beck 911 81 1 ZAGAS233 90 386 227 CH Temperature Control Potentio...
Page 29: ... r e 1 l I 0 0 29 ...
Page 30: ...ng See Section 17 m minutes Fan off Main gas vain and pilotvalve off m 1 Central Heating Mode D m Central heating temperature above set level Heat inputmodulated to maintainflow temperature set by Temperature Control Potenetiometet Operating Switch off EITHER DEMAND indicator off Main gas vain and pilot valve off Fan of Pump off orcontinue if pump M rrun is required AUTOMATIC START UP SEQUENCE Ini...
Page 31: ...e set level m Operating Switch OFE EITHER Hot water Demand satisfied SEE DETAILED SEQUENCE ABOVE 2 Domestic Hot Water Mode No demand and primary water temperature above 60 C Gas to waterheat exchanger excess temperature causes boiler overheat thermostat to trip m m Pump on until primary watertemperature falls below 60 C Gas valves and fan shut down butpump and indicator Hghts remain on m Of Demand...
Page 32: ...minal X7 pin 1 Is there a240V supply at the top end offuse F1 Replace the STANDBY indicator light START OF CENTRAL HEATING TEST Set the Operating Switch or programmer to HEATING WATER and set the temperature control potentiometer and room thermostat if htted to maximum Does the DEMAND indicator illuminate YES NO __ Is the STANDBYindicatorstill illuminated YES NO __ Check the mains electrical suppl...
Page 33: ...eating sensor resistance between 1 5and YES 1 _Y_E_S_ 25 kohms across the white wires Replace the main driver board Check the connections at the central heating sensor or replace the sensor Is there a240V supply at pin Lon tenninal CN1 NO ____ Check or replace theoverheat thermostat NO Is there a240V supply at pin L2 on ____ Replace the sequence board tenninal CN2 NO Is there a240V supply at pin L...
Page 34: ...O NO NO ___ Has the sparkelectrode stopped sparking ___ Check the overall condition of the ___ Replace the sequence board spark electrode Is it in poor condition YES Replace the sparkelectrode NO Is there a240Vsupply at pin ML on ___ Replace the sequence board terminal CN4 NO Check the gas supply to the appliance and check the burnerfor blockages Is the gas flowing correctly Replace the gas valve ...
Page 35: ...move the Molex plug from ____ Replace the temperature control terminal Xl Measure the resistance potentiometer on the facia panel as follows Between purple and yellow pins 10khoms between purple and pink pins between zero and 10khoms depending on the setting of the temperature control potentiometer Is this correct IYES NO Remove the left hand Molex plug ___ Replace the central heating sensor from ...
Page 36: ... the ____ Replace the pump centre of the pump and turn the Doesan automatic start up sequence occur ending in full burner Ignition YES NO Does the fun run 4 I I t YES 5 shaft with aflat bladedscrewdriver Does the pump now nun NO __ Does the fan run then stop then run etc Replace the ignition board 36 NO ___ Is there approximately 24V AC across the test pins on the moin driver board Is there olives...
Page 37: ...ulating solenoid terminals decrease as the flow rate reduces1 NO YES Replace the modulating solenoid __ The overheat thermostat has activated Reset the overheat thermostatand repeat this test NO __ Does the DEMAND indicatorlight go out immediately Es____ Replace the main driver board 6 NO Is there a240Vsupply at pin L2 on Replace the ignition board terminal CN2 NO Is there a240V supply at pin L3 o...
Page 38: ... below 60 C approx does the pwnp stop End of pump overrun test NO Is there a240V supply at pin 3on terminal X6 Replace the pump ____ Replace the pump overrun thermostat NO ____ Refer to section STANDBY Indicator does not illuminate NO ____ Replace the pump overrun thermostat OVFRHEAT PROTECTION TEST Does the burner shutdown if the Gas to Water heat exchanger exceeds too c NO ____ Replace the syste...
Page 39: ...39 ...
Page 40: ...619 This booklet is accurate at the date of printing but wtll be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued Improvement All goods sold are subtect to our nffiri l rnnrlltinns of Sale a copy of which may be obtained on application ISSUE 3 NOVEMBER 1995 8 716 45 167 ...
