Glow-worm SwiftFlow 120 Servicing Instructions

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221045A.05.97

Servicing Instructions

To be left with the user

120

G.C. No. 47 313 13

Fanned Flue Combination Boiler

4559

This is a Cat I 2H appliance

Customer Services: Tel: (01773) 828100

One Contact Total Service

Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

Page 2

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1 G e n e r a l

The instructions consist of three parts, Installation, Servicing and Instructions for Use which includes the Guarantee Registration Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.

CE Mark

This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.

Type test for purposes of Regulation 5 certified by:-

Notified body 0087. Product/production certified:- Notified body 0087. The CE mark on this appliance shows compliance with:-

1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

1.1 Servicing or Replacing Parts

To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary 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.

COLD WATER SUPPLY IN

SAFETY VALVE DISCHARGE

SLOT (CLOSED)

OUTER CASE SECURING SCREW (2)

SELECTOR SWITCH

DOOR

OUTER CASE

PLASTIC PLUGS (2)

GAS SERVICE COCK

HEATING FLOW

COVER PLATE

HOT WATER OUT

HEATING RETURN

SLOT (CLOSED)

DRAIN POINT

Diagram 1.1

Diagram 1.2

An Aid to Servicing

To obtain a products of combustion reading, make sure that the main burner is alight. Remove the plastic cap, see diagram 1.4 and connect the analyser probe to the tube, replace cap after use.

1.2 Data Label

The data label is positioned on the front of the inner case cover, see diagram 1.3.

2793

4578

The servicing of this boiler must be carried out by a competent person in accordance with the rules in force in the countries of destination.

Unless stated otherwise, parts removed or renewed during servicing should be fitted in the reverse order to removal.

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

Discard all used sealing washers, gaskets and “O” rings when renewing components.

Use the new ones supplied with the replacement.

2221045A

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1 G e n e r a l

1.3 Isolation of Boiler

Before commencing any servicing or the replacement of parts, isolate the boiler from the electrical supply at the external isolator and close the gas service cock, see diagram 1.1.

BEFORE DRAINING THE BOILER, REFER TO SECTION 1.6.

1.4 Outer Case Removal

The door opens to the left or right hand side. The door catch is spring loaded, to open, push the side opposite to the hinge then pull.

Remove the two screws securing the outer case then unhook the case at the top and pull it forward and off, see diagram 1.2.

1.5 Cover - Inner Case

Remove the cover of the inner case, secured by four screws, see diagram 1.3.

1.6 System Pressures and Draining

WARNING. All parts containing water of the central heating circuit within the boiler, are under the system pressure. Before any parts of this circuit are disconnected, reduce the system pressure at the external draining tap. Turn the central heating isolating valves off and drain at the drain points on the appropriate valves, see diagram 1.1.

SECURING SCREW (4)

DATA LABEL

INNER CASE COVER

PILOT WINDOW SCREW (2)

4579

Diagram 1.3

4580

PLASTIC CAP

All water containing parts of the domestic hot water circuit of the boiler will be under the supply water pressure. Before any parts of this circuit are disconnected, turn the domestic cold water isolating valve off, open the hot water taps to reduce the water pressure in the boiler, close the hot water isolating valve and drain the boiler at the valves, see diagram 1.1.

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” in the Installation Instructions.

Check for water soundness.

Diagram 1.4

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2 S e r v i c i n g

2.1 Pilot Check

Check that the pilot flame is burning correctly and of the correct size, see diagram 2.1. If the pilot flame is not correct, the pilot injector will require removing, as detailed later.

2.2 Isolation and Access

Before starting, refer to Section 1.1. Isolate the boiler from the electrical supply and close the

gas service cock, refer to Section 1.3. Remove the outer case and the inner case cover, refer to

Sections 1.4 and 1.5. Disconnect the electrical plug connector and air pressure

tube from the fan, see diagram 2.2. Follow steps 1 to 4 on diagram 2.2 to remove the

hooks bolts. Step 1 - Slacken the two thumb screws securing the

collector but do not remove. Step 2 - Unhook the hook bolts. Step 3 - Turn the hook bolts. Step 4 - Remove the hook bolts. Remove the fan securing screws.

SPARK GAP

4.5mm to 5.5mm

FAN OUTLET SEAL

FAN SECURING SCREWS

FLAME LENGTH 25mm

Diagram 2.1

PLUG

4574

4581

Pull the fan forwards, at the bottom and rotate to disengage the fan outlet to flue elbow and rear bracket.

Take care not to damage the seal. Tilt the fan and withdraw. Remove the flue collector, note, this may be a tight fit. Remove the combustion chamber front panel, secured

with four screws, see diagram 2.3. Slacken, but do not remove the gland seal

securing screw. Should the pilot burner assembly require servicing, it

will be necessary to disconnect the pilot and thermocouple nut as this stage, see diagram 2.4.

Remove the pilot burner assembly securing screws and washers.

When removing the pilot burner assembly, note the pilot injector is loose and that the electrode and lead are connected and must not be used to hang the assembly by, see diagram 2.4.

Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot assembly forward and clear, taking care not to damage the combustion chamber insulation or pilot burner assembly, see diagram 2.5.

THUMB SCREW (2)

FLUE COLLECTOR

AIR PRESSURE TUBE

STEP 1 Slacken do not remove

STEP 3

STEP 2

STEP 4

4221045A

Diagram 2.2

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2 S e r v i c i n g

2.3 Heat Exchanger

Place a sheet of paper or similar in the combustion chamber, to act as a collector for deposits removed.

Brush the heat exchanger with a suitable brush, remove paper together with any debris.

2.4 Main Injector

4582

HEAT EXCHANGER

Inspect the injector and clean as necessary. Do not use wire or a sharp instrument on the hole.

2.5 Main Burner

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

Do not use a brush with metallic bristles.

2.6 Service Checks

Before replacing any parts removed during servicing, inspect the condition of all seals and joints, renewing them as necessary.

Check the condition of the combustion chamber insulation.

Check that the spark gap is as shown in diagram 2.1.

2.7 Note. Reassembly

Make sure that the main burner baffle has located in the side guides and that the burner is located on the main injector.

Refit the hook bolts. The combustion chamber front panel should be fitted

loosely, then the flue collector also fitted loosely, make sure that it is seated onto the heat exchanger and over the top edge of the front panel.

SECURING SCREW (4)

COMBUSTION CHAMBER FRONT PANEL

SPARK ELECTRODE

SPARK ELECTRODE RETAINING CLIP

PILOT INJECTOR

SECURING SCREW AND WASHER (2)

Diagram 2.3

4583

THERMOCOUPLE NUT

IGNITION LEAD

To fit the fan, locate it into the rear bracket and ease the flue elbow onto the fan outlet, making sure that the fan outlet seal is correctly positioned. Secure with the two screws, see diagram 2.2.

Refit electrical connector making sure that the red spots are aligned.

Secure the flue collector and combustion chamber front panel by tightening the thumb screws and securing screws, see diagram 2.2 and 2.3.

2.8 Operational Checks

Light the boiler, carry out operational checks and any necessary adjustments as described in “Commissioning” in the Installation Instructions.

WING NUT

PILOT TUBE NUT

SEALING GLAND SECURING SCREW

Diagram 2.4

221045A

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2 S e r v i c i n g

WING NUT

BURNER BRACKET

STEP 1 STEP 3

45844585

BURNER

WING NUT

BURNER BRACKET

SECURING SCREW

4586

BURNER GUIDE

STEP 2 STEP 4

SIDE GUIDES

MAIN INJECTOR

BURNER

4587

6221045A

Diagram 2.5

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3.1 Initial Checks

3 F a u l t F i n d i n g

If the boiler fails to operate, first check the following:

1. That the electrical supply is available at the boiler and the fuses are in order.

NOTE: THE BOILER CONTROL BOARDS CAN BE DAMAGED BY INCORRECT TESTING WITH THE POWER ON.

2. Make sure that the system pressure gauge registers

0.7bar, minimum and that the automatic air vent works. Refer to Installation Instructions, Section 11.2.

3. That the gas supply is available at the boiler and purged of air.

4. Is the pilot burner lit? - If the pilot burner will not light refer to Section 3.2. If the pilot burner fails to remain alight, refer to Section 3.3

5. That the boiler is set for the required service.

6. With the boiler central heating selector switched “Off”, see diagram 3.2 check that the domestic water supply is available and water flows freely from the hot taps. Close the taps.

7. With the boiler central heating selector switched “ON”, see diagram 3.2, check that all heating system controls, if fitted, are working correctly and calling for heat. If not isolate the boiler from the electrical supply. Disconnect the rear multi-pole connector at the base of the boiler and release the cable from the clamp.

CABLE CLAMP/COVER SCREW (2)

SWITCH (OFF)

C.Htg. SELECTOR SWITCH

PIEZO BUTTON

SWITCH (ON)

CABLE TO REMOTE HEATING CONTROLS

MAINS CABLE

CABLE CLAMP

Diagram 3.1

GAS CONTROL KNOB

CLOCK/TIMER (IF FITTED)

2883

Remove the connector cover and dependent on the type of control fitted test for continuity, mains or low voltage at terminals 1 and 2, see diagram 3.1.

If this is satisfactory continue with the detailed fault finding.

PRESSURE GAUGE

Orange Light ‘MAINS’

Green Light ‘RUNNING’

Red Light LOW C.Htg. WATER PRESSURE

Diagram 3.2

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PILOT WILL NOT LIGHT START HERE

3 F a u l t F i n d i n g

Check gas line - open all cocks, rectify any blockages, purge out any air. Does pilot light?

Apply match to pilot burner instead of pressing piezo unit button. Does pilot light?

Undo tubing nut at pilot burner. Press multifunctional control knob. Does gas flow freely?

Rectify blockage in pilot injector, or renew pilot injector.

Undo tubing nut at pilot outlet of mulitfunctional control. Press multifunctional control knob. Does gas flow freely?

YES

Does pilot stay alight when multi-functional control knob is released?

PILOT SATISFACTORY

Does pilot flame envelope thermocouple?

Check aeration. If necessary clean pilot, rectify blockage in pilot injector, or replace.

Check thermocouple circuit using thermocouple and boiler overheat cut-off fault finding.

YES

Change blocked pilot tube.

Change multifunctional control.

On pressing piezo unit button is there a spark across electrode gap?

Remove electrode from pilot bracket. Hold tip close to pilot burner and operate piezo unit. Is there a spark across gap?

Pull ignition lead off piezo unit. Using blade of an insulated screwdriver, touch unit chassis and leave approx. 4mm gap from connection tag on piezo unit. Operate piezo. Is there a spark across gap?

Change piezo unit.

YES

Change electrode assembly.

8221045A

Check electrode gap. Reposition, or replace electrode as necessary.

Diagram 3.3

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3 F a u l t F i n d i n g

With the boiler cold, check connections of the thermocouple, boiler overheat cut-off and multifunctional control. Disconnect overheat cutoff connectors at points A and B at the multifunctional control, see diagram 3.5. Test continuity of the overheat cutoff. Is there continuity?

YES

Re-connect boiler overheat cutoff to points A and B. Disconnect thermocouple at point D of the mulitfunctional control. Test continuity between point C and the body of the multifunctional control. Is there continuity?

YES

Faulty boiler overheat cutoff, renew.

Faulty cutoff connectors into multifunctional control, either at A or C. Renew where faulty.

Test continuity of thermocouple between inner connection point D and point E. Is there continuity?

YES

Thermocouple and boiler overheat circuit satisfactory.

3.2 Pilot Burner and Ignition System

Symptom: The pilot burner will not light or stay alight. Test the pilot burner and ignition system as shown in

diagram 3.3.

3.3 Thermocouple and Overheat Cutoff

Symptom: The pilot burner fails to stay alight. On completion of initial checks, as Section 3.1. Test the thermocouple, overheat cutoff and thermocouple

connectors, as described in Fault Finding diagram 3.4 and shown in diagram 3.5.

Faulty thermocouple, renew.

CONNECTION 'A'

CONNECTION 'E'

MULTIFUNCTIONAL

CONTROL

Diagram 3.4

4588

Check the millivoltage of the thermocouple closed circuit at points “A” and “E”, this should be within the range of 6 to 11mV, see diagram 3.5.

BOILER OVERHEAT CUTOFF

CONNECTION 'D'

CONNECTION 'C'

CONNECTION 'B'

Diagram 3.5

221045A

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3 F a u l t F i n d i n g

3.4 Clock/Timer - if fitted

If the clock has failed it can be bypassed by disconnecting the plug at the wall frame.

Disconnect the plug at the control box and connect this plug to the connection at the wall frame.

This is a temporary measure and the clock should be repaired or replaced as soon as possible.

3.5 Electrical

Preliminary electrical system checks, as outlined in a Multimeter Instruction book, are the first checks to be carried out during a fault finding procedure.

Isolate the boiler from the electrical supply, refer to Section 1.3.

Gain access to the boiler controls by removing the outer case, refer to Section 1.4. Check that all cables and connectors are secure.

Gain access to the control board, refer to Section 4.13. Check all cables at the multi-pin connectors on the board.

PERMANENT LIVE 240V~50Hz

(L)

OPTIONAL SWITCHED LIVE FROM ROOM STAT. 240V~50Hz

(N)

(L)

COMMON

CLOCK/TIMER

0192M

Test the two fuses on the main control board and renew as necessary, the fuse are, type 2AT and type 3.15AT.

If a fuse fails repeatedly or the initial fault finding checks described in Section 3.1 indicate a boiler fault, check the boiler electrical circuits and follow the fault finding procedures, see diagram 3.5, 3.6, 3.7 and 3.8 and for clock/timer fault diagram 3.9.

On completion of a fault finding task that has required the disconnection and making of electrical connections then checks, for earth continuity, polarity and resistance to earth must be carried out.

KEY

PUMP

(N)

3 3

FUSE 1

br........................BROWN

b.........................BLUE

p.........................PURPLE

CONTROL BOARD

TERMINALS, CN 2 CONTROL BOARD

TERMINALS, CN 3 CONTROL BOARD

TERMINALS, CN 4

TRANSFORMER

LOW VOLT. 26V~

10221045A

240V~

CONTROL BOARD

Diagram 3.6

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3 F a u l t F i n d i n g

MAIN MULTIFUNCTIONAL CONTROL SOLENOID

DHW CUT OFF

CONTROL

N/C

N/O

WATER PRESSURE

SWITCH

(SHOWN IN

PRESSURISED

STATE)

DHW

FLOW

SELECTOR

SWITCH

THERMISTOR

USER

CONTROL

BOARD

THERMISTOR

DHW

TRANSFORMER

TO REMOTE

HEATING

CONTROL

SWITCH

p p

240V~

26V~

p p

5 WAY PLUG/SOCKET

r r

or or

p p

0195M

1 1

4 4

br br

4 4

AIR PRESSURE

D.C. FAN

Diagram 3.7

N/C

N/O

SWITCH

FAN DRIVER

P.C.B.

2 2 2 2 2 2 2 2

1 1 1

p g y b gry w r Screen

gry p

y or

KEY

br bk b g gry or p r v w y

- Brown

- Black

- Blue

- Green

- Grey

- Orange

- Purple

- Red

- Violet

- White

- Yellow

v r

gry

gry p or y

MAIN PCB FAN DRIVER PCB

CN 1

CN 4

CN 5

CN 6

CN 7

1 2

5 5 5 5

6 6

7 7 7 7

CONTROL BOARD

CN 1 CN 2

221045A

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3 F a u l t F i n d i n g

Carry out the initial fault finding checks described in Section 3.1.

Check that gas, water and electricity are available at the boiler.

Before commencing tests isolate the boiler, make sure that the remote controls are not calling for duty and there

is no domestic hot water demand.

Remove the outer case, control housing and it's cover. Check all connections on the control board and the boiler components, rectify or renew as necessary. Two dummy two way connectors are provided for ease of testing continuity. Remove fuses and test for continuity, if faulty, check cables and connections for shorting to E or N, rectify if necessary and replace fuse, with spare provided. Check central heating water pressure, repressurize if necessary. Make sure boiler is cold. Check all pipes and connections between the Air Pressure Switch (APS) fan and combustion sample point, also between fan and gas/air ratio unit. Make sure sample point cap is fitted correctly. Make sure the pilot is alight. Make sure venturi is not blocked.

Isolate supply remove CN6 is there continuity between Red and Violet?

Faulty APS. Replace.

YES

Replace CN6. With no demand to the boiler. Restore power. Does the mains Orange LED come on?

Does the boiler light?

Does fan run at full speed for approx 30 seconds?

Isolate supply. Restore supply. During the 30 second is there approx 26V ac on Black and Red from the transformer at CN1?

YES

Is there 240V ac at Blue and Brown on CN3.

YES

Faulty LED. Does not effect boiler operation.

Isolate supply, is there continuity at flow switch?

Faulty main PCB. Replace.

Faulty transformer. Replace.

Check electricity supply.

YES

Faulty flow switch. Replace.

continued (a)

Is there 26V ac on Orange and Yellow at CN7 and greater than 3V dc on Grey and Purple?

YES

Isolate supply. Is the resistance at CN2 on the fan driver pcb between White and Grey, Grey and Purple, Purple and White approx 2.5Ω ?

YES

Is there continuity at CN2 on the fan driver pcb between White and the fan motor laminations? (repeat with Grey and Purple)

YES

Faulty main PCB. Replace.

Faulty fan. Replace.

Faulty fan driver pcb. Replace.

Diagram 3.8

12221045A

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YES

(a)

3 F a u l t F i n d i n g

After about 30 seconds from “switch on” does fan go to low speed?

YES

Isolate supply. Restore supply with no demand. Is there 24Vac between grey wire on CN6 and Pin 2 on CN1 for about 30 seconds.

YES

Isolate supply. Reconnect CN6, restore power supply.

YES

Does pump run for about 30 seconds?

YES

Isolate supply disconnect central heating thermistor, is resistance of thermistor between 8KΩ and 11KΩ?

NO YES

Faulty thermistor. Replace.

Faulty APS. Replace.

During the 30 second period is there 240V at pump.

YES

Faulty main PCB. Replace.

After about 30 seconds

does pump go off?

YES

Open DHW tap at full rate. Does burner pressure go to 13.1mb?

YES

Faulty pump. Replace.

Faulty main PCB. Replace.

Is the burner pressure between

0.1 and 13.1 mb ?

Does green demand light come on?

YES

Check venturi air signal at test point Is this approx 2.5mb

YES

Faulty fan. Replace.

Faulty gas/air ratio unit. Replace.

continued (a)

continued (b)

continued (c)

Diagram 3.8 cont.

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3 F a u l t F i n d i n g

YES

(a)

(b)

YES

Restore supply. Is there about 24V ac multifunctional control?

YES

NOYES

(c)

Isolate supply disconnect Red in line connectors to flow switch, is there continuity across flow switch?

YES

Reconnect flow switch, disconnect Purple in line connectors to DHW thermistor. Is the resistance between 8KΩ and 11KΩ?

YES

Faulty LED. Does not effect boiler operation.

Faulty DHW thermistor. Replace.

Isolate supply, remove CN1. Is there continuity across DHW O/H stat?

YES

Faulty flow switch. Replace.

Turn the DHW flow off. Turn on the CH. Does pump run?

Faulty main PCB. Replace.

YES

Is burner pressure about 5.6mb?

SYSTEM O.K.

YES

Faulty multifunctional control.

Is there continuity across C and N/O at low water pressure switch?

YES

Faulty main PCB. Replace.

Faulty DHW O/H stat. Replace.

Faulty water pressure switch. Replace.

14221045A

Diagram 3.8 cont.

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3 F a u l t F i n d i n g

If a mains potential room thermostat is connected, ensure that the switch live is connected to PIN 1 in the 5 pole connector. Check continuity of clock/timer harness, ensure an electrical supply is available, ensure that remote controls are calling for heat.

Isolate the boiler from electrical supply, remove outer case.

YES

Switch on electrical supply, is there a display on clock/timer?

YES

Disconnect and insulate the purple cables from heating common and heating on.

YES

Advance clock/timer until a demand is indicated Is there now continuity between heating common and heating on?

YES

Clock/timer in order if no central heating, refer to main fault finding.

Faulty clock/timer. Replace.

DIGITAL CLOCK/TIMER STYLE 1 and 2 FAULT FINDING

CLOCK FAULT FINDING

If a mains potential room thermostat is connected, make sure that the switch line is connected to pin 1 in

the 5 pole connector.

Check continuity of clock harness, make sure an electrical supply is available make sure that remote

controls are calling for heat.

Make sure the override switch if fitted is in the " " position

Does clock keep time

Faulty clock replace

Yes

No Isolate electrical supply set clock to on period Is there continuity across common and heating on

Clock in order if no central heating refer to

Yes

Set clock to off period. Is there continuity across common and heating on

main fault finding

ELECTRO/MECHANICAL CLOCK/TIMER FAULT FINDING

Diagram 3.9

5667

Yes

Diagram 3.9

221045A

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4 R e p l a c e m e n t o f P a r t s

Before replacing any part please read points below:Replacement of parts must only be carried out by a

competent person. Unless stated otherwise all parts are refitted in the

reverse order to removal.

1. Refer to Section 1.1.

CLOCK/TIMER (if fitted)

4589

2. Always isolate the boiler from the electrical and as required the gas supply as Section 1.3.

3. Unless stated otherwise, gain access as appropriate parts of Sections 1.4 and 1.5.

4. On completion, make good any water loss and pressurise the system to initial design pressure, refer to “Commissioning” in the Installation Instructions.

If the red light “flashes”, momentarily interrupt the electrical supply.

4.1 Fan

Refer to the appropriate parts of Section 2.2. After fan has been fitted, check the burner pressure and

if necessary adjust.

4.2 Main Burner

Refer to the appropriate parts of Section 2.2. Note. There is no need to remove the fan or flue

collector assemblies.

CONTROL HOUSING SECURING SCREW (2)

SUPPORT BRACKET

FAN DRIVER CONTROL HOUSING)

TOP CONTROL HOUSING COVER

BOTTOM CONTROL HOUSING COVER

4.3 Main Injector

Refer to the appropriate parts of Section 2.2. Note. There is no need to remove the fan or the flue

collector assemblies.

4.4 Pilot Burner/Injector

Refer to the appropriate parts of Section 2.2 Note. There is no need to remove the fan or flue

collector assemblies.

4.5 Spark Electrode/Ignition Lead

Refer to the appropriate parts of Section 2.2. Note. There is no need to remove the fan or flue

collector assemblies. Remove the controls housing assembly and support, see

diagram 4.1. If this is not possible place on a surface, making sure that

the control knob is protected. Remove the spark electrode/ignition lead from the pilot

burner assembly, see diagram 2.4.

SCREW(2)

CLOCK/TIMER (if fitted)

Diagram 4.1

Disconnect the ignition lead from the piezo unit, refer to Section 4.11.

16221045A

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4 R e p l a c e m e n t o f P a r t s

4.6 Thermocouple

Remove the sealing gland, secured with a single screw, see diagram 2.4.

Remove the spark electrode/lead, see diagram 2.4. Disconnect the thermocouple at both ends, see diagram

2.4 and 4.2. Remove the thermocouple. Do not tighten the thermocouple nut more than a quarter

turn beyond finger tight or make any sharp bends in the capillary.

4.7 Boiler Overheat Cutoff

Remove the control housing as the appropriate part of Section 4.1.

Remove piezo unit bracket, disconnect lead, see diagram 4.3.

Disconnect the boiler overheat cutoff electrical connectors from the multifunctional control, see diagram 4.2.

Remove the boiler overheat cutoff, secured with two screws, see diagram 4.2.

SECURING SCREW (2)

OVERHEAT CUTOFF CONNECTORS

ELECTRICAL CONNECTORS

THERMOCOUPLE NUT

4591

Use the heat sink compound supplied, between the mounting plate and the cutoff, when fitting it.

4.8 Water Pressure Switch

Release the water pressure and drain the central heating circuit of the boiler, refer to Section 1.3 and 1.6.

Disconnect the electrical connectors at the water pressure microswitch, see diagram 4.4.

Remove pressure switch. Replace the “O” ring seal with the new seal provided. Make sure that the switch terminals are facing diagonally

forwards to give access, as shown in diagram 4.4. Reconnect the electrical connections, refer to

diagram 4.11.

PIEZO UNIT BRACKET

IGNITION LEAD

PIEZO UNIT

SECURING SCREW (2)

SELECTOR SWITCH

Diagram 4.2

2848

Diagram 4.3

4592

WATER PRESSURE SWITCH

Diagram 4.4

221045A

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4 R e p l a c e m e n t o f P a r t s

4.9 Pump

Release the water pressure and drain the central heating circuit of the boiler, refer to Section 1.3 and 1.6.

Disconnect the electrical connectors at the water pressure microswitch. Remove the water pressure switch, refer to Section 4.8.

Remove the terminal cover from the pump and disconnect the cable, see diagram 4.5.

Disconnect the pump at the unions. Discard the sealing washers.

PUMP SPINDLE

4593

PUMP ADJUSTER

TERMINAL COVER SCREW

FLOW DIRECTION ARROW

Make sure that the flow direction arrow is pointing upward when fitting and use the new sealing washers.

Refit water pressure switch, refer to Section 4.8. The flow adjuster on the new pump should be set to that

of the original, refer also to Section 4.6 in the Installation Instructions.

The flow rate should be controlled by means of a valve in the heating flow, refer to Section 11.10 in the Installation Instructions.

Note: Should the pump fail to operate, refer to diagram

3.8. If all is in order, but the pump still does not operate, remove the end screw, see diagram 4.5, then turn the pump spindle to release any temporary seizure.

DO NOT HIT THE SPINDLE.

4.10 Domestic Hot Water High Limit Control

Remove the pump, see Section 4.9. Disconnect the electrical connectors at the domestic hot

water high limit control, see diagram 4.6. Remove the high limit control from the flow pipe,

secured with two screws.

END SCREW

D.H.W. HIGH LIMIT CONTROL

UPPER PUMP UNION

LOWER PUMP UNION

Diagram 4.5

4594

Use the heat sink compound supplied, between the mounting plate and the control.

When refitting the electrical connections to the high limit control the polarity is not important, see diagram 4.11.

4.11 Piezo Unit

Remove the piezo unit bracket, see diagram 4.3. Disconnect the ignition lead at the piezo unit. Remove the piezo unit from the bracket.

D.H.W.

ELECTRICAL CONNECTORS

SECURING SCREW (2)

18221045A

HIGH LIMIT CONTROL

Diagram 4.6

Page 19

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4 R e p l a c e m e n t o f P a r t s

4.12 Pressure Gauge

Remove the control housing assembly, see diagram 4.1. Release the water pressure and drain the central heating

circuit of the boiler, refer to Section 1.3 and 1.6. Remove the pressure gauge bracket. Disconnect the pressure gauge connection from the

safety valve, discard the washer, see diagram 4.7. Remove the pressure gauge secured with the

retaining tabs. Locate the supplied new washer under the pressure

gauge connection when refitting the safety valve.

4.13 Control Boards

CAUTION. Great care must be taken when handling any control board.

THE MAIN CONTROL BOARD MUST BE KEPT IN THE ANTI STATIC HOLDER UNTIL NEEDED.

Note. Timer/clock may be removed to improve access, see Section 4.32 or the control housing bottom half can be removed.

Main Control Board

Remove control housing cover securing screw, see diagram 4.8.

Remove the control housing assembly as shown in diagram 4.1.

Lift the control housing cover to gain access to the board.

SAFETY VALVE

SEALING WASHER

PRESSURE GAUGE CONNECTION

SECURING SCREW (2)

PRESSURE GAUGE

FASCIA

CONTROL HOUSING SECURING SCREW (2)

FASCIA SECURING SCREW (3)

HINGE PIN

PRESSURE GAUGE BRACKET

Diagram 4.7

TEMPERATURE CONTROL KNOB

CONTROL HOUSING COVER SECURING SCREW

CONTROL HOUSING COVER

2831

4595

Disconnect all multipin connectors, see diagram 4.8. Remove the control board from the support posts. To reconnect the multipin connectors correctly, see

diagram 4.11. When replacing the main control board check and if

necessary adjust the main burner gas pressure in both the domestic hot water and central heating modes. Refer to “Commissioning” in the Installation Instructions.

Fan Driver Board

Remove the fan driver control housing assembly securing screws.

Remove the multipin connectors, see diagram 4.9. Release the board from its support posts then remove the

nut and screw securing the board to the cover, see diagram 4.9.

User Control Board

Remove the fascia, see diagram 4.8. Remove the multipin connector.

TRANSFORMER

MULTI-PIN CONNECTORS

USER CONTROL BOARD

SUPPORT POSTS

Diagram 4.8

Remove the control board from the supports posts.

221045A

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4 R e p l a c e m e n t o f P a r t s

4.14 Transformer

Note. Timer/clock may be removed to improve access, see Section 4.32 or the control housing bottom half can be removed.

Remove the control housing cover screw, see diagram 4.8.

Remove control housing assembly, see diagram 4.1. Remove the control housing cover and disconnect the

electrical connectors from the transformer, see diagram 4.8.

Remove the transformer securing screws (2 off) from beneath the control housing, remove the transformer and insulation.

To connect the transformer cables correctly, refer to diagram 4.11.

FAN DRIVER BOARD

SUPPORT POSTS

FAN DRIVER CONTROL HOUSING

SECURING SCREW NUT

MULTI-PIN CONNECTORS

Diagram 4.9

4596

g/y

KEY

PURPLE

RED

BLUE

BROWN

g/y

GREEN/YELLOW

240V~50Hz PERMANENT MAINS SUPPLIED FUSED AT 3A

g/y

Diagram 4.10

CLOCK/ TIMER

COMMON

(L)

(N)

HEATING ON

4774

20221045A

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4 R e p l a c e m e n t o f P a r t s

y+or 26Volts ac gry+p 3 Volts dc CN7

AIR PRESSURE SWITCH

✽ 230V-50Hz PERMANENT MAINS SUPPLY FUSED AT 3A

12 NL

p p g/y b br

gry

CENTRAL HEATING SELECTOR SWITCH

DC FAN

THERMISTOR CH

PUMP

DHW FLOW SWITCH

screened screened

r w

gry b

y g p

THERMISTOR DHW

WATER PRESSURE SWITCH

gry

MULTI-FUNCTIONAL CONTROL

b y

g p

FAN

DRIVER

BOARD

or ypgry

0205M

g/y

or y p gry w

CN3

p p

r r br br or or

p p

gry

p y or

TRANSFORMER

bbr

MAINS

bbr

FUSE 2AT

KEY:

CN4

w b bk br g/y gry or v r y p

CN5

MAIN CONTROL BOARD

NLNL 230V~

TXR

- WHITE

- BLUE

- BLACK

- BROWN

- GREEN/YELLOW

- GREY

- ORANGE

- VIOLET

- RED

- YELLOW

- PURPLE

bbr

CN7

FUSE

3.15AT

CN1

CNCNO

gry

p y or

p p

bk y

bk r

DHW HIGH LIMIT CONTROL

gry

CN6

g/y

USER CONTROL

BOARD

CHASSIS EARTH

Diagram 4.11

221045A

Page 22

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4 R e p l a c e m e n t o f P a r t s

4.15 Multifunctional Control and Gas/Air Ratio Unit Assembly: diagram 4.12

Remove control housing, see diagram 4.1. Remove the piezo bracket, see diagram 4.3. Disconnect the two electrical connectors at the front of

the multifunctional control. Disconnect the boiler overheat cutoff connectors. Disconnect the thermocouple nut at the

multifunctional control. Disconnect the pilot supply tube at the

multifunctional control. Disconnect the gas/air ratio unit tubes at the

bulkhead connectors. Remove the four, right hand, extended hexagon screws

from the multifunctional control. Break the gas connection at the wall frame. Remove the multifunctional control valve and gas/air

ratio unit assembly, taking care not to damage the tubes.

Multifunctional Control

Remove the four, left hand, extended hexagon screws from the multifunctional control.

GAS/AIR RATIO UNIT TUBE NUTS

ELECTRICAL CONNECTORS

HEXAGON SCREWS (4)

BOILER OVERHEAT CUTOFF CONNECTOR

GAS CONNECTION

MULTIFUNCTIONAL CONTROL

4597

HEXAGON SCREWS (4)

PILOT SUPPLY TUBE

THERMOCOUPLE NUT

'O' RING

Discard the “O” rings and fit the new ones, supplied. Check and adjust the main burner gas pressure in both

the domestic hot water and central heating modes, refer to “Commissioning” in the Installation Instructions.

Gas/Air Ratio Unit Assembly

Disconnect the gas/air ratio unit sensing tubes. Remove the two securing screws, see diagram 4.12.

4.16 Central Heating Selector Switch

Slacken the piezo bracket securing screws and remove the bracket from the keyhole slots, see diagram 4.3.

Pull the leads from the switch. To remove the switch press in the tabs on each side. The polarity of the electrical connections is not

important.

'O' RING

VENTURI AIR SIGNAL TEST POINT

SCREW (2)

GAS/AIR RATIO UNIT SENSING TUBE NUTS

22221045A

GAS/AIR RATIO UNIT

Diagram 4.12

Page 23

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4 R e p l a c e m e n t o f P a r t s

4.17 Domestic Hot Water Flow Switch

The replacement of this part can be done within the limits of “minimum clearances”. Should there be a side clearance of 150mm or more then the multifunctional control/air ratio unit assembly need not be removed.

Isolate the domestic hot water inlet and drain, refer to Sections 1.3 and 1.6.

When replacing the flow switch it is recommended that the water inlet filter is cleaned or renewed.

When replacing the flow switch make sure that it is correctly positioned, with the flow direction arrow pointing upward.

Remove the burner as Section 2.2. Remove the multifunctional control and air/ratio

assembly as described in Section 4.15. Disconnect the front sensing tube. Disconnect the flow switch connectors, see

diagram 4.13. Remove the locknut from the flow switch and lower the

domestic hot water inlet pipe assembly, including flow switch, from the base of the main panel.

FLOW SWITCH

FILTER UNION NUT

ELECTRICAL CONNECTORS

UNION NUTS

GAS/AIR RATIO SENSING TUBE

4599

WATER INLET PIPE ASSEMBLY

Disconnect the filter union nut.

ISOLATING VALVE

CENTRAL HEATING THERMISTOR

UNION NUT

Diagram 4.13

4598

'O' RING

ELECTRICAL CONNECTORS

D.H.W. THERMISTOR

'O' RING

Diagram 4.14

221045A

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4 R e p l a c e m e n t o f P a r t s

4.18 Thermistor - Heating

Release the water pressure and drain the heating circuit of the boiler, refer to Sections 1.3 and 1.6.

Gain access by removing the piezo bracket, see diagram 4.3.

Disconnect the cables from the thermistor, see diagram 4.14.

Remove the thermistor, complete with its “O” ring. The polarity of the electrical connections is

not important.

4.19 Thermistor - Domestic Hot Water

The replacement of this part can be done within the limits of the minimum clearances. Should there be a side clearance of 150mm or more then the pump need not be removed.

Remove the pump, refer to Section 4.9. Release the water pressure and drain the domestic hot

water circuit of the boiler, refer to Section 1.3. and 1.6. Disconnect the cables from the thermistor, see

diagram 4.14. Remove the thermistor complete with its “O” ring. The polarity of the electrical connections is not

important.

SAFETY VALVE

PRESSURE GAUGE CONNECTION

CAP NUT

SEALING WASHER

THROTTLE ADJUSTER

DISCHARGE PIPE

UNION NUT

Diagram 4.15

2794

46004601

4.20 Safety Valve

Release the water pressure and drain the central heating circuit of the boiler, refer to Section 1.3 and 1.6.

Remove the pressure gauge, refer to Section 4.12. Disconnect the union nuts to release the safety valve, see

diagram 4.15.

4.21 Water Inlet Filter

Refer to the appropriate parts of Section 4.17.

4.22 Domestic Hot Water Throttle

Release the water pressure and drain the domestic hot water circuit of the boiler, refer to Section 1.3 and 1.6.

Refer to Section 4.17 to gain access to the throttle. Remove the cap nut and carefully remove the throttle

adjuster, by unscrewing, it may be necessary to push the throttle adjuster out from the rear, see diagram 4.16.

Clean if necessary, taking care not to damage the throttle body.

‘O’ RING

Diagram 4.16

MINI EXPANSION VESSEL

SEALING WASHER

Diagram 4.17

Reset the domestic hot water flow rate refer to Section

11.7 in the Installation Instructions.

24221045A

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4 R e p l a c e m e n t o f P a r t s

4.23 Mini Expansion Vessel

Release the water pressure and drain the domestic hot water circuit at the boiler, refer to Sections 1.3 and 1.6

Remove the control housing as Section 4.1. Note. It may be possible, in some circumstance, to

remove the mini expansion vessel by hand. Remove the multifunctional control, refer to

Section 4.15. When refitting use the new sealing washer supplied, see

diagram 4.17.

4.24 Automatic Air Vent

Release the water pressure and drain the central heating circuit of the boiler, refer to Sections 1.2 and 1.6.

Remove the automatic air vent, see diagram 4.18. SLACKEN THE SMALL CAP ON THE AIR VENT.

THIS MUST NOT BE RETIGHTENED.

LOCATION SLOT

CAP

SEALING WASHER

4602

AUTOMATIC AIR VENT

When refitting use the new washer supplied.

4.25 Heat Exchanger

Release the water pressure and drain the central heating and domestic hot water circuits refer to Section 1.3 and 1.6.

Remove the fan from the flue collector, refer to Section 2.2.

Remove the flue collector, refer to Section 2.2. Remove the main burner, refer to Section 2.2. Remove the automatic air vent, refer to Section 4.24.

If renewing the heat exchanger, transfer the air vent, using the new sealing washers provided.

Disconnect the front gas/air ratio sensing tube, see diagram 4.18. Make sure that no water enters the tube.

Disconnect the union nuts of the heat exchanger to remove it, see diagram 4.18.

Reassembly Notes. Locate the raised location tabs on the combustion

chamber sides into the slots on the heat exchanger, see diagram 4.18.

UNION NUTS

GAS/AIR RATIO SENSING TUBE

Diagram 4.18

Make sure that the main burner baffle has located in the side guides and that the burner is located on the main injector.

The combustion chamber front panel should be fitted loosely, then the flue collector also fitted loosely, make sure that it is seated correctly on the heat exchanger and over the top edge of the front panel.

221045A

Page 26

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4 R e p l a c e m e n t o f P a r t s

SECURING SCREW (4)

COMBUSTION CHAMBER FRONT PANEL

Diagram 4.19

4.26 Combustion Chamber Insulation

Remove the combustion chamber front panel secured with four screws, see diagram 4.19.

Remove the front insulation, secured with a clip, see diagram 4.20.

4603

COMBUSTION CHAMBER FRONT PANEL

CLIP

FRONT INSULATION

4604

Slide out both side insulation pieces. Remove the burner as in Section 2.2. Pull the lower rear insulation forward, then slide the

upper rear insulation down from behind the heat exchanger, see diagram 4.20.

SIDE INSULATION PIECES

LOWER REAR INSULATION

26221045A

UPPER REAR INSULATION

Diagram 4.20

Page 27

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4 R e p l a c e m e n t o f P a r t s

4.27 Expansion Vessel

Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to Section 4.5 in the Installation Instructions.

Release the water pressure and drain the central heating and domestic water circuits, refer to Section 1.3 and 1.6.

Remove the fan from the flue collector, refer to Section 2.2.

Remove the flue elbow, refer to Section 10 of the Installation Instructions.

Disconnect the boiler water connection union nuts at the front of the isolating valves, see diagram 1.1.

Disconnect the gas service cock union. Disconnect the safety valve discharge pipe from the

boiler, see diagram 1.1.

4605

SECURING (2)

LOCATION CLIPS

Separate the two parts of the boiler multi-pole electrical connector.

Slacken the clips of the gas service cock and the water isolating valves.

Remove the boiler from the mounting frame, secured with two screws at the top, see diagram 4.21. Pull the boiler from the isolating valves. Unhook the boiler at the top and lift off.

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

Disconnect the union nut connection, see diagram 4.22 and discard the sealing washer.

Remove the expansion vessel, secured with three clamping screws.

Connect the union nut, when fitting the expansion vessel, before clamping it.

CLIP

(5)

UNIONS (5)

UNION NUT CONNECTION AND SEALING WASHER

Diagram 4.21

2861

CLAMPING SCREW (3)

Diagram 4.22

221045A

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4 R e p l a c e m e n t o f P a r t s

FRAME

GLASS

SECURING SCREW (2)

GASKET

Diagram 4.23

4.28 Pilot Viewing Window

Remove the pilot viewing window, secured with two screws. When fitting a new window use the gasket provided, see diagram 4.23.

4.29 Inner Cover Case Seal

Remove the old seal, clean out the old adhesive. Glue the new seal into place, make sure that there are no

breaks in it.

4.30 Air Pressure Switch

Remove the flue collector, refer to Section 2.2.

4606

CLEAR

GREY

AIR PRESSURE TUBES

4607

SCREWS (2)

AIR PRESSURE SWITCH

VIOLET

ELECTRICAL CONNECTORS

RED

Diagram 4.24

Disconnect the three electrical connectors at the air pressure switch, see diagram 4.24. Remove the flexible tubes from the switch. Remove the air pressure switch, secured with two screws.

When replacing the tubes to the air pressure switch make sure that the forward (clear) tube from the air pressure switch connects to the tee on the incoming air sensing tube.

The rear most (coloured) tube connects to the fan pressure sensing tube.

When reconnecting the electrical cables refer to diagram 4.11.

4.31 Air/Gas Ratio Sensing Venturi

Remove the fan assembly and flue collector, refer to Section 2.2.

Disconnect the tube nut and screw to release the sensing venturi, see diagram 4.25.

4608

SCREW

VENTURI TUBE NUT

Diagram 4.25

28221045A

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4 R e p l a c e m e n t o f P a r t s

CLOCK/TIMER

SECURING SCREWS (2)

ELECTRICAL CONNECTIONS

4609

SECURING CLIP (2)

4777

MOUNTING BRACKET

SPACER

TIMER/CLOCK

KEY

br BROWN b BLUE p PURPLE

MAINS NEUTRAL (N)

MAINS LIVE (L)

HEATING ON

RETAINING TABS (4)

DIGITAL CLOCK/TIMER STYLE 1 ILLUSTRATED

COMMON

Diagram 4.26

4.32 Clock/Timer - if fitted

Digital clock/timer - Style 1 - Release the mounting bracket securing screws, see diagram 4.26.

Disconnect the electrical cables, squeeze the retaining tabs to release the clock/timer, see diagram 4.26.

Electro/mechanical and Digital clock/timer - Style 2 Release the mounting bracket securing screws, see diagram 4.26.

Disconnect electrical cables, release securing clip to remove the clock/timer and spacer, see diagram 4.27.

ELECTRO/MECHANICAL and DIGITAL CLOCK/ TIMER STYLE 2 ILLUSTRATED

Diagram 4.27

221045A

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5 S p a r e P a r t s

5.1 Part Identification

The key number in diagram 5.1 and the first column of the list will help identify the spare part.

5.2 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 on the inner case cover, see diagram 1.3.

Key No Part No Description GC No

1 800512 Fan assembly 278 129 2 205724 Main injector assembly 278 130 3 203433 Pilot burner 379 485 4 202627 Spark electrode with lead 278 131 5 203518 Pilot injector 381 656 6 202435 Thermocouple 378 204 7 432869 Boiler over heat cut off assy 376 988 8 432868 DHW high limit control assy 313 024 9 900501 Piezo unit) 382 585 9 900501 Piezo unit) 384 146 10 800134 Pressure gauge assembly 313 294 11 202217 Control board inc fuses 278 132 12 800513 Transformer 278 133 13 800510 Multifunctional control 278 134 14 202068 Central heating selector switch 382 813 15A 800504 Thermistor assembly-Domestic 278 135 15B 800504 Thermistor assembly-Heating 278 135 16 800136 DHW switch assembly 313 277 17A 202226 Fuse 1 278 136 17B 202240 Fuse 2 *** ***

alternatives

}

18 800155 Water pressure switch assembly 278 142 19 202218 User PCB 278 141 20 202221 Air pressure switch assy 278 137 21 208214 Water inlet filter 281 359 22 800153 Automatic air vent assembly 313 285 23 800149 Safety valve assembly 397 677 24 203373 Gas/air ratio unit 278 138 26 800515 Fan driver board 278 140

30221045A

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5 S p a r e P a r t s

4610

17A

17B

Diagram 5.1

221045A

Page 32

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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 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.

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

32221045A