Refer to Figure 11.
a)
The boiler is supplied with 22mm copper tails for both
upwards and downwards (optional) flow and return pipe routing
suitable for compression or soldering connections.
USE EXTREME CARE IF SOLDERING THE JOINTS NEAR TO THE
APPLIANCE. IF BOILER IS LOCATED IN TIGHT SPACE IT IS
RECOMMENDED TO REMOVE THE PIPES FROM THE BOILER.
b)
Connect the central heating system pipes to the central heating
flow and return pipes on the boiler. If downwards routing is
required: The sealed ends must be removed before connecting to
the heating system pipes. The upwards pipes must be used for
connecting to a vent pipe (open system) or fitting to an automatic
air vent (sealed system). The remaining pipe must be solder sealed.
The flow and return sensors have to be removed from the upwards
pipes and reconnected to the downward pipes (Fig 47; flow is
nearest to the front).
c)
Commission the central heating system as described in section
5.1, and then proceed to section 4.5.
15
10
MOUNTING THE APPLIANCE
11
SERVICE CONNECTIONS
CONNECTIONS
4.4
CENTRAL HEATING SERVICE
Refer to Figure 11.
Connect the gas supply pipe to the gas service cock. It is
recommended that a minimum of 22 mm diameter OD copper
4.5
GAS CONNECTION
12
CONDENSATE CONNECTIONS
4.7
AIR / FLUE DUCT INSTALLATION
For correct flue installation please refer to the installation
instructions that are provided with the individual flue kit as
described in sections 2.5 - 2.7.
a)
Measure the required flue length as shown in Figure 13. Refer
to section 2.5 to determine whether any extension kits are
required. Installations using only the standard ducts or standard
ducts with straight extensions are described in this section.
Installation instructions for all other flue systems are included in
the various flue kits.
b)
Ensure that all (inner and outer tube) sealing rings are
Refer to Figure 12.
Connect either a Ø21.5mm or Ø22mm plastic push fit or
adhesive overflow pipe to the condensate outlet. It should be
piped to drain, preferably within the building, maintaining a
continuous 2.5° fall away from the appliance. Note; if an
additional “U” trap is fitted between the appliance and the
discharge point, then a visible air break is necessary between the
appliance and trap, because a trap is already provided within
the appliance. Ø32mm pipe should be used for external pipe
work, or if the appliance is installed in a garage. If the drain is
routed externally to a drain or soak away, then the external
length should be kept as short as possible and not exceed 3000
mm. Protection from freezing in cold weather conditions is also
advisable. Ensure that the condensate discharge system complies
with any local regulations in force.
In exceptional circumstances, such as when a boiler is installed in a
basement without drainage, it may be necessary to install a
condensate pump to carry condensate up to ground/drain level. Such
products are available from Grundfos Pumps Ltd on: 01525 850000
and Pump House on: 0115 922 2211.
22
ROUTINE SERVICING
6
6.1
COMBUSTION CHECK
The appliance incorporates a flue sampling point on the
appliance flue elbow, or appliance vertical flue adaptor. If the
service engineer has suitable equipment to analyse the flue gas,
the plastic cap may be removed and an adequately sized sample
tube fitted. Operate the appliance in Service mode, (see section
5.2). After ten minutes operation check the CO
2
/CO values and
compare with those figures stated in section 2.3. Do not forget to
replace the plastic cap after use.
When the appliance is operating at maximum output check that
the gas supply pressure is 20.0 mbar, using the inlet pressure test
point, located on the gas cock.
Before commencing any service operation, ISOLATE the mains
electrical supply, and TURN OFF the gas supply at the main
service cock.
To ensure continued efficient operation of the appliance, it is
recommended that it is checked and serviced as necessary at
regular intervals. The frequency of servicing will depend upon the
particular installation conditions and usage, but in general once a
year should be adequate. It is the law that a competent person,
such as British Gas or other CORGI registered personnel, must
carry out any service work.
Service the appliance by following the full procedure detailed below:
25
CONTROL PANEL
26
COMBUSTION CASE PANELS
from the igniter and detection electrodes.
e)
Unscrew the screw holding the gas valve lead plug, and
disconnect the plug.
f)
Disconnect the electrical leads from the fan (2 plugs).
g)
Undo the nut holding the gas valve feed pipe to the gas
isolating cock, and disconnect.
h)
Remove the gas control valve, fan & burner assembly, by
carefully pulling forward the combustion chamber front and
rotating the assembly anticlockwise so that the burner points
forward, then disengage the gas valve feed pipe from the casing,
by lifting up the assembly. Take care not to damage the
insulation.
i)
The assembly may then be inspected.
j)
Re-assemble in reverse order.
VALVE, FAN & BURNER ASSEMBLY
6.2
GAS CONTROL
Refer to Figures 25, 26, 27, and 28
a)
Remove the hinges and take off the hinged front panel.
b)
Remove the decorative front cover (4 screws).
c)
Remove the sealed chamber door (6 screws)
d)
Disconnect the igniter plug, earth lead and detection plug
6.4
IGNITION & DETECTION ELECTRODES
a) Inspect the ignition and detection electrodes in situ. If
necessary, clean using a soft brush. If either the electrode or the
ceramic insulation shows signs of damage or wear, replace the
electrode(s) and their gasket.
b) Check that the alignments of the ignition and detection
electrodes are correct. Refer to Figure 29. Adjust by carefully
bending the tip of the electrode rod whilst supporting the base of
the rod. Do not put any pressure on the ceramic insulation.
6.3
BURNER
Inspect, and if necessary clean the main burner ports using a soft
brush or vacuum cleaner. Do not use a wire brush or any
abrasive material.
4.6
CONDENSATE CONNECTION
pipe be used to within 1000 mm of the gas service cock.
