Glow-worm 40 GC 41 319 20, 55 GC 41 319 19 Installation & Servicing Instructions Manual

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220677A.05.95

COSHH

Installation & Servicing Instructions

T o be left with the user

40 GC No. 41 319 20 55 GC No. 41 319 19

Fanned Flue Sealed System Boiler

4746

This is a Cat I 2H appliance

Reference in these instructions to British Standards and Statutory Regulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

Customer Services: Tel: (01773) 828100

One Contact Total Service

Fax: (01773) 828070

BS 6332 BS 5258

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

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1 General

101

All dimensions in millimetres

KEY: 22mm COMPRESSION CENTRAL HEATING

Rc1/2(1/2 in. BSPT) GAS CONNECTION

STD FLUE TERMINAL = 63

LONG FLUE TERMINAL = 61

174

321

161

783

450

SAFETY VALVE DISCHARGE

346

3130

108

2.5

OVERALL DIMENSIONS

The instructions consist of two parts, Installation and Servicing and Instructions for Use. They are the property of the user and must be handed to them on completion of the installation.

1.1 Important Notices

This boiler is for use on natural gas (G20) as distributed in the United Kingdom and Ireland and cannot be used on any other gas.

Wherever possible, all materials, appliances and components to be used shall comply with the requirements of applicable British Standards.

Where no British Standard exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.

This boiler is not suitable for use out of doors. THIS BOILER IS FOR USE ONLY IN A SEALED

WATER SYSTEM. It can be used to provide domestic hot water from a

vented or unvented domestic system.

1.2 Sheet Metal Parts

WARNING. When installing or servicing the boiler care should be taken when handling sheet metal parts to avoid any possibility of personal injury.

1.3 Statutory Requirements

The installation of the boiler MUST be carried out by a

Diagram 1.1

competent person in accordance with the relevant requirements of the current issue of:

Manufacturer’s instructions supplied. The Gas Safety (Installation and Use) Regulations, The

Building Regulations, The Building Standards (Scotland) Regulations (applicable in Scotland) Local Water Company Bye-laws, The Health and Safety at Work Act, The Electricity at Work Regulations, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.

Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice,

BS4814, BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891, BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

Manufacturer’s instructions must not be taken as overriding statutory requirements.

1.4 BSI Certification

The boiler is certificated to the current issue of BS6332 Part 1, invoking the current issue of BS5258 Part 1 for performance and safety. It is, therefore, important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the BSI Certification of the boiler, the warranty and could also infringe the current issue of the Statutory Requirements.

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1 General

CE Mark

The CE mark on this appliance shows compliance with Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels.

The CE mark on this appliance shows compliance with Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to equipment designed for use within certain voltage limits.

1.5 Range Rating

The boiler is range rated and is factory preset to maximum, but may be adjusted to suit individual system requirements, refer to Range Rating, Table 2.

1.6 Equipment

The boiler is supplied with an integral expansion vessel, circulating pump, safety valve, pressure gauge, low water pressure warning light, automatic bypass valve, gas cock and valved water connections (with drain points).

Data Label

The data label is positioned on the inner case cover. Appliance Data refer to Table 1

MODEL

LIFTING WEIGHT

TOTAL WEIGHT

WATER CONTENT

GAS CONNECTION

WATER CONNECTION

ELECTRICITY RATING

ELECTRICITY SUPPLY

DATA LABEL

INJECTOR SIZE

DATA TABLE 1

40 55

33.3kg 33.3kg (73.4lb) (73.4lb)

47.8kg 47.8kg

(105.4lb) (105.4lb)

0.62 litre 0.62 litre (0.136 gal) (0.136 gal)

Rc 1/2 (1/2 in. BSPT)

22mm copper,

return at right, flow at left

135W, internal fuse F1A

240V~50Hz fused 3A

On the inner case front

3.1mm 3.6mm

1.7 Gas Supply

The gas installation must be in accordance with the current issue of BS6891.

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

On completion, test the gas installation for soundness using the pressure drop method and suitable leak detection fluid. Purge in accordance with the current issue of BS6891.

1.8 Electrical Supply

WARNING. This boiler must be earthed. All system components and wiring shall be of the

approved type and comply with and be connected in accordance with the requirements of current issue of BS7671 and any applicable local regulations.

Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A maximum. The method of connection should be, preferably, by a fused double pole isolating switch, provided it has a minimum contact separation of 3mm on both poles. This switch should be readily accessible and preferably adjacent to the appliance. It should supply the appliance only and be easily identifiable as so doing.

Alternatively an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower.

Wiring to the boiler must be to the current to the of BS6500 Table 16.

RANGE RATING

NOMINAL HEAT INPUT

NOMINAL HEAT OUTPUT

BURNER SETTING PRESSURE

APPROX GAS RATE

RANGE RATING

NOMINAL HEAT INPUT

NOMINAL HEAT OUTPUT

BURNER SETTING PRESSURE

APPROX GAS RATE

TABLE 2.

Btu/h

m bar

in.w.g

m3h

ft3h

TABLE 2.

Btu/h

m bar

in.w.g

m3h

ft3h

Complheat 40

min mid max

38,200 44,000 49450

11.2 12.9 14.5

30,000 35,000 40,000

8.8 10.3 11.7

7.6 10.3 13.3

3.1 4.1 5.3

1.0 1.2 1.4

37.7 43.4 49.3

Complheat 55

min mid max

50,500 59,750 68,000

14.8 17.5 19.9

40,000 47,500 55,000

11.7 13.9 16.1

7.9 11.4 14.5

3.2 4.6 5.8

1.4 1.7 1.9

49.8 58.9 67.8

220377B

220677A

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2 Water System

2.1 General Notes

The installation of the boiler must comply with the requirements of the current issue of BS6798.

2.2 Safety Valve

The safety valve, preset at 3bar, is an integral part of the boiler and cannot be adjusted.

2.3 Pressure gauge

A pressure gauge is incorporated into the boiler to indicate the system pressure.

2.4 Circulating Pump

The circulating pump is integral with the boiler. The remaining conveying capacity of the pump is shown

in diagram 2.1.

2.5 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of 8Litres (1.76 gallons), with a charge pressure of 0.75bar.

WATER FLOW RATE

AT 110C (200F) DIFFERENTIAL

UNIT 40 55

litre/min. 15.3 21.0 gal/min. 3.4 4.6

Flow rate (gallons/minute)

1.1

12 10

8 6 4 2

Available pump head (Ft)

Flow rate (litres/minute)

3.3

2.2

Nominal flow rate

C differential

for 11

10 15

5.5 6.6

4.4

20 25 30

3131/B

3.6

3.0

2.4

1.8

1.2

0.6

Available pump head (m)

The maximum heating system water content using the fitted expansion vessel ranges from 119litres with a cold fill pressure of 0.7bar, to 98litres with a cold fill pressure of 1.05bar. If, due to a high static head, the cold fill pressure is higher, then the expansion vessel pre-fill pressure must be increased, and the maximum system volume decreased, see the current issue of BS7074 Part 1.

Further information can be obtained from the British Gas Publication “British Gas Specification for Domestic Wet Central Heating Systems” and the current issue of BS4814, BS5449 and BS7074 Part 1 and 2.

2.6 Flow Rate

A valve must be incorporated in the main flow or return of the system, valve “A” shown in the flow diagram 2.2. This valve must be lockable and be positioned so that inadvertent closure or unauthorised interference is not possible. The design differential is 11oC (20oF) with the boiler thermostat set at “MAX” which is about 82oC (180oF). The pump adjuster should always be left at maximum (3).

REMAINING CONVEYING CAPACITY OF PUMP

3 LITRES MAKE-UP BOTTLE (if required)

AUTO AIR VENT

NON-RETURN VALVE

ADDITIONAL EXPANSION VESSEL (if required)

RETURN

Diagram 2.1

3131

BOILER

FILLING POINT

2.7 Bypass

An automatic bypass valve is incorporated in the boiler pipework it is preset and must not be adjusted.

WATER SYSTEM DIAGRAMATIC LAYOUT

220677A

HEATING

CIRCUIT

'A'

FLOW CONTROL VALVE

DRAIN COCK

Diagram 2.2

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2 Water Systems

2.8 Water Make Up

Provision should be made for replacing water lost from the system using a make up bottle mounted in a position higher than the top point of the system, connected through a non-return valve to the return side of the heating circuit, see diagram 2.2.

Alternatively, provision for make up can be made using a filling loop.

2.9 Filling Sealed Water Systems

Provision for filling the system at a low level must be made.

Three methods of filling are shown in diagram 2.3. There must be no permanent connection to the mains water supply, even through a non-return valve.

2.10 Corrosion Inhibitor

Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems.

If an inhibitor is to be used in the system, contact a manufacturer for their recommendations.

2.14 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE AND SHOULD NOT BE USED.

The domestic hot water cylinder must be of the indirect coil type. It must be suitable for a working at a gauge pressure of 0.35bar above the safety valve setting.

2.15 Domestic Hot Water System Unvented

Where a storage system will not have a vent to atmosphere the installation must comply with Building Regulations and local Water Company bye-laws, see also the current issue of BS6700.

If fitting into an existing system the local authority must be informed.

METHOD 1

TEMPORARY HOSE

COMBINED CHECK VALVE AND VACUUM BREAKER

HEATING SYSTEM

2819

2.11 Existing Systems

When fitting the boiler into an existing system, special care should be taken to drain the entire system, including radiators, then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor.

2.12 Draining Tap

A draining tap must be provided at the lowest points of the system, which will allow the entire system to be drained. An additional draining tap MUST be fitted close to the boiler.

Draining taps must be to the current issue of BS2879. The flow and return isolating valves on the boiler are

fitted with drain points for heat exchanger draining.

2.13 Domestic Hot Water System

General

The domestic hot water service must be in accordance with the current issue of BS5546, refer also to the current issue of BS6700.

SUPPLY PIPE

METHOD 2

TEMPORARY HOSE

SUPPLY PIPE

METHOD 3

CISTERN

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

SUPPLY STOP VALVE

DOUBLE CHECK VALVE ASSEMBLY

HOSE UNIONS

SUPPLY STOP VALVE

OVERFLOW

SERVICING VALVE

HOSE UNIONS

SERVICING VALVE

PRESSURE REDUCING VALVE

DOUBLE CHECK VALVE ASSEMBLY

HEATING SYSTEM

FILLING SEALED WATER SYSTEMS

Diagram 2.3

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3 Boiler Location

3.1 General

The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower.

Any electrical switch or boiler control using mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

The electrical provisions of the Building Standards (Scotland) Regulations are applicable to such installations in Scotland.

The boiler must be mounted on a flat wall which is sufficiently robust to take its complete weight, see Appliance Data, Table 1.

The boiler may be fitted to a wall made of combustible material. See diagram 3.1.

3.2 Boiler Clearances

The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram 3.1.

3.3 Timber Frame Buildings

If the boiler is to be installed in a timber frame building, it should be fitted in accordance with the British Gas Publication “Guide for Gas Installation in Timber Framed Housing” reference DM2. If in doubt, seek advice from the local gas undertaking or Hepworth Heating Ltd.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose.

An existing cupboard or compartment modified for the purpose may be used, refer to the current issue of BS6798 for guidance.

The doorway opening should be of sufficient size to allow easy removal of the boiler.

TABLE 3. COMPARTMENT AIR VENTS

VENTILATION REQUIREMENTS

MODEL

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

VENTILATION

132 20 132 20

FROM ROOM OR SPACE

VENTILATION

40 55

181 28 181 28

66 10 66 10 FROM OUTSIDE

91 14 91 14

3133

186

3.4 Room Vent

The boiler is room sealed, so when installed in a room or space, a permanent air vent is not required.

3.5 Cupboard or Compartment Vent

Where the boiler is fitted in a cupboard or compartment, permanent high and low level ventilation must be provided.

The vent areas required are given in Table 3. Where the installation of the boiler will be in an unusual

location, special procedures are necessary, refer to the current issue of BS6798 for guidance.

Make sure that the cupboard or compartment air vents are positioned to be clear of obstructions at all times.

800*

150

❋ WHERE EXTERNAL ACCESS TO

THE FLUE IS NOT PRACTICAL THEN

CLEARANCE MUST BE ADEQUATE TO

PERMIT INSTALLATION OF THE FLUE

MINIMUM CLEARANCES FROM WALLS, CEILING,

FLOOR, CUPBOARD, WORKTOPS AND

INFLAMMABLE MATERIALS

MINIMUM CLEARANCES Diagram 3.1

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4 Flue

The flue must be installed in accordance with the current issue of BS5440 Part 1.

The air and flue ducting connect to the top of the boiler using an elbow which can be positioned to the left or right hand side or the rear.

The rear and side flue assemblies are designed for internal installation, but if necessary, due to insufficient clearances (boiler/flue terminal location) they can be installed from the outside.

For a wall thickness up to 300mm the flue can be fully installed from the inside.

For wall thickness of over 300mm the external cut hole will need to be made good from the outside.

The standard flue will provide the flue length range as shown in diagram 4.1 and 4.2.

If a longer flue is required, do not extend the ducting. A 1, 2 or 3metre flue system must be used and can be supplied. This will provide the flue length range as shown in diagram 4.1 and 4.2.

A "Flue Bend Kit" and "Vertical Flue Kit" can be supplied.

STANDARD FLUE TERMINAL ILLUSTRATED

'R'

Rear Flue Lengths

R = Wall Thickness

Flue. STD 75mm to 598mm 1m 75mm to 913mm 2m 75mm to 1913mm 3m 75mm to 2908mm

REAR FLUE

STANDARD FLUE TERMINAL ILLUSTRATED

Diagram 4.1

3134

3135

'S'

Side Flue Lengths

S='External wall face’to‘boiler mounting frame’

Flue. STD 80mm to 547mm 1m 80mm to 857mm 2m 80mm to 1857mm 3m 80mm to 2852mm

SIDE FLUE Diagram 4.2

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4.1 Terminal Position

The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.3.

The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

Car ports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if it is made of plastic sheeting. If the car port comprises of a roof and two or more walls, seek advice from the local gas company before installing the boiler. If the terminal is fitted within 600mm below plastic guttering and aluminium shield 1500mm long should be fitted immediately beneath the guttering or eaves. If the terminal is fitted within 450mm below painted eaves or a painted gutter, an aluminium shield 750mm long should be fitted immediately beneath the guttering or eaves.

4.2 Terminal Guard

4 Flue

UNDER CAR PORT etc.

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION

B,C

H,I

B,C

2816

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal.

A suitable guard as shown, reference type K3, can be obtained from:

Tower Flue Components Ltd., Morley Road, Tonbridge, Kent. TN9 1RA

A DIRECTLY BELOW AN OPENABLE

WINDOW, AIR VENT, OR ANY OTHER VENTILATION OPENING 300

B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 D BELOW A BALCONY OR CAR PORT 200

E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 75

F FROM INTERNAL OR EXTERNAL

CORNERS 300

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

H FROM A SURFACE FACING THE

TERMINAL 600

I FACING TERMINALS 1200

J FROM OPENING (DOOR/WINDOW) IN

CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300

Diagram 4.3

0161M

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5 Preparation

INFORMATION PLATE

5.1 Unpacking

3137

Remove the top carton from the boiler. To remove the outer case, slide the information plate up

to access and remove the single securing screw, see diagram 5.1, unhook the case at the top and lift it off.

Remove the cover of the inner case, secured with four screws, see diagram 5.2.

Disconnect the gas service cock union and the front unions of the isolation valves, see diagram 5.3.

Slacken but do not remove the retaining strap screws of the gas service cock and the isolating valves.

OUTER CASE SECURING SCREW

OUTER CASE Diagram 5.1

GAS SERVICE COCK UNION

SECURING

31383139

SCREW (4)

INNER CASE COVER

INNER CASE COVER Diagram 5.2

FLOW WATER ISOLATING VALVE UNION

RETAINING STRAP

RETURN WATER ISOLATING VALVE UNION

RETAINING STRAP

Diagram 5.3GAS SERVICE COCK / WATER ISOLATING VALVES

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5 Preparation

Remove the two boiler securing screws, see diagram 5.4 then separate the boiler from the mounting frame, by pulling the location studs/clips apart then unhook it at the top.

BOILER SECURING SCREW (2)

3140

6 Installing the Flue

6.1

With due regard to boiler location, clearances and having determined the flue application, length and terminal position carry on as follows:

MINIMUM CLEARANCE

149

115 Diameter

FLUE CENTRE LINE

Top of Boiler

BOILER MOUNTING FRAME

LOCATION STUD(S) and CLIP(S)

BOILER MOUNTING FRAME

6.2 Marking

The boiler mounting frame is the same width as the boiler but the flue connection protrudes above. Place the boiler mounting frame on the wall in the required position, maintaining minimum clearances, see diagram 3.1.

3142

CORNER

(RIGHT FLUE)

173

(LEFT FLUE)

173

Diagram 5.4

3143

CORNER

629

FLUE

480

TEMPLATE

BOILER FIXING POINTS

220677A

BOILER

MOUNTING FRAME

FIXING POINTS

300

Diagram 6.1

SIDE FLUE

115 Dia.

FLUE CENTRE LINES

Diagram 6.2

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6 Installing the Flue

Make sure that the isolation valves are at the bottom facing forward and that the frame top is horizontal, then mark the four fixing points through the holes in the two horizontal straps, do not drill the holes, see diagram 6.4.

Position the flue template on the wall, the arrow points on the centres of the two upper fixing points previously marked, see diagram 6.1 which also gives dimensions.

For a rear flue, mark the rear flue position as required, centre or diameter.

For a side flue, mark the horizontal flue centre line at the sides of the template. Extend the flue centre line horizontally left or right to the internal corner where the flue is required to exit to the outside. Mark the position of the circular hole, on the flue exit wall, using the dimensions given in diagram 6.2.

From the flue position marks, check that the flue terminal will be in a suitable position, see diagram 4.3.

6.3 Flue Hole Cutting

WALL SLEEVE

3144

300mm MAX.

LENGTH

Diagram 6.3

Cut a horizontal hole in the wall, making sure that there is no downwards slope towards the boiler position, using, preferably, a core drill, to the diameter shown in diagram 6.1 and 6.2.

6.4 Wall Sleeve

Take the wall sleeve from the pack. If the wall thickness “Q” is less than 300mm, cut the wall sleeve to the required length, see diagram 6.3. If the wall thickness “Q” is greater than 300mm the sleeve must be fitted flush with the outside wall face.

Place the sleeve into the hole. Make good around the wall sleeve at both internal and

external wall faces, through the wall sleeve if internal access only is available.

For a wall thickness of over 300mm the external wall face will need to be made good from the outside.

6.5 Boiler Mounting Frame - Fixing

Position the flue template over the flue hole and check the position of the wall fixing points. Mark the position of the fixing holes again, if required, see diagram 6.1.

BOILER MOUNTING FRAME

FIXING POINTS

3145

Drill the four holes and insert wall plugs to suit No10x50mm screws.

Secure the boiler mounting frame to the wall using No10x50mm screws, see diagram 6.4.

Note: Remove the clear plastic protective film from the sides of the boiler mounting frame.

BOILER MOUNTING FRAME

Diagram 6.4

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6 Installing the Flue

6.6 Flue Preparation

Rear Flue

Mark and cut the air duct terminal assembly, see diagram

6.5 and the flue duct, see diagram 6.6 to the lengths required, cutting square and removing any burrs.

Refer to diagram 6.9, mark through the holes in the flue elbow assembly and drill the flue duct as shown.

Side Flue

Mark and cut the air duct terminal assembly, see diagram

6.7 and the flue duct, see diagram 6.8 to the lengths required, cutting square and removing any burrs.

Refer to diagram 6.9, mark through the holes in the flue elbow assembly and drill the flue duct as shown.

6.7 Flue Assembly

Note. At this point if side or front access is restricted, continue at “External Flue Assembly”.

Internal Flue Assembly

Locate the flue duct into the flue elbow assembly and secure with the screws provided, see diagram 6.9.

Fully locate the flue elbow and flue duct assembly into the air duct/terminal assembly as shown, ensuring correct terminal alignment of the “TOP”, see diagram 6.10.

STANDARD FLUE TERMINAL ILLUSTRATED

FLUE DUCT

'R' + 107

'R'

REAR FLUE - FLUE DUCT

1M, 2M, 3M LONG FLUE TERMINAL

STANDARD FLUE TERMINAL

'S' + 148

Diagram 6.6

AIR DUCT/ TERMINAL ASSEMBLY

3147

3148

1M, 2M, 3M LONG FLUE TERMINAL

STANDARD FLUE TERMINAL

'R' + 92

'R'

REAR FLUE - AIR DUCT / TERMINAL ASSEMBLY

AIR DUCT/ TERMINAL ASSEMBLY

Diagram 6.5

'S'

SIDE FLUE - AIR DUCT / TERMINAL ASSEMBLY

STANDARD FLUE TERMINAL ILLUSTRATED

3146

FLUE DUCT

'S' + 163

'S'

SIDE FLUE - FLUE DUCT Diagram 6.8

Diagram 6.7

3149

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6 Installing the Flue

Mark the position of the air duct terminal assembly securing holes and drill two 3mm diameter holes through the air duct/terminal assembly.

Secure the air duct/terminal assembly to the flue elbow and flue duct assembly with the two self tapping screws supplied in the loose items pack and then seal with the tape provided.

Fix the self adhesive seal to the air duct, see diagram 6.11.

Place the flue assembly into the flue hole. Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face, see diagram 6.11.

Note: The foam seal is a tight fit in the wall sleeve, so either the wall sleeve will need to be rigidly fixed in the wall, that is, the cement has fully set or it can be held from the other side whilst inserting the flue assembly.

External Flue Installation

Locate the air duct/terminal assembly into the flue elbow assembly as shown in diagram 6.10, ensuring correct terminal alignment of the “TOP”.

From outside, place the air duct/terminal assembly and flue duct into the flue hole. Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face, see diagram 6.11.

FLUE DUCT

3150

Mark the position of the air duct terminal assembly securing holes and drill two 3mm diameter holes through the air duct/terminal.

Fix the self adhesive seal to the air duct, see diagram 6.11.

SCREW (2)

3mm

DRILL SIZE

FLUE ELBOW ASSEMBLY

FLUE ELBOW / DUCT ASSEMBLY

SECURING SCREW (2)

Diagram 6.9

3151

AIR DUCT/TERMINAL & FLUE DUCT ASSEMBLY

FLUE ASSEMBLY

Diagram 6.10

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6 Installing the Flue

Locate the flue duct into the flue elbow assembly and secure with the screws provided.

Secure the air duct terminal to the flue elbow with the two self tapping screws supplied in the loose items pack, making sure that the flue duct is correctly located into the terminal, see diagram 6.11, then seal with the tape provided.

7 Gas, Water and Electrical Connections

7.1 Gas Connection

The gas supply can be connected from below or through the wall at the rear of the boiler, see diagram 7.1 for position.

Refer also to Section 1.7. Make the gas connection to the gas service cock. Slacken or remove the securing strap, whilst making the

connection. Do not subject the gas service cock to heat.

STD FLUE TERMINAL = 63

LONG FLUE TERMINAL = 61

FLUE TERMINAL

FLUE DUCT

Outside Wall Face

FLUE TERMINAL

'NOTCH' MARKING POSITION OF SAFETY VALVE DISCHARGE

346

WALL SLEEVE

SEAL

3152

Diagram 6.11

3153

7.2 Water Connections

Provision is made for the flow and return pipes to be connected from above, if required, passing down either side of the boiler, see diagram 7.2 for clearances.

Note: Take care that any pipework connected from above within the boiler mounting frame will clear the expansion vessel.

Clean out the heating system before connecting the boiler.

Make the connections to the heating system by way of the isolating valves, see diagram 7.1.

Slacken or remove the securing straps whilst making the connections. Do not subject the valves to heat.

Make sure that the drain points on the valves are positioned toward the front of the boiler, also that the drain and operating screw heads are accessible.

7.3 Safety Valve Discharge

WARNING. It must not discharge above an entrance or window or any type of public access area.

A discharge pipe is supplied loose with the boiler, which when fitted to the safety valve, will terminate below the boiler at the notch, see diagram 7.1.

GAS CONNECTION

SECURING STRAPS

SLOT (CLOSED)

GAS SERIVCE COCK

BOILER CONNECTIONS

This must be extended, using not less than 15mm od pipe, to discharge, in a visible position, outside the building, facing downward, preferably over a drain. The pipe must have a continuous fall and be routed to a position such that any discharge of water, possibly boiling water, or steam cannot create a hazard to persons or damage to property or external electrical components or wiring.

Note. To make future servicing easier it is advisable to use a compression type fitting when extending the discharge pipe.

WATER CONNECTION

DRAIN POINT

WATER ISOLATION VALVES

SLOT (CLOSED)

Diagram 7.1

220677A

Page 15

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7 Gas, Water and Electrical Connections

7.4 Electrical Connections

WARNING. The boiler must be earthed. Take the electrical connector from the loose items pack

and remove the two screws and cover, see diagram 7.3. Using cable at to the current issue of BS6500 Table 16

of a suitable length connect the mains supply cable to the appropriate terminals of the connector, see diagram 7.3.

Standard colours are, Brown - Live (L); Blue Neutral (N); Green/Yellow - Earth (E) or ( ).

The mains cable outer insulation must not be cut back external to the connector, see diagram 7.3.

Make the earth conductor of a greater length than the current carrying conductors so that if the cable is strained the earth conductor would be the last to become disconnected.

It is essential that the polarity is correct. After completing the connections secure the cable with

the connector’s cover using the two screws previously removed, make sure that no basic insulated wire is accessible outside of the connector, see diagram 7.3.

Clip the electrical connector into position on the boiler mounting frame and secure the mains cable with the cable clamp immediately behind the connector.

EXPANSION VESSEL POSITION

3154

320

If necessary also secure the cables to the wall using suitable cable clips.

Keep cables away from hot surfaces. Carry out preliminary electrical system checks, using a

suitable Multimeter, that is, earth continuity, polarity, short circuit and resistance to earth.

7.5 Heating System Controls

It is recommended that the system is controlled by a time switch and room thermostat, proprietary control system or by thermostatic radiator valve, refer to diagram 12.5. Refer to the current issue of BS7478 for guidance on the use of thermostatic radiator valves.

GAS CONNECTION WATER CONNECTION

Note: Keep any pipework clear of shaded area.

UPWARD ROUTING OF PIPEWORK

Diagram 7.2

COVER

CABLE CLAMP

3156

CONNECTOR

ELECTRICAL PLUG Diagram 7.3

MAINS CABLE

220677A

Page 16

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8 Boiler and Flue Fixing

8.1 Mounting the Boiler

After installing the boiler mounting frame, gas and water, making the electrical connections and preparing the flue components continue as below:

Lift the boiler into position, hooking it onto the boiler mounting frame at the top, see diagram 8.1 then loosely fit the two, previously removed, boiler securing screws at the top, see diagram 5.4.

3157

Locate the water pipes into the isolation valves and the gas service cock union halves, see diagram 5.3.

After positioning the location studs into the clips, see diagram 8.1, fully push the boiler back to the mounting frame.

Make the compression joint on the isolating valves and join the gas service cock union. Secure the valves and gas service cock with the securing straps.

Secure the boiler by tightening the two fixing screws at the top.

To fit the discharge pipe to the safety valve, release the single securing screw and pivot forward the fascia and control board assembly (PCB), see diagram 8.2. Secure the discharge tube with the nut and olive supplied in loose items pack, see diagram 8.2.

Refit fascia control board assembly (PCB). Connect the plug and socket of the electrical connector

together, see diagram 8.3.

LOCATION CLIPS and STUDS(S)

UNION CONNECTORS

BOILER MOUNTING Diagram 8.1

CONTROL THERMOSTAT CONTROL KNOB

3158

FASCIA/ CONTROL BOARD SECURING SCREW

DISCHARGE TUBE

UNION NUT

OLIVE

FASCIA / SAFETY VALVE Diagram 8.2

220677A

FASCIA SECURING SCREW (2)

Page 17

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8 Boiler and Flue Fixing

8.2 Flue Assembly to Boiler - Connection

NOTE. The fan could be fitted with transit clips, see diagram 8.6 which will need removing.

Slacken but do not remove the fan securing screws and flue hood wing nuts, see diagram 8.4.

Secure the flue assembly to the spigot on top of the boiler, see diagram 8.5.

Tighten the fan securing screws and flue hood wing nuts previously slackened, see diagram 8.4.

3159

FLUE SPIGOT

FLUE DUCT ASSEMBLY and FLUE ELBOW

3161

ELECTRICAL CONNECTOR

FAN SECURING SCREW (2)

FLUEHOOD SECURING ANGLE WING NUT

CABLE CLAMP

MAINS CABLE

Diagram 8.3

3160

SECURING SCREW (2)

FLUE ASSEMBLY CONNECTION

FRONT

Diagram 8.5

4856

REAR

FLUEHOOD / FAN Diagram 8.4

TRANSIT CLIPS

Diagram 8.6

220677A

Page 18

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9 Completion and Commissioning

9.1 System Commissioning

Commissioning must only be carried out by a competent person in accordance with the current issue of BS6798.

Check that the boiler is isolated from the electrical supply at the external isolator.

Open the two water isolating valves, slots in line with the length of the valves, see diagram 9.1.

Note: In addition to the automatic air vent, to speed the filling of the system, at any time, the air vent on the heat exchanger should be opened, see diagram 9.1.

Once the system is filled this vent should be closed, making sure that a watertight seal is made.

Flush out the whole system. Refill the system, check the operation of the safety

valve, by allowing the water pressure to rise until the valve operates. The valve should open within +/-0.3bar (+/-4.3lbf/in2) of the 3bar, preset, pressure. Where this is not possible carry out a manual check and test.

Clear any air locks and check for water soundness.

IMPORTANT

THE CAP ON THIS AIR VENT SHOULD NOT BE REMOVED

OR REPLACED

3162

BLEED SCREW

Release cold water to initial system design pressure.

Gas Soundness Test - Pilot

Temporarily disconnect the black cable from the main burner multifunctional control solenoid and insulate the connector with insulation tape to prevent the main burner from lighting.

Turn the gas service cock “On”, the slot in line with the length of the cock, see diagram 9.3.

WARNING: The multifunctional control and fan operate on mains voltage, the terminals will become “Live”.

With the control thermostat control knob in the “O” “Off” position switch on the electrical supply to the system.

Turn the control thermostat control knob fully clockwise to “MAX”, the fan will start, sparks will be generated and the pilot burner will light.

Check around pilot connections for gas soundness with a suitable leak detection fluid.

Turn the control thermostat control knob fully anticlockwise to “O” and isolate the boiler from the electrical supply.

DRAIN POINT

FILLING / VENTING

WATER ISOLATING VALVE

SLOT OPEN

Diagram 9.1

Remove the insulation tape and refit the black cable to the pilot solenoid valve.

220677A

Page 19

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9 Completion and Commissioning

9.2 Initial Lighting and Testing and Adjustment

The set pointer on the pressure gauge should be set to coincide with the cold fill pressure.

Refit the inner case, securing it with the four screws previously removed.

Make sure that the case is correctly fitted and sealed. Identify the controls by reference to diagram 9.2.

3163

Check that the boiler is isolated from the electrical supply.

Make sure that the control thermostat control knob is turned to “O” the “off” position.

The pilot gas rate is preset and cannot be adjusted.. For future reference stick the self adhesive arrow

indicator, from the loose items pack, to the data label against the rating that the boiler is going to be set to.

Remove the main burner pressure test point screw located on the underside of the gas manifold and fit a suitable pressure gauge, see diagram 9.2.

Make sure that any remote controls are calling for heat. WARNING. The multifunctional control and fan

operate on MAINS voltage, terminals will become “LIVE”.

Switch on or connect the electrical supply to the boiler and heating system, neon 1 will light.

PRESSURE GAUGE

CONTROL

NEON WARNING LIGHT

PRESSURE TEST POINT

BOILER CONTROLS

THERMOSTAT CONTROL

GAS PRESSURE ADJUSTMENT SCREW COVER

Diagram 9.2

3164

GAS SERVICE COCK Diagram 9.3

'SLOT' shown on

GAS SERVICE COCK

220677A

Page 20

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9 Commissioning and Completion

9.3 Testing - Electrical

Checks to ensure electrical safety should be carried out by a competent person.

In the event of an electrical fault after installation of the system. preliminary electrical system checks as below should be carried out.

1. Test insulation resistance to earth of mains cable.

2. Test the earth continuity and short circuit of all cables.

3. Switch on the electrical supply to the boiler, neon 1 will light.

Test the polarity of the mains supply.

Turn the control thermostat control knob fully clockwise to the maximum setting, neon 2 will light.

Note: The burner will not light between “O” and “MIN”. The lighting sequence is automatic, as follows:

The fan operates. The spark ignition operates. The pilot solenoid opens. The pilot burner lights.

The ignition spark stops. The main solenoid opens

and after a short period of time the main burner will light, check this by looking through the viewing window.

neon 3 will light

}

neon 4 will light

}

9.4 Testing - Gas

Test for gas soundness around the boiler gas components, using a suitable leak detection fluid.

Check the main burner gas pressure at least 10 minutes after the burner has lit, refer to Data label or Appliance Data, Table 2.

If The gas pressure requires adjustment, remove the screw cover, see diagram 9.2 for access to the main burner pressure adjustment screw. Adjust the gas pressure to obtain the required setting (turn anticlockwise to decrease).

Should any doubt exist about the gas rate, check it using the gas meter test dial and a stop watch, at least 10 minutes after the burner has lit, make sure that all other gas burning appliances and pilot lights are off.

The rates are as shown in Table 4. Turn the control thermostat knob to “O” “Off”. Remove

the pressure gauge from the test point and refit the screw, making sure that a gas tight seal is made.

When the control thermostat is turned to “O” “Off” position, by hand, wait at least 30 seconds before turning “On” again.

There may be an initial smell given off from the boiler when new, this is quite normal and will disappear after a short period of time.

OUTER CASE

3165

The main burner will remain alight until switched off, either by the boiler thermostat or a remote system control.

To make sure that the flame supervision device is working correctly the following should be done.

1. With the main burner alight, turn the gas service cock “Off”, see diagram 7.1.

After a short period the main burner and pilot will go out.

2. The correct working of the flame supervision device is shown by neon 4 going out within 10 seconds and the ignition spark starting up.

Neons 1, 2 and 3 should stay alight.

3. If the above does not happen refer to fault finding, Section 12.

4. To carry on turn the gas service cock “On”, see diagram 9.3.

When the boiler switches “Off”, both the pilot and main burner go out and the fan stops. The automatic lighting sequence will operate again when heat is required.

The neon indicator lights on the control board (PCB) are an aid to fault finding, for details, refer to Section 12.

OUTER CASE SECURING SCREW

CASE SECURING Diagram 9.4

220377B

220677A

Page 21

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9 Commissioning and Completion

9.5 Heating System

Check that all remote controls are calling for heat. Allow the system to reach maximum working

temperature and examine for water leaks. The boiler should then be turned off and the system drained as rapidly as possible whilst still hot.

Refill the system, vent and again check for water soundness.

Adjust the system to initial design pressure. The set pointer on the pressure gauge should be set to coincide with the indicating pointer.

9.6 Operational Checks

Adjust the control thermostat and any system controls to their required settings.

Do not attempt to adjust the thermostat calibration screw.

Operate the boiler again on full service and check that the balancing of the heating circuits and radiators is satisfactory, make adjustments as necessary.

TABLE 4

APPROX.GAS RATE min med max

MODEL 40

MODEL 55

m3/h

ft3/h

m3/h

ft3/h

1.0 1.2 1.4

37.7 43.4 48.8

1.4 1.7 1.9

49.8 58.9 67.1

3211/A

Refit the outer case, see diagram 9.4, slide the information plate forward and secure the case with the screw previously removed.

10 Instructions to the User

Hand the Instructions for Use to the user for their retention.

Instruct and demonstrate the efficient and safe operation of the boiler, heating system and if fitted, the domestic hot water system.

Show the user the position of “Lighting Instructions” by reference to diagram 9.5.

Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions.

INFORMATION PLATE

Advise the user, that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all person who let out any property containing a gas appliance.

It is the Law that servicing is carried out by a competent person.

Diagram 9.5

Reminder, leave these instructions with the user.

220677A

Page 22

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11 Servicing

11.1 Notes

To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

It is the Law that any servicing must be carried out by a competent person.

Unless stated otherwise, parts removed for servicing should be replaced in the reverse order to removal.

After completing any servicing of gas carrying components, ALWAYS test for gas soundness and carry out functional check of controls.

Slide the information plate forwards and remove the outer case securing screw, see diagram 9.4 and lift the case off.

Before starting any servicing, isolate the boiler from the electrical supply at the external isolator and close the gas service cock, see diagram 9.3.

As an aid to Servicing the air pressure switch tube connection can be used to obtain a products of combustion reading.

12 to 14 FLAME LENGTH

SPARK GAP 3 to 4.5

PILOT FLAME AND SPARK GAP DIMENSION

FAN SECURING SCREW (2)

3167

Diagram 11.1

3203

FAN ELECTRICAL CONNECTORS

Remove the RED tube from the connection on the air pressure switch and insert the analyser probe into the tube.

WARNING: The electrical components work on mains voltage and they will become live.

Switch on the electrical supply to operate the fan and turn on the gas supply.

On a satisfactory completion of the test, switch off the electrical supply and reconnect the red tube to the air pressure switch.

Routine Servicing

11.2 Inner Case

Remove the cover of the inner case, secured with four screws.

11.3 Pilot Check

Check that the pilot flame is burning correctly and of the correct size, see diagram 11.1. If the pilot flame is not correct, the pilot injector will require removing, see Section 11.7.

FAN ASSEMBLY

FLEXIBLE

SECURING SCREW (4)

BURNER SECURING WING NUT

COMBUSTION CHAMBER Diagram 11.2

COMBUSTION CHAMBER FRONT PANEL

TUBES

220677A

Page 23

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11 Servicing

11.4 Main Burner

Slacken the flue hood securing angle wing nuts, see diagram 11.2.

Remove the combustion chamber front panel, secured with four screws and a wing nut, see diagram 11.2.

Disconnect the pilot pipe union connector and ignition lead, see diagram 11.3.

Separate the pilot assembly from the main burner, secured with two screws, remove by lifting upward, see diagram 11.3.

Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly.

Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

Do not use a brush with metallic bristles. Note: On refitting and after cleaning the heat exchanger

make sure the main burner is fitted correctly, that is, located on the main injector and horizontal, see diagram 11.4.

3169

PILOT BURNER ASSEMBLY SECURING SCREW (2)

PILOT TUBING NUT

SEALING ANGLE

PILOT BURNER ELECTRODE ASSEMBLY

BURNER

INJECTOR

ELECTRODE SECURING SCREW

ELECTRODE

PILOT INJECTOR

IGNITION LEAD

Diagram 11.3

3170

11.5 Main Injector

With the main burner removed the main injector can be inspected and cleaned as necessary.

If removing for cleaning do not use a wire or sharp instrument on the hole.

Use new seal when refitting to ensure a gas tight seal is made.

BURNER REMOVAL Diagram 11.4

FLUEHOOD

FAN RETAINING BRACKET

3171

FLUEHOOD Diagram 11.5

220677A

Page 24

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11 Servicing

11.6 Cleaning Heat Exchanger.

Disconnect the two electrical connections at the fan, see diagram 11.2. It is not necessary to disconnect the green and yellow earth cable.

Disconnect the two flexible tubes from the fan, see diagram 11.2.

Remove the fan by releasing the securing screws, see diagram 11.2.

Remove the flue hood securing bracket, secured with two wing nuts and hook bolts, see diagram 11.2.

Remove the flue hood, see diagram 11.5. Remove the burner as Section 11.4. Cover the pilot assembly and main injector and place a

sheet of paper in the combustion chamber to catch any debris.

Brush the heat exchanger with a suitable brush. Do not use a brush with metallic bristles. Remove the paper and cover from the pilot assembly and

main injector together with any debris.

11.7 Pilot Injector

If the pilot flame is not burning correctly, it may be necessary to remove the pilot injector.

Unscrew the pilot injector from the pilot assembly. Inspect the injector and if necessary clean only by

blowing clear. Do not use wire or sharp instrument. When relighting check that the flame length is as shown

in diagram 11.1.

11.8 Operational Checks

Check the safety valve manually by turning the knob in the direction of the arrow.

Light the boiler, carry out operational checks and any necessary adjustments as described in the Commissioning Section 9 of these instructions.

When replacing, please note: (a) Locate the fan mounting plate assembly behind the

retaining bracket at the same time easing the fan outlet into the flue elbow, see diagram 11.5.

(b) Make sure the coloured flexible tube connects to the upper connection on the fan.

12 Fault Finding

12.1 Electrical

Important. On completion of the Service/Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

Refer to: Neon Indicators - Aid to Fault Finding, diagram 12.1, Fault Finding, diagram 12.2 Wiring, diagram 12.5 and Functional Flow diagram 12.3.

12.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Operation will normally resume on restoration of the electrical supply. If the boiler does not relight after an electrical supply failure the overheat cutoff device may need resetting.

To reset, pull the information panel forwards on the underside of the boiler and press the reset button, see diagram 12.4.

If the cutoff operates at any other time press the reset button and the burner should relight. If the fault persists refer to Fault Finding, diagram 12.2.

220677A

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12 Fault Finding

Neon Indicators - An Aid to Fault Finding

THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY.

FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE

REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD (PCB).

IF RED NEON ON FASCIA IS ILLUMINATED FILL CENTRAL HEATING SYSTEM,

PRESSURE 0.7bar MIN.

Is neon 1 lit?

YES

Is neon 2 lit?

YES

Is neon 3 lit?

YES

Is neon 4 lit?

YES

Is main burner operating?

YES

System satisfactory

Fault with mains supply, PCB fuse or low water pressure switch.

Overheat cut off device tripped. Thermostat, Overheat cut off device, Water differential pressure switch, or faulty Pump. - see detailed fault finding chart.

Air flow proving fault - that is fan or air pressure switch - see detailed fault finding chart.

Ignition, pilot or flame proving fault see detailed fault finding chart.

Multi-functional control/harness problem see detailed working? Fault finding chart.

NEON INDICATORS

3172

Diagram 12.1

220677A

Page 26

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12 Fault Finding

Before detailed checking of electrical components ensure that remote controls are calling for heat. Check that the gas

supply is free of obstructions and purged of air. Isolate the elctrical supply, check all cables, connections and the printed circuit board (PCB) fuse. Check the air tubes to the air pressure switch for kinks and splits. Switch on the

electrical supply and check for correct polarity. If red neon on the fascia is illuminated isolate the elctrical supply and

pressurise the sytem to 0.7bar minimum with the sytem cold. Switch on the electrical supply. Turn the control

thermostat to its maximum setting.

Is neon 1 lit ?

YES

Is neon 2 lit ?

YES

Is there 240V~between 3 and 2 ?

YES

Is there 240V~between 5 and 2 ?

Fill Central heating system to 0.7bar min. Does the red neon go off?

YES

Is there 240V~between N/o on Low water pressure switch and 2 ?

YES

Is there 240V~between yellow connection on overheat device and 2 ?

Faulty Neon

Correct power supply problem

Is Red neon on fascia

YES

illuminated ?

Is there 240V~between N/c

YES

on Low water pressure switch and 2 ?

Is there 240V~between C on Low water pressure switch and 2 ?

YES

Isolate electrical supply. Check continuity of purple cable.

4761/A

A B

Is there 240V~ between

YES

white connection on water differential pressure switch and 2 ?

Does the pump run?

YES

Is the tube to Water differential pressure switch kinked or damaged.

Faulty Water differential pressure switch. Replace.

MAIN TERMINAL STRIP

YES

Faulty Low water pressure switch. Replace.

Check overheat reset. If satisfactory replace overheat device.

Is there 240V~ between L and N at pump?

YES

Isolate electrical supply. Check continuity of pump cable.

Faulty pump. Replace.

Rectify tube or replace.

Diagram 12.2

220677A

Page 27

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12 Fault Finding

4761/B

Is neon 3 lit ?

YES

Is there 240V ~ between yellow connection on thermostat and 2 ?

Is there 240V~between N/c on air pressure switch and 2 ?

YES

Is there 240V~between C on air pressure switch and 2 ?

YES

MAIN TERMINAL STRIP

Replace thermostat

Check yellow cable between printed circuit board and air pressure switch. If satuisfactory replace printed circuit board (PCB)

Replace air pressure switch

YES

Does fan run ?

Replace fan.

Does fan hunt ?

YES

Is there 240V ~ between motor connections on fan ?

YES

Isolate electrical supply, test fan harness continuity. If satisfactory replace printed circuit board (PCB)

Replace printed circuit

board (PCB)

Diagram 12.2

continued

220677A

Page 28

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12 Fault Finding

4761

YES

Is neon 4 lit ?

YES

Is there 240V ~ between (N/o) on air pressure switch and 2 ?

YES

Is there 240V~between pilot multi-functional control soleniod blue and brown connections ?

YES

Does discharge tube flash on printed circuit board during ignition attempt ?

YES

Is there a spark at the pilot burner ?

YES

MAIN TERMINAL STRIP

Inspect air tubes for leaks kink and correct fitting. If satisfactory replace faulty air pressure switch.

Isolate supply, test harness continuity. If satisfactory replace printed circuit board (PCB)

Replace printed circuit board (PCB)

Check lead continuity and inspect electrode and lead for damage.

Does main burner light ?

YES

System satisfactory

Does pilot light ?

YES

With pilot lit does spark stop ?

YES

Is there 240V ~ between main multi-functional control solenoid black and blue cable.

YES

Replace multi-functional control

Check for pilot jet blockage, incorrect electrode adjustment. If satisfactory replace multi-functional control.

Inspect electrode lead/ connection for poor contact. Check electrical supply polarity. If satisfactory replace printed circuit board (PCB)

Isolate supply, test harness

continuity. If satisfactory replace PCB

220677A

Diagram 12.2

continued

Page 29

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12 Fault Finding

MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS CONTROL BOARD CONNECTIONS

N/O

L 3 POLE

CONNECTOR

FUSE TYPE F1A

SPARK ELECTRODE

N/C

OVERHEAT CUT-OFF

CONTROL THERMOSTAT

BLK

WATER DIFFERENTIAL PRESSURE SWITCH

FAN

BLK

NEON INDICATOR

LOW WATER PRESSURE SWITCH

PUMP

3173

PLATE

3174

RESET BUTTON

INFORMATION

RESET BUTTON

(N)

Diagram 12.4

AIR PRESSURE SWITCH

BLK

PILOT SOLENOID

BLK

NOTE: LOW WATER PRESSURE SWITCH

SHOWN IN UNPRESSURISED STATE

KEY

BLK BLACK BR BROWN BL BLUE W WHITE R RED Y YELLOW

N/O

N/C

MAIN SOLENOID

(N)

FUNCTIONAL FLOW

Diagram 12.3

220677A

Page 30

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12 Fault Finding

RED

PURPLE

WATER PRESSURE WARNING NEON

BLACK

BROWN

CHASSIS EARTH

G/Y

BLACK

BLUE

BLACK

FAN ASSEMBLY

BROWN

BLUE

FUSE TYPE F1A 1 AMP

BLUE

BROWN

BLUE

RED

GREEN/ YELLOW

SPARK ELCTRODE

PRINTED CIRCUIT BOARD

CIRCULATION PUMP

BLUE

BROWN

BLUE

G/Y G/Y

CHASSIS EARTH

AIR PRESSURE SWITCH

NCC

3175

G/Y

LOW WATER PRESSURE SWITCH

CONTROL THERMOSTAT

WATER DIFFERENTIAL PRESSURE SWITCH

YELLOW

WHITE

OVERHEAT CUTOFF THERMOSTAT

YELLOW

BLUE

G/Y

BROWN

RED YELLOW

BLACK G/Y

BROWN BLUE

BLUE

BLACK

MULTI-FUNCTIONAL CONTROL

N E L

240V~50Hz SWITCHED MAINS SUPPLY FUSED AT 3 AMP

220677A

Diagram 12.5PICTORIAL WIRING

Page 31

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13 Replacement of Parts

13.1 Replacement of parts must only be carried out by a

competent person. Before replacing any part isolate the gas and electrical

supplies. Unless stated otherwise all parts are replaced in the

reverse order to removal.

13.2 Access

Slide forward the information plate, remove the securing screw and remove the case, see diagram 9.4.

Unless stated otherwise gain access as Sections 11.2 and 11.4.

13.3 Boiler Pressure and Draining

All parts containing water within the boiler are under system pressure. Before any parts are disconnected, close the isolating valves and reduce the boiler pressure at the integral drains on the isolating valves, see diagram 9.1.

After replacing any water containing part of the central heating circuit, make up the water loss, vent all air and pressurise the system. Refer to Commissioning.

13.9 Pilot Injector

Gain access as the relevant part of Section 11.4 and proceed as Section 11.7.

When relighting check that the flame length is as shown in diagram 11.1.

Note. For Sections 13.10, 13.11, 13.13, 13.14, 13.15,

13.17, 13.18, 13.25, 13.26, 13.27 and 13.28 release fascia and control board (PCB) assembly by removing the screw and pivot forward, see diagram 8.2.

3176

GLAND PLATE

After replacing any gas carrying parts always test for gas soundness and if necessary carry out functional check of controls.

13.4 Fan

Remove as the relevant part of Section 11.6

13.5 Main Burner

Remove as Section 11.4

13.6 Main Injector

Remove as Section 11.5. Unscrew the main injector. When fitting the main injector, fit the sealing washer,

supplied, to ensure gas soundness.

13.7 Pilot Burner

Remove as the relevant part of Section 11.4.

13.8 Electrode

Gain access as the relevant part of Section 11.4.

GLAND PLATE SECURING SCREW

PHIAL

RETAINING CLIP

ELECTRICAL CONNECTORS

THERMOSTAT SECURING NUT

Disconnect the ignition lead from the electrode, see diagram 11.3.

Remove the electrode, secured with a single screw. Check the spark gap upon assembly, see diagram 11.1.

CONTROL THERMOSTAT

CONTROL THERMOSTAT Diagram 13.1

220677A

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13 Replacement of Parts

13.10 Control Thermostat

Gain access as Section 13.2 Remove the control knob and fascia by removing the

screws, see diagram 8.2. Remove the thermostat securing nut, see diagram 13.1.

3177

Remove the electrical connections from the thermostat body.

Slacken but do not remove the gland plate. Now remove the phial retaining clip and then the

thermostat phial from the pocket, see diagram 13.1. When refitting, make sure that the thermostat capillary is

correctly routed and the phial covered with heat sink compound, before it is secured in the pocket, by the phial retaining clip.

Reconnect the electrical connections, see diagram 12.5.

13.11 Overheat Cutoff: diagram 13.2

Remove the electrical connections from the cutoff body. Remove the capillary securing clamp. Remove the locknut securing the overheat cutoff to the

bracket and withdraw the assembly.

13.12 Ignition Lead: diagram 11.3

Slacken but do not remove the sealing angle securing screw.

Disconnect the ignition lead at both ends and withdraw. When refitting push the lead through the seal from the

top and make sure that the clear end is fitted to the spark electrode and that the lead follows the same route, being secured in the same manner, as the original.

PLASTIC RETAINING CLIP

CAPILLARY SECURING CLAMP SCREW

ELECTRICAL CONNECTIONS

VIEWED FROM REAR

OVERHEAT CUT-OFF

UNION NUT

3178

CONNECTION

OVERHEAT CUT-OFF LOCKNUT

Diagram 13.2

SAFETY VALVE

FIBRE WASHER

Take care not to damage the seal of the sealing angle.

13.13 Pressure Gauge: diagram 13.3

Release the water pressure and drain the boiler, refer to Section 13.3.

Disconnect the pressure gauge connection from the safety valve, discard the washer.

Remove the pressure gauge secured with the retaining spring tabs from the bracket.

Fit the supplied washer under the pressure gauge connection when refitting to the safety valve.

220677A

SECURING SPRING TAB (2)

SAFETY VALVE / PRESSURE GAUGE

PRESSURE GUAGE CONNECTION

PRESSURE GUAGE

Diagram 13.3

Page 33

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13 Replacement of Parts

13.14 Safety Valve: diagram 13.3

Release the water pressure and drain the boiler, refer to Section 13.3.

Remove the pressure gauge connection as Section 13.3. Disconnect the union nut to release the discharge pipe. Place a spanner on the hexagon on the volume vessel and

break the union nut connection to release and then unscrew the safety valve.

When refitting use a proprietary sealant to seal the joint. When fitting use a new washer for the pressure gauge

connection.

13.15 Water Differential Pressure Switch:

diagram 13.4

Release water pressure as Section 13.3. Remove the two electrical connections and release the

union connections, and remove the pressure switch, complete with the flexible tubing.

Fit the flexible tubing to the new pressure switch.

LOW C.H. WATRE PRESSURE SWITCH

3180

ELECTRICAL CONNECTORS

Refer to diagram 12.5 when remaking the electrical connections.

13.16 Low Water Pressure Switch: diagram

13.5

Release the water pressure and drain the boiler, refer to Section 13.3.

Disconnect the electrical connectors at the micro-switch. Remove the pressure switch. Use a proprietary sealant to seal the connection. Make sure that the switch is positioned as shown. Refer to wiring diagram 12.5 when making the electrical

connections.

3179

UNION CONNECTOR

WATER DIFFERENTIAL PRESSURE SWITCH

LOW C.H. WATER PRESSURE SWITCH

SUPPORT

CONTROL BOARD P.C.B.

POST (4)

PLASTIC RETAINING

CABLE TIE

CLIP

MULTI PIN CONNECTORS

TERMINAL CONNECTIONS

Diagram 13.5

3181

TERMINAL BLOCK SECURING SCREW (2)

UNION

HOSE ASSEMBLY

ELECTRICAL CONNECTORS

UNION

CHASSIS EARTH CONNECTION

CABLE

WATER DIFFERENTIAL PRESSURE SWITCH CONTROL BOARD (P.C.B)

Diagram 13.4 Diagram 13.6

CONNECTION

220677A

Page 34

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13 Replacement of Parts

13.17 Control Board (PCB): diagram 13.6

Disconnect all multi-pin connectors. Remove the blue and brown cables from terminals 4 and

5 also disconnect the yellow cable from the control thermostat and the white cable from the overheat cutoff and the chassis earth cable.

Remove the terminal block and cables complete. Remove the ignition lead. Remove the printed circuit board from the support posts,

noting their correct positions. Great care must be taken when handling the board.

To connect the multi-pin connectors, cables and terminal block correctly, refer to diagram 12.5

SOLENOID

13.18 Multifunctional Control and Pilot Solenoid: diagram 13.7

Disconnect all electrical connections at the multifunctional control.

Remove the four securing screws from the left hand side of the multifunctional control and pilot pipe, take care as there is a restrictor in this pipe.

Support the multifunctional control, disconnect the union nut of the gas service cock and remove the multifunctional control complete with inlet pipe.

Separate the multifunctional control from the pipe, four screws, noting the fitted position.

Discard the “O” rings and fit the new ones supplied. To reconnect the connections refer to diagram 12.5 Light and adjust the boiler as necessary, refer to

Section 9.

Pilot Solenoid

3182

Disconnect the electrical connections at the solenoid, remove the retaining clip and solenoid.

ELECTRICAL CONNECTORS

SECURING SCREWS (8)

SOLENOID RETAINING CLIP

GAS SUPPLY PIPE UNION

When reconnecting refer to diagram 12.5.

END SCREW

UNION CONNECTOR

3183

PILOT PIPE CONNECTOR

MULTI-FUNCTIONAL CONTROL

220677A

Diagram 13.7

PUMP

UNION CONNECTOR

IN-LINE ELECTRICAL CONNECTORS

Diagram 13.8

Page 35

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13 Replacement of Parts

13.19 Pump: diagram 13.8

Release the water pressure and drain, refer to Section 13.3.

Disconnect the “in-line” connections at the pump. Disconnect the pump at the union connections. Discard the sealing washers and fit the new ones

supplied. When fitting the replacement make sure that the flow

direction arrow is pointing upward. Set the flow adjuster to position 3, see Section 2.6. Note: Should the pump fail to operate, and all is in order

but the pump still does not operate, remove the end screw, turn the pump spindle to release any temporary seizure. DO NOT HIT THE SPINDLE.

13.20 Automatic Air Vent: diagram 13.9

Release the water pressure as Section 13.3. Remove the automatic air vent. Discard the sealing washer and use the new one supplied.

HEAT EXCHANGER

LOCATION SLOT

AUTOMATIC AIR VENT

3184

Slacken the vent cap on the air vent of the new item. This cap must not be re-tightened.

13.21 Heat Exchanger: diagram 13.9

Isolate the boiler from the gas and electrical supplies. Remove all the necessary internal parts. Fit the automatic air vent to the new heat exchanger,

using the new washer provided. Disconnect the union nuts at the heat exchanger. When fitting new heat exchanger use the new sealing

washers provided. Locate the raised location tabs on the combustion

chamber sides into the slots on the heat exchanger when fitting it.

UNION CONNECTORS

HEAT EXCHANGER

Diagram 13.9

220677A

Page 36

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13 Replacement of Parts

13.22 Combustion Chamber Insulation:

diagram 13.10

Remove the securing clip and insulation panel. Take care when sliding the replacement insulation into

position securing it with the original clip. The rear insulation cannot be removed until the heater

exchanger is removed, see Section 13.21, then slide the insulation from behind the heat exchanger.

13.23 Expansion Vessel: diagram 13.11

Renewal of the expansion vessel requires the removal of the boiler from the wall. As an alternative, in certain circumstances, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position.

Isolate the boiler from the gas and electrical supplies. Release the water pressure and drain, as Section 13.3. Remove the fan from the flue hood, see Section 11.6. Disconnect the flue elbow, by reversing the instruction

in Section 8.2.

INSULATION PANEL

INSULATION RETAINING CLIP

COMBUSTION CHAMBER FRONT PANEL

3197

Disconnect the boiler water connections union nuts, see diagram 5.3.

Disconnect the gas service cock, see diagram 5.3. Disconnect the electrical plug, see diagram 8.3. Remove the boiler from the mounting frame secured

with two screws at the top, see diagram 5.4. Pull the boiler from the isolating valves and clips at the bottom. Unhook the boiler at the top and withdraw it forward.

Carefully lay the boiler down on its side to gain access to the expansion vessel.

Disconnect the union nut connection. Remove the expansion vessel, secured with three

clamps. Discard the sealing washers and use the new ones

supplied. Connect the union nut, when fitting the expansion vessel,

before clamping it.

13.24 Pilot Viewing Window: diagram 13.12

Remove the two screws and then the window.

SIDE INSULATION PANEL(S)

REAR INSULATION PANEL(S)

When replacing take care not to damage the gasket.

13.25 Inner Case Seal: diagram 13.12

Gain access as Section 13.2. When removing seal make sure that all the old adhesive

is removed. When fitting the new seal make sure that it fits correctly

and has not buckled.

220677A

COMBUSTION CHAMBER INSULATION

Diagram 13.10

Page 37

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13 Replacement of Parts

13.26 Air Pressure Switch: diagram 13.13

Remove the pressure tubes and electrical connections. Release the air pressure switch from its bracket by

unfastening the two screws.

UNION NUT CONNECTION AND SEALING WASHER

CLAMPING SCREW (3)

When refitting make sure that the coloured tube is fitted as shown and that the electrical connections are made as shown in diagram 12.5.

The polarity of the electrical connections is important.

13.27 Bypass Valve: Diagram 13.14

Release the pressure and drain as Section 13.3. Break the union connections

3187

Note: The replacement valve will be supplied preset and must not be adjusted.

13.28 Warning Light

Disconnect the electrical connections, see diagram 12.5, squeeze the securing tabs and remove from the fascia.

3189

EXPANSION VESSEL

PILOT VIEWING WINDOW

INNER CASE

INNER CASE SEAL

Diagram 13.11

ELECTRICAL CONNECTORS

3210

SECURING SCREW (2)

(WHITE)

PRESSURE TUBES(S)

(RED)

CONNECTION(S)

AIR PRESSURE SWITCH

BYPASS VALVE

Diagram 13.13

3190

FRAME

SECURING SCREW (2) GLASS

GASKET

PILOT VIEWING WINDOW / INNER CASE

Diagram 13.12

BYPASS VALVE Diagram 13.14

UNION CONNECTIONS

220677A

Page 38

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14 Spare Parts

14.1 Part Identification

The key number in diagram 14.1 and the first column of the list will help to identify the spare part.

14.2 Ordering

When ordering any spare part, please quote the part number and the description from the list together with the model name and serial number information from the data label. The data label is positioned at the top right of the inner case.

If ordering from the local gas company also quote the GC number of the appliance from the data label and the GC number of the spare part, from the list.

Key No Part No Description GC No

1 800628 Fan assembly 278 259 2 800203 Main injector - 40 313 446 2 800204 Main injector - 55 313 458 3 230209 Pilot burner 397 980 4 203516 Pilot injector 376 968 5 800211 Hose Assembly 313 482 6 800205 Thermostat - control 397 982 7 800206 Thermostat knob 313 484 8 230212 Thermostat - cutoff 397 981 9 WW4613 Ignition lead 136 399 10 800134 Pressure gauge assembly 313 294 11 800207 Control board (PCB) 313 475 12 800208 Multifunctional control 313 445 13 202015 Fuse 334 750 14 208302 Sight glass 312 419 15 900834 Air pressure switch 278 260 16 800153 Automatic air vent 313 285 17 800149 Safety valve 397 677 18 800209 Bypass valve 313 451 19 800210 Water differential pressure switch 313 452 20 441581 Low central heating water pressure neon indicator 313 589 21 800150 Low central heating water pressure switch 319 862

220377B

220677A

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14 Spare Parts

3198/A

Diagram 14.1

220677A

Page 40

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Control of Substances Hazardous to Health

Information for the Installer and Service Engineer.

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

THERMOSTATS These contain very small amounts of dichlorotrifluoroethane in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

CUT-OFF DEVICES These contain a very small amount of ethylene glycol and methanol in the capillary. If broken, under normal circumstances the fluid does not cause a problem, but in cases of skin or eye contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.

Because of our constant endeavour for improvement details may vary slightly from those given in these instructions.

220677A