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18

221658B

5 Boiler Installation

Diagram 5.2

Diagram 5.1

CONTROLS
COVER

WING
NUT

FRONT
COVER

SHAKEPROOF
WASHER

22mm HEATING
RETURN

22x28 GRAVITY
DOMESTIC
CONNECTION

✽

22mm GRAVITY
DOMESTIC HOT
WATER STUB

22mm HEATING
FLOW

✽

NOTE: When cutting leave

sufficient length for fittings

4115a

4133

SECURING
NUT

5.1 Boiler Preparation

With the boiler still in the bottom tray, slide the controls cover
upward and remove it as shown in diagram 5.1.

Remove the front cover by undoing the wing nut, nut and
washer, lift the front cover off, see diagram 5.1.

Place front cover on one side until required.

Fit suitable compression fittings to the required tappings on the
boiler.

Note. For gravity domestic hot water use 22x28mm connections
on the stubs, see diagram 5.2.

5.2 Mounting the Boiler

As necessary, fit the blanking plate, see diagram 5.5.

Now make sure that the top, swing brackets are UPRIGHT.

Lift the boiler into position, hooking over the mounting bracket.

Swing the brackets over the two screws at the top. Hold the
swing bracket(s) in place whilst tightening the screw(s) onto it,
see diagram 5.3.

Remove the blue and red electrical connections from the fan,
see diagram 5.4.

Break the air pressure switch tube connections, see diagram
5.4.

Remove the fan assembly by removing the screws at the front,
slackening the screws at the rear and sliding it out, see diagram
5.4.

Taking care not to damage the gasket, secure the flue assembly
to the boiler using the previously fitted dogpoint screws noting
that these are keyhole fixings, see diagram 5.5.

Make sure of the correct fitting of the flue to the boiler.

For a side outlet cut the fan duct extension to the length
required, see diagram 5.6.

Remove any burrs and fit as diagram 5.6.

Fit the fan duct extension to the elbow and assemble to the fan
as shown in diagram 5.6.

Do not secure at this point with the screw.

Position the fan assembly and engage the fan duct extension
over the flue manifold. Make sure, by pushing the flue duct
extension that a secure seal is made.

Mark the final position of the fan duct extension through the
screw hole on the elbow, remove the assembly and secure with
the screw as diagram 5.6.

Secure the elbow to the fan outlet with the Jubilee clip.

For rear outlet cut and fit the fan duct extension, as diagram 5.6.
Secure with the Jubilee clip.

Fit fan assembly by engaging the fan duct extension over the
flue manifold spigot, see diagram 5.7.

Secure the fan assembly with the screws previously slackened
and removed.

Reconnect the blue and red electrical connections to the fan,
the polarity of the connections is not important.

Reconnect the air pressure switch tubes as shown in diagram
5.4.

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Содержание Xeon 50ff

Страница 1: ... the Heatcall Customer Service number 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of Guarantee Registration Fanned Flue Boiler S I T This is a Cat II2H3P Appliance Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For Ireland the rules in force must be u...

Страница 2: ... The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health CERAMIC FIBRE INSULATION PADS These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow n...

Страница 3: ... electrical supply failure the overheat safety cutoff device may need resetting remove the controls cover and press the reset button refer to diagram 1 Overheat Safety Cutoff If the overheat safety cutoff device operates on any other occasion than an electrical supply failure press the reset button as in Electrical Supply Failure If the overheat operates again turn the appliance off and contact yo...

Страница 4: ...iler being full of water consult your installation servicing company ALL SYSTEMS Turn the electrical supply on to the boiler and check that all remote controls are calling for heat To Turn the Boiler On Remove the controls cover by withdrawing it forward and off see diagram 1 Turn the control thermostat knob clockwise to any position between MIN and MAX The maximum temperature setting is about 82o...

Страница 5: ...f The manufacturer s instructions supplied TheGasSafety InstallationandUse Regulations TheBuilding Regulations The Building Standards Scotland Regulations applicable in Scotland Local Water Company Bye laws The Health and Safety at Work Act Control of Substances Hazardous to Health The Electricity at Work Regulations and any local regulations which may apply Detailed recommendations are contained ...

Страница 6: ...BS6500Table 16 not less than 0 75mm2 24 0 20mm 1 7 Contents of Packaging The boiler is delivered in one pack refer to Section 4 1 for contents 1 8 Water System This boiler may be fitted to an open vented or a sealed water system 1 9 Drain System A drain tap must be provided at the lowest points of the system which will allow the entire system boiler and hot water cylinder to be drained Draining ta...

Страница 7: ...l be in an unusual position special requirements are needed the current issue of BS6798 gives detailed guidance on these requirements A compartment used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment modified for the purpose may be used Details of essential requirements for cupboard or compartment design are given in the cur...

Страница 8: ...d to the external air the position allowing free passage of air across it at all times Car ports or similar extensions of a roof only or a roof and one wall requirespecialconsiderationwithrespecttoanyopenings doors vents or windows under the roof Care is required to protect the roof if it is made of plastic sheeting If the car port consists of a roof and two or more walls seek advice from the loca...

Страница 9: ...ver the feed and expansion cistern 3 5 Domestic Hot Water System General Thedomestichotwaterservicemustbeinaccordance with the current issue of BS5546 refer also to the current issue of BS6700 3 6 Cylinder For all systems supplying domestic hot water the cylinder must be indirect It is recommended that the cylinder be fitted with some form of temperature control 3 7 Gravity Domestic Hot Water with...

Страница 10: ... LOCKSHIELD VALVE FLOW RET There must always be a cold water path to the return connection of the boiler PUMPED RETURN PUMPED FLOW 4124 Diagram 3 4 1metre Min 27 metres Max 22mm VENT 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 INDIRECT CYLINDER ALTERNATIVE SYSTEM CONTROL VALVES HEATING SYSTEM PUMP FULLY PUMPED CIRCULATION SYSTEM DIAGRAMMATIC 6461 IF REQUIRED BYPASS 15mm MIN WITH LOCKSHI...

Страница 11: ...m volume Note A higher initial design pressure requires a larger volume expansion vessel Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 The charge pressure must not be less than the static head of the system that is the height of the highest point of the system above the expansion vessel The water content of the boiler is given in Data Table 1 3 13 Pressur...

Страница 12: ...BREAKER PRESSURE REDUCING VALVE 0051M Diagram 3 6 3 16 Filling a Sealed Water System Provision for filling the system at low level must be made Three methodsareshownindiagram3 6 Theremustbenopermanent connection to the mains water supply even through a non return valve 3 17 Water Makeup Provision must be made for replacing water lost from the system A make up vessel mounted above the highest point...

Страница 13: ...4 1 Unpacking Open the carton check the items supplied against the boiler pack contents list on the flap and diagram 4 1 4 2 Flue Position and Length Determine flue application length and terminal position before starting Refer to diagram 4 2 or 4 3 If you are using a Flue Bend or a Vertical Flue Kit please follow the instructions supplied with that kit To make a neat finish to the flue outlet a f...

Страница 14: ...ionalwallliner kit isusedtheflue can be fully installed from the inside For a wall thickness of over 300mm the external flue hole will need to be made good from the outside This applies also if you use the flue kit without the optional kit irrespective of wall thickness 4 4 Rear and Side Flue Application Select the boiler location and flue application with due regard to the terminal position Take ...

Страница 15: ...am 4 5 Drill holes and plug to suit No 12x2in wood screws fit the screws allowing sufficient clearance about 5mm to accept the swing brackets see diagram 4 5 Secure the mounting bracket to the wall with No 12x2in wood screws and plugs see diagram 4 5 4 7 Flue Duct Mark the duct to the length required this length allows for expansion see diagram 4 6 for rear flue and diagram 4 7 for side flue then ...

Страница 16: ...e manifold secure with the two self tapping screws supplied in the loose items pack It should now not be possible to remove the manifold 4 10 Rear Fitting Fit the self adhesive foam seal provided in the flue pack around the air duct terminal at the position shown in diagram 4 13 4 11 Side Fitting Fit the self adhesive foam seal around the air duct terminal such that when installed the seal will be...

Страница 17: ...ler is not to be fitted for some time cover the hole in the wall On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room see diagram 4 12 Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured 4 13 Internal Access Flue If access to the outside wall is not practical...

Страница 18: ... Remove the fan assembly by removing the screws at the front slackening the screws at the rear and sliding it out see diagram 5 4 Takingcarenottodamagethegasket securetheflueassembly to the boiler using the previously fitted dogpoint screws noting that these are keyhole fixings see diagram 5 5 Make sure of the correct fitting of the flue to the boiler For a side outlet cut the fan duct extension t...

Страница 19: ...clip from the loose items pack peel off the backing paper and position it in a suitable place to secure the incoming cable Using heat resistant 85o C cable of at least 0 75mm2 24 0 2mm to the current issue of BS6500 Table 16 and of a suitable length thread through the cable clamps secure into the plastic clips and connect to appropriate terminals see relevant diagram 5 9 or 5 10 Standard colours a...

Страница 20: ...RATED VERTICAL REAR RIGHT LEFT SCREW 2 JUBILEE CLIP Cutting MARK lengths Lefthand flue does not require cutting SIDE LEFT FAN DUCT EXTENSION SIDE RIGHT REAR FLUE ELBOW FAN DUCT EXTENSION FAN DUCT EXTENSION 2 5mm dia drill 4618 4106 Diagram 5 5 BLANKING PLATE NUT 3 KEYHOLE LOCATION LUG 4617 4134 GASKET ...

Страница 21: ...iring diagrams for either a sealed water system or fully pumped open vented diagram 5 10 and 9 7 PUMPEDHEATINGANDGRAVITYDOMESTICHOTWATER Make sure that the red link is connected between terminals SL and 9 on the terminal block as diagram 5 9 Make sure that the supply cable and all external cables are secured and away from hot surfaces 5 11 Testing Checks to ensure electrical safety must be carried...

Страница 22: ... is isolated from the electrical supply Makes sure that the control thermostat is turned to O the Off position Turn the gas service cock On see diagram 6 1 Testthepilotsupplytubeanditsconnectionsforgassoundness as follows Disconnect the ignition lead from the PCB see diagram 5 9 Remove the combustion chamber front see diagram 6 3 WARNING The fan operates on mains voltage terminals will become live...

Страница 23: ...off either by the control thermostat or a remote system control To make sure that the flame supervision device is working correctly the following should be done 1 With the main burner alight turn the gas service cock Off see diagram 6 1 After a short period the main burner and pilot will go out 2 The correct working of the flame supervision device is shown by neon 4 going out within 10 seconds and...

Страница 24: ...er Adjust the pump to the system design setting then balance the system Having achieved a satisfactory condition operate the boiler with the bypass fully closed on minimum load normally this will be central heating only with one radiator in the main living area operating The bypass valve should be gradually opened to achieve a temperature difference no greater than 20o C between the flow and retur...

Страница 25: ...ervicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness and carry out functional check on controls Unless stated otherwise all parts are replaced in the reverse order to removal 8 1 Access Refer to diagram 6 6 and slide the controls cover forwards and off Remove the outer case see diagram 6 5 Note As an aid to Servicing the...

Страница 26: ... 4 Main Injector Withthemainburnerremovedthemaininjectorcanbeinspected and cleaned as necessary see diagram 8 5 If removing for cleaning do not use a wire or sharp instrument on the hole Use a little suitable sealant on the external thread when refitting to make sure a gas tight seal is made 8 5 Pilot Burner Electrode and Pilot Injector Clean the pilot burner and electrode To remove the electrode ...

Страница 27: ...inuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter Refer to neon indicators An Aid to Fault Finding diagram 9 1 Boiler Fault Finding diagram 9 2 Pump Overrun Fault Finding diagram 9 3 the Functional Flow diagram 9 4 Gravity Domestic Hot Water and Fully Pumped Central Heating diagram 9 5 Fully Pumped Open Vented or Sealed Water System the Picto...

Страница 28: ...ard With pilot lit does spark stop Isolate supply test harness and replace as required Is there 230V between main multi functional control solenoid black and blue cables YES Replace multi functional control Is Neon 4 lit Does main burner light System satisfactory Is there 230V between SL and N and between L and N Is there 230V between yellow connection on overheat device and N Is there 230V betwee...

Страница 29: ...s applied Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility The pump should run for several minutes after remote controls have stopped calling for heat Before using the fault finding chart ensure all wiring is correct and in good condition the pump is not faulty and check the PCB fuse F2 FOR FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS ONLY Diagram 9...

Страница 30: ...f no switch is fitted link will make the circulation pump run constantly F1 F2 or or or p Diagram 9 4 Diagram 9 5 FUSE TYPE F1 F2 F1A SPARK ELECTRODE O H CUTOFF CONTROL STAT FAN AIR PRESSURE SWITCH PILOT SOLENOID MAIN SOLENOID N N N N N N N N O C N C L K2 K1 2 3 N N bl w w br y y y r bl r bk bl y br bl bl bk bl KEY bk BLACK br BROWN bl BLUE p PURPLE or ORANGE w WHITE r RED y YELLOW SL PUMP WIRED I...

Страница 31: ...ntral heating system remote controls and not to control box Yellow link fitted to bridge out the overheat cutoff b g y E N g y K1 K2 ELECTRODE PN 5859 GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING b bk AIR PRESSURE SWITCH g y g y CHASSIS EARTH g y w p or y br b y w y OVERHEAT CUTOFF MULTI FUNCTIONAL CONTROL br 2 Ensure RED LINK connected between 9 and SL r 3 PLUGS FUSES F1 F2 F1A SEQUENCE ...

Страница 32: ...T 3 AMP N E N g y br CIRCULATON PUMP L r See Note SL P PN FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEM 5860 b N b br b MULTI FUNCTIONAL CONTROL br b Remove red link between 9 and SL when fitting a time control etc If no switch is fitted link will make the circulation pump run constantly ELECTRODE NC KEY b BLUE bk BLACK br BROWN g y GREEN YELLOW or ORANGE p PURPLE r RED y YELLOW w WHITE 3 2 y p ...

Страница 33: ...oof washers in the front of the control box Remove the split pin and withdraw the thermostat phial from its pocket Releasethecapillaryfromthebaseandplasticretaining clip then remove it from the split grommet Release the capillary from its clips Remove the thermostat complete from the boiler Re assembly note When fitting the thermostat make sure that the thermostat phial is covered with heat sink c...

Страница 34: ...he PCB to the main terminal strip control thermostat and earth connection Release the main terminal strip and plastic label Carefully pull the board away from its supports When refitting refer to wiring diagram 9 6 or 9 7 as appropriate 10 5 Pilot Burner and Pilot Injector Proceed as Section 8 3 and 8 5 10 6 Electrode Proceed as Section 8 3 and 8 5 Gain access as Section 5 6 to remove lead from co...

Страница 35: ...s 10 8 Solenoid diagram 10 3 Remove the electrical plug from the multifunctional control Remove the securing screw and then the solenoid Assembly 10 9 Main Burner Remove the main burner as Section 8 3 10 10 Main Injector Remove the main burner as Section 8 3 Remove the main injector as Section 8 4 Diagram 10 3 4360 SOLENOIDS ...

Страница 36: ...moved the rear insulation can be removed and replaced 10 12 Viewing Window diagram 10 6 Remove the old self adhesive aluminium foil gasket and the old mica window Replace with a new mica window Peel off the backing paper and secure with new self adhesive aluminium foil gasket see diagram 10 6 Ensure no air bubbles are trapped underneath the foil Important Make sure that the mica window fully cover...

Страница 37: ... sure that the plastic tubes arefittedasshownindiagram10 7andthatelectricalconnections are made as shown in diagrams 9 6 or 9 7 10 14 Fan diagram 5 4 Remove the electrical connections and disconnect the air tubes Remove the fan assembly securing screws at the front and slacken those at the rear and withdraw the assembly Make sure that the earth connection is remade onto the new fan assembly The po...

Страница 38: ...e GC number of the appliance and part Key No Part No Description GC Part No 1 801020 Multifunctional control E25264 2 208040 O ring 334 592 3 203096 Injector 50ff 313 305 4 203431 Pilot burner 379 204 5 801236 Mica window Gasket 6 800432 Fan assembly 50ff 278 000 7 202626 Spark electrode and lead 313 998 8 K3580 Clip 390 983 9 800849 Thermostat control 50ff 10 202201 Air pressure switch 313992 11 ...

Страница 39: ...39 221658B Diagram 11 1 7910 1 2 6 4 5 10 9 8 7 11 13 14 15 3 11 Spare Parts ...

Страница 40: ...40 221658B Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions ...

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