2
Page
1. Introduction
3
2. Boiler Specification
4
2.1 Technical Data
4
2.2 Dimensions
5
2.3 Boiler connections
5
2.4 Function diagram
6
3. General Requirements
7
3.1 Related documents
7
3.2 Boiler location
8
3.3 Gas supply
9
3.4 Flue system
9
3.5 Air suply
11
3.6 Electricity supply
11
3.7 Guide to system requirements 11
4. Boiler installation sequence
14
4.1 General
14
4.2 Boiler delivery
14
4.3 Preparation of boiler location 15
4.4 Pipework connections
17
4.5 Installing the flue system
18
4.6 Mounting the boiler
18
4.7 Connecting the flue assembly 20
4.8 Electrical installation
22
4.9 Controls
23
5. Commissioning
25
5.1 Preliminary electrical checks
25
5.2 Gas supply
25
5.3 Water supply
25
5.4 Filling the heating system
26
5.5 Initial system flush ('cold')
26
5.6 Filling condensate trap
27
5.7 Initial lighting
27
5.8 Gas inlet working pressure
28
5.9 Adjusting central heating
output (range rating)
28
5.10 Main burner pressure
29
5.11 Functional checks
30
5.12 Checking flame
supervision device
32
5.13 Final system flush ('hot')
33
5.14 Fitting case
33
5.15 Handing over to user
33
Page
6. Servicing
34
6.1 Initial inspection
35
6.2 Routine maintenance
35
6.3 Recommisioning the boiler
37
7. Parts replacement
38
7.1 Initial preparation
38
7.2 Fan
40
7.3 Air pressure sensor
41
7.4 Burner
41
7.5 Electrodes
42
7.6 Condensate sump
43
7.7 Condensate trap
44
7.8 Temperature sensors (NTCs)
44
7.9 Gas valve
44
7.10 Main Heat exchanger
45
7.11 CH expansion vessel
46
7.12 Main safety isolating
transformer
47
7.13 Ignition transformer
48
7.14 Pump
48
7.15 Automatic air release
49
7.16 Automatic bypass
49
7.17 Diverter valve
50
7.18 Pressure gauge
51
7.19 Water section
51
7.20 DHW microswitch
52
7.21 DHW heat exchanger
53
7.22 Circuit boards
53
8. Fault finding
57
8.1 Introduction
57
8.2 Logical fault finding procedure 58
8.3 Fault finding using fault mode 60
8.4 Fault diagnosis using
status mode
62
9. Electrical diagrams
65
9.1 Functional flow diagram
65
9.2 Wiring diagram
66
9.3 Schematic appliance
circuit diagram
67
10. Short parts list
68
11. Supplementary information
for ECOmax
70
THE GAS SAFETY (INSTALLATION AND
USE) REGULATIONS 1994:
`In your own interest, and that of
safety, it is law that all gas appliances
are installed by competent persons, in
accordance with the above regula-
tions. Failure to install appliances
correctly could lead to prosecution.'
Leave these instructions with the user
when the installation is completed.