Chaffoteaux & Maury STERLING PP Installation And Servicing Instructions

STERLING

PP

Room SeaIed Fanned Balanced Flue

Combination Boiler

GAS SAFETY (INSTALLATION AND USE) REGULATIONS.

It is the iaw that all gas appliances are installed by a competant person

in accordance with the above regulations

(For use on natural gas only. GZO)

G.C. No 47 980 07

from serial number 495 089

010

- 32.

CC

Installation and

Servicing Instructions

(leave these instructions with the user)

Looking Good.Heating Better

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

CONTENTS

Health and Safety information

1

1.

INTRODUCTION

1.

1.1.

12.

1.3.

1.4.

1.4.1. .

1.4.2.

1.4.3.

1.5.

1.6.

1.6.1.

1.61

1.63.

1.6.4.

1.65.

1.6.6.
l-6.7.

General description, special features. guarantee
Dimensions Fig. 1
Technical Data
clearances
Wall thickness
Rear flue outlet Fig. 2
Side flue outlet Fig. 3. Fig. 3a. Fig. 3b
Other flue arrangements Horizontal Fig. 3c

Description of components and location Fig. 4
Description of operation
Central heating Fig. 5
Hot water Fig. 6
Gas (also see 2.7)
Functional flow diagram Fig. 7
Safety controls
Functional flow wiring diagram Fig. 8

Illustrated wiring diagram Fig. 9

2. INSTALLATION REQUIREMENTS

2.1. General

2.2. Location

23.

Water circulation system

2.4. Siting the flue terminal Fig. 10

2.5. Air suppiy

2.6. Elecaicai supply

2.7. Gas supply

3.

SYSTEM GUIDANCE

3.1.

General

32

System controls

3.3.

Bump Fig. 11

3.4.

Expansion vessel

3.5.

Mains water connection

3.6.

Fiig and recharging Fig. 12. Fig. 13 (page 12)

3.7.

Make up system

3.8.

Pipzwork

3.9.

Domestic expansion vessel

39.1.

Boiler replacement

3.9.2.

Existing systems

3.10

Cylinder

3.11

Inhibitors and water conditioners

3.12

Add on devices

3.13

Heating and hot water systems Fig. 14, Fig. 15. Fig. 16. Fig. 17

3.14

Shower application Fig. 17a

2
2
3
3
3
4
4
4
5
6
6
6
7
7
7
8
8

9
9
9
9

10
IO
10

10
11
11
11
11
11
11
11
11
12
12
12
12
12
13
14

(4

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

CONTm (cant )

4.

INSTALLING THE BOILER

Page.

4.1.

4.2.

4.3.

4.4

4.5.

4.6. .
47

4.8.

4.9.

4.10.

4.11.

4.12

4.13.

General information
Positioning the boiler Fig. 18
Rear outlet flue Fig. 19
Side outlet flue Fig. 20
Jig plate Fig. 2 1
Gas and water connections Fig. 22

Water connections

Gas connection

Fitting the boiler Fig. 23
Fitting the safety valve Fig. 24
Fitting the flue (up to 700 mm long) Fig. 25
Fitting the flue (over 700 mm long)
Connection the pressure switch Fig. 26
Electrical connections Fig. 27

5.

EXTERNAL CONTROLS

5.1.

Time clock - Time clock and room stat Fig. 28

19

5.2. Time clock and zone valves (spring return) Fig. 29

19

53. Programmer and zone valves Fig. 30

20

5.4. Honeywell & Satchweil controlled zones Fig. 3 I

20

5.5.

Frost thermostat Fig. 32

20

6.

COMMISSIONING

6.1.

Hot water circuits. filing Fig. 33

21

62.

Central heating circuits. filling, Fig. 34

21

6.3. Lighting the boiler Fig. 35

21

6.4.

Gas rate adjustment Fig. 36. Fig. 37, Fig. 38

22

6.5. D.H.W. flow rate adjustment (see also 6.7. Fig. 39a)

23

.6.6. Adjusting the heating system by-pass Fig. 39

23

6.7.

D.H.W. flow rate adjustment Fig. 39a

23

6.8. Pump switching adjustment Fig. 39b

23

6.9. Fitting the casing Fig. 40

24

7.

ROUTINE SERVICING

7.1.

7.2.

7.3

7.4.

7.5.

7.6.

7.7.

Generai requirements
To remove front casing Fig.4 1
To remove combustion chamber Fig.42
To remove burner assembly Fig.43
To remove pilot Fig.44
To clean heating return filter Fig.45
Cleaning and replacement of parts
To check operation of safety valve Fig.46

15
15
15
16
16
16
16
16

17
17
17
18

18

18

25

25

25

26

26

26

27

27

(4

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

(cant ) CONTENTS

Pace.

8.

REPLACEMENT OF PARTS

8.1.

82.

8.3.

8.4.

8.5.

8.6.

8.7.

8.8.

8.9.

8.10.

8.11.

8.12.

8.13.

8.14.

8.15.

8.16.

8.17.

8.18.

8.19.

8.20.

821.

8.22.

823.

824.

8.25.

8.26.

827.

8.28.

8.29.

8.30.

8.31.

8.32.

8.33.

8.34.

To remove thermocouple Fig. 47. Fig. 48
To replace electrode and lead assembly Fig. 49
To repiace overheat thermostat Fig. 50

To replace ignition microswitch Fig. 5 1
To replace C.O.V. microswitch Fig. 52

To replace flow switch assembly Fig. 53

. To replace venturi Fig. 54

To replace primary heat exchanger Fig. 55

To remove electrical control box Fig. 56. Fig. 56a (page 33)

To replace pump head Fig. 57
To replace change over valve Fig. 58. Fig. 58a (page 34)

To replace secondary heat exchanger Fig. 59
To replace air separator Fig. 59a

To replace boiler thermostat Fig. 60

To replace boiler limit thermostat Fig. 61
To replace D.H.W. thermostat Fig. 62
To replace spark generator Fig.63

To replace P.C.B. Fig. 64 Electrical box layout Fig. 65
To replace therm0 electric vaive Fig. 66
To replace solenoid valves Fig. 67

To replace heating body linings Fig. 68
To replace fan assembly Fig. 69
To replace pressure switch Fig. 70
To m-pressurise expansion vessel Fig. 7 1
To replace pressure gauge Fig. 72
To replace the domestic expansion vessel Fig. 73
To repiace main burner Fig. 74
To replace burner manifold assembly Fig. 75
To replace piiot injection Fig. 76
To replace expansion vessel Fig. 77
To replace viewing window Fig .78
To replace main gas valve body Fig. 79
To replace the thermometer Fig. 80
To replace safety valve Fig. 8 1

9. FAULT FINDING

9.1.

Logic sequence

9.2.

Central heating operation

9.3.

Domestic hot water operation

9.4. Fault finding tabular chart

28
28
28
29
29
29
30
30
30

31
31
32
32
33
33
33
34
34
35
35
35
35
36
36
36
37
37
37
38
38
38
39
39
39

40
41
42
43

SHORT SPARE PARTS LIST

Rear cover

(iii)

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

CO&TRO

COF SUBSTANCE HARMFUL TO HEALTU

PORTANT

To comply with the Conuoi of Substances Harmful to Health Regulation 1988 we are required to
provide information on the following substance that is contained in this appliance.

Combustion Chamber Lining

bLia&al

Alumina Silicone Fibre
During servicing, keep the dust generation to a minimum and avoid

inhaling any dust and contact with the skin and eyes. Normal handling
and use will not present any discomfort. although some people with a
history of skin complaints may be susceptible to imitation.

When disposing of the lining ensure that it is securely wrapped and
wash hands after contact.

1

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. . .

L INTRODUCTION

The STEELING PP is a waii mounted. low water content
fanned balanc& Bue appliance suitable for central heating
and hot water via a non storage waler lo water heat
fachanger. The

maximum output is 23 kW (78460 Btwh).
The boiler is designed for sealed systems only and included
in the appfiance is the expansion vessel. circulating pump,
temperature and pressure gauges. safety valve. electric
connection box. and domestic expansion vessel.

The standard tlue assembly supplied with the boiler is
100 mm (4 in) dii pip. CM be directed to the rear or to
the left or right and can be extended to a maximum

length of 3 m. or 1.6 metres horizontally using the avai­lable 90” bend (see sections 1.4.1. 1.4.2 and 1.4.3
figures

2.3.3a.

3b. 3~).

Special features tndude :

- Output to central heating fully range rated between
l/3 and fuil output.

- High efficiency.

- Special jig plate enabling all pipework io be instai­led before instailing appliance.

- Independent control over central heating Bow tem-

perature

and

hot water.

- Fully adjustable central heating flow temperature.

- Regulation between 50” C and 62” C.

- High limit thermostat for both boiler and hot water.

- Water flow switch to protect appliance.

- Suitable for showers with compatible mixer valves.

G-tee -

The manufacturer’s guarantee on this appliance is for 12 months from the -iate of purchase. The guarantee is void. if the
appliance is not installed in accordance with the recommendations made herein.

,

1.1

Fg. 1

REARounEr

FLUE

SIDE OUM

FLUE

A
B
C
D
E
F
G

H
J
K
L
M
N
P
R
S

T

mm

820.5

391.0

365.0

100.0

169.5

654.5

43.0

50.0

75.0

260.0

150.0

972.5

13.0

61.0

30.0

152.0

112.0

in

32.3

15.4

14.4

4.0

6.7

25.7

1.7

2.0

3.0

10.2

6.0

38.3

0.5

2.4

1.2

6.0

4.4

2

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

.. . Technical Data

Eat mta

Input

...........................................

28.90 kW 98612 Btwh

output ........................................

23.00 kW 78480 Btuh

Water 5ow raised

45 “C (81 "D

..............................

7.4 bin

1.7 gahin

Water flow raised

35 “C (63 "D .............................. 9.5 vrnin

2.1 galhin

Water flow raised

30 “C (54 OFI.. ............................

11.1 Ymin

2.5 @hnin

Maximum temperature.. ............. 60 “C

140 OF

Maximum pressure.. ...................

10 bar

150 psi

hfinimurn wo*g pressure.. ......

.6 bar

Qpsi

Gas me ......................................

2.743 m%h 96.87

R3/h

Bumer pressure..

........................

11.8

mbar

4.7 in wg

Central heating
hbximum input

..........................

27.64 kW 94313 Btwh

Maximum output.. ......................

22.00 kW 75068 Btuh

Gas mte (maximum).

..................

2.63 m%‘h

92.98

A3h

Burner pressure.. ........................ 11.2 mbar

4.5 in wg

Minimum input.. .........................

10.85 kW 37020 Btu/h

Minimum output..

.......................

7.64 kW

26062 Btuh

Gas rate (minimum) ................... 1 .O mJ/h

35.31

R3/h

Burner pressure..

........................

I .5 mbar

0.6 in wg

Minimum flow me

.....................

3OOm

1.1 galmn

Maximum pressure..

...................

2s bar

36.5 psi

NaturaI gas

Manifold injectors 14 of..

............

1.28 mm

0.05 in

Filot injector.. .............................. 0.3 mm

0.01 in

Gas section restrictors 2i3 valves

4.4 mm

0.17 in

l/3 valve..

2.3 mm

0.09 in

­I

,

conoatioo8

Gas ._... . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22mmcopper

Heating ilow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

=mcopper

Heating return

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

x=ncopper

Mains coid water inlet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15mmcoppef

Hot water outlet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1s mrncopper

Electrical supply 240 V - 50 Hz. fused

at

3A

Electrical consumption

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 watts

IntemaiQ

fused. two at 2A

(BS 4265)

weight

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 kg 92.4Ib

Water capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 litres 7 pints

Ignhh - Anstoss continuous spark generator

EIectmde -

Chatkteaux

et Maw-y

Ltd. spark gap 5 mm

Bofla thamosmt -

EGO, lMlT (82°C)

Boila

iknit thermostat -

SOPAC /JAEGER (85°C)

Hot

wata

fitnit

thermostat

- SOPAC /JAEGER (57°C t 3°C)

Safety overheat thertnosmt (Tokoswitch - (105”C-l

klmwood - (105”O

Guvahw -AEMF
Fan motor - SEL
Pressure switch - DUNGS 102 Pa i 55 Pa
Pump head - GRUNDFOS UP 15160
c.Eexpa&n~initial&~gep1wsm-0.6Sbar(9.6psi~
Domestic,a&~nvess&ithfch~gcprarmr-2bar(30psi)

1.3

lvIfaimrrm Clearances around Boiler

Top above air duct ..........

somm (2il-l)

Bottom below case..

........

15Omm (6in)

Sides ...............................

1wmm (4in)

Front.. ............................. 600 mm (24 in)

1.4 Wall Thicknesses

The standard flue assembiy can accomodate the

following thicknesses.
Rear:h-n55mmto576mm
Side : from 55 mm to 392 mm
(this allows for a

minimum clearance of 100 mm between the appliance and the side wall. As this dime&On
increases. so the maximum side wail thickness avaiiable decreases).
Extension flue assemblies are available to accomodate wail thicknesses of :

Rear : hn-n 577 mm to 2876 mm
Side : from 393 mm to 2692 mm
See figs. 2 and 3 for

details of

number of extensions required.

IMPORTANT NOTE : The extension ducts supplied. up to a maximum

of

3. will in fact permit a greater length than

indited to be covered. The

ducts MUST be

cut

so that the maximum length from the centre line of the flue turret to

the outermost point of the air duct DOES NOT FXCEED 3 metres horizontal. Greater length must not be used.
Seesections 1.4.1. 1.4.2. 1.4.3.

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. . .

1.4.2

Side Fke Orrtfet Horizontal

A0.l

SlDE DIJTLET ASSEMBLY

Fig.33

PLASTIC AIR DUCT

1.4.3

Rear FIae

Outlet

Horizontal

To cat flat assembly to length

- Measure wall thickness tn.

- Add 74 mm. this wiii give required length (L).

- hiark plastic air duct for length (L) and cut off
surplus (from piain end).

N.B. If extension sections are used ensure these are
6rmiy pushed together. see fis. 3b and 3c and a faII of 5
mm per metre length should be provided (see section

- Cut off same amount from aluminium flue duct

flue exreneion frcceesofy

Paft No. 82823.00

REAR

OUTLET

ASSEMBLY

To cat flae usaubtp to length

- Measure from external walI face to centre line of
appliance and substract 37 mm (this will give
required length “L”) .

- Cut off surplus from plastic air duct (plain end).

N.B. If extension sections are used ensure these are
fitmiy pushed together. see figs.

3b and 3c and

a tXI of 5

mm per metre length should be provided (see section

Flue extension accessory

- Cut off same amount from

Pefl No. 62623.00

akuninium flue duct (plain end).

(GC. 264459)

(1 meue length)

Other flue Arrangements Horhontal

*

“OE

.-E

9%

OE

.

1

2

.-

Fig. 3c

1. Distance from internal comer 300 mm without
kit.107 mm with kit No 76216 (GC No 264 833).

2. Distance beIow balconies or eaves 200 mm
without kit, 107 mm with kit No 76216 (GC No
264 833).

3. Appliance is normally supplied packed with
standard 650 mm staight flue section. Additional
straight extension lengths of 1 metre, part No
62823 (GC No 264 459). can be use up to a total
straight length of 3 metres. It is also possible to
incorporate one bend in the Bue using part No
65572 (GC No 264 835). In this case the length
Ll + 12 should not

exceed

1.6 metres

horizontaily.

4

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

1.5 Description

of

Components and Location

6

27

19 li i8

Fig. 4

The appliance is mounted in a steel case which has a
white epoxy resin paint f&h.

1. chaarir:
The chassis is a rigid plated mild steel pressing on which
alI components are mounted.

2. PIue hood:

Is an ahknium alloy casting onto which the two speed
fan is mounted.

3. comhuation chamki:

Thk is assembled kern a number of components
mounted onto the chassis. The front panel is simply
removed for servicing complete with the expansion vessel,
a hook is fitted below the appliance to accept and retain
the panel during servicing.

4. EqJanrion veuch

The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is stied for a .normai system

water

content where the

toad is equivalent to the maximum output of the boiler.

The charge pressure is 0.65 bar.

5.

Pilot uwrity is by thermocouple flame f%.ue.

6.

Multigas borner comprh&g: stainless steel blades ( 14)

and a manifold with injectors ( 14).

7. Gas aation induding thermoelectric valve and two
stage solenoid valves.

8. Saondaq hut erchanger :
The secondary heat exchanger is a plate type heat

exchanger.

A thermostat

is litted on the

pipework limiting
the domestic hot water temperature to a maximum of 57
do c.

Q.c6pzL8cOVUV8fVC:
The valve is

activated by a demand

for domestic hot

water,

doses

the heating drcuits, and directs water to the

secondary heat exchanger.

lO.EIairidal

box containing :

Mains

connection

Fuses

Printed circuit board
Conneaions for extemal controts
Connections for fan. pressure switch and flow switch
Connections for pump
Connections for change over valve and for gas solenoid

Wve

11. Solenoid v&e I

Blcck

on which 3 valves are mounted :

l/3 valve -1 st stage valve-heating and hot water (blue)

- .:5-~e - full output to hot water (black)

,-

2’3 valve - ,i?ariable valve) centi heating (orange)

12. C~rEldfOS pump

motor

13. Air aepaxtor and

vent

directly

connected to the pump

inlet (not illustrated).

14.

Regdation

saew to adjust output to heating (u3

valve).

15. Hutiug body compriring :
Copper

tinned tube heat exchanger proteaed with silicone

resin paint Combustion chamber in aluminium coated

steeL Combustion chamber iining -

Ceramic

fibre paneis.

16. High Emit thcmnostat

17.

Water remice t8p (not illustrated).

18. Flow iroktfng valve - heating (not illustrated).

19. Gas r&r

tap

(not illustrated).

20.

Domestic

hot

umet outIe( with regulator (not

illustrated).

21. Safety vaIve with dmin tap (not

illustrated).

22. Heating mua idating vahm with filter (not
illustrated).

23. Ignition button.

24. Thumomaer irldicatlng boiler flow tempemture.

25. Purr.

26.

Selector switch - hot water on&/OFF/heating and hot

water.

27.

lbenaosm to regulate heating tlow temperature.

28. Presrrur gauge.

29.

Prcrr~rr

stich (not illustrated).

30. Domestic expansion versei (not ilIustmted).

31. Water flow swieh (not illustrated).

32. Data badge position.

5

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. . .

1.6 Description of Operation

The appliance is combination boiler providing central
heating and hot water. Hot water is provided on a
demand bask For the duration of the demand for hot
water the central heating is intemrpted.
The appliance

operates

in two modes. A hot water onky
setting where it operates only on hot water demand
and a hot water:+ central heating setting providing
central heating and switching to hot water on demand.

1.6.1 CentA Hat@ (see fq. 5)

‘fhe pump (21) circulates water which returns to the

The limit themxntat (16) set to 85” C closes both soie-

boiler via the return valve (31) which incorporates a fd­ter (30). Before reaching the pump

it passes

through an
air separator and air purger (17). The return water
passes through the heat exchanger (2) where it is hea­ted. It then passes through the change over valve (19)
which in heating mode is in its rest position and out via

the flow wlve (27)

to

the radiator ckcuits (34).
The boiler thermostat (8) controls the temperature of
the circulation water between a minimum of 50” C
approx and a nominal maximum of 82” C. The boiier
thermostat also controls the opening of the l/3 (11)
and variable solenoid valve ( 10).

1.6.2 Hot Water

(see

fig.

6)

When there is a demand water flows in from the cold
mains supply (26) through the water section part (35) of
the change over valve (19). The indusion of a venturi (24)

produces hi4

pressure under the diaphragm (23) causing
it to rise. This movement is transmitted to the change over
valve dosing the heating port and opening the hot water
port, as shown (20). The primary water heated by the
baiter now passes through the water to water heat
exchanger (18) where it flows through alternate plates
indiicUy heating the DHW.

A domestic exoansion vessel is fitted in the D.H.W. circuit

(36). ’

The rising of the change over valve spindle causes :

1. The opening of a microswitch stopping the pump.
This circuit is remade by a second microswitch making
when the hot water port is fUny open.

2. The by-passing of the boiler thermostat brings the
boiler under control of a fixed temperature thermostat

(32) which operates on the 2/3 f=ed solenoid (12).
lhe D.H.W. flow rate is adjustable by a restrictor (25) and
a limiting thermostat (32) reduces the gas rate when the

domestic hot water reaches 57°C by interrupting the
electrical supply to the hot water solenoid (12).

If the primary circuit reaches 85°C the limit thermostat (16)
doses both solenoids valves.

noids vatves in the event of its set temperature being
reached as could occur under the low tlow conditions.
The boikr is protected by a high limit thermostat (4)’
the operation of which intemrpts the thennocoupie and
extinguishes the pilot. If the hiih limit thermostat op-
rates it is necessary to manually re-establish the pilot.
An expansion vessel (13) is fitted in the primary circuit.

Central Heating

Hot Water

16

Fig. 6

6

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

1.6.3 Gas (see figs. 5 and 6)

When the ignitor button is siowiy released gas is admitted
to the underside of the solenoid valves ( 10.11 and 12).

When the main gas tap

(33)

is turned to the on position

gas is admitted to the gas section

(7).

Pressing the ignitor

There are 3

solenoid valves: the centre (blue) valve (11)

button (9) operates a miuoswitch causing the commence-

frxed at l/3 of max rated output the right hand hot water

ment of a firing cyde. The fan changes from low to hiih

(black) Wve (12) fzed at 2/3 of maximum rated output.

speed and aRer a purge period of approx 14 seconds a

the left hand central heating (orange) valve (10) which is

axMinuous stream ot sparks are

delivered

lighting the pilot

variable up top 2/3 maximum rated output. The gas

@is (3). Simukaneouslv the thermoelectric vaive (14) is

admitted by the orange valve is varied by adjuster (6) (see

opened and after a

further 5 seconds sufficient energy is seaion 6.4).
king produced by the thermocouple (5) for the thermo­electric valve to be retained in the open position.

1.6.4

FUNbIONAL FLOW DIAGRAM

Fig. 7

““‘” “--’ 1

Generator -

Fan

t-hgh

Soeed

L

SO02

I

1 Domssoc ]

1 Heatii 1

limit

I

Thermostat

Limit

Thermostat

WI

Boiler 82%

Control

Thermostat

1.6.5 Safety Controls

Should the central heating water flow reduce to beloW 300

In addition to the normal safety controls the appliance

Vh ( 1.1 gal/min) the gas suppiy to the burner is turned Off.

incorpomtes the following feature.

see fq. 4 (31)

and figs. S&6 (37).

7

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

1.6.t

1.6.7

RYNCTIONAL FLOW
WIRINGJXlLGRAM

PRINTED CIRCUIT BOARD

ORANGE
BLUE
BLACK
BROWN
RED

VIOLET
WHITE
GREY

Rg..8

ILLIISTRAIED WIRING DIAGRAM

i

W

AU CABLES ARE 240V EXCEPT WHERE THEY ARE INDICATED 24V

GR

FAN

i-m1

- CHANGE OVER VALVE

SOLENOID VALVE

213 li33

r

f

>

8

SPARK GENERATOR

IGNITION BUllON

WATER FLOW

SWITCH

Fig. 9

8

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

2

INSTALLATION REQUIREMENTS

2.1

General

?-he instalIation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations.
Buildiig Regulations and current Byefaws of the Local
Water Undertaking. It should be in accordance also
with the current B.S. Codes of Practice and the British
Gas Specifications for Domestic Wet Central Heating
Systems and any relevant requrrements of the iocai
Gas Region. Local Authority Building Standards
(Scotland) Regulations. and the Safety Document 635.
The Electridty at work Regulation.

Detailed recommendations are stated in the fotlowing
British Standard Codes of Practice:

B.S. 6891. B.S. 6798. B.S. 5440 : 1 and 2. B.S. 5449: 1.
B.S. 7593. BS 5546 B.G.DM2. B.S. 4814. B.S. 7074 1
e 2. B.S. 7671.

2.2

Note : Gas Safety (Installation and Use) Reg. It is the
law that all gas appliances are installed by competant
persons in accordance with the above regulations.
Failure to install appliances correctiy could lead to
prosecution. It is in your own interest and that of
safety to ensure compfiance with the law.

LOCZitiOXl
The boiler is not suitable for external installation. The

position chosen for the boiler must permit the
provision of a satisfactory flue termination. The
location must also permit adequate space for servicing
and air circulation around the boiler. The surface on
which the boiier is mounted must be of non
combustible material.
The boiler may be installed in any room or internal
space although particular attention is drawn to the
requirements of the current B.S. 7671 and. in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland. with respect to the
installation of a heater utilising mains electricity in a

room or internal space containing a bath or shower.
Where the installation of the boiler will be in an
unusuaf iocation special procedures may be necessary
and BS 5546 gives detailed guidance on this aspect.
A compartment used to enclose the boiler must be
designed and constructed specikaUy for this purpose.
An existing cupboard or compartment may be used
provided that it is modified for the purpose.
Details of essential features of cupboardkompart­ment design are given in BS 6798.

2.3

Water Ckulation System

The appliance is suitable for SEXED SYSTEMS ONLY
and should be installed in accordance with the
relevant recommendations given in BS 6798. BS
5449:l (for the smallbore or/and microbore systems)
and the British Gas Specifications for

Central

Heating

systems.

2.4

Siting the Fhe Terminal

Refer to section 1.4 for details of wail thicknesses
which can be covered

Detailed recommendations for ffueing are given in BS
5440 Pt 1. The following notes are intended to give

general guidance.
The boiler must be installed so that the flue terminal is

exposed to external air. The boiler must NOT be

installed so that the terminaf discharges tnto another
room or space e.g cuthouse or closed in lean-to. It is

important that the position of the terminal allows a

free passage of air across at all times. The minimum
acceptable clearances from the terminal to
obstructions and ventilation openmgs are specified
below (fig. 10).

Horizontal FItre

Termid posaions

Minckallulces

A - Direuly below an opening. windows etc

or adjacent to an opening . . . . . . . . . . . . . . . . . . . . . .

300 mm

B - Below gutters soil pipes or drain pipes . . .

75 mm

C - Bebw eaves .._....................................... 200 mm*

D - Below balconies or car port roof . . . . . .._.... 200 mm’

E - From a vertical drain pipe or soil pipe . . . .

75 mm

F - From an internal or external comer . . . . . . . . 300 mm*

G - Above ground roof or balcony level . . . . . . .

300 mm

H

- From a surface facing the terminal . . . . . . . . .

600 mm

J-Fromanopeninginthecarport

(e.g. door or window) into dwefiing . . . . . . . . 1200 mm

K; Vertioaity from a terrninai on the same

. . . . . ..-......................................-.........

1SOOtllnl

L - Horizontally from a terminal on the

same wall

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3oomm

l

(107 mm) minilnlnn clearance using

kit No. 76216.00 (G.C. 264 833).

9

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

BUILDING REGUIADONS excerpt.
Aqcoved document J Part B 1.4 (0 (D).

Q Protect with a tem%nai guard ftited centraiiy over
the terminal if it could come in contact with people

near the building or be subjected to damage.
D) Designed so as to prevent the entry of any matter

which might restrict the flue.
(A terrniruti guard G.C. NO 381 782 is available from).

Quinnei Barret 8 Quinnel Wireworks
Old l&t Road

London SE15 lNL TeL [phone]

The air

inlet/outlet

duct and the terminal of the

appliance must

not

be closer than 25 mm (1 in) to
any combustible material. Detailed recommendations
on the protection of oambustiabie materiai are given
inBS544oPtl.

MPOXIlSNI NOTICE : IRdBBR FRiWBD HOUSES
IFTHEAPPLIANCEISTOBEFITTEDINATIMBER

FRAMED

BUILDING IT SHOULD

BE FITTED IN

ACCORDANCE

WITH THE BRITISH GAS

PUBLICATION - “GUIDE FOR GAS INSTALIATIONS IN

TIMBER FRAMED HOUSING’ reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCAL REGION OF BRITISH GAS OR C.O.R.G.I.

2.6

=s=PPlY

The room in which the boiler is instaiied does not
require a putpose provided air vent
Ifthe boiler is installed in a cupboard or compartment
permanent air vents are required in the cupboard or

canpartment. one at high Ievef

and

one

at low level

either direct to the outside air or to a room. Both high

and

low ieveJ air vents must communicate with the

same space

Highlevel

261 cm2 (40 in2,

130 an2 (20 ir?)

Lowlevel

261 cm2 (40 in2)

130 cm2 (20 in2)

2.6

Elerkal Supply

- This appliance must be

earthed.

- AII wiring externai to the appliance must conform to

the current B.S. 7671.

- The appliance requires a 240

V - SO Hz suppiy.

- Connection of the appliance

and any

system controls

to

the mains

suppiy must be through a common

‘rsohtor and must be

fused at 3A maximum.

This should preferably be an unswitched shuttered
socket outlet and 3 pin plug to BS 1363. AItemativeiy,

a double

pofe koiating switch may be

used.

provided
ithasaminimumcontactseparationof3mminboth
poles The isolator shouid be ciearfy marked showing
its purpose. preferably positioned close to the

appliance.

-Fuse the supply at 3A.

-The supply cord must be 0.75 mm2 (24 x 0.2

mm)

threecuetoBS65OOTabie16.

2.7

Gas Supply

The appliance requires:

2.743 m3/h (96.87 ft31h) gas flow.

The meter and supply pipes should be capable of
delivering this quantity of gas in addition to the
demand from any other appiiances in the house.

The complete Installation must be tested for
soundness as described in BS 6891.

3

SYSTEM GUIDANCE

3.1

Gened

The low water content appliance boiler inciudes the
expansion vessels. safety overheat thermostat,
temperature

and

pressure

gauges.

and safety valve.

The fiow temperature is adjustable and gives a
nominal

82

“C (180” F) on its maximum setting.

Detailed recommendations for water circulation are
given in BS 5546. Whiist the boiler provides hot water,
there may be occasions when a

cylinder wiil be used,

for instance. if the property has two bathrooms.
Detaiied recommendations of this appiication is given
in section 3.13. Thermostatic control should be used
in the heating circuits and the @rider if one is fitted.

It must be remembered that a combination appliance
has a limited volume of hot water that can be
supplied at any one time for a given temperature.

Indeed in most respects it is equivalent to a muitipoint
water heater and many of the contra&s associated
with muitipoints appiy equally to combination boilers.

The appliance has two separate functions. to provide
heating and hot water on demand. It can have a

third

which is to supply hot water high demand through the

use

of an indirect cyiiider. where there is more than

one bathroom or if the standard

and

appointments of
the property, such as basins in ail bedrooms and a
large kitchen indicate a high usage of hot water.

Hot water produced indirect& through a cylinder can
be used to satisfy high simukaneous demand outlets ­bathrooms etc. whilst the

benefits

of high efficiency in

general& small quantities of

hot

water, can be fuiiy

utilised in kitchens, cloakrooms and so on.
Separate time and temperature control over hot water

generated in this way can be achieved by the use
either of two port valves or three port vaives of a flow
share or priority pattern.

It is also possible, where the occupation of the house
is variable. to provide either for a small or large load.
This is best achieved with

a tail.

small diameter cyiinder.

See section 5 for possible wiring anangements.
A domestic expansion vessel is fitted to the boiier with

a capacity of 0.16 litres. prior to the secondary heat
exchanger which enables the boiler to be

connected

to a cold main water supply containing a non-return
valve or

any

device containing a non-return valve.

10

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

IF THE MAINS

COLD

WATER SUPPLY IS IN

EXCESS

OF 10 BAR (150 PSI) A PRESSURE
LIMITER MUST BE FITTED TO AVOID EXCESSIVE
PRESSURE BEING APPLIED IO THE BOILER.

When replacing an existing cylinder storage system

with

appliance it is essential that all redundant

pipework is removed and dead legs eliminated.
In properties where there are multiple dmw-off Points

on

different

levels consideration shouid be

given to

the use of non-return valves in the secondary hot
water system to avoid -active dead legs-. No non­tetum valve should be less than 1 m (3 A) above the
top of the appliance and ideaiiy shouid be as dose as
possible

to the hot water outlet.

3.2

System controfs

The boii is eiec&aiiy cot&oiled and is

suitable

for
most control schemes currently available in&ding
thermostatic radiator valves and motorised valves.

When using motorised vaives the controis should be
arranged to switch off

the

boiler when circuits are
satisfied. The boiier requires a minimum ffow rate of
300 L/h (1.1 gai/min) and consequently, if
thermostatic radiator valves are fitted to ali radiators. a
by pass will be necessary. Thii wiii ensure that the
boiler wilI operate correctly when ail TRVs are dosed.
(see fig. 17).

3.3 Pump

The boiler is fitted with a Grundfos iJP.l5/60 pump
head. The graph (6g. 11) indicates the residual head
avafiabie

for

the system.

flow rate in g.p.m.

flow rate in litres/hour .

Fig. 11

3.4 Expansion vessel

The expansion vessel which is fitted on the front of
the combustion chamber accomodates system water
expansion. The vessel has a capacity of 5.4 litres
(1.19 gals) and is charged to a pressure of 0.65 bar
(9.7 p.s.i.).

THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHARGING AND NOT

A

VENT POINT.

At the design 5ow temperature

and the initial system

pressures quoted the maximum

allowable system

volume is 75

iitresif the water voktrne

is not known

and cannot be

accurately

assessed from
manufacturers data the foiiowing volumes may be
used to give a conservative estimate of the system
volume.

Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Iitres (0.8 gals)

Smaii bore

pipework . . . . . . . . . . . . . . . . . . . . 0.3

iitres (0.07 gals)

per 0.292 kW

Micro&x-e

pipework . . . . . . . . . . . . . . . . . . . . . . . . . . 7

iitres

(1.5 gals)

Steel panei

radiators

. . . . . . . . . . . . . . . . . . . . . .

2.3

litres (0.5 gals)

per 0.292 kW (1000 Btti) of system output

Hot water cyiinder ..,..................... 2

litres (0.44 gais)

If the volume exceeds 75 litres an additional vessel
wiii be required fitted in the tlow from the appliances.
Refer to BS 7074 Pt. 1 or BS 5449 for detaiis of siring.

3.5

Mains water connection

There

shall be no permanent connection to the
Iiratng system Pipework for filling or replenishing
without tt;e approval of the Local Water Authority (see
Byelaw No.14

and figs. 12 and 13).

3.6

Filling point (see

B-S. 5449)

FUling and recharging

can

be

done :

1) Through a temporary hose connection to mains

water.

A

stop-valve should

be fitted to the service main outlet

and a

double check vaive

assembly

and stop-vaive

should be fitted to the

system

side of the temporary

hose (see tig. 12).

2)

A cistern used for no other purpose connected to

the mains water.

The static

head provided by the cistern myzt be
sufficient to satisfy the designed initial system
pressure. The supply pipe from the cistern should
include the double check valve assembly and

stopcock (see fig. 13).

3.7 Make

up

system

Provision must be made for repia&-g water lost &om

the system indicated by a reduction in pressure
shown on the pressure gauge. Recharge through the

tilling

point

(see section 3.6).

3.8 Pfpework

Pipework can be of copper or suitable plastic. smaif
bore or microbore with capillary or COmpreSSiOn

jointing to

a high

standard.

leak sealant

must not be

used in the

system.

3.9 Domestic expansion vessel

The expansion vessei which is fitted on the cold water
supply to the secondary heat exchanger accomodates
domestic hot water expansion. The vessel has a

capacity of

0.16

litm

(0.035 gals) and is charged to a
pressure of 2 bars (30 p.s.i.); it has a maximum
working pressure of 10 bars with an allowable
pressure peak of 14 bars.

11

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

Air inlet

valve

Double check

Hose

valve

- .

Test co&

(a) Non-automatic

filling and make-up. Temporary hose filling loop avaible, Pt.No.CHL112

Fig.12 .

Heating

circuit /

retum WT

valve

Test cock

satisfy the
designed initial
system

pressure

Fig. 13

(b) Automatic

filling

and

make-up.

3.9.1

3.9.2

3.10

3.11

Bolter replacement (retrofit)

Inanddsystemwheretheboikrisbehgrepked,

we recommend the use of

a strainer,

fitted with a

drain tap

on the heating return.

designed to retain

scale prtides and other solid debris It is good practice
to use a chemicai cleaner with a floctuating agent.
used as reaamrnended by the deanser manufacturer,
to clean the syst+xn before the old boiler is removed.

(see BS 7593).

VaIves and joints should be carefully checked for leaks
and the appmpdate action should be taken either as a

repair

or repiacement. The

old open system has
probably only been subjeaed to a pressure of 0.4 bar
or leas. When you change to a sealed system where
thechargepressurewillbe1.Obarandtherunning
pressure exceeding 1.5 bar. consideration should be
given to the replacement

of radiator valves with a

pattern capable of seaiing at the higher pressures.

Cylinder.

Where a domestic

hd water

cylinder is used with the
appliance it MUST be of the indire~ and high recovery
type to BS 1566 Pt 1 Single feed cylinders are not
suitable for use with this appliance. Flow and retum
pipework to the +nder should be in 22 mm pipe.

Inhibitor and water

conditioners

(see Bs 7593)

Chaffoteaux et Maury generally recommend the use
of inhiirxs in systems using the appliance boiler.

3.12

The following are the appliance manufacturer’s

recommendations :
I) Use only a British Gas or similar approved inhibitor.

These manufacturers can

assist with the selection.

Grace Dearbom Ltd - Wlclnes - Cheshire WA8 8 UD

Tel: [phone].
Femox Manufacturing Company Limited Britannica

Works, Clavedng. Essex CB II 4QZ
Tel: [phone].

2) Use only the quantities specitied by the inhibitor
manufacturer.

3) CIeanse the system as required by the inhibitor
manufacturer.

4)

Add

inhibitor only after flushing when

finally re-

filhg the system.

5) In-line water conditioners both of chemical and

magnetic type are suitable for use with the appliance.

Add-on devices

It is important that no external control device; e.g..
economisers be directly fitted to this appliance unless

covered

by these installation instructions or agreed
with the manufacturer in writing. Any direct
connection of a

control

device not approved by the

manufacturer could make the guarantee void and

also

inkinge the Gas Safety (installation & Use) Regulations.

12

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

STERLING PP

Heating

& stored hot

water - spring return

3.13 Heating and hot water systems

Figs. 14. 15. 16 and 17 indicate various layouts

for

the production of hot water. It is recommended

that

only a high recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special saturated heat exchanger in an indirect
cylinder may be

desirable.

When replacing an exisiting cylinder storage system
with an instantaneous type system it is essential that
all redundant pipework is removed and dead legs
eliminated.

Heating

& stored hot

STERLING PP

water using flow share

I

relay required

The consideration of heating systems using
thermostatic v6alves should ensure that the minimum
flow rate thrcr:::h the appliance is maintained at all
times and in ?X znnection the remote by-pass is
preferred (see fig. 17).

1 Fig. 16

STERLING

PP

1

Remote

by-pass

remote by pass

with US valve

instant

hot water

13

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

3.14

Shower Application

The appfianoz can be used to supply hot water to separate shower draw-off. It m not be used to suppty more than
cne shower mixing valve.

The recommended pipework arrangement for a shower is shown below and the hot supply to the mixing vatve should
be the tirst draw off.

HOT

COLD WATER

COLD

I

Fig. 17a

It is important to select a compatible shower for the appliance. The following manufacturers can assist with the
seiection

New Team Ltd

Brunell Road
Earlstree Industrial Estate

@bY
Nolthants NNl7 2LF

Meynell Valves Ltd

Shaw Road

Bushbury
Wohrerhampton
West Midlands WV1 0 9LB

Tel.No.56 32 40 Tei.No.0902-28621

Aqualisa Products Ltd

Hortons Way
London Road
Westerham
Kent TN1 6 1 BT

Barking Grohe
1 River

Road
Barking
Essex 1Gll OHD

Tei.No.0959-63240 Tel.No.081-594-8898

Do not use the appliance with push on hand showers that fit over hot and cold taps.

14

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

4

INSTALLING THE BOILER

A vertical

ffat

area is required for the boiler: 1122 mm high x 591 nun wide (44 in x 23.25 in). The surface on which the

boiler is mounted must be of a non reverberating

and

of a non

combustible

materiaL The appliance is Supplied in a Singe

carton which contains :

1) The chatis with aiI functional parts attached.

2) casing compeshlg :

2

side panels
1 front panel
1 controls fascia cover
1 glass

door

complete with hinges

3) ?dOpnting bracket comprising :

flueguide

top support plate

spacins strip

bottom support plate

4) Plastic bag coat&niag :

plastic jig plate connection

gas filter/washer

5) Box containing :

gas and water connections ix4 above.

6) Box conrpining :

control knobs
safety vatve
wau plugs

saews and fixings.

7) Flue l ssanbfy :

ff ue turret with pressure differential switch and 1 st tlue duct section
plastic wall finer with terminal
Ihe duct
plastic turret cover
2nd tlue section

6) Plastic bag

containing

:

5ue

lockiig ring
‘0’ ring
2

gaskets

- one cork and one rubber

4

mounting screws with washers for tl ue turret

NB. (i) Flue accessories are not supplied as standard, and must be ordered to suit (see section 1.4)

4.1

4.2

PosSoning

the boiler

a) Select the location for the boiIer referring to the

dimensions shown in 1.1

and

1.3 terminal Iocation

positions (2.4 - fig. 10). b) Check flue length (see 1.4 -

figs. 2 and 3).

c) Check clearance on externai wail for flue terminal

position

(see table 2.4 - fg.

10)

d) Assemble the mounting bracket made up from 4

pieces (fig. 18)

using 4 thread

forming screws.

c) If for rear ff ue installation. remember to include the tlue

guide plate E. using 2

thread

forming screws.

‘ig. 18

Rear outlet fIuc

a) Mark vertical centre fine for boiler on wall.
b) Mark horizontal centre line for 107 mm (4.2 in) dia

wail opening and one for upper bracket 6xing saews

(A).

c) Using

bracket as template mark 4 tixhg points

(A)

and

@I.

d) Mark wail for ff ue opening using flue guide plate.
e) Drii the wati for the flue opening using a 107 mm (4.2

in) core drill.

f) Drill 4 i&zing holes (A) and (B) 7.9 mm (5/16 in)

and

plug.

:ig.

19

g) Fo:iet to waU

using 6 mm

x 50

mm

wood mews

N.B. Ensure

bracket is

square and plumb to vertical

centre line &fore tightening.

15

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

4.3

4.4

4.5

4.6

Water connections

1) Make

COMeXtiOtlS

to copper

tails

using either solder capillary fittings or compression type.

4.7

Gas connection

1) The gas connection is 22 mm diameter.
b) Make the gas connection using solder cap&q fittings.

N.E.

The gas supply pipe must not be less than 22 mm diameter

I

Side outlet &se

1

7

6

0 (2BS mm mmmum)

I

a) Mark vertical centre line for boiler on wail (see Sg. 20).

3

b)

Using bracket as a template mark 4 fixing slots (A) an

0lx)mn * --

“1

Slope 5 mm. per mare

(Bl.

Acc’c ------- -----

c) Mark horizontal line through the fixing slots (A) ant

/-

2, *

I

&O 4

project to side wall.

d)

Mark vertical axis of flue opening 112 mm (4.4 in) &on

Dmm Hmm

300

168

iii

107.5
107

-T-

comer of wall.

c) Mark wail for centre of flue opening 169.5 (6.7 in) mr

above the horizontal on side wall.

lG%

1700

lg5

f) Drill the wall fcf the flue opening using a

110 mm (4.:

z

158.5

in) core drill

z

g) Drill 4 f&g holes (for (A) top of

slot)

and (for 03)

h)Fixbradretto~uusing6mmxSOmmwoodscrew

N.B. Dtmenston (H) decreases as dimension

(D)

provided.

~duetothequtreddedtneofffueof5mm

N.E. Ensure bracket is square and plumb to vertical centi

Fig.20 per-

line before tightening.

N.B. By using the

plastic jii plate the piping system can bc
compieted before the boiler is mounted.
a) Attach plastic jig plate to bottom bracket using 4.6 mn

x 10 hexagonal screws provided (fig. 211.

b)

Fit copper tails and washers to jig plate. the main:
~~inleCtail(M)ischesh~~ofthetwo 15mmtails
e) AU co~ectkms can either come hfn above or beiou
using the standard tails provided.

N.E. IF THE GAS CONNECTION IS FROM ABOVE THI
PIPE WILL HAVE TO BE SET ABOUND THE FLU1
oDILEI.IFIHEomr.EIIsToIHEBExB.

Fig. 22

4% ++ +: f-

J K L M N

CCasmd-ta

Tabedimleta

co8muioas
J)

Heatingretum

22mm

K) Hot water outlet domestic

15mXl-l

L) Gasinlet

22mm

M) Mains water inlet

domestic

15nXl3

N) Heating tlow

22mfn

Pipcwrk

a) Copper tails are 22 mm and 15 mm to accep
straight connectors.

IMPOETILNT NOTE :

At this stage the pipework can be completed and tested before the boiler is positioned. Having completed a sat&&tory

test on the

pipework the boiler can now be fitted or nztained

for fitting at a later date.

16

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. .

Fltthtg the boiler
a) Before hanging the boiler. uncoil wiring harness

(connections to pressure

switch)

stored by
changeover valve. route through front of chassis and
up front of boiier. place into dips.

b) Remove plastic jig plate from bracket and retain

screws.

c) Hang boiler on mounting bracket, ensure that it is

properiy located.

N.B. Insert

washer into

union nut

and offer assembly to
boiler. Use the piain black 3/4 and l/2 diameter graphited
fibre washers for water unions. and the white 314
filter/washer for the gas union.,
d) Connect water union using plain washers, working

from left to right.

e) Connect the gas union using the filtedwasher packed

separately either way round.

Fig. 23

N.E.

As an akemative to using the

plastic jig piate the tails

can be fitted to the boiler

before

mounting, then

connected to the seivices.
provtded.

N.B.

The drain must be 22 mm and the 14 mm drain

bend from the safety valve

must be

installed so that
discharge of water is directly over the 22 mm drain and
readily visible. A tundish arrangement is acceptable. The
connection must NOT be made by a capiiary or
compression fitting direct& between the 14 mm drain
bend and the 22 mm discharge pipe without a 2 mm air
gap (see fig. 24).

Fig. 24

THE 22 NM DISCEXRGE PIF’B MUST DISCEABGE IO =

OUYSIDE OF THE BUILDING WEEBE POSSIBLE OVEB A

DBAIN. w? DISCEARGE MUST BE SUCE TElLI If WILL

NOT BE -US TO OCCDPANYS OR ULUSE DRMLGE
TO ExTxtNAL ELECTRICALCOMPONENTSORwIBwc.‘IHE
PIPE SEOUID EE D-m DOWIUW~S. IT NUSY NOT

DISCEARGE ABOVE AN

ENTRANCE ox WINDOW OR ANY

TIPEOPPUEUCACCESSASTEB

TEMPER&TUREOPTE

d)fitl4rnmtaildiainbendusingwasher

Wm BEING DISCHHBCED M&Y BEACH loo” C

held by two screws.

6) Peel off protective paper from adhesive side of cork
gasket (A) place on mating side of flue

turret

(B) fining

up with four dearance holes. press together.

c) Assemble second part of flue duct (H). push fit.
f) SEde locking ring (0 and ‘0’ ring over plastic air duct.
g) SEde air dud over flue duct. engage end of ffue duct

into terminal and locate air duct into turret (B).

h) SEde ‘0’ ring along air duct (C). to contact with the face

of the

turret

(B). Locate lugs on locking ring (C)
between lugs on flue turret (B). Push together and
turn to kxk.

J) Position square channelled rubber gasket (E) on the

flue hood outlet of the boiler. channel facing

downwards.

It) Pass the flue assembly through the wali and seat turret

(B). onto the flue outlet. secure with 4 screws
provided.

Fig. 25

N.B. The

terminal must extend 13 mm (0.5 in) past the

surface of the external wall.

Pittfng the flue up to 700 null 1oug

I) Pit wall plate (P) provided with mastic sealing ring over

a) Cut plastic

duct (G) to length required (see fig. 2 or 3

air duct to structure.

dimensron (L)).

m) Make good internal wall face where the

aidflue

duct

b) Cut same amount from alumniurn

the duct (Hl.

assemblies exit the room.

NB.

In very cold weather the plastic

air

duct becomes britde,

a) Do not fit plastic turret cover ‘D’ until electrical

warm before fxtting.

co~ections

to the pressure switch have been made

c) Remove piastic turret cover (D) from ffue turret (B)

(see fi9.26).

4.8

4.9

4.10

17

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. . .

4.11

4.12

Fittfag the ffac over 700 mm long
a) Assembly is pre&zQ as detailed in section 4.10 using

the requisite number of extension flue and air ducts. In
particular note the foLIowing.

b) The standard flue duct is always used (both sections)

at the appliance end (uncut).

c) The standard air duct is always used at the terminal

end (uncut).

d) When cutting, always cut one extension flue duct and

the same amount kom one extension air duct AIways
cut the plain end NOT the socket end

c) FuU details of dimensions and assembly are given in

tigs. 2 or 3 as applicable.

f) If internal f-es prevent the assembled ducts being

passed through the wall from the inside, the ducts
may be pushed through from outside (remove the
locking ring (Cl and 0 ring first).

N.B. see also section 4.3

Connection to the presaorr switch

a) The 3 wires on the harness must be connected.

b) Push spade terminais onto tags COM 8) No (1) and

No (2)

c) Fit b-ret cover (D) (fig.251 ensuring that both the air

tube and cables are not trapped.
Ensure that the cable retaining clip is positioned inside
of the cover as shown, (see fig. 26).

Iaddngtbeelec~coMdoa
N.B. See Section 2.6 for electrical supply requirements
THIS APPLTANCE MUST BE EARTHED.
a) Pull out fuses (AI.
c) Open door to left hand side of electrical box.

ecmr d) Cut the cable entries to the size of the cable beiig used

which should not be less than 0.75 mm’
e) Remove cable damp.
f) Connect permanent Jive to L terminal (I) and neutral to

N terminal

(2).

g) Connect earth to earth saew on the spade connector

block.
h) Connect external controls - room thermostat etc. aaoss

tetminals 3.4 and 5, (see

section

5. fg. 28).

j) SLxrtrzbJsssh cable clamp and locate flex into

clip

k) Close door

I) Replace fuses.
N.B. The length of the earth wire between the cable

clamp and the terminal must be such that the live and
neutral wires become taut before the earth wire if the
supply cord is puked.

[n the event of an electrical fault after installation preliminary electrical system checks must be carried out. Checks

to

ensure eIectri&

safety

should be carried out by a competent Person i.e earth continuity. poiarity

and

resistance to earth .

USE ONLY VOLTAGE FREE EXIEBNAL CONTROL SWITCHING. NO SUPPLY VOLTAGE SHOULD BE CONNECTED

TOERMINAB3,4ORS.

18

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

5.

EXTERNAL CONTROLS

5.1

‘ilme clock - Time clock and room stat

Fig. 28

4

M

Or‘.

-s-s----

&

N

L

Supdy thmugh :

1. Oouble pole

t

fused swim sour

or

2.13A

~~~i~~~~~~~~~~~~n

untitied olug
and sodcet

Fused

at 3 A.

. The time clock contact must be voltage free (remove extemal links) and should be connected between temGna& 4 and

5.

The mom stat accelerator should be connected if ftited to terminal 3.

5.2

Time clock and zone valves (Spring

retrun)

room

thermostat

honey-&l T60 6OE

---------------------

N.6. For additional information
omact fime Control Manufactums.
connected

cylinder

mermosrat

hcneywall L6 41 A

tabs
40V50Hz
tseU 3 A. double
ale fuse sw~tied
wr or unswitched
!iganasccka

ig. 29

baler termmas

(remcwe link 4-5)

19

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

5.3

5.4

proSrammer and zone valves

External programmer

L

L N tmmter ’ heam

1

ON

iOFF ON IOff

1 I

spring return

motorised valves

with end switch.

room thermostat

cylinder thermostat

240

V - 50 Hz supply

N. 30

boiler terminal

blocks

ioneywcfl Y plan, satchweff flow chart or Satchwell
dni valves to contmf zones.

kfer to controls manufacturers literature. Ike to relay coii
i the wire in their literature which canies the signal to the,
Boiler.

relay

boiler terminal block

rg. 31

ig. 32

5.5

Frost thermostat

It is

advisable. if the appliance is fitted in

a location

subject to adverse weather

conditions,

to proted

the system from frost damage by fitting an
additional remote frost thermostat which will over
ride the controls whilst the selector switch is set to
hot water + central heating (for systems without
zone wdves).

. ­I

131415,

boiler terminal block

frost thermostat

20

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

6.

COMMISSIONING

6.1

Fig. 33

6.2

Fig. 34
Central heat@ ckaits - fa

1) Ensure that the isolating valves are open (fig. 34 B

and

C). N.B.

Vahm

(C) muat he ttxmed anti-cfoci&r by

the knurled abaft tmtff it didocatcr httt the thread
and then puffed out horizontalfp to its extremity
(appndmatdy 30 mm (1 114 &as)).

2) Fili system to charge condition. see section 3.

3) Vent radiators and any high points.

4) Vent air separator by loosening screw (fig. 34) (E) and
purging until no air is apparent N.B. : ensure screw E
is tightened.

6.3

Hot

wma &&ts - fgtng

1) Check that stop cocks up stream of appliance are of a

-jumpertype.

2) Open mains cold water inlet valve (fig. 33) (A).

3) Vent installation by opening taps and closing.

4) Check that “dead iegs’ have been eliminated.

5) Chedt for water soundness and rectify if necessary.

6) Set D.H.W. [Iow rate as required by adjusting screw
(D) increase (anti&ckwise) decrease (clockwise), see
section 6.7.

5) Set system charge Pressure to design cold pressure.
For a new installation we suggest 1.0 bar. For an old
system see section (3. 9. 2) set to system static head
or 0.8 bar whichever is the greater.

6) Chedt for water soundness and rectify any kaks.

7) Switch on electriral supply.

8) Manually check pump is free to rotate. Remove cap
(fig. 35 D).
Insert small electrical screwdriver (3 mm

blade),

locate
in slot in pump shaft. rotate &ciwvise to ensure that
pump is free replace cap (D).

9) Switch to HOT WATER + CENTRAL HEATING on
selector switch (A) (fig. 35) switch position (II).

10) AlIow pump to run for further lo-15 minutes. Switch
OFF.

11) Isolate water supply and drain boiler by

disconnecting iill system and opening the drain valve

(P). This is incorporated in the safety valve and is

achieved

by screwing down the head until the valve

liRs.openaa1owleveidraincocks.

12) Remove t’iker in the return isolating valve (C) and

inspect for any installation debris (see section 7.5). to
dean and replace.

13) Re6U system as above.

N.B. It is recommended that this is repeated atIer the.
system has been

operated

up to temperature to ‘hot

flush’ to remove fkrxcs and remaining debris.

.!i

Li@ing the boifer

1) Purge gas supply. Switch on eledrical suppfy

2) Turn the lever on the gas service tap (fig. 34) (G) to the

let?. In the open position the &me sign is to the front

3) Temporarily locate the two control ‘knobs’ one ther-

mostat knob, one ignition button extension.

4) Swikh to HOT WATER +

CENTRALHEATING@)on

the selector switch (A). The fan wiU run at low speed.

5) Press the ignition button (R) and hold in.

a) The ian wiU change to high speed to purge the com­bustion chamber. Gas is admitted to the piiot.
b) After appmx 14 seconds the spark generator passes a
continuous stream of sparks to light the pilot.
c) When the pilot is alight -

viewed

through the sight glass

wait for a further 5

seconds

before slowly releasing the

button.

6) When the button is released, while the boikr is

set

to

heating and any ancillary controls are in

demand

position.

the boiler will fire.

7) Check for gas soundness using leak detection firrid or

Yg. 35

gas detector.

8) Check

and

adjust gas press&gas mte. see Section 6.4
N.B. The thermocouple output should be checked at this
stage, should be greater than 12 mv.

21

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

6.4

ca8 trtc 8djttrtment

N.B. Before adjustment check gas pressure on the iniet to
the appliance. with the appliance working - this should be
20 m bar (8 in wg) for natural gas (G 20).
The maximum gas rate on hot water is faed and is a

function of the restrictor size. The central heating variable

adjuster is factory set at 75 % i.e for an output of appmx

16.5 kW (56248 BtuIh).

1) Switch boiler to the off (0) central position. see section

6.3 (fig. 35).

2) Remove the pressure test point screw - (B) and
connect a suitable pressure gauge.

3) Remove the hexagonal cap from gas rate adjuster

exposing the adjusting screw (0.

4) Switch the boiler to hot water and central heating (II)

and check that any fitted external

controls are calling

for heat.

5) Adjust. Setting pressures are given in graph figs. 37

and 38. The pressure will be reduced by clockwise
movement of screw, increased by anticfockwise
movement. Now select hot water only. adjust hot
water regulator, see 6g. 4 (20). to minimum and open
the largest volume draw-off tap. The gas pressure

should now be the maximum as indicated in Technical

Data.

6) Switch boiler off (0). Remove pressure gauge and

replace test point screw and gas rate adiuster hexagon
cap.

Check

for gas soundness around screw.

7) Mark the data badge, located on the front of the

combustion chamber below the sight glass to indicate
output to heating system.

Output / Burner pressure

Input / Burner pressure

Outout kW

lnwt f&h

40 so 60

70 84 90

100

.6

5

12

10

4

6

3

Output 8twl1 x 103

Input m3ih

22

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

6.5

6.6

6.7

6.8

D&W f&w rate adjastmaxt
This is set by the installer during commissioning.
See section 6.1 and 6.7.

Remote by-pass

~ustittg the heating qstent by-pus

Where a by-pass is &ted. see section 3.2, i! is necessary
to adjust to obtain the boiler minimum flow requirement
of 300 Vh (1.1 gaVmin).

1) Set boiler thermostat to maximum, switch boiler to
HOTWATER + CENTRAL HEATING (II).

2) Open alI radiators and dose the by-pass. Check the

remote

by

pass

vtnth US valve

temperature rise aazross the boiler which should not
be greater than 20” C (36 “FL

-. -

3)

Adjust system to minimum foad. This is nonnaliy done

by dosing valves on all but two radiators.

4) Open by-pass gradually until the boiler operates
quietly and the temperature rise is maintained.

N.B. The by-pass valve should be of the lock shield
pattern. The tlow switch operates at approx 300 Vh (1.1

Fig. 39

gUmin).

Hot water

adjustmeat

A tlow restrictor (A) is fitted on the domestic hot water

outlet. Adjustment of this restrictor enables regufation of

the tlow fate of the D.H.W. to suit individual instaUation
conditions and requirements.
Adjustment is made by either turning the screw in a
clockwise direction to reduce the 5ow tate and inuease
the temperature or by turning the screw anti-&&wise to
increase the ffow rate and decrease the temperature.

Pump nwit*g

l ~eat

The pump is set to turn ON/OFF via the room

thermostat

along with the burner. when the central heating mode is
selected.
It is possible if required. to have the pump Iunning
continuously by turning the switch 0 anti-do&wise. see

fig. 39 b. The room thermostat then only switching the
burner on and off.

Pump and burner

4%

Burner only

Pi& 39b

switched

switched

23

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

6.9

Fitting the using

1) Take t?om the carton the controls cover 0. the g
door @ the top bnt panel 0 the side panels (A)

the rubber grommets 0.

2) Remove control knobs used during testing
commissioning and fit the four grommets into the h
at the top of each side panel (0.

3)

Fit side panels (A) and secure with screws at

bot

rear (B).

4) Put the control cover (I-B in position

and secure I

Eve screws.

5) Fit the ti-ont top panel over the pins at the top of
boiler (0 and secure with two screws at the bottom

6)

Fit the central heating control

knob.

7) To fd the giass door proceed as folkxvs :
N.B. -ITIE TIE ROD (G) MUST BE USED

a) Remove the nuts &om the machine screws securing

tie rod to the hinges-

b) Offer the door up vertically. Engage part (E) in

pro6le of the right hand side panei . Fix assembiy T
screwfrornben~th0.

c) Pivot the left hand hinge and engage into profile of

left hand side panel. Fix assembly with screw ft
beneath.

d) Remove protective film before use.

Bass

and

and

Ok

torn
with
‘the

03

the
the

Nith

the

cml

HAND OVER THE USERS INSTRUCTIONS AND EXPLAIN THE BASIC FUNCTIONS OF OPERATING THE
APFUANCE. LEAVE THE lNSTALlATION AND .SERVKING INSTRUCTIONS WITH THE USER.
IF THE ELECTRlUlY SUPPLY IS INTERRUPTED THE PILOT MAY HAVE EXDNGUISHED. WHEN THE SUPPLY IS
RESTORED RELIGHr THE PILOT SEE SECTION 6.3.

24

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

7.

ROUIINESERVK.ING

7.1

7.2

To ensure continued efficient and safe operation of the appliance it is recommended

that

it is checked and

Serviced

as
neces~ at regular inter&s. The i?equency of servicing will depend upon the particuiar installation condition and
usage, but in generai once a year should he adequate.
It is the law that any service work must tx camed out by a compelant person, such as British Gas. other C.0.R.G.L
registered personnel or your local Chaffoteaux Sewice Centre. in accordance with the Gas Safety (hstaUation and Use)
kgulations. This routine

Service

will normally be coniined to :

1) aeaning

the burner.

2)

aeaning

the heat exchanger.

3) Checking the gas controis.

4) CIeaninq water filter, hoses and heating titer.

5) Check opmtion of safety vaive.

The following schedules are recommended :
a) Check the function of appiiance. burner pressure. gas &xv rate and soundness.
b) Observe &me picture and undertake combustion test.
c) Check. clean or repiace components as necessaty.

N.B. Before commencing any work turn off gas at the gas iniet tap (fig. 34) item (G) and ensure that the edacity
suppiy is discoMected. koiate water suppiy and dtain appliance if required.

To remove front using
a) Remove two screws (A) bottom rear of boiier.
b) Remove suew (B) centre of Iower front panel.
c) Remove thermostat knob and ignition push button.
d) Remove case by easing forward at bottom and lifting

off lugs at top.

Fig. 41

To remove scaled

th8mbtr front pad uld tombustion

chamber

front

ptnti to export heat exchanger

(P-P)

a)

Remove four screws (A) securing the combustion

chamber front panei.
b) Lift off kont panel complete with expansion

vessel

and

hang on hooks provided below boiler

throu4

matching

holes on top folded edge.
N.B. Aitemativeiy support on worktop or iIoor to avoid

damage to ilexible tube.

I

Remove 2 screws (Fl) and remove closure plate (see

section 7.3).
c) Remove 8 screws (C) and lift off heating body front

panel with access panel (B).

d)

Clean the heat exchanger after removing the burner.

see section 7.6.

Tg. 42

- Replace in reverse order.

25

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

. . .

7.3

IO

mnovt

bunter assembly

a) Remove two screws

(FI) and remove closure plate by

withdrawing forward.

6) Remove two screws (Ft) and remove burner by
withdrawing forwards. taking care not to trap ignition
eIectrode lead.

c) Remove gasket and retain in safe place. or if adhered

to one surface. leave alone as removal may damage
the gasket. Replace gasket if necessary.

d) To clean burner (see section 7.6).

7.4

To mnwe piIot
a) Remove two screws (A) securing deflector plate and

pilot head. Lifl off deflector plate (D) taking care not to
damage the electrode tip.

b)

Remove pilot air titer (B).

c) Using

a 7 mm

spanner, remove pilot body (C) from

piiot burner base.

d)

Check injector and clean the filter. N.B. The pilot
injector (F) is retained in the base of the body with an
‘0’ ring (G). If the injector is replaced it is fitted bright
side uppermost.

t) Ensure deflector plate (D) is correctly located on the

piiot

Fig. 44

r

To than

heating

rtturn fdttr

a) Close heating Bow and return valves (B and Cl and

drain

throu4

safety valve (F) l section 6.2).

b) Using spanner remove return valve spindle guide

assembly (D). N.B. Take care not to damage the

capillary tube right hand side.
c) Lift filter (E) off assembly.
4 Clean in wam7 water.
t) Replace in reverse order. Replace ail components

removed in reverse order.

I

Fig. 45

I

26

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

7.6

7.7

Cluning aad

rcpkcrmmc of

puts

l

)Thebumercanbecleanedbyinvertingand~

wtth a soft brush. inspect injectors. ensure they are

dear.

b) The heat exchanger

flueways

can be cleaned by
thoroughly brushing the tinned surface. After brush@
inspect to ensure that the tlueways are completely

dear.

d)Thethermocouplecanbewipedwi~aiint~doth

to remove any deposits. if the thermocouple tip
appears burnt or cracked. exchange to avoid a
possible

break at a later date - (see

section 8.1).

d)

Examine ekctrode and dean, the tip. if the tip appears

damaged

replace electrode and lead assembly - see

section 8.2.

t)

Replace all components in reverse order ensuring that

the gasket between the gas section and the manifoid k
axmely positioned

upon

reassembiy.

f) Open all isolation valves and repressurise system if

newsary.

g) Recommksion and check controk.

6) After the boiler is lit. check all gas connections for
soundess .

1) Allow

the

boiler to warm up thorough!y. then chedr the
burner pressure and adjust as necessary to that given
in the

table

for

required

output (see section 6.4).

j) Restore any sytem controk

and

docks

to their orighai

setting.

To thtck opuation of

safttymh?t

Turn

off the

appliance

by selecting the 0

position

on the

Summer and Wmter switch.

Engage the knurled ring (A) to the thread and turn it
dodwke until water can be seen to discharge kom the
outlet (B). Turn

the

knurled ring (A) anticiockwise until it

disengage from the thread.

Ensure that the pressure has not

decreased below

1 bar
and repressurise if necessary (see section 6.2).
N.B. If the water does not discharge,

replace vaive (see

section

8.34).

27

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

._

8.

REPLACEMENT OF PARIS

N.B. Before commencing

ensure

gas and electricity supplies are isolated.

TO tcmovt

thermocoapic

a) Remove

font

case.

see

section

7.1.

b)

Remove outer &ont panel, see section 7.2.

c) Remove burner, see section 7.3.

d)

Remove high limit stat see section 8.3.

t) Remove thermocouple from thermoelectric valve

connection (F).

0 Loosen securing drew (G) two fuif turns to relieve

knsion km bcking spring.

g) Remove thermocoupie by sliding down through gas

section.

h)

Remove grommet (E) ti base of gas secrion.

j) Carefuily form a 4 inch radius to thermocouple and

insert Ihermocoupie through gas section.

k)

Slide grommet 0 over the thermocouple.

I) Continue feeding the thermocouple into its location

until it is hard against the fhermocoupie stop (H) in the

piiot head.
m) lighten fixing screw (G), previous&y loosened.
n) Reposition grommet in base of gas section.
o) Form Ihe new thermocouple and

connect to

thtm~oehxrric valve (Fl .
p)

Replace, high limit thermostat.
NOTE : When replacing the thermocouple the conductor

may need manipulating -

avoiding bending at acute

=gl=

Tortp&tttItctnadttad feadossemhfy
a) Remove kont case. see

section

7.1

b)

Remove outer front

panel and combustion chamber

fmntpafd.seesection7.2

c) Remove burner, see section 7.3

d) Remove deflector plate (D). see section 7.4

t) Disconnect from eiectrical box by pulling off eiectrode

lead at lower left hand rear.

Q Feed cable up through gas section (H) removing

grommet 0.

g) Remove electrode by puhg upward from location

imJ=-

Tg. 49

h)

Replace in reverse order locating electrode in deflector
plate (D). spark gap 5 mm.

To ttpkct ttftrp ovaheat thermostat
a) Remove front case, see section 7.1
b) Remove two screws

securing high limit thermostat to

c) Remove high limit stat and thermocoupfe see 8.

1.
d) Withdraw noting route.
t) Replace in reverse order. Use heal sink grease
between high lit stat and bracket (B).

'ig.50

8.1

8.2

8.3

28

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

8.4

8.5

8.6

To repkcr ignitioamiaoswkh

a) Remove front case, see section 7.1.
b) Remove outer front panel and combustion chambe

kont cover. see section 7.2.

c) Remove burner see section 7.3.

d)

Remove electrical control box. see section 8.9.

l

) Remove plugs from solenoid valves (A). notinf

coIours.

f) Pull off three tab connectors (C) from

microswitci

noting their

position (blue top, red centre. blacl

!,xtsrn) . Note t Microswitch

connections must bc

-5; ?Z .3xdance with wiring diagram. (fig. 9).

g) fi.:.i=.;c I: ‘: zzmn (B).

6)

Remz.~ VT wo screws (D) retaining gas section.

j) Slide out

gas

section

(H) by pulling forward!
(comprises solenoid valves. gas valve. pilot assembh
electrode. etch

Fig. 51

k)

Remove two screws (S) retaMng microswitd~
m) Remove microswitch.
n) Replace in reverse order.

To repkace change ovcrlI8fve miaondtch

a) Remove &ont case see section 7.1

b)

Undo screw (A) and remove microswitch box cover.
N.B. Upper microswitch operates for D. H. W mode.
Lower

microswitch

operates

for C

H mode.

c) Lift spring (B) and pull operating lever off mounting

pUls.

i) Rzmove respective microswitch

from

mounting pins.
c) Note colour code and pull off electrical tags.
f) Replace in reverse order. When repfacing box

cover.

ensure that the lugs on the connector block are damped
inside the box
N.B. Refer to fig. 9 for colour codes.

Fig. 52

To lephce the flow switch 8sq.
a)

Remove air separator see section 8.13.
b) Disconnect high pressure tube at union A.
c) Disconnect low pressure tube at union B.

d)

Replaoz reverse order.
e) Check for leaks

4g. 53

1

r

29

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

a.7

a.8

8.9

To r+plce ventok

a) Remove front case see section 7.1.
b) Isolate from cold mains water supply (A). open an ho1
water outlet and drain down kom valve (E).
c) Remove plug Q from left hand side of change over
valve.
d) Use small screw driver to gently push out venturi
ensure screw driver does not enter throat of venturi.

l

) Replace in reverse order.
f) Ensure that valve E is closed, restore cold mains watet
supply, check for leaks.

To replace primary heat

achanger

a) Remove kont case. see section 7.1.

b)

Isolate appiiance from svstem by closing heating flow
and retum valves (B and Cl. see fig. 34.

c) Drain boiler (primary side) through safety valve (FJ (f$.

34).

d) Remove four screws securing the sealed chamber

&ont panel and remove (see section 7.2).

c) Remove letI and right hand side on chamber Panels by

pulling thzrn carefully towards you.

1) ;y combustion chamber front panel. see section

. .

g) Remove burner. see section 7.3.

6)

Remove four screws 0 securing heating body panels
to chassis.

Fig. 55

1) Undo flow and return pipe unions (E). remove pipes

and slide primary heat exchanger forwards.

f) Replace in reverse order.

io remove rhctrfuf contfd box
a) Remove kont casing, see section 7 1.

b)

Remove fuses by pulling fuse carrier (B) from electrical

box.

c) Remove 3 screws (C) lift eiectricai box cover away and

unplug from PCB.

d)

Pull off plug from solenoid vaives at PCB.
e) Unplug pump connector at PCB and earth wire.
f) Unplug connector to change over valve at PCB.
g) Unplug connector t?om fan at PCB.

6)

Remove one saew (D) and two screws (a. (Electrical
box support bracket to lower chassis).

I) Careful& ease electrical box forward to allow access to

flow switch lead. also to eiectrode at

bottom

rear

of

E C

box.

Fig. 56

j) Disconnect lead from flow switch.

k) Disconnect electrode hm

rear of eiectrical box.

I) Carefully move the electrical box away from the

appliance and to the right whilst straightening the
capillary tube from boiler limit thermostat and
domestic hot water thermostat.

30

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

-_

a.10

a.11

q)

Continue moving electrical box until bottom support
bracket

can

be positioned on hook at

bottom of
appliance (see 63. 56 a). To remove the ekcttkal box
completely, continue in the following manner.

r) Isolate appliance tiom the system by closing valve A.

(see section 6.2 (Fig. 34)).

s) Drain secondary side by opening drain plug (I-0 <fq.

34).

(I) Remove clip and phial Ram DHW thermostat pocket.
w) Undip and remove limit boiler thermostat phiaL
x) Remove box completely.
To replace ekctrid box in reverse order note :
a) Hang box on hook.

b)

Capillaries must be routed behind any pipework.

To repface pmnp had
a) Remove tront case.see section 7.1.

b) Isolate boiler riom systan by dosing flow and

retttm

valves (see section 6.2 fB and 0).

c) Drain boiler (primary side) through safety valve (see

section 6.2 0).

d)

Open electrical box cover

(B)

and unplug pump

connection.

c) Remove four screws (A).
f) Remove pump head noting orientation.

g) Remove lead and transfer to new pump head.

h)

Replace in reverse order.

J) Open flow and return valves Top

up system if

Fig. 57

--

N.B.
For the Celtk phs the pump is a Grundfos UP 15-60

Fig. 58

:.

. ­L
;<

To fcphu change over dve (C, 0, VI

%

a) Remove &ont case. see section 7. I.

$ -.

b)

Disconnect and remove electrical box, see section 8.9.

c) Tum off main water at valve see section 6.2 (A).

g :.
L

d) Tum off central heating flow and return

valves

see

E&-

section 6 (B).

$

a) Drain secondary side by opening drain pkrg on bottom

6-:- 7 of change over valve (H).

4 :-q$

0 Remove safety overheat thermostat from tube and

carelixlly position to one side.

- &,

g) Remove front tube (1) 6rom change over Mive ttndip

thermometer sensor, undip high limit thetmostat

h) Remove flow pressure tube (2) from C. 0. V, to flow

switch.

N.B. Swing micro-switch box to give access

to union nuts.

1 H E 4

31

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

J) Remove rear tube (4) from C. 0. V. to

secondary

heat

exchanger.

k)

Unscrew union nut (5) of mains water inlet to C. 0. V.
0 Unscrew heating return tube nut (6) horn C. 0. V.
at) Unsaew union nut (7)

of

C. 0. V. to secondary heat

exchanger.
n) Remove C. 0. V.
o) To inspect diaphragm remove eight screws (E)

seating valve to water secrlon.
N.B. To service the C, 0. V. piston remove spring dips.
remove piston &an and grease.

p)

Clean or replace diaphragm.

q) Flush out water section.

r)

Replace in reverse order.

I

Fig. 58a

s) Open flow and return valves. Top up system if

necessary

a.12

8 A

To replace mondy

hat exchanger

II

a) Remove font case. see section 7.1.
bj Disconnect and remove electrical box (see section 8.9).
c) Remove change over valve (see section 8.11).
d) Unscrew union nut (8) at top of secondary heat

exchanger.

e) Unscrew bottom left hand union nut (9) of secondary

heat exchanger.

Fig. 59

0 Slacken top screw (A) of heat exchanger to chassis.
g) Remove bottom saew (B) and spacer.
h) Remove secondary heat exchanger.
I) Replace in reverse order.
N.B. Do not unscrew the four tie rods in the secondaty

heat exchanger.

a.13

Fig. 59 a

To repbee air sepanttor
a) Remove front case (see section 7.1).
c) Close heating flow and return valves (B & C) (see

section 8.11 (fg. 58 a)).

d) Dram boiler down through safety valve (F) (see section

8.11 (fg. 58 a)).

C) DiSCOMKt BOW Switch

pipe

UtliOll hfll PUl’llp VOiUte

0.

fI Diiconnect manual vent tube (B) be carefull not to

loose blackwasher.

g) Pun out spring clip (A) with pliers.

6) Disconnect pump connection at union (D) at pump
OutIeL

j) PuII pump complete with volute forwards and remove.

k)

Disconnect union nut at base of air sepatator.

m) Ease air separator forward and disengage integral peg

hn chassis bracket,

q) Replace in reverse order, Ensure that washer is

replaced in lower union of separator.

r)

Open flow and return valves. Re-pressurise system if

necessary.

32

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

a.14

To rrpkce

boikr

thermostat
a) Remove front case (see section 7.0.
b) Remove five screws (A) and remove electrical box

cover. Unplug kom the PCB the single connector for

the switch.
c) Remove dip retaining thetmostat phial.
d) Remove two screws (D) which secure boiler

thermostat to the electrical box cover.

e) Remove the spade connectors noting position, see

ihstrated wiring diagram fig. 9.

f) Feed out capillary through electrical box having

removed the split grommet.

g) Replace in reverse order.

I

a.15

8.16

Fig. 61

To reukcc boiler Emit thamostat
a) R x25-z

titxu

case (see section 7.1).

b)

‘:

;:xe eiectrical box. see section 8.9.

N.B. ;hermostat is situated to right top of electrical box.

sensor in pocket on ffow pipe on right hand lower

side.
c) Remove split pin from dry pocket on ffow pipe (A).
d) This thermostat is located on moulded pins - ease

forward and remove spade connectors.

e) Feed cap&q through the control box having removed

the split grommet.
f) Replace in reverse order (polarity immaterial).

To repface domestic hot water theostat
a) Remove font case (see section 7.1).

b) Remove electriozl box Rant cover (see section 8.9.(c)).
c) Isolate mains water supply - drain 6om valve beneath

the change over valve (see section 8.11 fg. 58 (H)).
d) Remove clip which retains phial in wet pocket
e) Remove phial from pocket
t) Ease thermostat off moulded pegs and pull of spade

mnnections.
g) Feed capillary through the control box. having

removed the split grommet

6)

Replace in reverse order. Polarity immateriaL

Fig. 62

33

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

8.17

To rephe spark genentor
a) Remove front case (see section 7.1).
b) Remove electrical box cover (see section 8.9 (Cl).
c) Remove PCB (see section 8.18).
d) Pull

tab

connections from spark generator noting

position.

e) Slacken bottom f&g screw and remove top screw

from generator.
f) LiA up off bottom screw and pull forwards.
g) Replace in reverse order. (Connect

leads

before

locating generator).

Fig. 63

8.18 1

To @ace printed circuit board (PCB)
a) Remove iront case (see section 7.1).

b)

Remove electrical box front cover (see section 8.9(C)).
c) Remove ail plug-in connections (10).
d) Disconnect mains input cable at terminals 1 and 2 but

A

not the earth.

e) Disconnect external controls. if Wed, from terminals 4

and 5.

f) Remove one screw (A).
g) Slide PCB slightiy upwwards to disengage guide.
h) Pull PC B

forward.

j) Replace in reverse order.

I

Ffg. 64

I

16 17

1 11 13

9

4 6 14

1 Summer/Winter Switch

capillary 9 Push Button Ignition 14 D.H. W. Thermostat

2 Pump

6 Water Flow Switch

10

Solenoid Gas Valve

15

Limit Thermostat

3 Earth

7 D.H.W. Thermostat

11

Fan connection

16

Fuse

4 Boiler

Thermostat

Capillary

12

24OV- 50Hz connection

17

Room thermostat

5 Limit Thermostat

8 Change Over Valve

13

Igniter

connection

Fig. 65

ELECTRICAL BOX SHOWING POSITION OF COMPONENTS WITH IAYOUT OF PLUGS AND

WIRUUC.

34

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

8.23

8.24

1

Fig.71

8.25

Fig. 70

To repI8ce prtssure switch

a) Remove two screws (A) retaining plastic turret cover

and remove terminal cover.

b)

Note position of spade

co~ectors

and remove (COM-

P. No 1 and No 2).

c) Disconnect pressure sampling tube by pulling off

nipple.

d)

Remove two screws retaining pressure switch (B).

c) Repiace in reverse order.

N.B. Ensure ‘0’ ring is positioned on rear of pressure
witch to seal pressure switch - high pressure sampie

joint. Transfer 4 mm support screw (0 and nut onto

the new switch if not supplied.

To re-pressoritl

sfxpadmvessel

a) Remove case (see section 7.1).

b) Close heating flow and retum valves and drain boiler

through safety vaive (see section 6.2 fig. 34 0).

c) Remove protective cap and check pressure on

schroeder valve with gauge.
N.B. The setting pressure is 0.65 bar (9.5 psi).
d) To re-pressurise use car foot pump or bicycle pump

with adaptor.
c) Close safety valve.
f) Open heating flow and return valves.
g) ReElI and commission boiler.
N.RDonotuuahQhpreu~~Ene.

Fig. 72

To fepiocc pressure gauge
a) Remove case (see section 7.1).

b)

Close heating flow and return valves and drain boiier
through safety valve (see section 6.2 fg. 34 (PI).

d)

Undo union nut (A) on pressure tube at rear of gauge.
c) Withdraw gauge.
f) Replace in reverse order.
g) Open flow and return valves. Re-pressurise system if

necessary.

36

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

8.26

8.27

8.28

I

Fig. 73

To repku the domestic eqmsion vessel

a) Isolate cold water mains supply (see section 6.2).
b) Drain from valve beneath the change over valve see

section

8.11

(see tig. 58H).
c) Remove electrical control box (see section 8.9).
d) Undo connection (B) and remove domestic expansion

VeSS4

Replace in reverse order.
Check for ieaks.
N.B. Care should be taken to ensure support for

pipework when working on this component.

TOlVpf8Um;rinbUlVlU

a) Remove case (see section 7.1).
b) Remove outer front panel (see section 7.2).
c) Remove burner (see section 7.3).
d) Replace in reverse order ensuring that the gasket is

cortect!y positioned between the injector cover plate
and the manifold.

Fig. 74

Fig. 75

F2 /

To

rep&e

the burner manifo&i assembly
a) Remove the front case (see section 7.1).
b) Remove the combustion chamber front panel to

expose the burner manifold (see section 7.2 (a to c)).

c) Remove the two saews FI and remove the closure

plate.

N.B. When repiacing the manifold it is advisable to

replace the gasket at the same time.

d) Remove the two saews F2 and lift off from Burner

base.

c) Replace in reverse order.

37

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

.

:.

8.29

8.30

8.31

To replace pilot injector, air

filter.

deflector plate/

burna

head

a) Remove as detailed in section 7.4.

b) Replace in reverse order.
N.B. FiIot injector fitted bright side uppermost.

To @ace expansion vessel
a) Remove 6ront case (see section 7.1).
b) Isolate appliance from system by closing flow and

return valves (see section 6.2 tig. 34 (B et Q).

c) Drain boiler (primary side) through safety valve fig. 34

(F) and vent expansion vessei at (C).
d) Remove flexible pipe from expansion vessel. at (A).
c) Loosen upper securing screw (B) support and loosen

lower saew. Slide out expansion vessel.
0 Replace in reverse order. engaging the thread of the

flexibie pipe before screwing fully home screws (B).

The vessel must be central on the Eront panel.

0) Re-pressurise expansion vessel (see section 8.24).

6) Open tlow and return valves. If necessary, repressurise

(sze%n 6.2).

Fig. 77

To repka viewing window

a)

Remove front case (see section 7.1).

b) Remove combustion chamber front panel (A) (see

section 7.2 ).

c) Remove the screws (B) securing the sight glass bracket

(C). Take care not to Loose the two nuts (D).

d) Replace in reverse order referring to diagram opposite.

Fig. 78

38

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

8.33

8.34

TompIacethemaiugu~bo*
a) Remove tiont case (see section 7.11.

b) Remove combustion chamber kont panel (see section

7.2).

c) Remove burner assembw (see section 7.3).

d) Remove elect&J control box (see section 8.9).

l

) Part thermocouple connections to high limit

rhelmostat.
r) Pull connectors off miaoswitch (MI noting colours.
g) Remove two screws (PI retaining bracket to gas

section and ease bracket down to dear gas section.

h) SIacken

and undo the gas supply union (D) beneath

gas

section.

f) Remove two screws (RI retaining gas section to

combustion chamber base.

k)

Remove gas section by pulling forward.
m) Reassemble in

reverse

order and check for gas

SOUlldlleSS.

8

A

a) Remove ux. :I’;,-.: c.xe (see section 7.1).

b) Undip and remove thermometer sensor from

flow

pipe (A).
c) Withdraw gauge (B) by compressing the two f%ng lugs
and pushing the gauge towards you. Feed the sensor

through the bracket.

d)

Replace in reverse order.

Fig. 80

To rrpkce safety valve

a) Remove case (see section 7.1).
b) &se

heating flow and return valves

and drain the
appliance through safety valve (see section 6.2 fig. 34 (D
and section 7.8).
c) Ensure that the boiler is complete drained and the
pressure gauge is reading zero (0).

d)

Undo the grub screw (A) and remove the complete
assembly by care&& pulling it in a downwards direction.
e) Replace in reverse order.
0 Ensure that the vaive is in the dose position and
repressurise system (see section 6.2).
g) Open heating flow and return ties.

6) Check for ieaks.

I

Fig. 81

I

39

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

3. FAULT FINDING
I.1 Logic sequence

I

ew suppry

I

1 fan high speed 1

no

no

time delay 5 sec. max.

time delay 5 sec. max.

2nd stage soienoid opens 2nd stage soienold opens

40

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

9.2

FAULT FINDING

CENTRAL HEATING OPERATION

SEQUENTIAL FLOW CHART 1

READ IN CONJUNCTION WITH SECTIONS (9.1 & 9.3)

hhasun mdlivdl oumui al lhetrm
elsdnc valv. (XV) gmala than

* 12mV

Ou@uttoTCfbuihm12mV.

I

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

,

:.

9.3 FAULT FINDING
DOMESTIC HOT WATER OPERATION

SEQUENTIAL FLOW CHART 2

READ IN CONJUNCTION WITH SECTIONS (9.1 & 9.2)

START

T

No

t

YeS

t

No

Ensure alI 1SOlP­ltng valves

and

Check dwhragm
is OK
Spindle OK
Rsplaw d necas-

SW.

42

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

9.4 FAULT FiNDING TABULAR CHART

PROBLEM

CAUSE

REMEDY

) Explostve tgnition

i) Poor ptlot flame

a) Inlet pressure low - should be 8’ wg

la) Check meter end pipe sizing

(20 mbar) working pressure

see sections 2.7 and 4.7

b) Blocked gas

filter

lb) Clean

c) Pilot injector dirty

lc) Clean replace, see section 8.29

ii)

If3 valve not operating

a) 24 volts supply to valve

2a) Replace solenoids, see section 6.20

b) No voltage at solenoid

2b)

Check plugs on printed circuit board

2c) Replace printed circuit board,

see sections 6.18

iii) Crosslighting stfip - missing/incorrectly

3) Replace or reposition

positioned

!) Unstable burner

I) Incorrect injectors

ii) Gas pressure at manifold

a) Too high

a) Too low

iii) Terminal incorrectly positioned
Iv) incorrectly assembled flue duct

v) Fan inconectiy located

1) Replace manifold 1.28 mm injectors
for natural gas, see section 8.28

a) Adtu~: .:x section 6.4
2b) C~hactc resuictors and inlet pressure,

see sectioll 1.2

3) See section 2.4

4) Check and reassemble,
see section 4.10

6) Remove and refit correctiy.
see section 8.22

vi) Combustion chamber front cover not sealing

6e) Tighten

6b) Replace sealing strip

vii) Heat exchanger fins blocked

7) Clean. see section 7.2 and 7.7

viii) Neoprma gasket in turret not conecay fitted

8) Fit or refit, see

se&On

4.10

or missing

3) Central heating
low Aow
temperature

i) Boiler thermostat out of calibration

1) Replace. see section 8.14

ii) Limit stat out of calibration

2) Replace, see section 8.15

iii) Insufficient gas pressure

3) Check pressure at meter and Pipe
sizing, see sections 2.7 and 4.7

Iv) 113 Mue or 2l3 orange gas valve not opening

a) 24 volts at solenoid

4a) Replace solenoid, see section 8.20

b) No voltage at solenoid

4b) Replace print circuit board,

see section 8.18

v) Change over valve assembly

sticking
a) Dead leg on hot water system

5a) Eliminate

b) Sent spindle in valve

5b) Replace, see section 6.11

vi) By-pass, if fitted. incorrectly adjusted

6) Adjust see section 3.16

vii) Pressure switch hunting

7) Replace, see section 6.23

viii) System incorrectly balanced

8) Balance system.

43

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

PROBLEM

CAUSE

REMEDY

3) Boiler noisy

9

On heating only
a) Low flow rate as result of system resistance

b) Air in system

ii)

On hot water and central heating

a) Low pressure in sealed system

b) Pump running slow

ii9

Blocked filter on heating return

iv) Gas filter fitted to heating flow or return pipes

v) Heat exchanger scaled

v9

Over-gassed

OW)

isolating valves not fully open

la) Check and if omitted fit by-pass

see section 3.16

1 b) Purge by venting radiators

2a) Repressurise to 1 bar cold

see section 6.2 (5)

2b) Replace pump head, see section 8.10

3) Clean and replace see section 7.6

4) Remove and reposition see section 4.5

Sa)

Descale

5b) Replace, see section 6.8

6e) Check gas pressure and adjust, see

section 6.4

6b) Check restrictors, see section 1.2

7) Open fully see section 6.2

5) Hot water does not

9

Low inlet water pressure 1) Ensure all down stream stop cocks

0pem.e over

open

temperature range

ii)

Incorrect venturi fitted 2) Replace with 5.4 mm diameter,

see section67
iii) Hot water limit stat out of calibration 3) Replace, see section 8.16
iv) Solenoids not operating 4) See section 9.2. flow chart 1

v) Pressure switch hunting

5) Replace, see section 8.23

vi)

Low inlet gas pressure 6) See section 6.4

vi9

Control stat out of calibration

7) Replace see section 8.16

i) No main burner

9

Lack of water flow

ii)

Pump jammed
iii) No water
iv) Flow switch not operating

v) Heating thermostat faulty (CH only)

vi) Pressure switch not operating

1) Checks valves are open
see sections 6.1 and 6.2

2) Manually check see section 6.2 (8)

3) Fill system, see section 6.2

4) Replace switch, see section 8.34

5) Replace, see section 8.14

6) Replace, see section 8.23

r) Safety valve

discharges

9

System pressure too high

1) Adjust 1 bar cold

ii) Not isolated from mains

2) Remove filling loop

iii) C.H.expansion vessel lost air charge 3) Recharge 0.65 bar. see section 8.24
iv) Secondary heat exchanger (water to water) 4) Replace, see section 8.12

internal water leak

I) Pump noisy

9

Air in system

ii) Air separator

iii) Debris in pump
iv) Retumr filter blocked

1) Vent radiators

2) Open vent on air separator,
see section 6.2 (4)

3) Clean and replace, see section 8.10

4) Clean and replace, see section 7.5

44

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

PROBLEM

CAUSE

REMEDY

1) Excesstve

i) Return falter blocked 1) Clean and replace, see sectron 7.6

temperature
rise across boiler

ii) Low water How rate

a) Pump defectrve 2a) Replace, see section 8.10
b) High system reststance

2b) Fit by-pass, see section 3.16

c) Gas fitter inadvertandy fitted in flow

2c) Remove and refit.

or return connectton

see sections 4.5

iii) Gas rate too high 3) Adjust, see section 6.4

IO) Rapid cycling

i) Low water flow rate

I) See System guidance’ sectton 3.3

higMow or
high/low/off

ii) Limit stat out of calibration 2) Replace. see section 8.15
iii) By-pass, if fitted. not regulated 3) Adjust, see section 6.5
iv) Blocked heat exchanger 4) Clean or replace, see section 6.8

I1 ) Fan on high speed

i) Defective printed circuit board

1) Replace, see section 8.18

continuously

ii) Microswitch fault 2) Replace, see section 8.5

12) Loss of pressure

i) Leak on system

1) Locate and rectify

ii) Leak on appiiance 2) Locate and rectify

13) Gain in pressure

i) Filling loop still fitted and letting by

I) Close stop cocks and remove

shown on gauge

ii) Blockage in expansion chamber flexible hose 2) Clear blockage
iii) Secondary heat exchanger (water to water)

3) Replace, see section 8.12

internal water leak

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388

SHORT LIST

“O’

2909

2214

2303

2215

1435 .

*

2245

520 -

3

&

+ 2509

3105 ­3001 - -

a---- 2507

:ey N”

Description

TLpe

G. C. NO.

MAN F. PT. NO.

STERLING PP

507 THERMO. & OVERHEAT STAT 105°C..

.........................

264602

74723.00

510 ELECTRODE 8 LEAD ASSY.. ....................................... 264828

70308.00

511 SOLENOID VALVES

KIT..

.............................................. 366865

81030.00

520 MICRO SWITCH. ........................................................... 264793

78989.00

601 BURNER HEAD..

............................................................ 264592

69106.00

701 MANIFOLD NAT KIT..

....................................................

NAT 266032

8101i.00

702 GASKET (ManhId). .......................................................

264477

71226.00

1 101 WATER

FLOW SWITCH

................................................ 266005

1000658.00

1435 MICRO SWITCH. ..........................................................

379073

1001157.00

2102 PUMP UP ls60.. ........................................................... 266013

1000772.00

2202 PRINTED CIRCUIT BOARD.. ...................... ................

1011304.00

2214 AQUASTAT 57-C KIT .....................................................

266060

100606.30

2215 HEATlNG THERMOSTAT 85°C.. .................................... 264849

56974.00

2245 REGULATING THERMOSTAT ASSY.. ........................... 277666

81426.00
6

2302 PRESSURE GAUGE ASSY..

.........................................

277591

8102i.00

z

2303 THERMOMETER ASSY

........................................... .;

... 277592

al 022.00

0

2507 AQUASTAT KNOB.. ........................................................

277670

1004996.00

f
d

2509 SUCK BU-ITON.. ..........................................................

277671

59600.10

ii
%

2909 PRESSURE

REUEF VALVE..

........................................

277770

76584.00

3001 277768

1009106.00

i5

FAN MOTOR ASSY 24OV.. ............................................

3105 PRESSURE SWITCH KIT.. 277609

81611 .oo

E

............................................

Chaffoteaux et Maury Limited,

Trench Lock, Trench, Telford, Shropshire TFl 4SZ

Telephone :

Telford (09521222727 - Telefax : [phone]

Lookhg

Good. Heating Better

ESP037

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ

01274 488 388