Section 1 - General ..................................................................................... 6
1.1 Introduction ................................................................................... 8
1.2 Operation ...................................................................................... 8
1.3
Safe Handling ............................................................................... 8
1.4
Optional Accessories .................................................................... 8
1.5 Safety............................................................................................ 9
1.6
Safe Handling of Substances ....................................................... 9
1.7
Location of Boiler ......................................................................... 9
1.8
Air Supply ................................................................................... 10
1.9
Gas Supply ................................................................................. 10
1.10 Water Circulation System ........................................................... 10
1.11
Boiler Controls ............................................................................ 10
1.12 Electrical Supply ......................................................................... 10
1.13 Condensate Drain ....................................................................... 10
1.14 Boiler Dimensions, Services & Clearances .................................11
1.15 System Requirements - Central Heating .................................... 12
1.16 System Requirements - DHW ..................................................... 13
1.17 System Balancing ....................................................................... 13
1.18 Water Treatment ......................................................................... 13
Section 2 - Installation .............................................................................. 14
2.1
Boiler Assembly - Exploded View ............................................... 14
2.2 Unpacking ................................................................................... 15
2.3
Wall Mounting Template.............................................................. 16
2.4
Preparing the Wall ...................................................................... 16
2.5
Fitting the Wall Mounting Plate ................................................... 16
2.6
Mounting the Boiler ..................................................................... 16
2.7
Flues and Locations.................................................................... 17
2.8
Flues and Locations - Continued ................................................ 18
2.9
Horizontal Flue Positions ........................................................... 19
2.10 Vertical Flue Positions ............................................................... 19
2.11
Flue System Dimensions ........................................................... 20
2.12 Fitting the Turret.......................................................................... 20
2.13 Cutting the Flue .......................................................................... 21
2.14 Assembling the Vertical Flue ...................................................... 22
2.15 Condensate Drain ....................................................................... 23
2.16 Condensate Drain - Cont. ........................................................... 24
2.17 Connections & Filling .................................................................. 25
2.18 Connections & Filling Cont. ........................................................ 26
2.19 Electrical Connections ................................................................ 27
2.20 Installer Wiring ............................................................................ 27
2.21 External Wiring ........................................................................... 28
2.22 Wiring Diagram ........................................................................... 29
2.23 Replacing Pre-Fitted Mains Cable .............................................. 30
2.24 Commissioning and Testing ........................................................ 30
2.25 Initial Lighting .............................................................................. 31
2.26 User Interface Commissioning .................................................... 32
2.27 Changing Boiler Operating Mode .............................................. 32
2.28 Preheat Function ....................................................................... 32
2.29 Intelligent Preheat Function ....................................................... 32
2.30 Menu Operation .......................................................................... 33
2.31 Setting Maximum and Minimum Rates ....................................... 33
2.32 General Checks .......................................................................... 34
2.33 Restart Procedure ....................................................................... 35
2.34 Handing Over.............................................................................. 35
Section 3 - Servicing ................................................................................. 36
3.1
Servicing Schedule ..................................................................... 36
3.2
Removal / Replacement of Components .................................... 37
3.3
Draining the Boiler ...................................................................... 37
3.4
Boiler Front Panel Removal / Replacement ................................ 38
3.5
Flue Manifold Removal/Replacement ......................................... 38
3.6
Fan and Venturi Assembly Removal and Cleaning ..................... 39
3.7
Burner Removal and Cleaning .................................................... 40
3.8
Cleaning the Heat Exchanger ..................................................... 40
3.9
Ignition / Detection Electrode Replacement / Inspection ............ 41
3.10 Cleaning the Condensate Trap ................................................... 41
3.11
Burner Injector Replacement ...................................................... 42
3.12 DHW Filter & DHW Flow Regulator Cleaning/Replacement ....... 42
3.13 External System Filter Cleaning Guide ....................................... 42
3.14 Burner Replacement ................................................................... 43
3.15 Return Thermistor Replacement ................................................. 43
3.16 Spark Generator Replacement ................................................... 43
3.17 Gas Control Valve Replacement ................................................. 44
3.18 Diverter Valve Actuator Replacement ......................................... 44
3.19 Condensate Trap Replacement / Cleaning ................................. 44
3.20 Primary PCB Replacement ......................................................... 45
3.21 DHW Flow Turbine Sensor Replacement ................................... 46
3.22 Pressure Gauge Replacement ................................................... 46
3.23 PRV Replacement ...................................................................... 47
3.24
Pump Automatic Air Vent Replacement ..................................... 47
3.25 Replacement of DHW Thermistor ............................................... 48
3.26 DHW Plate Heat Exchanger Replacement ................................. 48
3.27 Diverter Valve Body Assembly Replacement .............................. 49
3.28 Pump Head Replacement ........................................................... 50
3.29 CH Water Pressure Switch Replacement ................................... 50
3.30 Flow Thermistor Replacement .................................................... 51
3.31 Heat Engine Replacement .......................................................... 52
3.32 Expansion Vessel Recharging & Replacement .......................... 53
Section 4 - Fault Finding ........................................................................... 54
4.1
Main Menu, Fault Help ................................................................ 54
4.2
Overheat Lockout ....................................................................... 54
4.3
Ignition Lockout........................................................................... 55
4.4
Flame On Before Gas Valve On ................................................. 55
4.5
Low Water Pressure ................................................................... 55
4.6
Flame Loss ................................................................................. 56
4.7
Fan Fault..................................................................................... 56
4.8
Flow Thermistor Fault ................................................................ 57
4.9
Return Thermistor Fault ............................................................. 57
4.10 Outside Sensor Fault .................................................................. 58
4.11
No CH Operation but DHW works OK ........................................ 58
4.12 No DHW but CH Works OK ........................................................ 59
4.13 No Display .................................................................................. 60
4.14 DHW Thermistor Fault ................................................................ 60
Section 5 - Spare Parts ............................................................................ 61
Section 6 - Benchmark to Commissioning ................................................ 62
CONTENTS
5
Installation and Servicing
