Halstead Ace High, Halstead Ace Installation And Servicing Instructions

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G. C. APPLIANCE No. 41 333 77 Ace G. C. APPLIANCE No. 41 333 78 Ace High

0086

Ace and Ace High

Wall Mounted Gas Combination Boiler

Installation and Servicing Instructions

To be left with user adjacent to gas meter

EC 0087/BM/37

CONTENTS INTRODUCTION

The Halstead Ace and Ace High are fully automatic wall-mounted, fan-assisted, balanced flue, gas combination appliances for use with natural gas (G20). They incorporate a microprocessor based, fully modulating, gas control system with direct burner ignition. The Ace High has a higher domestic hot water heat output and provides a higher flow rate.

Both the Halstead Ace and Ace High feature an attractive white stove enamelled casing with an inset control panel. The flue elbow and air ducts are also white stove enamelled to give a clean, attractive appearance to the installation.

The Ace High provides both central heating and instantaneous domestic hot water at outputs between 11 kW (37,500 BTU/h) and 30 kW (102,000 BTU/h). The Ace provides both central heating and instantaneous domestic hot water at outputs between 8.8 kW (30,000 Btu/h) and 24 kW (82,000 Btu/h).

Heat output is controlled according to demand (in both domestic hot water and central heating mode) by the modulating gas control valve. The appliance always gives priority to domestic hot water supply.

The appliance is supplied with a standard telescopic concentric air and flue duct system suitable for flue lengths of up to 820mm (32in). The duct assembly is connected to the boiler via a turret which can exit the boiler in any horizontal direction. Horizontal extension ducts may be fitted in accordance with and up to the maximum dimensions stated in these instructions.

A vertical outlet kit is also available for installations where an outside wall is not accessible and it is desired to fit the duct ‘through the roof’.

Installation using the standard flue kit is described in the main text of these instructions and supplementary instructions at the rear of this booklet describe installation involving the vertical outlet kit. NO OTHER

FLUE KITS OR EXTENSIONS MAY BE USED WITH THIS APPLIANCE.

The appliance can be installed from inside the room without access to the external wall providing that a wall liner is fitted and that the wall thickness is less than 0.5m (19in).The wall liner is available as an optional extra. See section 4 for further details. (Note: If the vertical outlet kit is to be used, access to the roof is necessary).

The appliance is designed for use with sealed primary water systems and incorporates a circulation pump, diverter valve assembly, pressure gauge, flow switch, safety valve and system expansion vessel. A separate DHW expansion vessel is not required. Isolation valves are fitted to the service connections, and an automatic heating bypass is fitted to maintain an adequate flow rate through the boiler.

If thermostatic radiator valves are installed we recommend that one radiator is fitted with lockshield valves (normally in the bathroom) to allow pump overrun circulation.

Internal frost protection is fitted as standard equipment. The boiler may be used with any certified mains voltage room thermostat.

An electro-mechanical 24hr time clock is fitted as standard.

NOTE: British Standard BS7593: 1992 stresses the importance of cleansing and flushing of the system to ensure it continues to run efficiently with the minimum of maintenance necessary. Halstead Boilers fully support this professional approach and recommend that the system is cleansed with an effective chemical cleanser and protected long term with a suitable inhibitor. Such products are available from Fernox and Sentinel.

Gas Consumer Council

The Gas Consumer Council (GCC) is an independent organisation which protects the interest of gas users. If you need advice, you will find the telephone number in your local directory under ‘Gas’.

1 GENERAL DESCRIPTION

2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . .1

2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.2 Performance data, Halstead Ace & Ace High . . . . . . . . . .1

2.3 Minimum clearances, Halstead Ace & Ace High . . . . . . .1

2.4 General specifications, Halstead Ace & Ace High . . . . . .1

2.5 Overall appliance dimensions . . . . . . . . . . . . . . . . . . . .1

2.6 Concentric air/flue duct specifications . . . . . . . . . . . . . .3

2.8 Exploded diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.9 Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3 INSTALLATION REQUIREMENTS . . . . . . . . . . . . . .8

3.1 Statutory requirements . . . . . . . . . . . . . . . . . . . . . . . . .8

3.2 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.3 Flue terminal position . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.4 Ventilation requirements . . . . . . . . . . . . . . . . . . . . . . . .9

3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.6 Central heating system . . . . . . . . . . . . . . . . . . . . . . . . .9

3.7 Domestic hot water systems . . . . . . . . . . . . . . . . . . . . .10

3.8 Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.9 External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.0 INSTALLING THE APPLIANCE . . . . . . . . . . . . . . .12

4.1 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . .12

4.2 Preparing the wall . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3 Mounting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.4 Service connections . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.5 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.6 Pressure relief valve connection . . . . . . . . . . . . . . . . . .13

4.7 Air/flue duct installation . . . . . . . . . . . . . . . . . . . . . . .14

4.8 Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5 COMMISSIONING AND TESTING . . . . . . . . . . . .18

5.1 Filling the water system . . . . . . . . . . . . . . . . . . . . . . . .18

5.2 Commissioning the appliance . . . . . . . . . . . . . . . . . . .19

5.3 DHW flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.4 Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.5 Ignition lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.6 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.7 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.8 Other features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.9 User’s instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.10 Boiler logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

6 ROUTINE SERVICING INSTRUCTIONS . . . . . . . . .21

7 INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . .23

7.1 Functional flow diagram . . . . . . . . . . . . . . . . . . . . . . .23

7.2 Illustrated wiring diagram . . . . . . . . . . . . . . . . . . . . . .24

8 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . .25

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.2 Diagnostic indicator LED’s . . . . . . . . . . . . . . . . . . . . . .25

8.3 Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.4 DHW fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.5 Central heating fault finding . . . . . . . . . . . . . . . . . . . .25

9 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . .27

9.1 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.2 Combustion chamber insulation . . . . . . . . . . . . . . . . . .27

9.3 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.4 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.5 Ignition and detection electrodes . . . . . . . . . . . . . . . . .27

9.6 Multifunctional gas control . . . . . . . . . . . . . . . . . . . . .27

9.6.1 Gas control replacement . . . . . . . . . . . . . . . . . . . . . . .27

9.6.2 Gas control and PCB burner pressure setting procedure . .27

9.7 Air Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.8 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.9 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.10 CH/DHW Microswitches . . . . . . . . . . . . . . . . . . . . . .29

9.11 Thermistors D.H.W. or Heating . . . . . . . . . . . . . . . . . .29

9.12 Water flow regulator . . . . . . . . . . . . . . . . . . . . . . . . .30

9.13 DHW heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .30

9.14 DHW flow switch body . . . . . . . . . . . . . . . . . . . . . . .30

9.15 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.16 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.17 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.18 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.19 System expansion vessel . . . . . . . . . . . . . . . . . . . . . . .31

9.20 Time clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . .31

11 Supplementary instructions for flue systems

with a vertical outlet. . . . . . . . . . . . . . . . . . . . . . . . . .32

Central Heating

DHW

Max. gas rate (after 10 mins operation i.e. hot) 2.81 m3/h (100 ft3/h) Factory set gas rate (after 10 min operation) 2.0 m3/h (71 ft3/h)

Min. domestic hot water flow rate 2.8 l/min (0.6 gpm) Design domestic hot water performance 9.8/min (2.1 gpm) raised 35°C Max. domestic hot water temperature 73+/-2°C Max. mains water inlet pressure 10 bar (146 psi) Min. mains water inlet pressure for operation 0.3 bar (4.4 psi) Min. mains water inlet pressure for max heat output 1.0 bar (14.6 psi) Max gas rate (after 10 mins operation, i.e. hot) 2.81 m3/h (100 ft3/h)

TECHNICAL SPECIFICATIONS

HALSTEAD ACE

HALSTEAD ACE HIGH

2.2

PERFORMANCE DATA

. .

100mm DIA.

325mm

188mm

225mm

760mm

455mm

900mm

95mm

1(a)

200mm

5mm

200mm

5mm

SEE NOTE

•

The appliances are Certified to comply with the requirements of EN 483 and EN 625 for use in GB and IE (Great Britain and Ireland) using the following gas categories:

Ace/Ace High: I

(G20 with a governed gas supply at 20 mbar

(8 in.wg) inlet pressure) The appliance classification (as defined in EN 483) may be any of the

following depending on the chosen flue option: C12 or C32.

2.1

GAS CATEGORIES AND APPLIANCE CLASSIFICATION

2.3

MINIMUM CLEARANCES

Main burner injector ø 1.30 mm x 13 Total water capacity 1 litre Minimum CH system pressure (static head) - Cold 0.5 bar Maximum CH system pressure (static head) - Hot 2.5 bar Empty weight 45.5kg Max lift weight 35kg Total weight (full) 46.5kg Electrical supply 230V - 50 Hz Fuse at 3A Internal fuses

F 4 amp ceramic Maximum power consumption 160W Max CH flow temperature 85°C 185°F Integral expansion vessel capacity 8 ltr. capacity

Minimum clearances for installing and servicing the appliance refer to Fig. 1(b) below.

Gas 15mm compression Central heating flow 22mm compression Central heating return 22mm compression Domestic water inlet 15mm compression Domestic water outlet 15mm compression Pressure relief valve outlet 15mm tail

CONNECTION SIZES

2.4

GENERAL SPECIFICATIONS

1(b)

NOTE: 10mm for normal

operation 450mm for installation and servicing

2.5

OVERALL DIMENTIONS AND MINIMUM CLEARANCES

The Seasonal Efficiency (SEDBUK) is 78.1 % and conforms with Band D. The efficiency value is used in the UK Government Standard Assessment (SAP) for energy rating of dwellings.

Central Max 24 (82,000) 26.6 (90,900) 29.5 (100,890) 9.5 (3.8) Heating Min. 11.6 (39,670) 13.5 (46,220) 15.0 (51,300) 2.5 (1.0)

DHW Max 24 (82,000) 26.6 (90,900) 29.5 (100,890) 9.5 (3.8)

Min. 8.8 (30,000) 11.1 (36,360) 11.8 (40,350) 1.4 (0.5)

Factory 16.7 (57114) 18.6 (60000) 20.6 (70430) 6.0 (2.3) set CH

MODE RATE OUTPUT INPUT INPUT BURNER

Net Gross PRESSURE

kw (Btu/h) kw (Btu/h) kw (Btu/h) mbar (in.wg)

GENERAL

Central Heating

DHW

Max gas rate (after 10 mins operation, i.e. hot) 3.6 m3/h (128 ft3/h) Factory set gas rate (after 10 min operation) 2.0 m3/h (100 ft3/h)

Min. domestic hot water flow rate 2.8 l/min (0.6 gpm) Design domestic hot water performance 13.01 l/min (2.9 gpm) raised 35∞C Max. domestic hot water temperature 73+/-2°C Max. mains water inlet pressure 10 bar (146 psi) Min. mains water inlet pressure for operation 0.3 bar (4.4 psi) Min. mains water inlet pressure for max heat output 1.0 bar (14.6 psi) Max gas rate (after 10 mins operation, i.e. hot) 3.6 m3/h (100 ft3/h)

The Seasonal Efficiency (SEDBUK) is 78.5 % and conforms with Band D. The efficiency value is used in the UK Government Standard Assessment (SAP) for energy rating of dwellings.

Central Max 30 (102,400) 32.6 (111,547) 36.2 (123,800) 14.6 (5.8) Heating Min. 11.0 (37,620) 13.5 (46,220) 14.2 (48,564) 2.4 (1.1)

DHW Max 30 (102,400) 32.6 (111,547) 36.2 (123,800) 14.6 (5.8)

Min. 8.8 (30,000) 11.1 (36,360) 11.8 (40,350) 1.4 (0.5)

Factory 16.7 (57,114) 18.6 (60,000) 20.6 (70,430) 6.0 (2.3) set CH

MODE RATE OUTPUT INPUT INPUT BURNER

Net Gross PRESSURE

kw (Btu/h) kw (Btu/h) kw (Btu/h) mbar (in.wg)

GENERAL

EXAMPLES OF ALTERNATIVE FLUE SYSTEMS

•

STANDARD TELESCOPIC FLUE

•

FLANGED ELBOW

2(a) HORIZONTAL STRAIGHT FLUE

SUPPLIED AS STANDARD

•

FLANGED ELBOW

STANDARD DUCT (telescopic flue outer)

EXTENSION DUCT

2(b) HORIZONTAL STRAIGHT FLUE

•

TERMINAL DUCT

•

EXTENSION DUCT

•

90° EXTENSION ELBOW

•

STANDARD DUCT

•

VERTICAL TURRET SOCKET

2(c) RAISED HORIZONTAL STRAIGHT FLUE

3 COMPONENTS AS SHOWN

•

TERMINAL DUCT

•

EXTENSION DUCT

•

VERTICAL TURRET SOCKET

•

90° EXTENSION ELBOW

•

STANDARD

DUCT

•

90° EXTENSION ELBOW

•

EXTENSION DUCT

2(d) FLUE WITH 90° BEND

•

TERMINAL

DUCT

•

STANDARD DUCT

•

FLANGED ELBOW

•

90° EXTENSION

ELBOW

•

EXTENSION

DUCTS

2(e) HORIZONTAL FLUE WITH 90° BEND

2(f) VERTICAL STRAIGHT FLUE

•

VERTICAL COWL

•

EXTENSION DUCT

•

EXTENSION DUCT

•

EXTENSION DUCT

•

STANDARD DUCT

•

VERTICAL TURRET SOCKET

2(g) OFFSET VERTICAL FLUE

•

EXTENSION DUCTS

•

90° EXTENSION ELBOW

•

FLANGED ELBOW

•

STANDARD DUCT

EXITS APPLIANCE AT REAR OR EITHER SIDE

2(h) TYPICAL VERTICAL INSTALLATION USING 45° ELBOWS

•

VERTICAL

COWL

•

45° ELBOW

•

EXTENSION

DUCT

•

45° EXTENSION

ELBOW

•

STANDARD

DUCT

•

VERTICAL TURRET SOCKET

•

VERTICAL COWL

TERMINAL DUCT (telescopic flue inner)

EXTENSION DUCT

The appliance is supplied complete with a standard telescopic flue kit. This comprises a standard duct and a terminal duct and can be used for flue lengths between 506mm and 820mm without cutting the ducts. To use terminal duct for flue length between 300 and 506 mm the ducts need cutting. Avoid swarf and sharp edges to maintain telescopic function

The following additional concentric kits are available as optional extras. Extension duct (each extension extends the flue length by up to

767 mm) 90° Extension Elbow (Allows an additional bend in the flue

and has an ‘equivalent length’ of 767 mm.) This elbow is mechanically different from the flanged elbow supplied as standard with the appliance, but has the same equivalent length of 767mm.

45° Extension Elbow Allows an additional bend in the flue and has an ‘equivalent length’ of 384mm.

Vertical Turret Socket (for use with elevated horizontal flues and vertical cowls)

Vertical Roof Terminal. (For use where an external wall is not available)

2.6

CONCENTRIC AIR/FLUE DUCT SPECIFICATIONS

SPECIFICATION FOR STANDARD AND EXTENDED STRAIGHT FLUES

(Refer to section 2.6(a) for maximum allowable lengths)

•

‘L’

‘S’

‘L’

‘R’

3(a)

•

‘L’

3(b)

•

Fig 3a - Standard flue assembly using either side or rear outlet.

Flue length ‘L’ (measured from the boiler outlet centre line to the outside wall face) = max 820

‘R’ distance from boiler outlet centre to rear of boiler = 188mm ‘S’ distance fron boiler centre to side of boiler = 225mm (Allow for minimum clearance of 5mm at side of boiler)

Fig 3b - Standard flue assembly with optional straight extensions using either side or rear outlet

Maximum flue length ‘L’ (measured from the boiler outlet centre line to the outside wall face).

Ace = 4000mm, Ace High = 2000mm

These optional kits may be used with the standard flue kit to produce an extensive range of flue options. Examples are illustrated in Figure 2. Variations upon these illustrations may be used providing that the following rules are strictly obeyed.

a) The maximum/minimum permissible allowable length of the flue system is:

Ace

horizontal flue terminal - maximum 4000 mm (118 in) vertical flue terminal - maximum 4618 mm (182 in) horizontal flue terminal - minimum 300mm vertical flue terminal - minimum 565 mm

Ace High

horizontal flue terminal - maximum 2000 mm (157 in) vertical flue terminal - maximum 3851 mm (151 in)

horizontal flue terminal - minimum 300mm vertical flue terminal - minimum 565 mm

•

SPECIFICATION FOR FLUE SYSTEMS WITH AN EXTRA 90° ELBOW

Fig 4 - Use of the flanged elbow, extension(s), 90° extension elbow, and standard flue assembly.

Maximum allowable flue length of ‘a’ + ‘b’ = Ace 3233mm, Ace High 1233mm.

(i.e maximum horizontal flue lengths minus resistive length of 767mm for 90° extension elbow.)

SPECIFICATION FOR FLUE SYSTEMS WITH AN ELEVATED FLUE SYSTEM

SPECIFICATION FOR FLUE SYSTEMS WITH AN ELEVATED FLUE SYSTEM INCORPORATING BENDS

•

Fig 5 - Use the vertical turret socket, 90° extension elbow, standard flue assy & extension(s)

‘a’ measured from the top of the boiler casing to the centre line of the extension elbow.

‘b’ measured from the centre line of the extension elbow to the outside wall face .

Maximum allowable flue length of ‘a’ + ‘b’ = Ace 4000mm, Ace High 2000mm.

Fig 6 - As fig. 5 but with additional 90° extension elbow.

‘a’measured from the top of the boiler casing to the centre line of the extension elbow

‘b’ measured from the centre line of the extension elbow to the centre line of the second extension elbow

‘c’ measured from the centre line of the second extension elbow to the outside wall face.

Maximum allowable flue length of ‘a’ + ‘b’ + ‘c’= Ace 3233mm, Ace High

1233mm.

•

SPECIFICATION FOR VERTICAL FLUE SYSTEMS

Refer to Figures 3 to 7 to determine which option kits are required before commencing the installation.

Installation instructions for installing the appliance with a standard flue and straight extension ducts (Fig. 3) are included in the main text of these instructions (section 4.7). Additional instructions for flue systems incorporating a vertical outlet (Fig. 7) are given in the supplements at the rear of this booklet.

b) The standard terminal must always be fitted horizontally. The

vertical terminal must always be used if a vertical outlet is required.

c) The flue must only terminate in a horizontal or vertical

position. However 90° flue elbows may be used to drop the height of the flue system by 500mm.

d) The flue system must use either a flanged elbow or a vertical

flue turret socket at the entry/exit to the appliance.

e) All joints must be correctly made and secured in accordance

with the installation instructions.

7(a)

•

7(b)

•

Fig 7(a) Vertical flue assembly with:

Vertical turret socket, standard duct, vertical roof terminal and extension(s) where required.

‘L’ measured from the top of the boiler casing to the underside of the air cowl.

Maximum allowable flue length of ‘L’ = Ace 4618mm, Ace High 3851mm

Fig 7(b) - Offset vertical flue

‘a’ measured from the boiler outlet centre line to the centre line of the exension elbow

‘b’ measured from the centre line of the extension elbow to the underside of the air cowl..

Maximum allowable flue length of ‘a’ + ‘b’ = Ace 3084mm, Ace High 2317mm

EXPLODED DIAGRAM (for key no. references see spare parts catalogue)

Drawing amended 8/6/00

HYDRAULIC CIRCUIT

AUTOMATIC AIR VENT

EXPANSION

VESSEL

Heating

Return

PRESSURE

GAUGE

PUMP

Cold

Water IN

Plate Heat Exchanger

Overheat Stat

DHW out

Heating Flow

By-Pass

3 bar Pressure Relief Valve

DOMESTIC HOT WATER

MODE

AUTOMATIC AIR VENT

EXPANSION

VESSEL

Heating

Return

PRESSURE

GAUGE

PUMP

Cold

Water IN

Overheat Stat

DHW out

Heating Flow

By-Pass

3 bar Pressure Relief Valve

CENTRAL HEATING MODE

Plate Heat Exchanger

INSTALLATION REQUIREMENTS

The following limitations MUST be observed when siting the boiler: a) The boiler is not suitable for external installation. The position

selected for installation should be within the building, unless otherwise protected by a suitable enclosure, and MUST allow adequate space for installation, servicing, and operation of the appliance, and for air circulation around it. (Section 2.3 and 3.4)

b) This position MUST allow for a suitable flue system and

terminal position. (Section 2.6 and 3.3) The combination boiler must be installed on a flat vertical wall which is capable of supporting the weight of the appliance and any ancillary equipment.

c) If the combination boiler is to be fitted in a timber framed

building it should be fitted in accordance with the British Gas publication ‘Guide for Gas Installations In Timber Frame Housing’, Institute of Gas Engineers document IGE/UP-7. If in doubt, advice must be sought from the Local Gas Supplier.

d) If the appliance is to be installed in a room containing a bath

or a shower, any electrical switch or control utilising mains electricity must be so situated that it cannot be touched by a person using the bath or shower. Attention is drawn to the requirements of the current l.E.E. Wiring Regulations (BS7671), and in Scotland the electrical provisions of the Building Regulations applicable in Scotland.

e) A compartment used to enclose the appliance MUST be

designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly. BS 6798 gives details of the essential features of cupboard / compartment design, including airing cupboards.

f) Where installation will be in an unusual location, special

procedures may be necessary. BS 6798 gives detailed guidance on this aspect.

3.1

STATUTORY REQUIREMENTS

3.2

BOILER LOCATION

It is the law that all gas appliances are installed by a registered person, in accordance with the rules in force. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with.

In addition to the above regulations, this appliance must be installed in accordance with the current IEE Wiring Regulations for electrical installation, (BS 7671), local building regulations, the Building Standards (Scotland) (Consolidation) Regulations, bye laws of the local water undertaking and Health and Safety Document No. 635 ‘The Electricity at Work Regulations 1989’.

It should also be in accordance with the relevant recommendations in the current editions of the following British Standards and Codes of Practice: BS5449, BS5546, BS5440-1:2000, BS5440-2:2000, BS6798, BS6891, Institute of Gas Engineers document IGE/UP-7, BS7074 (Expansion vessels)

IMPORTANT NOTE: Manufacturer’s instructions must NOT be taken in any way as overriding statutory obligations.

FLUE TERMINAL POSITION

Position Minimum

spacing

A Directly below an openable window, 300mm 12in

air vent, or any other ventilation opening

B Below gutter, drain/soil pipe 75mm 3in C Below eaves 200mm 8in D Below a balcony 200mm 8in E From vertical drain pipes and 150mm 6in

soil pipes

F From internal or external corners 300mm 12in G Above adjacent ground or

balcony level 300mm 12in

H From a surface facing the terminal 600mm 24in I Facing terminals 1200mm 48in J From opening (door/window) in 1200mm 48in

carport into dwelling

K Vertically from a terminal on the 1500mm 60in

same wall

L Horizontally from a terminal on the 300mm 12in

same wall

M Adjacent to opening 300mm 12in N Below carport 600mm 24in O From adjacent wall 300mm 12in P From adjacent opening window 1000mm 40in Q From another terminal 600mm 24in R Minimum height 300mm 12in

GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION)

•

D,N

•

H,I

•

B,C

•

B,C

•

300mm MIN.

•

430 mm MIN.

•

SPECIAL REQUIREMENTS FOR A VERTICALLY BALANCED FLUE

3.3

FLUE TERMINAL POSITION

Detailed recommendations for flue installation are given in BS 5440:1. The following notes are for general guidance.

a) The boiler MUST be installed so that the terminal is exposed to

the external air.

b) It is important that the position of the terminal allows free

passage of air across it at all times.

c) It is ESSENTIAL TO ENSURE that products of combustion

discharging from the terminal cannot re-enter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation / air conditioning.

d) The minimum acceptable dimensions from the terminal to

obstructions and ventilation openings are specified in Fig.12.

e) If the terminal discharges into a pathway or passageway

check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway.

f) Where the lowest part of the terminal is fitted less than 2m

(78ins) above ground, above a balcony or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed guard. (Available as an optional extra)

h) The air inlet / flue outlet duct MUST NOT be closer than

25mm (1in) to combustible material.

i) In certain weather conditions the terminal may emit a plume of

steam. This is normal but positions where this would cause a nuisance should be avoided.

Detailed recommendations for air supply are given in BS 5440:2. The following notes are for general guidance.

a) It is not necessary to have a purpose provided air vent in the

room or internal space in which the appliance is installed.

b) If the boiler is to be installed in a wall cupboard permanent air

vents are required for cooling purposes in the cupboard at both high and low levels. Both air vents must communicate with either the same internal room / space or be on the same wall to external air. Each air vent communicating with another room or internal space must have a minimum effective area of:

Ace - 300cm

(46.5in2)

Ace High - 337cm

(52.in2)

If the ventilation is direct to air from outside the building, the necessary areas quoted above may be halved.

If the cupboard or compartment is full room height (2.3 m min.) then NO purpose made ventilation is required.

3.5

GAS SUPPLY

a) The Gas Supplier should be consulted at the installation

planning stage in order to establish the availability of an adequate supply of gas.

b) An existing service pipe MUST NOT be used without prior

consultation with the Gas Supplier.

c) A gas meter can only be connected by the Gas Supplier or by

their contractor.

d) An existing meter and/or pipework should be of sufficient

size to carry the maximum boiler input plus the demand of any other installed appliance. (BS 6891: 1988). A

minimum of 22mm dia. pipework is required to within 1 metre of the appliance gas cock.

e) The governor at the meter must give a constant outlet pressure

of 20mbar (8 in.wg) when all appliance’s on the system are running.

f) The gas supply line should be purged. WARNING: Before

purging open all doors and windows, also extinguish any cigarettes, pipes, and any other naked lights.

g) The complete installation must be tested for gas soundness .

3.6

CENTRAL HEATING SYSTEMS

a) This appliance is designed for connection to sealed central

heating water systems. Refer to Fig. 15 for a typical system design.

b) A sealed system must only be filled by a competent person. c) The available pump head is given in Fig. 13. d) A minimum heating flow rate corresponding to a heating

differential of 15°C must be obtained at all times.

e) An automatic heating bypass is fitted within the appliance.

However if thermostatic radiator valves are fitted, a radiator must be fitted with two lockshield valves.

f) The following paragraphs outline the specifications of the

items fitted to the boiler.

PUMP

The available head shown in Fig. 13 is that in excess of the appliance hydraulic resistance, i.e. that available for the system.

AVAILABLE PUMP HEAD

3.4

VENTILATION REQUIREMENTS

0 2 4 6 8 101214161820 22

Flow Rate ltr/min

Available Head Metres

2m HEAD

Ace Ace High

Bth/hr. Kw Flow rate ∆t°C Flow rate ∆t°C

82,000 24.00 17.5l/m 20.0 19.5l/m 17.7 72,000 21.00 17.5l/m 17.7 19.5l/m 15.5 65,000 19.00 17.5l/m 15.5 19.5l/m 14.6 61,500 18.00 17.5l/m 13.3 19.5l/m 13.8 30,700 9.00 17.5l/m 7.5

EXPANSION VESSEL

The table below shows the maximum system volume that the integral expansion vessel can sustain under different charge pressure conditions (pre-charged to 0.75 bar). If the system volume exceeds that shown, an additional expansion vessel must be fitted and connected to the heating system primary return pipe as close as possible to the appliance. If an extra vessel is required, ensure that the total capacity of both vessels is adequate. Further details are available in the current issues of BS5449 and BS6798.

NOTE: If the pressure gauge indicates 2.65 bar or greater when the appliance is at maximum temperature with all radiators in circulation an extra expansion vessel is required.

PRESSURE GAUGE A pressure gauge is situated on the appliance control panel.

PRESSURE RELIEF VALVE A pressure relief valve set at 3 bar (43.5 psi) is supplied with the appliance.

a) Check that the mains water pressure is sufficient (as stated in

2.4 “General Specification”) to produce the required DHW flow rate, but does not exceed the maximum DHW pressure (10 bar). If necessary, a pressure reducing valve must be fitted to the mains supply before the DHW inlet connection.

b) The final 600mm (24in) of the mains supply pipe to the boiler

must be copper.

c) Avoid long DHW pipe runs and several hot water draw off

points

d) Insulate the Hot water pipes if accessible to minimise the heat

losses within the pipes to keep the water hot longer.

e) A domestic hot water regulator is fitted within the group set to

control the maximum water flow rate. This may be removed to

obtain higher flow rates. Higher flow rates will not damage the appliance but may reduce the water temperature below an acceptable level.

f) If the appliance is installed in an area where the temporary

hardness of the water supply is high, say over 150ppm, the fitting of an in-line scale inhibitor may be an advantage. Consult the Local Water Supplier if in doubt.

g) For specific information relating to fittings (eg. Showers,

Washing Machines etc) suitable for connection in the DHW circuit, consult the Local Water Supplier. However the following information is given for guidance:

DOMESTIC HOT/COLD WATER SUPPLY TAPS AND MIXING TAPS. All equipment designed for use at mains

water pressure is suitable. SHOWERS & BIDETS. Any mains pressure shower or bidet

complying with the Local Water Undertaking bylaws is suitable.

h) Consider IRN 116 and Byelaw 90 + 91. Ensure that

necessary action have been carried out to account for thermal expansion of water. If thermal expansion is not provided then high water pressure may result in damaging to fittings and devices.

a) Wiring external to the appliance must be in accordance with

the current l.E.E. Wiring Regulations (BS 7671) for electrical installation and any local regulations which apply.

b) The mains cable must be at least 0.75mm

(24/0.2mm)

PVC Insulated to BS6500 table 16.

c) THIS APPLIANCE MUST BE EARTHED. (Failure to provide

a satisfactory Earth connection will result in appliance malfunction)

d) The method of connection to the mains supply must facilitate

complete electrical isolation of the appliance. Either a 3A Fused three pin plug and unswitched shuttered socket outlet, both complying with BS1363, or a 3A fused double pole switch having a 3mm contact separation in both poles and serving only the boiler (and its external controls) may be used.

The appliance may be used with any Certificated mains voltage room thermostat and/or single channel programmer as described in section 4.8.

3.7

DOMESTIC HOT WATER SYSTEM

3.8

ELECTRICITY SUPPLY

3.9

EXTERNAL CONTROLS

EXPANSION VESSEL REQUIREMENTS

Vessel charge and initial system pressure

Total water content of system using 8ltr. (1.54gal) capacity expansion vessel supplied with appliance

For systems having a larger capacity multiply the total system capacity in litres (gallons) by the factor to obtain the total minimum expansion vessel capacity required litres (gallons)

bar 0.5 0.75 1.0 1.5 psi 7.3 11 14.5 21.8

96ltr 84ltr 73ltr 50ltr

21gal 18gal 16gal 11gal

0.0833 0.093 0.109 0.156

ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM

•

MAINS WATER SUPPLY

•

DOUBLE CHECK VAL VE ASSEMBLY

•

STOP VAL VE

•

STOP VAL VE

•

HEATING SYSTEM RETURN

•

CISTERN & OVERFLOW

•

MAINS WATER SUPPLY

•

PRESSURE PUMP & REDUCING VALVE IF REQUIRED

•

STOP VAL VE

•

HEATING SYSTEM RETURN

FLEXIBLE HOSE UNION TEMPORARY CONNECTION To be removed immediately after filling

RECOMMENDED AND APPROVED METHOD FOR FILLING A CLOSED CIRCUIT IN A HOUSE. (R24-2a WATER REGULATIONS GUIDE)

TYPICAL SYSTEM DESIGN

Note: The boiler incorporates an automatic bypass, hence no other system bypass is necessary. However, it is recommended to fit TRV’s on all radiators except in rooms with a room thermostat.

If no room thermostat is fitted, at least one radiator (preferable in the bathroom) must be permanently open, i.e. fitted with two lockshield valves.

•

APPLIANCE

•

CH FLOW

•

DOMESTIC HOT WATER OUT

•

GAS SUPPLY

•

MAINS IN

•

CH RETURN

•

RADIATOR WITH 2 LOCKSHIELD VALVES IN OPEN POSITION

PRESSURE RELIEF VALVE OUTLET TO DRAIN

•

DOMESTIC HOT WATER

•

DOMESTIC COLD WATER

•

PRESSURE REDUCING VALVE IF REQUIRED

•

BS STOP VALVE (FIXED SPINDLE)

•

MAINS WATER

•

DRAIN COCK AT LOWEST POINT(S) OF SYSTEM

INSTALLING THE APPLIANCE

MOUNTING THE BOILER

PAPER TEMPLATE

Before installing the appliance, check that the chosen location is suitable (section 3.2), and that the requirements for flue position (section 3.3), and minimum clearances (Fig. 1b) are satisfied.

a) Fix the paper template in the required position (ensuring that

the necessary clearances are achieved) and mark the position of the fixing holes as shown in Fig. 16. Three holes are provided at each side of the wall bracket.

4.2

PREPARING THE WALL

4.1

UNPACKING THE APPLIANCE

The appliance and standard flue kit are supplied in a single box. In addition, various optional flue kits are available as described in section 2.6. If the appliance is to be installed without access to an external wall, a wall liner kit is also required.

LOCATING TABS

LIFTING POINT

•

Mark the position of the flue outlet as described in Fig. 18. Mark the position of pressure relief outlet if required and the water and gas connections. Remove the paper template and proceed as follows.

b) Cut the hole in the wall for the air/flue duct. The diameter

must not be less than 100mm and the hole must be horizontal. If the hole is not accessible from outside, it’s minimum diameter must be sufficient to allow insertion of the wall liner (130mm, 5

/4in). The wall liner is available as an optional extra and must be sealed in position with mortar (or equivalent). It is recommended that the flue assembly falls slightly downwards away from the boiler.

c) Drill two fixing holes using a 8mm drill and insert the wall

plugs provided in the hardware pack. If any of the holes fail to provide a secure fixing, use one of the adjacent holes instead.

d) Fix the bracket into position and secure to the wall using the

two screws provided. Ensure it is level.

FLUE

0 100

WALL FIXING HOLES

5 SIDE CLEARANCE 5 SIDE CLEARANCE

65 115

130

18.5 65

146

PRESSURE

RELIEF

CH FLOW

GAS INLET 1/2" BSP

DHW HOT OUTLET

COLD INLET

RETURN

200 CLEARANCE

ABOVE CASE

200 CLEARANCE

BELOW CASE

CENTRE LINE OF BOILER

DETERMINING THE POSITION OF THE AIR/FLUE DUCT HOLE

a) Commission the central heating system as described in section

5.1, then proceed to section 4.5.

a) Use a 15mm copper tube or bend to connect to the gas

service cock to a 15mm compression fitting.

a) Lift the boiler into position using the lifting points shown in

Fig. 17. Position the top of the boiler approximately 10mm above the top of the wall bracket and use the tabs on the wall bracket to locate the boiler in a horizontal direction, then carefully lower the boiler ensuring the two locating tabs are securely engaged (see Fig. 17).

b) Locate and tighten the water and gas valves to the boiler.

(Seals are pre-fitted).

c) Connect the central heating system to the boiler flow and

return using the connections shown in Fig. 19.

d) Connect the mains water supply and outlet to the appropriate

connections as shown in Fig. 19.

4.4

SERVICE CONNECTIONS

4.3

MOUNTING THE BOILER

4.5

GAS CONNECTION

•

PRESSURE RELIEF

45mm

SERVICE CONNECTIONS (rear view)

a) Connect a suitable discharge pipe to the pressure relief valve

tube. The pipe should be a minimum diameter of 15mm copper and should avoid any sharp corners or upward pipe runs where water may be retained. The discharge pipe must terminate in an area where any discharge will not cause a hazard but will be noticed.

4.6

PRESSURE RELIEF VALVE PIPE CONNECTION

•

CENTRAL HEATING FLOW

•

DOMESTIC HOT WATER OUT

•

GAS COCK

•

MAINS COLD WATER IN

•

CENTRAL HEATING RETURN

65mm

133mm

63mm

78mm

18(b) SIDE FLUE

18(a) REAR FLUE

POSITION OF DUCT HOLE

•

POSITION OF WALLPLATE

•

94mm

227.5mm

188mm

94mm

4.7

AIR/FLUE DUCT INSTALLATION

4.7.1

PREPARING THE AIR/FLUE DUCTS

MEASURING THE EXACT FLUE LENGTH

AIR/FLUE DUCT ASSEMBLY

If the wall thickness is less than 800mm (31 in) the air/flue duct may be fitted without access to the external wall providing that the optional wall liner is used. (This is necessary to seal any cavity and to allow the sealing ring to pass through from inside but still open and provide an adequate seal). The wall liner is a tube diameter 130mm with a wall thickness of 0.8mm.

a) Measure the required flue length as shown in Figure 20. Refer

to section 2.6 to determine whether any extension kits are required. Installations using only the standard ducts or standard ducts with straight extensions are described in this section. Installation instructions for all other flue systems are described in the supplements at the rear of this booklet.

b) Fit the external sealing ring to the terminal assembly and

assemble the air/flue ducts as shown in Figure 21. The standard duct is always used at the entry / exit to the boiler, and the sliding (telescopic) terminal is always slid into the end of the standard or extension duct (where appropriate).

c) Achieve the correct flue length using Figure 22 as a guide.

Note that the flue length is measured to the inside of the external wall sealing ring. In most cases it will be possible to achieve the required flue length without cutting the ducts, however where necessary the plain ends of the extension ducts may be cut. Never cut the swaged end, and always ensure that the cut is square and free of burrs or debris. The minimum overlap of the telescopic section is 50mm (2 in).

d) Assemble the flue using Figure 23 as a guide. It is important

that the steps are carried out in the order stated in Figure 23. When securing the ducts in position always drill two 3.3 mm diameter holes in each extension air duct joint and use the self tapping screws provided to secure each joint.

NOTE IT IS ESSENTIAL THAT THE TERMINAL IS FITTED THE CORRECT WAY UP See Fig 21 (i.e. rainshield at the top).

•

STANDARD DUCT Fits Outside Elbow

•

EXTENSION DUCT(S) Fits Over Duct

•

STANDARD TERMINAL Fits Inside Duct

•

EXTERNAL SEALING RING

•

TOP

FAN OUTLET EXTERNAL Dia. 60mm

•

TOTAL FLUE LENGTH FROM FLUE OUTLET CENTRE TO OUTSIDE WALL FACE:

= LENGTH

WALL

•

Ensure the “O” ring (fitted in the flanged end of the flue elbow only) is located correctly.

ACHIEVING THE CORRECT FLUE LENGTH

ASSEMBLING THE FLUE SYSTEM

•

INSIDE EDGE OF EXTERNAL SEAL IN POSITION ON AIR DUCT

•

767mm EXTENSION

MIN. OVERLAP 50mm (2in)

425mm

76mm

MAX. 319mm

•

TOP

•

1 SLIDE EXTERNAL SEALING RING UPTO FLUE TERMINAL

STANDARD DUCT Push ducts fully over elbow and drill two 3·3mm dia. holes. Secure with self tapping screws

•

3 EXTENSION

Push extension duct (if required) over standard duct, engage fully. Drill two 3·3mm dia. holes and secure with self-tapping screws

Drill and screw telescopic overlap

5 STANDARD

TERMINAL Slide telescopic section to achieve length ‘L’

Check terminal is correctly aligned (see Fig. 27)

•

INTERNAL SEALING RING

•

17mm

•

FITTING THE FLUE RESTRICTOR

•

FLUE RESTRICTOR

•

APPLIANCE TOP

FLUE RESTRICTOR LOCATION

(Do not disturb if extension ducts are to be fitted)

90° ELBOW

ALUMINIUM FAN OUTLET

RESTRICTOR

•

4.7.2

FLUE RESTRICTOR

A flue restrictor is supplied with the appliance for use, only if no extensions or additional flue extension elbows are fitted.

If any extension ducts or additional elbows etc are to be used, proceed to section 4.7.3.

If only the standard flue components (i.e. those packed in the same carton as the appliance) are to be used fit the restrictor as follows:

a)) Note the position of the flue restrictor ring. This is fitted on top

of the appliance and is secured by the air pressure switch bracket screws (Fig. 24). Loosen the air pressure switch screw by 1/2 turn only, to release the ring, and tighten the two screws.

b) Fit the restrictor ring inside the flue elbow bottom as shown in

figure 25 ensuring that it is the correct way round.

NOTES (i) Failing to fit the restrictor when installing the appliance with a

standard flue system will not provide optimum appliance performance.

(iii)Fitting the restrictor on a flue system incorporating extensions

or additional bends will adversely affect performance and

TOP

4.7.3

INSTALLING THE AIR/FLUE DUCT FROM INSIDE THE ROOM

Wall thickness up to 800 mm (31in) only. a) Push the terminal through the wall liner taking care to ensure that

the terminal is the correct way round and the external wall sealing ring does not become dislodged.

b) Pull the flue system towards the boiler to seat the external sealing

ring against the outside wall and secure the elbow to the boiler using the four screws provided.

c) Finally use the internal sealing ring to make good the internal

hole, and check that the terminal is correctly located on the outside wall (Where possible this should be visually checked from outside the building).

Figure 26 shows a view of the flue system correctly installed.

d) Assemble as shown in Figure 26.

•

2 ALIGN ASSEMBLED

FLUE SYSTEM ELBOW TO APPLIANCE AND SECURE

3 SLIDE INTERNAL

WALL SEALING RING TO WALL TO FORM A GOOD SEAL

1 INSERT

ASSEMBLED FLUE SYSTEM FROM INSIDE THE ROOM. EXTERNAL WALL SEALING RING OPENS

•

EXTERNAL WALL SEALING RING

130mm Dia.

HOLE WITH

WALL LINER

INTERNAL WALL

SEALING RING

TOP

•

FIBRE SEAL FITTED

INSTALLING THE FLUE SYSTEM FROM INSIDE THE ROOM

may constitute a safety hazard.

(iii)Failing to comply with these instructions will invaildate the

appliance Certification and therefore may contravene the appropriate EC legislation and local statutory requirements..

ELECTRICAL CONNECTIONS (rear view)

INSTALLING THE FLUE SYSTEM FROM OUTSIDE THE BUILDING

4.8

WIRING INSTRUCTIONS

Connect the electricy supply and external controls (using suitable mains cable) as follows:

Wire the cable(s) into the appropriate connections in the electrical plug provided (Figure 28). Live supply to L2, Neutral and Earth as indicated. Check that L1 and L3 are linked.

To provide correct cable retention, fit the piece of tubing supplied over the cable as it passes through the clamping arrangement. The cable will be held in position as the plug cover is fitted.

If a room thermostat is to be fitted remove the red link between L1 and L3 and connect the thermostat across these terminals. Any external controls fitted must be rated at 230V 50Hz and have voltfree contacts.

NOTE: Assuming that the appliance is to be commissioned immediately after installation it is not necessary to fit the casing panels at this stage.

•

4 REFIT AND SECURE

ELBOW TO AIR DUCT, THEN TO APPLIANCE

1 FIT ELBOW

(AFTER SETTING CORRECT LENGTH AND ALIGNMENT)

3 SLIDE INTERNAL

WALL SEALING RING OVER AIRDUCT. PUSH AGAINST THE WALL TO FORM A GOOD SEAL

2 INSERT FLUE

LENGTHS FROM OUTSIDE THE ROOM. ENSURE EXTERNAL WALL SEALING RING FORMS A GOOD SEAL

•

EXTERNAL WALL SEALING RING

TOP

100mm

Dia. HOLE

INTERNAL WALL

SEALING RING

•

FIBRE SEAL FITTED

(Flue hole diameter 100mm - wall liner not necessary) a) Secure the flue elbow with seals and flue adaptor (where

necessary) to the appliance using the 4 screws provided.

b) Fit external wall sealing ring over flue and then from outside

the building, push the flue system through the wall taking care to ensure that the terminal is the correct way around.

c) Fit the internal wall sealing ring over the inside end of the flue,

then fit the air duct to the elbow, drill and secure with the two screws.

d) Pull the flue system towards the boiler to seat the external

sealing ring against the outside wall and secure the air duct to the elbow using the two screws provided.

e) Finally use the internal sealing ring to make good the internal

hole. Check that the external wall sealing ring is correctly located, on the outside wall from outside the building.

Figure 27 shows a view of the flue system, correctly installed.

4.7.4

INSTALLING THE AIR/FLUE DUCT FROM OUTSIDE THE BUILDING

Note: If room thermostat is to be fitted remove the link and connect room thermostat across L1 and L3.

Note: It is recommended, where possible, to flush the CH system without the boiler fitted, to avoid debris

and flux blocking the plate heat exchanger. 1 Check that the CH flow and return valves are in the open position. 2 Fill the system with water using one of the approved methods described in section 3.6 to about 2.0 bar. Vent the system via the

radiator valves and system air vents in accordance with normal practice. Ensure that all system air vents are closed.

3 Check the system for soundness. 4 Check the operation of the pressure relief valve (Fig. 32) by rotating the plastic head anticlockwise 1/4 of a turn and checking

that water is discharged. Ensure that the valve seats correctly and does not leak. If the valve leaks or is stuck closed, replace it..

5 Drain the entire system to flush out any debris, and refill to 0.2 bar above the system design pressure (between 0.5 and 1.5

bar) by repeating the above procedure. Follow the commissioning procedure described below, then repeat this instruction with the system hot. It is recommended that the system is cleaned with a recognised system cleaner such as Fernox or Sentinel.

6 Open the DHW inlet valve and open and close each hot water tap in turn to clear all the air from the pipes and the boiler. 7 Remove the pump end cap and rotate the rotor, replace the cap. 8 If filling loop is used, disconnect filling loop. 9 Prior to firing up the boiler to check the gas rates, the Central Heating and Boiler system should be checked for circulation by

running the boiler and pump with gas turned off, to ensure no air locks occur.

COMMISSIONING AND TESTING

5.1

FILLING THE WATER SYSTEMS

Before commissioning the appliance, the whole gas installation including the meter MUST be purged and tested for gas soundness in accordance with BS 6891:1988.

IMPORTANT: Open all doors and windows, extinguish naked lights, and DO NOT SMOKE whilst purging the gas line.

Before commencing the commissioning procedure, ensure that the gas service cock is turned on, the electricity supply is isolated, and that the DHW and CH pipe work is complete.

Fill the water systems by following the procedure detailed below Fig 29, steps 1 to 9.

VALVE POSITIONS FOR COMMISSIONING THE WATER SYSTEM

(rear view)

•

PRESSURE RELIEF

•

CENTRAL HEATING FLOW

•

DOMESTIC HOT WATER OUT

•

GAS COCK

•

MAINS COLD WATER IN

CENTRAL HEATING RETURN

•

5.2

COMMISSIONING THE APPLIANCE

a) Loosen the screw and connect a manometer to the burner

pressure test point on the gas valve (Fig. 35).

b) Turn the hot water control (Fig. 30) to maximum (fully

clockwise). Turn on the electrical supply and select the Hot Water position on the Main Switch – the Power On LED will be illuminated.

c) Fully open any DHW tap and the ignition sequence will

commence. The Hot Water and the Burner On LEDs will be illuminated. If the burner fails to light, ignition lock-out occurs. In the event of ignition Lock-out the safety Lock-out LED will be illuminated. To re-set the appliance and initiate a further ignition attempt it is necessary to turn the Main Switch through to the Reset position (spring return).

d) After ignition, allow the boiler to run for at least 10 minutes

and check that the burner pressure is as stated on the data badge ±10%. The DHW burner pressure is factory set and should not require adjusting. If the burner pressure is low, check that the appliance has not started to modulate (This will occur if the DHW flow rate is low. If modulation is suspected, open all DHW taps to maximise flow and re-check burner

pressure) If it is necessary to adjust the DHW burner pressure the method is described in section 9.6 Gas valve replacement.

e) Close the DHW tap and ensure that the Burner On LED (Fig. 30)

goes off, the burner goes out, and the pump stops after an overrun period.

f) Ensure that the room thermostat (if fitted) is calling for heat. Turn

the Main Switch to Heating & Water and turn the heating control knob (Fig. 30) to maximum (fully clockwise), and finally turn the clock override switch (Fig. 30) to the I position. The burner will light at an ignition gas rate of approx. 5 mbar. After ignition the burner pressure drops to approx. 1.3 mbar and over a period of time the heating load will ramp up to factory set burner pressure.

NOTE: that the central heating burner pressure is factory set to 6.3 mbar (app. 19.5kW or 66,000 Btu/h, gross heat input) and should not require adjusting. If it is necessary to adjust the CH burner pressure the method is described in section 9.9.1 Gas valve replacement.

g) Set the clock to the desired times by setting the tabs. h) Slide the clock override switch to the 'timed' position and

check the operation of the clock and room thermostat (If fitted).

FASCIA PANEL AND CONTROLS

•

ARROW INDICATES CURRENT TIME

•

CLOCK OVERRIDE

= Continuous ON = Timed = OFF

•

TABS OUT = ON PERIOD

•

TABS IN = OFF PERIOD

5.3

DOMESTIC HOT WATER FLOWRATE

5.4

FINAL CHECKS

FITTING THE CASING PANELS

5.7

FROST PROTECTION

5.8

OTHER FEATURES

5.9

USERS INSTRUCTIONS

A flow regulator is supplied factory fitted to the appliance to ensure that no adjustment is necessary. Should the mains flow rate be below the minimum required it is possible to remove the flow regulator from the appliance as instructed in section 9 (Fig. 37).The nominal preadjusted flow rate may vary by ± 5% due to factory tolerances and mains water pressure fluctuation.

a) Turn the appliance off and remove the manometer and tighten

the burner pressure test point screw. Re-light burner and test for gas soundness.

b) Fit the boiler casing as described and illustrated in Figure 31: Fit

each side panel (both are identical) with two screws at the top and bottom of each panel. Fit the front panel in position and locate by gently sliding it downwards over the supporting tabs. Screw into position using the single fixing screw at the top of the casing.

c) Set the heating and hot water controls (Fig. 30) to the required

settings. Ensure that the clock override switch is in the timed position, and check that the time clock is set at the desired time periods. Set the room thermostat (if fitted) to the required setting.

This appliance is fitted with an overheat thermostat. In the event of overheating, the appliance will shut down and the safety lockout LED will light. If an overheat condition occurs, allow the appliance to cool, then press the overheat reset button once (located underneath the appliance at the left hand side). The Ignition safety lockout LED will also be illuminated and require re-setting. To re-set, turn the main switch through to the Reset position (spring return).

5.5

IGNITION LOCKOUT

5.6

OVERHEAT THERMOSTAT

In the event of an ignition failure, the safety lockout LED will be illuminated. To re-set, turn the main switch through to the Reset position (spring return).

This appliance is fitted with a frost protection device. In the event of very cold conditions the pump may operate and the boiler may light for a few minutes to protect the appliance and system from potential frost damage. This can only function if the gas and electricity supplies are maintained and the main switch on the appliance is left either in the Hot Water or Heating & Water mode. The clock can be switched to the off setting.

The following additional features are included in the appliance specification:

ANTI-CYCLE DEVICE: When the appliance cycles on it’s central heating control setting, a slow cycle device operates. The timer (set to 3 mins) is activated after the end of burn cycle to prevent rapid cycling of the burner.

ANTI PUMP SEIZURE DEVICE:

Providing that a power supply is maintained and the Main Switch is either in the Hot Water or Heating & Water mode, the pump will operate for at least 20 seconds every 23 hours (regardless of heat demand) to prevent pump seizure during periods where the appliance is not used.

WATER FLOW SWITCH:

This device prevents the burner from firing if there is inadequate water flow through the main heat exchanger.

Upon completion of commissioning and testing the system, the installer should draw the user's attention to the following.

a) Give the 'Users Instructions' to the householder and emphasise their responsibilities under the 'Gas Safety (Installation and Use) Regulations 1996' (as amended).

a) Explain and demonstrate the lighting and shutdown procedures. b) Advise the householder on the efficient use of the system,

including the use and adjustment of all system controls for both DHW and CH.

c) Advise the user of the precautions necessary to prevent damage

to the system, and to the building, in the event of the system remaining inoperative during frost conditions.

d) Explain the function of the boiler overheat thermostat, and how

to re-set it. Emphasise that if cut-out persists, the boiler should be turned off and the installer or service engineer consulted.

e) Stress the importance of an annual service by a registered

heating engineer.

f) The electrical mains supply to the appliance must remain ON

and the Main Switch must left either in the Hot Water or Heating & Water mode for the frost protection circuit to operate.

5.10

BOILER LOGBOOK

A logbook is supplied with this appliance to record installation and commissioning details and make future servicing of the appliance easier.

This logbook forms part of the industry's Benchmark code of practice for the installation, commissioning and servicing of central heating systems.

Please ensure that the logbook is fully completed and left with the customer for future reference along with Users Instructions and this Installation and Servicing Instruction manual.

ROUTINE SERVICING

LOCATION OF SERVICEABLE COMPONENTS

6.1

MAIN BURNER ASSEMBLY

6.2

BURNER INJECTOR

6.3

IGNITION AND DETECTION ELECTRODES

To ensure continued efficient operation of the appliance, 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 adequate. It is the law that any service work must be carried out by a competent person, such as British Gas or other CORGI registered personnel.

The boiler incorporates a flue sampling point on the top panel in front of the flue outlet. If the service engineer has suitable equipment to analyse the flue gas, the plastic cap may be removed and a 6mm inside diameter sample tube fitted. Do not forget to replace the plastic cap after use.

Before commencing any service operation, ISOLATE the mains electrical supply, and TURN OFF the gas supply at the main service cock.

Service the appliance by following the full procedure detailed below:

a) Remove the casing front panel by unscrewing the panel

retaining screw and lifting off the panel.

b) Remove the sealed chamber front panel (4 screws). c) Remove the combustion chamber front panel (7 screws). Take

care not to damage the insulation.

Do not attempt to light the burner with Front Panel removed.

d) Remove the 4 screws securing the burner on the gas manifold. e) Unscrew and remove the two screws securing the control

panel in the upright position and pivot the panel forwards.

f) Remove the two spark and one detection electrode leads from

the electrodes.

Check that the injectors fitted in the gas manifold are free from dirt and debris. If necessary clean the injector orifice carefully using a soft brush or vacuum cleaner. Do not use a wire brush or any abrasive material.

It is not necessary to remove the injectors. If there are signs of injector(s) being blocked please call the Halstead Service Department.

a) Inspect the ignition and detection electrodes in situ. If

necessary clean using a soft brush. If either the electrode or the ceramic insulation show signs of damage or wear, replace the electrode(s).

b) Check that the alignment of the ignition and detection

electrodes are as shown in Figure 34. Adjust by carefully bending the tip of the electrode rod whilst supporting the base of the rod. Do not put any pressure on the ceramic insulation.

g) Remove the burner by lifting it forward with reference to

Figure 33.

h) Inspect and if necessary clean the main burner ports using a

soft brush or vacuum cleaner. Do not use a wire brush or any abrasive material.

•

COMBUSTION CHAMBER FRONT PANEL FIXING SCREWS (7)

•

AUTO AIRVENT

FAN ASSEMBLY BASE PLATE SCREWS

PUMP

GROUP SET

CONTROL COVER

AIR PRESSURE SWITCH & PIPES

DETECTION ELECTRODE

BURNER

IGNITION ELECTRODES

•

GAS CONTROL VALVE

•

PRESSURE RELIEF VAL VE

FAN ASSEMBLY

•

PRESSURE GAUGE

•

OVERHEAT THERMOSTAT

•

CONTROL PANEL

BURNER REMOVAL

ELECTRODE ALIGNMENT

6.5

AIR PRESSURE SWITCH PIPES

6.6

HEAT EXCHANGER

6.7

GENERAL

6.8

RE-ASSEMBLY

6.9

RE-COMMISSIONING

6.10

SEALED WATER SYSTEMS

6.11

FINAL CHECKS

Check that the pressure switch sensing pipes are not blocked or damaged. It is not necessary to remove the air pressure switch, this is not adjustable and does not require any servicing.

a) Inspect the heat exchanger from both above and below the fins. If necessary, clean the fins with a soft, non metallic brush.

a) Check that the combustion chamber insulation is not

damaged.

b) Clean the inside of the sealed chamber using a soft brush or

(preferably) a vacuum cleaner.

c) Check that the sealed chamber front panel seal is intact and in

good condition. Replace if necessary.

Always wear a protective mask when cleaning the appliance.

Re-assemble all components in reverse order except do not pivot the fascia panel back into position or fit the casing front panel until the servicing work has been completed.

When re-fitting the burner it is essential to ensure that the burner is level as shown in Figure 33 and that it is correctly assembled into the injector.

Check that all joints and seals are correctly fitted. Note that fan polarity is immaterial.

a) Loosen the screw at the burner pressure test point and connect a

pressure gauge to this point (Fig. 35). Turn on the gas and electricity supply and light the boiler as described in section 5.2

b) Check the operation of the appliance in both central heating

and DHW modes and ensure that the DHW maximum and minimum burner pressures after ten minutes running are as stated on the data badge.

c) Remove the pressure gauge and tighten the sealing screw.

Re-light the appliance and test for gas soundness.

a) Carefully disconnect the tab connectors on the fan wiring from

the fan.

b) Disconnect the air pressure switch sensing pipes from the fan,

noting their positions

c) Remove the fan assembly by unscrewing the two screws,

lowering the assembly and lifting it forwards.

d) Inspect the fan assembly (especially the impeller and the

venturi) for dirt, damage, or signs of wear. If necessary clean the impeller or/and venturi using a soft brush or vacuum cleaner. Spin the impeller and check that it rotates freely, without noise, and without imbalance. If there is any sign of deterioration or damage, replace the fan.

a) Check the operation of the pressure relief valve as described

in section 5.1.

b) Check the correct operation of the pressure gauge by noting

the reading when cold and check that the pressure increases with temperature. Replace the gauge if readings are suspect.

c) Check that the system is at it's original (cold) design pressure

(indicated by the pointer on the pressure gauge). If necessary, re-pressurise the system as described in section 5.1 and search for and rectify any leaks causing loss of water.

a) Pivot the fascia panel into the upright position and secure with

the two screws, then re-fit the front casing panel (Fig. 31).

b) Return all appliance and external controls (if fitted) to their

original settings.

IGNITION ELECTRODE

DETECTION ELECTRODE (flame sensor)

6.4

FAN ASSEMBLY

12.2

20.0

2.5 ± 0.5

•

INTERNAL WIRING DIAGRAMS

7.1 : FUNCTIONAL FLOW WIRING DIAGRAM

7.2 : ILLUSTRATED WIRING DIAGRAM

FAULT FINDING

8.1

GENERAL

8.2

DIAGNOSTIC INDICATOR LED’S

8.3

IGNITION FAULTS

8.4

DHW FAULT FINDING

8.5

CENTRAL HEATING FAULT FINDING

Before looking for a fault condition, check that: The mains electrical supply is turned on. The clock and / or room thermostat (if fitted) are calling for heat

(CH 'faults' only) The gas service cock is open. The DHW and CH isolation cocks are open. The system is at design pressure. Before attempting any electrical fault finding, always conduct the

preliminary electrical system checks as described in the Instructions for the British Gas Multimeter or other similar instrument.

On completion of any service or fault finding operation involving making or breaking electrical connections always check for EARTH CONTINUITY, POLARITY, and RESISTANCE TO EARTH.

Detailed procedures for replacing faulty components are described in section 9 (Parts Replacement)

The LEDs on the fascia panel (Fig. 30) show the status of the boiler as described below:

Power ON LED illuminated. (Green): Boiler is in service. If no other LEDs are illuminated, the appliance is awaiting a demand for heating or hot water.

Burner ON LED illuminated (Green): Burner is alight. Hot Water LED illuminated (Green): Boiler is in DHW mode. Heating LED illuminated (Green): Boiler is in Heating mode. Safety Lockout LED illuminated (Red): Burner has failed to light

and gone to ignition lock-out and possibly overheat cut-out. Re-set the appliance by turning the mains switch through to the Reset position (spring return) and if necessary, re-set the button on the overheat thermostat (left hand underside of casing).

NOTE: There may be a fault condition preventing ongoing operation of the appliance. Follow fault finding procedure.

In the event of the boiler failing to light, investigate the problem by following the flow chart.

When the hot water tap is turned on, the controls should carry out a set of start up checks (flow chart 1) followed by an ignition sequence (flow chart 2)

If the control has powered up correctly but does not respond to a DHW demand, investigate in the following order:

Check for 0V d.c. across pins 10 and 11 on X4. If 5V is present across pins 10 and 11 check water flow switch and wiring.

If 0V is present, check DHW thermistor and wiring. If DHW thermistor and wiring are OK, replace PCB.

If DHW temperature heavily fluctuates during a long draw off and occasionally goes in an overheat Lock-out condition, check the secondary plate heat exchanger for debris and replace.

Upon a demand for Central Heating, (closure of the time switch and room thermostat if fitted) the appliance should respond to the demand.

If the control does not respond to a CH demand, investigate in the following order:

If 230 Va.c. is present across pins 1 and 2 on X1 but no start up procedure occurs ensure that the control is not in anti-cycle mode by removing power from the control and restoring it after a delay of 10 seconds, or open a hot water tap for a few seconds.

If the control still does not carry out start up checks, check CH thermistor (pins 12 and 13 on X4) and wiring.

If CH thermistor and wiring are okay, replace PCB.

NOTE: Whenever a CH demand is removed, either by the timer, the room thermostat or the boiler internal temperature control, an anti cycle mode is initiated which prevents the boiler firing in CH mode for 3 minutes.

FLOW CHART 1: START/POWER UP FAULT FINDING

FLOW CHART 2: IGNITION SYSTEM FAULT FINDING

YES YES

Is APS in closed

position

Check overheat thermostat and

RESET if necessary

YES

When fan stops is

red LED (Safety lockout)

illuminating?

YES YES

Replace flow switch

Check water pressure. Switch

mains off to reset flow switch.

Does green LED continue to blink

When fan stops is green

LED (Power ON) blinking?

YESNO YES

Is APS in closed

position?

Is 230V present across

pins 7 and 8 on X6?

Replace

PCB

Start

YES

NO NO

YES

Is 230V present across

pins 1 and 2 on X1

Gain access to boiler

control then switch on

electrical supply

Turn Main Switch to

Heating & Water mode

Is green LED (Power ON)

illuminating?

Activate a heat demand via

Timer/Roomstat or open

a hot water tap

Is the pump running?

Is the fan running?

Replace APS

Re-check main connector at

the back including fused outlet

Check PCB F4 Amp fuse, if

blown replace. If fuse OK

replace board

Check pump rotation

Is 230V present across

pins 1 and 3 on X3?

Replace

PCB

Replace fan

YES

Start

YES

Is green LED (Power ON) illuminating, primary flow

switch contacts closed?

Replace

flow switch

Turn Mains Switch to

Heating and Water mode

PCB should carry out APS,

pump flow switch and

overheat checks

Is red LED (Safety Lockout)

illuminating?

Are sparks present at

the spark electrode?

Is the burner light and

the green LED (Burner ON)

illuminated?

Does burner remain lit?

Ignition sequence complete

Is green LED (Power ON)

blinking

See Chart 1

Is spark gap distance to

burner as described in Fig. 35?

Re-adjust as necessary

Is 230V DC present across

pins 4 & 3 0n X6

Check polarity, i.e. is Live and

Neutral to boiler crossed

Check Detection electrode.

Replace as necessary

Check water pressure.Switch

mains off to reset flow switch.

Does green LED continue to blink.

Replace PCB

Replace gas valve

Replace PCB

Note: An anti-cycle timer is built into the control system. If the appliance does not light, wait a minimum of three minutes before restarting the boiler.

REPLACEMENT OF PARTS

9.1

HEAT EXCHANGER

9.2

COMBUSTION CHAMBER INSULATION

9.3

FAN ASSEMBLY

9.4

BURNER

9.5

IGNITION & DETECTION ELECTRODES

9.6.1

GAS CONTROL REPLACEMENT

a) Remove the casing front panel by unscrewing the retaining

screw (on top of panel) and lifting off the casing panel.

b) Remove the sealed chamber front panel (4 screws). c) Remove the nut securing the burner to the burner locating

bracket (and burner earth wire).

d) Remove the combustion chamber front panel and burner locating

bracket (7 screws). Take care not to damage the insulation.

e) Unscrew and remove the two screws securing the fascia panel

in the upright position and pivot the control panel forwards.

f) Remove the three electrode leads from the electrodes and

unclip the grommet in the bulkhead below the burner to release the earth, ignition, and detection wires.

g) Unscrew and remove the four screws securing the burner to

the gas manifold and remove the burner by sliding it forwards with reference to Figure 33.

h) Turn the CH flow and return valves to the closed position to

isolate the boiler. Drain the appliance.

i) Carefully remove the LH combustion chamber insulation panel,

the clip must first be removed from the rear LH lower corner of the combustion chamber, to reveal an access hole to the heat exchanger union connections.

j) Using a suitable spanner, unscrew the heat exchanger

connections from inside the combustion chamber.

k) Lift the heat exchanger clear of the two pipes, then remove the

heat exchanger by sliding it forwards.

l) Replace the heat exchanger and re-assemble in reverse order.

Ensure that all joints and seals are correctly re-fitted and recommission the system using the procedure in section 5.1.

a) Remove the burner as described in section 9.1 steps (a) to (g). b) Transfer the ignition and detection electrodes to the new

burner and check that their alignment is as detailed in figure

34.

c) Replace the burner (with reference to figure 33) and re-

assemble in reverse order. Ensure that all joints and seals are correctly re-fitted.

a) Remove the burner as described in section 9.1 steps (a) to (g). b) Replace the ignition and /or detection electrode(s) and check

that both electrodes are aligned as detailed in figure 34. Re-assemble in reverse order. Ensure that all joints and seals

are correctly re-fitted.

a) Remove the casing front panel (as described in section 9.1

step (a) and lower the controls fascia panel after removing the two retaining screws.

b) Carefully pull off the electrical connector plug from the

multifunctional gas control (Fig. 35)

c) Check that the gas service cock is turned off, and unscrew the

union on the gas cock followed by the four screws securing the inlet flange of the gas control

d) Remove the four screws securing the outlet flange to the gas

control.

e) Replace the multifunctional gas control and reassemble in

reverse order ensuring that the ‘O’ rings are correctly fitted.

The design of the appliance is such that the combustion chamber insulation should not require replacement unless mechanically damaged. It is recommended that the insulation is dampened prior to removal to prevent dust.

a) To replace the combustion chamber insulation front panel

remove the front panel as described in section 9.1 steps (a) to (c) and replace the insulation.

b) To replace the combustion chamber insulation side and rear

panels remove the heat exchanger as described in section 9.1 and replace the insulation.

c) Re-assemble in reverse order. Ensure that all joints and seals

are correctly re-fitted and re-commission the system (if necessary) using the procedure in section 5.1.

It is recommended that a protective mask is worn when changing or handling the insulation material.

a) Gain access to the fan assembly by following section 9.1

steps (a) to (d).

b) Carefully disconnect the tab connectors on the fan wiring. c) Disconnect the air pressure switch sensing pipes from the fan,

noting their position.

d) Remove the fan assembly by unscrewing the two screws,

lowering the assembly and lifting it forwards.

e) Replace the fan assembly and re-assemble in reverse order.

Ensure that all joints and seals are correctly re-fitted. (Polarity is immaterial on the fan connections.)

Before commencing any service operation, ISOLATE the mains electrical supply, and TURN OFF the gas supply at the main service cock.

It is the law that any service work must be carried out by a registered person.

9.6

MULTIFUNCTIONAL GAS CONTROL

9.7

AIR PRESSURE SWITCH

9.8

OVERHEAT THERMOSTAT

9.9

PCB

a) Remove the casing front panel and lower the control fascia

panel as described in section 9.6.1 step (a).

b) Remove the PCB plastic cover (Fig. 32).

a) Remove the casing front panel as described in section 9.1 step

(a) and remove the sealed chamber front panel (4 screws).

b) Disconnect the pressure sensing pipes from the pressure switch

(note that the short pipe (from the flue gas sampling point) is connected to the rear (-ve) connection on the pressure switch).

c) Unscrew the two screws securing the pressure switch, and

transfer the electrical connections to the new switch.

d) Fit the new pressure switch and re-assemble in reverse order

referring to the wiring diagrams (section 7) if necessary.

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Unclip the thermostat phial from the pipe, and disconnect the

two electrical connections (Fig. 36).

c) Unscrew the four screws (underneath) securing the appliance

base plate and controls fascia panel. Carefully support the fascia panel and unscrew the nut securing the overheat thermostat.

d) Replace the thermostat and re-assemble in reverse order.

Ensure that the phial is correctly clipped onto the pipe.

g) Set the minimum gas valve stop by adjusting the small screw

on the gas valve (Fig. 35) until the burner pressure is set to

1.3 mbar.

h) Maximum Hot Water Heat Input: On the PCB, turn

potentiometer P3 (max CH set point) to its maximum position (fully anti-clock).

i) Set the maximum gas valve stop by adjusting the large gas

valve screw (behind the screw cap, Fig, 35) until the burner pressure is 9.7 mbar.

j) Minimum CH heat input: Turn the potentiometer P6 until the

burner pressure is set at 2.5 mbar.

k) The maximum CH heat input may be set at any point between

the minimum and maximum gas control setting (originally factory set at 6.3 mbar). This can be adjusted with the potentiometer P3.

l) Isolate the appliance and remove the link between pins 1 and

2 on terminal X4A. Switch the appliance back on at the mains isolation switch.

m) Check that the pressures are correctly set by turning on and off

the DHW tap several times and on each occasion allowing the burner to ignite.

n) Reduce the DHW draw off rate progressivley and check that the

burner pressure reduces in response to DHW temperature rise.

o) Close the DHW tap and ensure that the burner is extinguished

and the pump stops (after a brief overrun period). Remove the pressure gauge, open the DHW tap to re-light the burner and test for gas soundness.

p) Close the DHW tap, re-seal the adjusted potentiometers, re-

assemble the control panel and casing, then set all boiler controls as required.

ELECTRICAL CONNECTOR PLUG

BURNER PRESSURE

GAS INLET PRESSURE

a) Connect a suitable manometer to the gas inlet and burner

pressure test points (see Fig. 35). Turn on the gas supply. Check for gas soundness taking the precautions described in section 5 and re-commission the appliance in accordance with section 5.3. In addition, it will be necessary to set the heat inputs for hot water.

b) Remove PCB cover and establish link between pin 1 and 2

on terminal X4A.

c) Set the Main Switch to the Heating & Water position and the

temperature control knobs to high.

d) Set the clock to the ON position (I) and ensure any external

controls are calling for heat.

e) Ignition: Disconnect spark electrodes and open hot water tap

fully. During the 10 second ignition attempt turn the potentiometer P4 until the burner pressure is approx. 5mbar.

f) Minimum Hot Water Heat Input: Open a hot water tap fully

and as soon as the appliance has lit turn the potentiometer P3 (-CH set point) to its minimum (clockwise) position (Fig. 35a).

9.6.2

GAS CONTROL AND PCB BURNER PRESSURE SETTING PROCEDURE

MAXIMUM GAS VALVE STOP

MINIMUM GAS VALVE STOP

35a

PCB SECTION

•

WATER HOUSING GROUP SET

9.11

THERMISTORS - DHW OR HEATING

The thermistors are immersed in the waterways hence slight water loss is likely during this operation. Provision should be made to collect a small amount of water underneath the appliance.

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Isolate the appliance from the system as follows:

If replacing DHW thermistor turn off the inlet water valve (see section 5) and open all DHW taps to empty the DHW circuit).

If replacing CH thermistor, turn off the boiler flow and return from the system using the isolation valves as shown in section 5.

c) Unclip and remove the electrical connector plug from the

thermistor. Unscrew the thermistor from the waterway.

d) Replace the thermistor and re-assemble in reverse order. Ensure

the copper washers are correctly fitted to provide a sealed joint. Re-commission the system as described in section 5.

PLATE HEAT EXCHANGER

SOCKET HEAD CAPSCREWS (2) (Secure plate heat exchanger)

DHW FLOWSWITCH (Pink Wires)

LARGE BRASS NUT (Water flow regulator behind)

DHW PRESSURE SENSING PIPES

PRESSURE RELIEF VAL VE

BYPASS (Underneath)

FLOW SWITCH

SECURING SCREWS (2)

PRIMARY/FLOWSWITCH (Violet Wires)

LARGE HEXAGON NUT

‘O’ RING SEAL

FILTER

WATER FLOW REGULATOR (Small diameter towards small hexagonal nut)

SMALL HEXAGONAL NUT

PUMP

DHW THERMISTOR (Black Wires) CH THERMISTOR (Grey Wires)

9.10

CH/DHW MICROSWITCH

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Release the appropriate micro switch assembly from the spindle

by sliding out the retaining spring clip (Refer to figure 37).

c) Unscrew the three screws fixing the plastic housing halves

together and slide the micro switch forwards to release it from the housing.

d) Transfer the electrical connections to the new micro switch, fit the

new micro switch and re-assemble in reverse order.

9.9.1

a) On completion of replacing the PCB the CH maximum heat

input will require setting.

b) Connect a suitable manometer to the gas inlet and burner

pressure test points (see Fig. 35).

c) Set the clock to the ON position (I) and ensure any external

controls are calling for heat.

d) Set the Main Switch to the Heating & Water position and turn

the temperature control knobs to high.

e) Wait until appliance has lit (in CH mode only) and turn

potentiometer P3 (max CH set point) to the required burner pressure between 9.7 and 1.3 mbar (originally factory set at

6.3mb)

PCB CH HEAT INPUT SETTING PROCEDURE

OVERHEAT THERMOSTAT

PHIAL

PIPE CLIP

ELECTRICAL CONNECTIONS

SECURING NUT & OVERHEAT RESET BUTTON

c) Remove carefully the control knob clips holding the control

knob in position and pull out the three control knobs from the front of the fascia panel (Fig. 30).

d) Unclip the electrical connector plugs from the PCB (refer to

section 7).

e) Remove the six self taping screws securing the PCB f) Remove the PCB. Re-assembly is in reverse order

9.14

DHW FLOW SWITCH BODY

9.15

PUMP

9.16

PRESSURE RELIEF VALVE

9.18

AUTO AIR VENT

9.17

PRESSURE GAUGE

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Turn the CH flow and return valves to the closed position to

isolate the boiler (see section 5.1), then drain the appliance.

c) Remove the screw securing the electrical connections cover on

the pump, and remove the electrical connections.

d) Either unscrew the two pump unions and remove the entire

pump (using new sealing gaskets) OR unscrew the four socket head cap screws and remove the pump head only.

e) Replace the pump (or pump head), re-assemble in reverse

order, and re-commission the system as explained in section

5.1.

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Turn the CH flow and return valves to the closed position to

isolate the boiler (see section 5.1), then drain the appliance.

c) Unscrew the union connections to the pressure relief valve,

and remove the valve.

d) Replace the valve, re-assemble in reverse order, and re-

commission the system as explained in section 5.1.

a) Remove the casing front panel and sealed chamber front

panel as described in section 9.1 steps (a) and (b).

b) Remove the combustion chamber front panel and burner

locating bracket (7 screws). Take care not to damage the insulation.

c) Turn the CH flow and return valves to the closed position to

isolate the boiler (see section 5.1), then drain the appliance.

d) Remove the plastic pipe from the top of the air vent, and

unscrew the auto air vent using a suitable pipe wrench.

e) Fit replacement and re-assemble in reverse order.

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Turn the CH flow and return valves to the closed position to

isolate the boiler (see section 5.1), then drain the appliance.

c) Unscrew the pressure gauge connection from the valve

assembly, unclip the pressure gauge head out of the fascia panel, and remove the pressure gauge.

d) Replace the pressure gauge, re-assemble in reverse order, and

re-commission the system as explained in section 5.1.

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Remove the complete controls fascia panel and base plate as

described in section 9.13.

c) Isolate the cold water inlet valve and drain the DHW circuit by

opening all DHW taps.

d) Refer to Figure 38. Unscrew the two screws securing the

switch body to the main brass block. Note the position of the alignment pin.

e) Remove the two spring clips, which secure the pressure

sensing pipes into the switch body and pull out the pipes, taking care to collect any residual water.

f) Remove the switch body by sliding to the right. g) Replace the flow switch and re-assemble in reverse order.

Ensure that the alignment pin is correctly aligned. Re-commission the hot water system as explained in section

5.1.

9.13

DHW HEAT EXCHANGER

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Turn the CH flow and return valves to the closed position to

isolate the boiler (see section 5.1), then drain the appliance.

c) Unscrew the pressure gauge, unplug the PCB connectors from

the PCB, unscrew and remove the base plate and the controls fascia panel from the appliance after disconnecting one end of the restraining lead and the earth lead.

d) Isolate the cold water inlet valve and drain the DHW circuit by

opening all DHW taps.

e) From underneath the appliance, remove the two spring clips

securing the bypass pipe, and pull out the pipe. (Collect any discharged water).

f) Unscrew the two socket head cap screws supporting the heat

exchanger (from above the heat exchanger - see Figure 37) and push the heat exchanger downwards to release it. (Collect any discharged water).

g) Replace the heat exchanger, then re-assemble in reverse order,

ensure the ’O’ ring seals are correctly positioned, and recommission the heating and hot water systems as explained in section 5.

h) Check for leaks.

9.12

WATER FLOW REGULATOR

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Isolate the cold water inlet valve (see section 5.1) and drain

the DHW circuit by opening all DHW taps.

c) Make provision to collect any discharged water and unscrew

and remove the large brass nut (Fig. 37) supporting the regulator assembly.

d) Unscrew the small nut at the opposite end of the assembly and

carefully remove the plastic water regulator. Replace the water flow regulator. Ensure that the regulator is the correct way around (Fig. 37). The filter should be cleaned.

e) Carefully re-assemble in reverse order then re-commission the

DHW circuit as described in section 5.

SHORT PARTS LIST

SUPPLEMENT

Supplementary instructions for flue systems with a vertical outlet.

a) Read the installation requirements and flue specifications

described in section 3.

b) Follow the installation procedure described in section 4 up to

section 4.7 (but making the necessary hole(s) in the ceiling/roof instead of the wall). Use the following instructions in place of section 4.7.

c) Measure the vertical distance from the top of the boiler case to

the roof line (Fig. 39). Use this length to calculate the number of extension ducts required.

d) Starting at the boiler, fit the vertical socket, standard duct and

extensions required. Then fit the adaptors. Ensure that they are in line (level).

e) Now working from outside fit the balanced flue roof terminal,

ensuring the roof flashing and sealing components are secured to the roof.

f) Ensure the inner and outer ducts are correctly fitted to the

adaptor.

Note: All the joints should be secured using the self-tapping screws supplied.

9.19

SYSTEM EXPANSION VESSEL

SHORT PARTS LIST

In the unlikely event of failure of the expansion vessel diaphragm it is acceptable to leave the vessel in position and to fit a replacement vessel (of similar or greater capacity) external to the appliance but as close as possible to the CH return.

To replace the expansion vessel it is necessary to isolate the central heating and DHW systems from the appliance, drain the appliance and remove the appliance from the wall. The vessel can then be unscrewed and replaced.

9.20

TIME CLOCK

a) Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a).

b) Unplug the four electrical connectors from the back of the

clock.

c) Remove the clock from the panel by releasing four retaining

screws, transfer the wires to the new timer (referring to the wiring diagrams in section 7 if necessary), and re-assemble in reverse order.

Key G C Part Description No Makers

No. off Pt No.

1 BURNER (Natural gas) 1 700560 2 MANIFOLD SET (Natural gas) 1 700561 3a IGNITION ELECTRODE L/H 1 500620 3b IGNITION ELECTRODE R/H 1 500621 4 DETECTION ELECTRODE 1 500622 5 GAS CONTROL 1 500616 6 PCB 1 500615 7 AIR PRESSURE SWITCH 1 500592 8 FAN ASSEMBLY 1 988416 9 OVERHEAT THERMOSTAT 1 550519 10 THERMISTOR 2 500590 11 MAIN HEAT EXCHANGER 1 450979 12 DHW HEAT EXCHANGER 1

450997 TEN PLATE

13 PRESSURE RELIEF VALVE 1 450987 14 AUTO AIR VENT 1 450908 15 PRESSURE GAUGE 1 450961 16a PUMP 5M (ACE) 1 851214 16b PUMP 6M (ACE HIGH) 1 851213 17 MICROSWITCH ASSEMBLY 2 500593 18 WATER FLOW REGULATOR 1 19 FLOW SWITCH BODY 1 500594 20 EXPANSION VESSEL 1 450999 21 HEATING CLOCK 1 600520 22 ACE RETURN MANIFOLD 1 500554

450985 TWELVE PLATE

FLUE SYSTEM ASSEMBLY AND DIMENSIONS

•

180mm

430mm

1045mm max

30mm

767mm

425mm

50mm

ACE = 4618 (4 extensions)

BALANCED FLUE

ROOF TERMINAL

•

ROOF LINE

•

100/60mm TO

118/80mm DIA

ADAPTOR

•

100/60mm DIA

EXTENSION DUCT

•

STANDARD DUCT OUTER

SECTION TELESCOPIC

•

100/60mm DIA

EXTENSION DUCT

•

100/60mm DIA

EXTENSION DUCT

•

VERTICAL

SOCKET