Myson Apollo 30Si, Apollo 40Si, Apollo 50Si Installation And Servicing Instructions

lWYSOnr

HEATIh'G

4UC3r24

-01

Apollo

30Si,40Si and

for.

the

wall mounted

G.C. Appliance No's.

Apollo
Apollo 40Si 41 494
Apollo

30Si
50Si

gas

41 494
41 494

37
38
39

50Si

boilers

Read

FOR

instructions

these

Leave

IMPORTANT

USE WITH NATURAL

thoroughly

instructions

these

adjacent to the

GAS ONLY.

before working

gas

on the boiler.

meter.

LIST OF CONTENTS

Section

I
2
3
4
5
6
7
8
9

l0
ll
t2
t3
l4
l5
l6
t7
l8
19

20
2r

22
23

u

Subject Page
Introduction

Technical
Creneral
Delivery

Gas
Electricity
Air

Flue

Boiler location
Important installation noles
Boiler dimensions

Water system schematics 6

Sealed

Instnllation
Commissioning 12
Boiler controls 13
Final
Annual
Lighting
Replacement
Wiring diagrams
Fault
Exploded view
Short

data 3

requirements

supply

supply

supply 4

syslem

position

and

system requirements

procedure

parts

of

guide

parts

handing

assembly and

servicing 14

instructions

finding

list

spare

water and

of

over the

instqllation

gas

connections

3

4
4
4
4

4
5
5
6

7
8

13

15

15
20
23
U
25

you

If

have

model,

boiler
Address for return:

Adminisration

Spare
Curzon Components
Earlsway

Team Valley Trading Estate
Gateshead,
NEII OSA

Page 2

any

your

Tyne

reason

!o compliain of any shortage

name,

address and any

ldanager

Ltd.

Wear

and

of

information

components listed in Figs

which may help

us avoid further

5 or 6, supply a list

error.

of the

item(s)

concerned,

1. INTRODUCTION
These fanned

Apollo

The

models

All
The boilers
THEY MUST NOT

2. TECHNICAL DATA

For

boiler model see

the bottom of tle

draught

boilers are nmge

Apollo
Apollo40 Si:
Apollo 50 Si: I1.7 to

are

are

room-sealed wall mounted

Si: 4.4

30

factory

designed

s€t to the

BE

lighting instruction

inner case

rated

at the

kW

8.8

to

kW

ll.7

8.8 to

14.7

maximum outpuL

for

use only

CONNECTED

just

on

above

borlers are

following

(15

(30

kW

fully

TO A DIRECT CYLINDER.

label

the control box

outputs:

000 to 30 000

000 to40 000

(40

to 50 000

000

pumped

inside the bottom cover or the

for
Btu/h)

Btu/h)

vented

open

(visible

use on

Btu/h)

after removing the bottom

natural

or sealed

data

gas

only,

watcr

plate

and are

systems

on the

cover).

suitable for

with an

inner

case. For serial

rear

or side

indirect hot water

No.

exit flue.

cylinder.

see tag on

Boiler
Burner

type
Burner injector
Pilot

injector

Pilot flame

gap

Spark

lgnition

Weight
Lifting weight

water
Max.
Design
Maximum
Minimum

'

Head loss

Height

(empty)

content

flow

temperature

temperature

static

static

width

Depth

Clearance

required

for
ServrCrng

Flue

terminalsize

Water

I Too 50 mm /2 in't
I

, Fronl | 3fn mm r 1 13,. Inl

I

connections

Gas connection

(installing)

rise

head

head

Bottom

Sides

Aoollo

&ay A82,1013M o.

Furiqas 179500-018

30 Si

bray AEzz+ucr+M

Furigas 175-50G032

40

Aoollo

Si

Apollo

50 Si

Eray 482401

Furioas 1 75-500-01 7

4M or

Bray 16/800 Bray 2811000 Bray 16/1400

Honeywell 4500-41

35 to

08-005

40

3.0 to

lntermittent

.3 kg

27

21.8 kg

gal)

(0.08

litre

0.36

150 mm

(15

0.38 m

|

in) 0.54

100

Compression

(6

mm

fittings

in)

dia. x

above the

lire

0.€
g20c

goc

m

30.5

m

711 mm

mm

340

mm

300

mm

90

mm

5

mm

65

deep

to accept

RpV"

marked

mm long

4.0

mm

oilot

(60

lb)

(48

lb)

gal)

(0.1

(100

ft)

(28

in)
(13%
(113/

(3'r'z

in)

p'.In)

(4

in

point

in)
in)

dia.

copper tube to

highest

QlYzinl

22 mm

424

56/

in

the system

tn

x 2'/z

0.50 lite

0.71

d*9\

852871

(0.11

(28

m

gal)

in)

'

Head loss

litres/h

910

given

(3.3

is

applicable only

gal/min)

for

the

when the flow

40

Apollo

Boiler OuFut

kw

Apollo

30 Si

40

Apollo

Apollo 50

Si

Si

4.4 15

8.8 30 000

8.8 30 000

11.7 40

11.7 40

14.7

Si

and

NOMINAL

Btu/h

50 000

through

1 146 litres/h

the

(4.2

BOILER

kw

000

000

000

5.8

11.0

11.4

14.7

14.9

18.3

boiler

gal/min)

RATINGS

Input

litreVh (2.5

is

690

for

the

Apollo

Btu/h mbar

19

600

37 500

39 000
50 000
50 900
62 500

gal/min)

50

Burner

4.1

14.9

10.0

16.5

9.0

12.2

for

Si.

setting

pressure

the

in wo

6.0

4.4

6.6

3.6

4.9

Apollo

't.6

30 Si,

Page

3

3.

GENERAL

The

boiler
the Building Regulations, Building Standards
Underuking Byelaws and IEE
Detailed recommendations
8S5440:2:1989

Note:

Gas

in

accordance

and

4.
The
In
A plug-in
with
A
A
A
not
casc

of

that

DELIYERY

unit

addition a

external control systems

all

from

lit
Vertex flue

pump

and by-pass

rcquire adjusung and

extension

REQUIREMENTS

must be installed in accordance

Wiring Regulations.

in the following British

stated

are

B55449:1:1977

and

(Installation

Safety

with

the above

safety to

is

delivered

965 mm

progr:rmmer

tie

ensure

in

inside kit
kit

is available

kit is

which increases

that

packagcs (

two

(38

in)

kit is

also available to

is

available

available
allows the

.

and Use)

regulations.

'Jre

law

I

fiuc

extcnsion

shown

which

which

allows the boiler !o

which

combined cold

the

boiler

with:

Regulations 198^l:

Failure

is

comnlied

cased

the

)

is avarlable.

fit inside

in

system

the

enables

posiitions

heieht

The Gas
(Scotland)

to

to 861

Safety

Regulations, Local Building

Standards:

It is

install

applnnces

wit}t.

boiler and

the boiler casing. This

wiring

the

the

feed

(2)

Under no circumstances should more

diagrams supplied

flue/terminal

connecrcd to

be

pump

in

a

vent

and

mm.

(lnstallation

85689l :1988, B56798: 1987,

law

the

conectly could lead

fludterminal

the

assembly to

readily

to be connected directly to the

and Use)

gas

that all

programmer

vertical

a

accessible

Regulations 1984

Regulauons,

appliances

prosecution.

to

assembly type A, B,

simplifies

with

the boiler.

fitted

be

flue

from inside

system.

position,

includes

and the current

Model

855!16:1990, BS5440:l:1990,

installed

are

than

boiler.

by competent

It is in

C, D or E as

two

extension

wiring

and

the building.

in

a

built

The kit includes

local Water

and

your

own

required.

kits

is

suiuble

by-pass

which

issue

of:

persons,

interest,

be used.

for

use

does

an outer

5.
The natural
Apollo30Si:
The
in
Thc

6. ELECTRICITY SUPPLY
210V - 50FIz
and
Fuse
least
All wiring

The
In
Earth

7.
The
If
level
with
as stated
Apollo
If the
and the door

SUPPLY

GAS

gas

requirements

l.l m3/h(37 ft3lh) Apollo40Si: l.4m3lh(51ft3/h)

meter

house.

thc

complete

shuttered socket outlet

the

0.75

appliance

evenl. of an

the

Continuity, Short

AIR

room in

the boiler

and one at

the

30 Si: 99 cm2

boiler

supply

and

installation

via

fused

a

supply

mm2

external to

SUPPLY

which

is installed in

same room

below. The frec

is insulled in

for

A. The minimum requirement

at

3

(24

x

0.2

must

be earthed.

electrical

the

low

level,

or

movemenL

air

pipes

must

must be

double

(both

mm)

the

boiler

fault

Circuit,

boiler

a cupboard or

either dircct

must

be on

area of each

(

15

inz)

cupboard or compartment

a

follows:

are as

be capable of delivering

gas

for

tested

pole

switch

complying

(code

designation HO5

shall

comply

inslallation

after

Polanty

is insnlled

compartment,

to

same

the

vent

Apollo 40

anC

soundness and

with

contact separation of

a

with

the

with

of

ResisLancc

not

docs

the outside air or to a roorn. Both high level

rcquire

wall

to outside air. Both the high level

may

be

133

Si:

quantity

this

purged

requircments

power

for the

VV-F

or HO5

latest IEE Wiring

the

the

appliance,

Eanh.

to

purpose provided

a

permanent

halved

cm2

with

air

ventilation

if

the

(20

inz) Apollo

a door, allow

gas

of

described in 85689l.

as

least 3 mm in

at

BSl363)

of

supply

cable

VVH2-F)

Regulations,

preliminary

vents

are

at

Apollo50Si: 1.8

in

addition

adjacent

is

it

that

specified in table 16

as

and any local

elecnical systems checks must

vent.

air

required in

and

and low

provided

is

50

Si: I 65 cm2

least

100 mm

mt/h(62ft3/h)

the

to

demand

poles

both

to the

should

0re cupboard or compartrncnt,

low level

directly from

clearance between

or

boiler.

PVC

a

be

regulations

air

level vent

(25

in2)

from

any other

preferably

sheathed

856500:1984.

of

vents

must

must each have a free

outside.

the

appliances

fused

a

be carried out i.e.

front

3

flexible

which

apply.

one at high

communicate

of the

pin plug

cord at

area

boiler

FLUESYSTEM

E.
Five

telescopic
The flue
Sizp A:

B: 17l

Siire
Sizr C:

Siz.c D: 362 - 652 mm
Sze
Unless
The following
RearflueA=C+83 mm(3%in)
Where A = required flue
If
Note: The maximum

274 - 478 mm

E: 582 - lW2 mm

otherwise

greater

A is

Poge 4

flue/terminal

lengths

123

are:

-

175 mm

-275mm(GA -

specified

method

than

-

(43A

7

lUAin)

-

(|Glr

l8% in)

-

(l4t/e

251/t in)

-

(23

the C

should be

length, B

1092

mm

allowable

asscmblies

n)

43

in)

size
used

(43

flue length is3022

available and a fixed length,

are

flue/terminal will

to

determine the

=

inside wall

in) one or two

be

required

flue

Side

to

extension

A

side

of boiler and C

(119

mm

965 mm

supplied

=

kits

in).

with

the boiler.

flue/terminal assembly.

B +

C+ 127

may be

mm

=

finished

used.

(5

(38

in)

wall

in),

extension

thickness.

kil

BOILER

9.
The boiler
The

boiler

The

boiler

25 mm

than
25 mm
If

rhe boiler

for

Gas
Gas or
The boiler
Regulations and,
of the troiler
Wherea room-sealed appliance
mains
Where
give

detailed

A

cupboard
cupboard
compartment
The

boiler
for installation any adjacent
The

boiler
allows the
The minimum acceptable

LOCATION
is not suitable
musr be

is

suitable

(l

in)

to

(l

in)

annular

is to be

Installation

from Myson

may

be

in

Scotland,

in a room

electricity

the

should be so situated

installation

guidance

or compartment

or compargnent

design

requires

must

be

passage

free

for external

mounted on a

for installation to a

combustible

Further

space.
installed in a timber
in Timber

Framed Housing"

Heating.

installed

in

any

the electrical

containing

is installed in a room containing abath

boiler

of the

on this aspecl

used to

may

including

airing

only the clearances

kitchen units or

installed so that the

of air across

spacings

table:

installation.

flat wall which

combustible

material.

A metal sleeve should bc

guidance

framed building

room, although

provisions

or shower.

a bath

it

that

cannot be touched

will

in an unusual

be

enclose the boiler

be used

provided

cupboard

stated

fitments may have to be

flue

terminal

it

at all ttmes.

from

terminal to obstructions, corners

the

is

sufficiently

wall e.g.

given

is

reference

particular

of the

in BS5440:l:1990, sub-clauses 3.3 and

it

robust

woo<l

be fitted

should

DM2. If in

attention

Building

by a

position,

must

be designed

it is modified for the

that

installations are

given

in the technical data,

is

exposed to

take the

to

cladding,

installed

provided

surround the airlt'lue tube

to

in accordance with the British Gas

advicc

doubt

is drawn to thc

Standards

applicable

or shower, any
person

special

using

procedures

and constructed

purpose.

in 856798 and

page

3, after

installation. If it is felt

removed.

the external air.

ventilation

and

weight of the boiler.

that the airlflue tube

assembly

assembly to

is not closer

provide

4.2.5.

-

"Cuide

British

of

IEE Wiring

installation

the

must

be sought

rcquirements

in

Scotland

publication

from

the

local

of the current

with respect

region

to

electrical switch or appliance control, utilising

the bath or shower.

may be

B55546

necessary

specifically

Details

of essential

and should be complied

for

It is important that the

openings are

856798

and

pupose.

this

features

extra space

that

position

specificd

855546

and

An existing

of cupboard/

with.

is required

of the terminal

in

following

the

a

Termlnal
Directly
Below
Below eaves
Above adjacent
From vertical soil
From inlernal or
From a surlace
From
Vertically

Horizontally
Adjac€nt
From

*

If

rhe rerminal

shield of ar
**

If

the terminal

a suitable

A

type

r555.

35

guard

The

IMPORTANT

I().

The Apollo is to be used

l.

{Jnly

2.

posltlon

below an openable

gutters,

soil

or a balcony

ground

pipes

external corn€rs

lacino the lerminal

a lerminal

lacing the terminal

lrom a terminal

trom a lerminal on

to an op€ning

an opening

in a car

is fitted

least 750

mm

is fiaed

terminal

protective

Kl

guard

must be securely

INSTALLATION

pumps producing

head

high

30 Si,910litreJh

pump

3. Connect

the

4. Mains electricity
It is important that the

5.
For open

6.

vented

schematics.

7. A
and

system

by-pass

return

pipes
adjust as described
Tbe

8.

9.

system wiring

When

commissioning,

air vent or any other

pipes 75 mm

level

pipes

pipes

or balcony

or drain

window,

or drain

on the same

lhe same wall

window

pod

i.e. door

within

(30
less
must

guard

850

in) in length

than

be

is availble

fitted to the

(34

mm

(6.6

2 m

provided

from Tower Flue

wall

NOTES

only on

fully

at

(33

gaVmin)

in the

and the

polarity

systems
is

essential.

least 1.5 m

and at

in

the commissioning

for

pipe

flow

pump

must

of the

a combined

The by-pass should

away

must be completed

the system

must be

ventilation opening

wall

or window into the

plastic

in)

of a

should be

ft)

and

fitted to the underside of

a balcony, above

above

fitted.

and centrally

pumped

least

Apollo 40

the

as shovrn

systems,

3.35
in

m

house

painted gutter/pipe

or

Components

located over the

with

and

(ll

f0 head

1146litresih

Sior

water

the

system schematics.

ground

Ltd. at:

flue

an

flow rate

at a

(4.2

450 mm

or

gutter/pipe

the

or

above a

Vale Rise, Tonbridge, Kent TN9 1TB, Tcl: 0732

terminal.

indirect

cylinder.

of 690

gaVmin)

always be connected to the boiler to allow the

mains

supply

or close coupled

from

the boiler. Install

is

correct and that the boiler

feed

be of 15 mm

vent must

and

pipe

and

the by-pass as shown

be connected as sho*r

must

be

instructions.

in

accordance

vented

with

and the

the diagrams supplied

pump

running

before the main

Minimum spacing

300 mm

(12

(3

mm

(8

(12

(3

(1

(24

200 mm

300

75 mm

25 mm

600 mm
1200 mm
1500 mm

300 mm

150

(12

mm

1200 mm

(18

in)

of

painted

or

flat roof

Refer

litres/h

for

is

as short

with

which

to

to the

(25

Apollo 50 Si

the

pump

overrun to

adequately earthed.

possible

as

in

water

the

the boiler.

burner

in)

rn)

in;
in)
in)

in)

in)

(48

in)

(60

in)

in)

(6

in)

(48

in)

painted

an aluminium

eaves,

surface.

people

havc

manufacturers

gaVmin)

for

must

function.

in

water system

the

across the

system schematics

is lit.

then

access

instrucLions.

Apollo

the

be used.

22 mm flow

and

Page

5

10. The

system must

heating.

11.

Where

12. In

areas with hard

instructions for

13.

The inner

the

Apollo

casc

of

flushed

be

replaces

an older

twice;

initially

boiler in

cold with

an existing

or aggressive wet€r we recommend

details of

the boiler

use.

should not

be removed

the

system,

that

during

pump

removed
make

Fernox CP3

installation.

and all

valves

open,

and then

sure the cylinder is indirect.

inhibitor

should be

used. See commissioning

after the

first

T1. BOILER DIMENSIONS
Refer
Overall

Clearances

See
Water
connections

12.

a. Fully
The

Some water
b. Length

The
these

F,g.

to

1.

cased dimensions:
Height:
Width:
Depth:

7ll mm
340
300

required for
Top:
Bottom:

Front

Sides:

section 9

connections:

50

90 mm
300 mm

mm

5

for installation

Compression

to accept 22mm

WATER

SYSTEM

pumped

open vented

combined cold feed

authorities

wet

of

and

distance

pipes

between the

should be as

mm
mm

servicin

mm

SCHEMATICS

vent

and

require

vents for

dry

cold feed

close to

AND POSITION

g:

clearances.

fittings

copper tubing

are

to BS287l.

system with

must

rise

from

a stop cock

and

the boiler

close

vent

as

in the

coupled

connection

practicable.

WATER

OF

supplied

combined

the boiler.

feed,

cold

cold

to

for flow

feed

cold

in

which

-

feed

the

system must

AND GAS

CONNECTIONS

and return

-

vent

and

case a separate vent

Fig.

see

3.
not

s€e

be

22 nn
Relurn.

Fig.2.

more

.

145

must

than

zJo

-

be

connected as

150

mm. The

22 mm

-^
Flow

Fig.I

-bE-

shown.

point

of connection

of

The

by-pass

pipe

each

side between it
Always
The

ensure that

flow

through
910 litres/h
Ensure that

Fit

one

more

or

Optronal
Zone
Valves

Optrona

.3

va

Fig.2

the

valve

pump

balancing

the boiler must not

(3.3

gaVmin)

pump

the

is

draining taps

pos

See 8S5449

clause

t

on

ve

should

and the

for

boiler.

has

sufficient

Apollo

the

accessible

(BS2879)

I

Alternative
arrangement

i

cold feed is

I

l

24

be

of a type that is non-adjustable

static head.

be

allowed

40

Si or l146 litres/h

for

servicing.

to enable

vent

It

valved

Check the

fall

ao

below 690 litreVh

Isolating

the

valves

water

(4.2

system

A - length

-

length

B

-

150

C

by the householder

pump

manufacturers

(2.5

ga[min)

gaVmin)

must

to be

for

positioned

be

fully

drained.

the Apollo

of dry venl
ol water filled

mD

min

minimum

for

as close ro

vent

HEATII{G

Bu,n

5C
40

3C 000
20 000

.0

Fig.

3

and musr have

head.

the Apouo

50 Si

while

pump

rhe

30
rhe burner

T

2CDmm

I

LOAD

000

000

000

least 1.5

ar

Si,

possible.

as

VENT

(mm)

A

4n
3(n
z&

140

50

m

is

alight

LENGTH

(mm)

330

m
m
no
no

of 22 mm

Page

6

13. SEALED SYSTEM

Refer
a.
b.

c.
d. A diaphragm

Frg. 4.

to
The installation must
A safety
between
creating
A

must
of
Hot Water"

valve

set to operat€ at 3 bar

the

ahazard

pressure gauge

be chosen tro

valve

safety

to occupants or cause damage !o electrical components and

covering at

type

expansion

suit

connection. Further

published

Sizing table:

REQUTREMENTS

comply

with

and the boiler.

least

vessel,

volume

the

requirements

the

(45

lbf/in2)

The

range 0 m 4

the

to BS48

water in

of

shall be

valve

14,

the system and the

details can be obtained from

British

by

Gas and

BS7074:1.

of

should

bar

shall

be

"Material

856798

fitted in

(0

and

the

positioned

be

lbf6nz;

!o

60

connected

charge

and

BS5449:1.

pipe

flow

on

a discharge

shall be

point

a

at

pressure

Installation

Maximum

close !o the

water

boiler.

pipe fitted

wiring.

fitted

in

the system.

in the return

must

pipe

not be less

Specification

temperature

There must

prcvent

[o

to

close

than the

the

static

for Domestic

is

82oC t

not

be

any

boiler.

head

Central

3oC.

valves

any

discharge

The vessel

point

at the

Heating

and

NiEogen

Air or

Pre-pressurisation

Expansion vessel volume

=

A

The hot water

e.
f. Water lost

volume

System

from the

system on the

provided

g.

The
mains

system may be filled from the mains

pre-pressurisation

by

pressure, provided
perrnanent part
i)
iD
iii)

valve

a stop
a test cock.

anti-vacuum valve

an

iv) a non-return valve

h. Fill

the system until

Refer

to

the

commissioning
Examine for leaks
the required

value.

prsssure

cfiarge

pressure (bar)

(lifes)

(litres)

cylinder shall

either be the

system shall be

return

side

of the cylinder or

that

of fre system and

complying

to tle

of a typ€ approved by the Narional

of an approved

pressure gauge

the

instructions, light

then turn off

The

by-pass

at ieast 1

between it and

Exoansron
Vessel

(bar)

indirect

replaced

the syste.

of

via

procedure

this

fitted

in the order stated:

requiremenLs

type.

registers 1.5

boiler. Drain the

the

balancing valve

5rn of

22mm

the boiler.

0.5 1.0

None

A x 0.07 Ax0.120 A x

coil type

from

a make-up

radiators.

Lemporary hose

a

is

Where

accepuble

BSl0l0:2.

of

(22lbflinz).

bar

boiler and

the

system

must have

pipe

each side

Pressure
Gauge

1.0

cylinder fitted

or a

vessel

non-return valve,

and

access to a make-up

connection

to

the

Water

from

local water

Council.

a draw-off tap

Examine for

allow the

while it is

l5mm

Balancrng

valve

-

systern

hot. Refill,

still

with

authority. The following

Optional
Zone
Valve

None 1.5

0.088

immersion

an

A x 0.160

calorifier.

mounted higher

vessel

would

be difficult,

supplied

leaks

reach

to

and

ils

vent

and adjust

whcre

rectify

maximum working

than the top

make-up

from

a service

pipe

fittings should form

neccssary.

temperature.

the

cold

pressure

fill

the

of

can be

under

to

a

Fig.4

Optronal
3-position
valve

Page 7

INSTALLATION

14.

14.1 Unpack the boiler

Note:

Do

not

stand the

PROCEDUR.E

-

Fig.5.

see

boiler on

its

end as

valve.

Do not

bottom

off the

case

discard the

cover

fixing

from

found.

pulling

the boiler.

the
the

l. Carefully unpack

items

the

are

2. Carefully slide off
Remove the outer case by slackening the

3.

firmly

and

4. Keep the outer case, bottom cover and
place

IF REAR
TO

SECTION

PROCEED

14.2 Prepare the

L Decide upon the

template supplied

not

so as

to damage them

EXIT FLUE IS TO

l42.IFSIDEEXITFLT.IE

TO

SECTION

(rear

wall

position

with

flue).

of the

the boiler.

before fitting.

BE

USED

14A.

boiler

The

using the

overall

clearances.

you

2. When
Make sure

3.

4. Mark
Remove

5.
Reposition the template on the

6.

7. Make a
the
Remove

8.
way

have

decided on the

that the

position

the

the template

note

of the

fl ue/terminal

the template and

(studs

up

at the bottom). Secrrre the

position

the hole for the flue.

of

finished wall

assembly.

(do

position

of the flue terminal

not

discard

i0

wall, mark,

thickness,

position

wall mounting

the

it will damage

packing

boiler.

the

the

until

botlom fixing screw

pins.

panels

infrll

in

a safe

CONTINUE ON

IS TO BEUSED

wall mounting

size

of the template

of the boiler

tape

will meet

cut the I 15 mm

and

drill and

this

plug

the

is

very important

plate

mounting

plate

o

gas

all

t!

plate

mountrng

is

size

the

the

template

the requirements

in) diameter hole in the wall for

@th

hve fixing holes

and

cenrally over the hole

the wall with

of the boiler

to the wall, ensuring it is level

given

to accept

is required for

four

21h" lg. No.12 woodscrews

No 8 x

cover

Flnd these

parls

in the

pack.

Fis.5

plus

minimum

the

and the correct

in

section

9.
flue/terminal

the

215" lg. No.12 woodscrews.

section

in

the wall,

14.5 when
ensuring

adjusting

it is level and

T??TTT??

12 19

scraaa

8 off

6@

nuts

M6

2 off

side, top and bottom

way

up.

assembly.

the length of

right

the

(not

supplied).

14.3

Secure the boiler

Note: The

L Lift

inner

boiler into

the

the boiler

2.

the

Secure
woodscrew

case

wall

to the

bottom

(not

does not

position

of the

supplied)

wall

to the

need

and

mounting

boiler

via

plugged.

Remove

3.
not to damage

4.

Connect the
unions

Refit the flue diverter facing to the rear.

5.

14.4 Unpack the

Carefully
packing

until all the

14.5 Adjust

(rear

flue).

l.

Using

flue/terminal

the

mm

83
terminal flange !o the

1

Note:

2. Drill through
mm drill
No.8 x l0lg.
Note: When
to damage the

3. Seal

the

terminal

flue

the

the

system

(see

water system

diverter

from the

gasket

flow

and

return

schematics, section

flue/terminal assembly - see

unpack

the

the measurement

(3V

Ensure

and

flue/terminal

the

items

length of

found.

are

flue/terminal

the

noted in

the

of

in

holes,

that

OUTER air
the

assembly so

+ finished wall

in)

end

the

that

the

seams

three

pilot

secure the two nrbes ogether using the three

supplied with the flue/terminal

screws

drilling through the outer air tube

inner flue

centre

joint

with the tape

tube

with

assembly.

(rear

flue).

to be removed during

locate

plate

with

wall wildl.

to the

the hole

top of

pipes

the

holes

two

M6 nuts

two

a2th"

previously

the boiler

to the top

compression

l2).

Fig.6.

assembly.

Do

not

assembly

section

thickness,

14.2

it

is:

from

tube as

air tubes are

outer

in Fig. 7, with a 2.8

shown

adjust the

the

shown

assembly.

take

care

drill.

the

supplied

with

the

installatron

in the top

supplied

lg. No.l2

drilled and

care

taking

Fig.

see

length

of the

the

of

discard

-

back

in Fig.

inline.

not

flue/

of the chassis over

with

the boiler.

Clamping

ring 2

gggg

M4 ' 16 19

7

F+

screws

I roll

oi sealing

o

'O'ring

Seal

this

wtth

tape

supplied

Finished

wall thickness

fte studs

off

4

tape

Flue./lerminal

Flnd there

loint

Keeo seams

on the

off

parts

wall

llll

AAAg

x

1"

No. 8
screws 4 of{

ass€mbl!

in lhe

Fig.6

notes

Prlot

In lrne

*

83

mounting

lg

sra nress

pack.

t3 off)

(3%

mm

---

plate.

Outer

Outer seaftng

AAJ

No

lO lg

8'

3 of{

in)

Secure

plate

wall

plate

screws

Page I

Fig. 7

14.6

Fit

the

Note:

If the

need

not be used.

1. Fit

2. Fit

the outer

the
section.
From

3.

outside

wall. Ensure

4. Push
into

the

the

tube slides

into

slides

that the

Check
Push fully home

flue/terminal

wall

is to be

plate

wall

'O'

ring in

position

the building

that the

flue/terminal

flue

diverter

INTO

the

the

diverter.

'O'

ring

until

ess€mbly - s€e Fig. t

good

made

over

up o

flue/terminal

the

over the

the

outer

insert the flue/terminal

slots in

the

end

of the terminal are

assembly lowards the boiler

on

top of the

inner

is

on the boiler'side of the flared section.

the flared

boiler,

of the

tube

end of the ouler

(rear

flue).

terminal,

the

assembly.

air tube

against

assembly into the

and

ensuring that the

diverter and the outer

tube

outer wall

the flared

vertical.

engage

the tube

inner flue

air

in

is

contact with

plate

tube

the

flue

diverter.

Fig.

t

14.7

Connect

l. Fit

that the
the flared

2.

Secure the clamping
the
Tighten

3.

4. Proceed

14.E

Prepare the wall - see Fig. 10

l.

Decide upon
with
minimum side,

the two

flat

the flue

halves

part

to the boiler - see Fig.

of the

side is

against the

of the air

ring

threaded

holes in

the screws to seal

lo section 14.14.

position

the

the boiler. The overall

top and
the longest flue/terminal
the

2. Tape
way

3.

Continue
the

4.

Tape
in

5. Make sure that

in
Mark

6.

of the white

side

wall

the

mounting

up.

line,

the red

wall.

side

side flue template,

the

Lhe corner and that

posirion

the

section

9.

positions

the

of the

case to the OUTSIDE

clamping

wall mounting

tube.

flue diverter

to the

the clamping

flue

the

(side

of the boiler

size

bottom

clearances.

assembly and

template to the

on

the template,

supplied

the line

just

drawn

of the

four wall

ring

ring).

assembly.

of

flue

mounring

(rear

9

over the air

flue).

tube

plate,

using the

flue).

the wall mounting

using

the template is

Note

that

965 mm

two

wall is 2895

of the

wall,

ensuring it

horizontally

with

the boiler,

lines

up

across

with

terminal n ill meet

plate

fixing screw.

7. Drillandplugthefivefixingholes!oaccept2th"
position

8.

Cut

of the hole in the

ll5

the

mm

(4rh

wall for

side

in)

diameter hole in

the

lg. No.l2

flue/terminal

the side

assembly.

9. Make a
the

side

important

10.

Remove the

botrom).

at the

note
of the white case

and are

finished

of tle

required in

templates

Secure

and

the mounting

wall thickness

shown on

as

section

place

the wall mounting

plate

and the

distance

the template. These

14.10 when

adjusting the

plate

!o

the wall with four 21h" lg. No.l2 woodscre*

as shown in Fig.

recessed

the

and

four M4

screws

template

of

size

the

(38

the boiler

maximum

in) flue

extensions) from

distance

mm

is level
the

and the correct

wall until

to the side wall so

red

the

line

on

tie requiremcns

fixing scre

*s

and the lo*er

*mdscre*s.

asse mbly.

wall for

rhe

from

the side

measurements

length

position

in

Ensure

9.

side against

supplied

(use

supplied

plus

the

(using

(114

in).

itreaches

it is

that

the template.

given

\{ark

r}r

flueAcrmrnal

*all

to

ver)'

are

of

flue/termrnal

tlre

on tlre wall

ensuring rr rs le

,!?'

asse

(

nor

s

Fig.9

'.u.r'r€

Fig. I0

mbly.

vel

and the

supplied).

right way

up

(studs

14.9

Secure the boiler to the

Note:

I . Lift

2.

inner

The

the boiler into

the

boiler to

the bouom

Secure

case does

the

plugged.

3. Remove the flue

4.

Connect

5. Refit

6.

Unpack

the

system

flue

the

diverter

the flue/terminal

wall

not

need

position

and

wall mounting

the

of

boiler to

flow

facing

from

return

and

left or right as determined

diverter

assembly as described in

(side

flue).

be removed

to

locate

the wo

plate

with

wall

the

top

the

of the boiler

pipes

during insnllation.

holes

in

the top

nvo M6 nuts

with

lg. No.12 woodscrew

a2l5"

taking care

to the

top compression

section

of fte chassis over the

supplied with the

not

to damage

unions

by the flue

direction.

14.4.

boiler.

(not

(se€

water

studs on the

supplied)

gaskcr-

the

i'ia

system schematics,

wall

mounting

rlre hole

plate.

previously

drilled

section l2).

Page

Secure

and

9

14.10 Adjust the length

l.

Using

length of the

127 mm

the end

to
Where A
between
Note:

2. Drill

2.8
No.8 x l0lg.
Note:
to damage ihe

3. Seal the cenre

m@surements noted in

the

flue/terminal assembly so

(5

in) + A + B,

the

of

OUTER

is

finished wall

the

the side wall and the side of the

Ensure that the seams

through the three

mm

drill and

secure the

screws sup'plied

When drilling through the outer air tube take care not

inner

joint

flue/terminal

the

of

from

the back

air tube as shown

thickness and

in the

pilot

holes,

tubes

two

with

flue tube

with

with

the tape

assembly - see

that

14.8,
it is:

adjust the

section

of the terminal flange

in

Fig. I l.

B is

the distance

white

case.

outer air tubes are

in Fig. I l, with

shown

together using the three

fluelterminal

the

assernbly.

the drill.

supplied

with

the flue/terminal

inline.

Fig. 11

a

(side

flue).

Seal thrs;oint
wrlh
supplied

+--

Finished

assembly.

tape

Keep

seams

wall thickness

Fig.11

Pilor

,

rn lrne

+8+

holes

127 mm

(3

off)

(5

tn)

l4.ll Flue

The flue

be

to
A maximum

extension - see

extension

extended by 965

of two flue

l. If the flue

extension to
assembly. Ensure

terminal

fis INSIDE

the outer aL

kit

allows the standard

mm

extension

extension kit

the

swaged end

thatthe

the

tube fits

OVER the air tube of

Fig. 12
(38

is

(side

in).

may be used,

used, connect the

of

the sondard

innerflue

inner flue

tubeof

tube of the extension and

Push fully home.
Note:

Ensure that the seams

2. Drill three equally

spaced

in

the outer

holes

using a
and the extension tube sleeve. Serure the two
Note:

When drilling through the outer air tube take care

Seal the

3.

4.

Adjust the OVERALL

Fit

14.12

Note:

plate

l. Fit

2. Fit

the flue/terminal

If

the

need not

the outer

'O'

the

with the tape

lrints

wall

is to be made

be us€d.

wall

ring in

length

pssembly -

plate

over the

position

supplied

as described

good

up to the

flue/terminal

over

the outer air tube

section.

From

3.

4.

outside the building

wall. Ensure

that

the slos

Push the flue/terminal assembly towards the

into

tube
flue tube
tube slides
Push

the flue
slides INTO

into

the

fully home

diverter

until the

insert

in

on top of the

inner

the

diverter.

flared

the

the end of the terminal

tube

Check that the

end of the

flue).

flue/terminal

if required.

plain

flue/terminal

the standafiflue/

the extension.

air tubes

mm

2.8

drill

&bes

with

s€€

flue extension.

the

in

section

13

(side

Fig.

terminal, tlre outer

assembly.

flue/terminal

boiler and engage the

ensuring

boiler,

of the

diverter

'O'

ring is on the

outer tube

assembly

end of

the

inline.

are

position

in the

together using

not

to

14.10.

Secure and

flue).

against

assembly

the flared

vertical.

are

that the

into

inner

and the outer

is in

contact

this

Seal
with

shown

the three

damage

loint

tape supplied..

Extension Keeps

seams

Fig.

in Fig. 12,

through

No.8 x l0lg. screws

inner

the

seal

the

flue

joins.

tube

in line

12

with

wall

the

air

boiler side of the flared section.

with

the flue

diverter.

Standard
assemblv

both the standard

flueltermrnal

fluelterminal

supplied with the flue extension.

tlre drill.

14.13

Connect

the

flue

to

the

boiler - see

Fig. 14

(side

flue).

l. FitthetwohalvesoftheclampingringovertheairtubeasshowninFig.14.Ensure

that the
flared

2.

Secure the clamping

flat

part

the threaded
Tighten

3.

4. Make

Page

the screws

good

I0

is

facing

side

of the air tube.

ring

in

holes

the

the clamping ring).

to

seal

gap

on

the

away

the flue

to

the flue
inside

from the

boiler, and the

diverter using the

assembly.

wall

around the

recessed

four M4

flue

tube.

is

side

against the

screws supplied

(use

Fig.14

Fit the outer sealing

14.14
l. Make

good

the outside
Note: The outer sealing
terminal.

2. Place

the outer sealing
fixing holes.
Remove the

3.

sealing

plate
woodscrews.
Note: The terminal

should

terminal.

4. Remove any covering
terminal
terminal

and secure to the

assembly).

-

plate

wall

plate

plate

and drill and

be

Fig. 15.

see

around the

flue duct

need not be used

over

covered

terminal and

the

plug

the

before drilling

from the terminal.

with four I " lg. No.8 screws

wall

if

wall

the

mark the

fixing holes,

prevent

lo

Position

the

is

good

made

position

of

up

the

to

four

suitable for I " lg. No.8

entering the

debris

plate

with

over

the

the

flue/

sealing

(supplied

the

14.15

Connect
Connect a 15
Do not

14.16

Connect
Note: A

mm

turn the

permanent

l. Remove the

2.

Slacken two screws
wires,

brown to

3. Keep

the wiring centre

cable clamp,
power

supply cable.

When

Note:

out of

slips

pump

4. The

lead

wiring centre, and

programmer

If

5.

a

Do

not switch

on the electricity

gas

the

the

supply

gas

supply to the

gas

supply on at

power

live

and

securing the

screw

in the cable clamp below the

L

and blue to N on

tighten

then

connecting

the

cable clamp

and any

connected

is not fitted,

-

see

F

supply

pump

the

in

the open

cable clamp screws.

the

power

the

the

external controls

16.

Fig.

service

this

cock.

stage.

I6

cabh - see

must

be connected to

front

of the

the

terminal

position,

supply cable, ensure that the

live

neutral wires become taut before the

and

wiring should be

to the terminal block. See

remove link HW

supply at

this

Fig. 17.

the

boiler.

wiring

centre and carefully

take

block and
up

wiring

centre.

excess

Check that

Feed the

green

slack

the

and

in

the

wiring

length of

passed

through one or both of the

wiring

diagram

to ON and connect a switched

stage.

iL

lower

power

supply cable under the

yellow

to the earthing screw

power

supply cable between the terminal block and the

will open and

centre

earth wire is such,

the

earth wire.

page

20.
live to

lr

Fis. I7

close

that

bushes,

terminal ON.

Fig. l5

clamp and

(

f

).

wiihout sraining

freely

po*,er

if

the

provided

at

the

connect

supply

cable

rear

of the

the

the

14.17 Remove
l. With the

2.

Unscrew

remove the

If

3.

the

facia

Fit

14.18

1.

With the

2.

Connect

3. Close the

the inner case
wiring
the four

inner

programmer

panel

at this

programmer

the

wiring

programmer

the

wiring

14.19 Complete the
l. Thoroughly

2. With the

flush the

pump

in readiness for commissioning.

centre open slide out

inner case

fixing

screws, two at the top,

case.

kit is

not

to be

fitted

stage.

kit.

lowered,

centre

centre

and

6-pin

secure

engage

plug

in

installation.

whole

system

fitted, fill, vent

and check

the facia

close the

panel

wiring

programmer

the

the

on

centre and secure

to the 6-pin socket on

position

witlr

with

water without

cold

for water

fixing

the

soundness,

of the connol box.

side

one

above the

fixing into

wiring

the

screw.

pump

the

rectifying

gas

in

the slot

centre,

posirion.

in

where

valve

and one

position

in

the conrol

push

fully home

Ensure

necessary.

to

with the

bor

all

left

the

fixing

push

and

until the

valves

*

of thc

inng

scre* . Do

fully

latch

engages.

are open.

centre, and

not

replace the

home.

Page

II

15. COMMISSIONING
for

See section

1. Test for

a.
b. Remove the

c. Loosen the

2. Check the
With the
a. Set the
b. Switch

c.

3. Check the
a.
b. Remove the two screws securing
c. Disconnect and
d.
e.

f.
g.
h.
Test

4.
a. Apply a suitrble

b.

5. Check the
After
a.

b.

c. Set the boiler thermostat switch

d.

Note: The

the
Replace

6.
Replace

7. Replace
a.

b. Ensure that the
c. If

16

gas

soundness

With the boiler service cock closed

pipework

inlet

gas

in

accordance

ignition

gas

supply

programme

on the electricity supply and set

fan

will start

the ignition

ignition

the

the boiler thermostat switch

Set

pilot

Ensure that

Set the
Checkthatthepilotflame(35to40mmlong)envelopstheelecrodeandextendsl0mmpastit.Adjustifnecessary(clockwise
to reduce the flame).
Test the
Set
Replace the

of the
Set the
A
connections

Set the
connect
Set the
Turn the adjusting screw
Note: The

thermostat
suitable
Check
the correct boiler

If
of the control box.

sufficiently to
If

boiler

pilot

the boiler thermostat switch

main

the

gas

valve

boiler

or

second

main

main

the

boiler thermostat switch to O.

pressure gauge.

a

boiler

boiler

switch to

leak

that

the

pilot

thermostat requires heaL

boiler

gas

the

gas

the

inner

the

programmer

a

programmer

a

programmer

a

controls.

boiler

purge

and

connection

securing the

screw

pressure

inlet

with 85689l. Retighten the test

sequence

isolated

switch

purge

after a

and

will

sparks
sparks

flame and

the boiler

thermostat

supply connections

pilot
burner

thermostat

so after

for

burner

burner

thermostat switch

detecting

arrow on fte data

burner

valve

valve

inner

form

also

will

continue

test

thermostat

isolate

one

switch to

Note: The

shield

and

supply
leak detecting fluid
manifold.

switch

pilot

the

gas

soundness.

setting

has

been

clockwise to decrease the

is factory

HIGH

fluid. Set the

rating.

is

tumed

cover

cover,

case

is fiued

is fitted replrce
is

open

case seal

a seal.

not

fitted

the supply

(the

cock

boiler

o the

gas

test

check

CONT, if a

to

period

heard. The

be

the

of the

pilot
to

secure

gas

for

to HIGH. The

is lit

pressure

alight

to HIGH and if necessary
the maximum

set to

to

light

to

off every time the

ensuring that the

the wiring

is intact

open rhe

service cock

valve

point

screw one nrrn.

the ignition sequence as follows:

the boiler

of about

until either the electricity supply
to

O to terminate the

pilot

supply for

switch is

pilot

the

(black

leads

HIGH. The

throttle is factory set

gas

at

the

O and

with

two
soundness
to the

the main

for l0 minutes:

Remove

O, disconnect the

main burner

the

boiler

plate

(positioned

centre, disconnect the

around

and reconnect

wiring

is

cover and

point

programmer

l0

ignition

set !o O.

shield

or

unit

valve

reconnect

screws.

main

burner

unit

gas

solenoid

input See Technical

thermostat swirch

cable

the

cenEe,

when

closed

for soundness

lift off

Ensure

screw and test

is

fitted and

thermostat switch

seconds a click

sparks

continue

ignition

gas

soundness

lift

and

white)

and

the burner setting

main

clamp is located correctly in

boiler chassis

the

off the

from

go

will

pilot

main

tlte

manifold

go

will

will

seuing

pressure gauge

test for

and

on the front

burner is off. The ignition

programmer

replrce

the operating slot

in

accordance

cover.

the

gas

the

the

through

fully

assembly

gas

through
open

adjust

pressure.

!o O

the

supply

gas

for

check

!o HIGH.

will be heard

until the

is switched off

sequence.

shield.

gas

main

the ignition

open.

for

solenoid

joint

the chassis

at

the

automatic ignition sequence

and

gas

of

programmer

and

main

tlre

pressure

the

burner sening

Data,

and
soundness around the

to

turn the boiler off.

the inner

replace

replace

then

panel

facia

is

vertical),

with 85689l.

is

on and open the boiler service cock to

soundness.

that all system controls are calling

The

automatic

indicating

pilot

is lit.

or the

solenoid on the

sequence but only the

gas

soundness

lead.

and

burner will light. Test

point

test

pressure

page

3, for the boiler ratings and

replace

qrse

the

pressure

the

at the bottom

sequence is

the cover, and secure

plug

and socket

inner

the wiring centre.

replace

then

pressure

ignition sequence

that the

gas

As

the

boiler

gas

using a suitable leak detecting

gas

the

screw

on the
to

test

pressure

s€cure

case,

the

test

gas

start
thermoslat switch

valve

give

right hand

automatically

and

winng

solenoid

supply is not

valve.

pilot

and chassis

and the

the

burner

gas

valve manifold

the heat

point

screw. Set the

point

test

with

slide

tle

with

four

centre.

gas

the

supply and

heat

for
will

start.

has

opened,

yet

turned

is

set to O.

will light-

connections

pilot

will light.

and manifold

input

required.

pressures.

setting

screw

using

corner)

is

against

activated when

its

screw.

programmer

screws. Tighten

purge

fluid.

boiler

The

on

and

a

out

Page

12

t.

Final

When

a.

hot
When

b.

boilers

water

system

the system

in order

inhibitor is

an

and

check and addition of

has

been tested,

complete

to

the flushing

added to the

should be used

this
is required. The system should be drained and
quantity

4Vtpins and
c. After the
By-pass valve

9.
Fully

a.

balance tle

b. Adjust the

the

of

CP3

system

close the

by-pass

by-pass.

for the system

radiattr

a 9

has

been

adjustment

by-pass

system

using

valve

volume.

system about6%

filled,

valve

and

pump

necessary

as

inhibitor

ensure the boiler

process.

system,

in

accordance

Fernox Manufacturing Co. Ltd.

guide

As a

pints.

vent

then

and

make a final

and

open

radiator

give

to

is

off

Soiler

with
flushed

instructions. Where

their

out, ensuring that all

radiator

a 3

check

it

full

one

valves

a temperature

turn.

give

to

rise of 9oC across

thermostat

switch

recommend

the

radiators

will on average

system

for water soundness.

Light

an

the boiler

loC

l

temperature

with

the

se

t to O), drain the

Fernox

boiler is used

are

drained.

require

about 2%

heating

the

drop

across the

CP3

on an

circuit

water while it is still

for

with

use

old system,

copper tube
special

When filling add

pints,

radiator

a 6

only in operation and

individual

radiators.

the

care

correct

system

boiler flow and return, i.e. measured before

BOILER

16.

Refer to

CONTROLS

Fig. 18.

(inner

case,

/

bas
servrce
cock

gas

valve

cover and

Pilot

burner

pressure

Inlet

point pressure

lest

Prlot

Burner selting

adlustlng screw

facia

throtlle

panel

removed)

Eurner setttng Boiler
pressure

polnt sw{tch

test

Thermostat

Fis.18

17. FINAL ASSEMBLY AND

l Before fitting

panels,
in

2. Lift
the case
If

3.

if

side exit

the case side and

outer cas€

the

in

programmer

a

switches to

4. Hand

5.

6.

7.

the User
Advise
rem

ain

the

in g i

AdvisetheUserthatforcontinuedefficientandsafeoperationoftheboileritisimportantthatadequateservicingiscarriedout

least

at
Leave
a.

b.
c.

once a

permanent

a

Name and

Date

of

A wiring

out€r case, the

the

flue has been

s@ure with four of the N0.8 x 12

into

position

by retightening the bottom

is fitted, set the

the required settings. See User

instructions to the user and

User

of

the

noperati ve

year

by a
card auached to the boiler

address of

installation.

diagram

of

HANDING

inhll

used

position

over

clock

precautions

frost

during

qualified

installer.

circuit-

the

OVER

panel(s)

fit

one of the

the

boiler

to the conect time

necessary

condi

l.ions.

service engineer or the

THE INSTALLATION

must

and

fixing

fitted

be

panels

to

lg.

screws supplied

push

back to engage the

screw.

(do

instructions.

instruct in

prevent

to

safe

the

damage to

local

giving:

to

the

side

of the

the side opposite the

with

fixing

not rotate

the dial anti-clockwise) and the

If

case.

rear exit flue

flue. To fit

the boiler.

pins

on

an

the chassis side

operation of the boiler and controls.

the system and to the building

Region.

Gas

has

panel, place

infill

in

been used,

it

into

the

case.

programme

tle event

of

fit

the two

position

in

Secure

and selector

the system

Page

13

{\\T AL

IIt.

Ti

r.oSUre conrinued

rrrt!-n

als.

should be
registered
The following aspects of the boiler and

l. Run

switches

2.

Check the

If it is necessary

L Remove

2. Remove the

Examine the main

3.

4.

If a sufficiently large
When refitting

5.

SER\-ICTNG

of

the appliance,

will

depend upon the

frequency

The

adequate.

efficient operation

of servicing

It is

the

law

that any service

personnel.

installation

the boiler and check the operation of

programmer.

and

installation

to dismantle the boiler the

the combustion

combustion chamber

injector

inner

the

flue terminal

of the

fan

and ensure

front

orifice and ensure

pilot

flame

cannot be achieved

case check that the

following

that it is

and check if the burner or heat exchanger requires

it is recommended that

particular

work must

be carried out by a competent

should be examined, and

its

controls, observe the

and ensure

it is not

checks should be

clean and

it

is clear and undamaged.

free

examine

seal is in

good

condition and ensure that

Instellstisn

obstructed.

of debris. Check the

the

On completion of the service run the boiler and ensure that it operates
The

boiler data

plate
WARNING: Before
supply. Slide off the bottom cover and turn off the
IMPORTANT: Always

positioned

is
commencing

gas

for

test

inner

on the

work

case at the bottom

set the boiler thermostat

gas

supply

right hand

switch to O.

gas

the

at

soundness after completing any servicing of

checks of controls.

it is

conditions and

rectified

picture

flame

made.

pilot

injector orifice

satisfactorily.

corner.

Allow

service

cock.
gas

checked and

person

nec€ssary.

as

cleaned as

usage

but

such

as

and ensure that the boiler

impellor for freedom

necessary

general

in

British

Gas or other Corgi

responds

rotation.

of

cleaning.

to ensure

it

compresses

the boiler to cool and

it is

clear and undamaged.

satisfrctorily.

isolate

carrying components and carry

regular

at

per

once

year

to any

the electricity

functional

out

18.1

Dismantling

I .

Slacken

Place

case.
Remove

2.

wiring

centre and

3. If a

programmer

centre and

programmer

If

a

4.

Unscrew the four
gas

valve

-

Fig. 19.

see

the screw securing

the case safely aside to avoid

the one screw,

lower

is fitted,

slide

out the

is not fitted,

inner

and one o the

case.

Disconnect

5.

tle two

wires from
is not importanl
Remove

6.
assembly to
with impellor from

7,

Remove the two

8. Slacken the
Remove

9.

10.

Undo the securing nut and
lead from the

I l. Remove

12.

Remove the clamping bracket

13.

Undo the tubing

14.

Carefully

15. From

16.

Carefully

17.

Cover the exposed

the three hex. hd. screws

the fan housing

the

hex. hd.

nuts

the

two

four

burner

securing

screws and

air

the screw secunng the

nuts

and

remove

and

underneath the base of the chassis

the

pilot

move

gas way

the bottom of the outer case and

possible

the

above

the

unplug the

boiler therrnostat switch, securing the

wiring

centre.

programmer plug

programmer.

slide out the

fixing

case

left

of the

the

and carefully

screws,

wiring

fan motor,

and

facia

two at the top, one above the

centre, and

the

washers

securing the fan

withdraw

fan housing.

screws securing

the flue hood

wing

nut

secunng Ore combustion

remove

the electrode, see Fig. 19, from

flue hood

the

to the combusrion

guide.

disconnect

reuin

the

gas valve

*

hich
pilot

cover

retains

the

pilot

the

injector,

supply,

see

remove

supply to one side and lift

in

the base of the chassis.

pull

off the

damage.

from

the

wiring

panel.

remove

polarity

of these

the

inner

wires

motor

motor

the

complete

cover and

remove

the

chamber.

the

front

pilot

both the

and

pilot

lift

off the cover.

supply

and electrode

Fig. 19, from

see

chamber

Fig. 19.

the two

pozi

screws securing the

out the burner assembly. Take

cover.
cover

assembly.

lead

at the bottom left hand

pilot

withdraw

and

Remove

assembly and

manifold.

burner

not

care

to

Fig. 19

the

lose

the burner

4.omm

3.O to

the

cover.

grommet

corner

gas

valve.

on the

elecEode

of the chassis.

'O'

flange

ring.

lE.2

Cleaning the boiler.

Brush

L

deposits

2. Examine the fan impellor and

the

from

heat

exchanger

the boiler base.

from

above and

carefully clean

3. Turn the burner upside down and tap

4.

Clean the

5. Unscrew the
wire.

To

clean or

pilot

injector from

Clean the

replace

burner and spark

the burner

pilot

the

pilot

injector in

a similar manner.

filter

in the

electrode

Page 14

below using a suitable brush. Brush

if necessary.

gently

manifold,

gas

remove

to

with a fine wire

any debris.

brush if necessary.

clean by blowing through or washing. Do NOT

valve

refer

to section 20. I l.

back to

front NOT

sideways. Remove

any

clear the injector with

fallen

pin

a

or

18.3 Reassemble
L Replace

Remove

2.
Check that the

3.

4. Replace
Replace the

5.
Replace

6.
gap

Replace

7 .

the clamp.
Replace

8.
nuL
Fully

9.

10. Replace the flue
I l. Replace

12. lf
Refertothecommissioninginstructions,sectionl5.Lightthepilotandchecktheflame,testthepilotandmainburnersupplies

13.
for

14. Lift
in
If

15.
switches to

16. Replace

19. LIGHTING INSTRUCTIONS
See section
With the

l Turn

2.

Set the

3. Set

of
The
Note: The
the

4.

If
programme

the burner

the
the
the spark

is 3.0 to

the clamping bracket
the combustion chamber

tighten the

the

programmer

a

gas

soundness, check the

outJer

the

position

programmer

a

the bottom cover.

16 for

gas

supply on, electricity

on the

programme

boiler thermostat switch to

the

l0

about

pilot

will

thermostat requires

boiler

programmer

a

boiler.

the

injector

protective

'O'

ring is in

assembly

burner
pilot

injector

electrode.

4.0 mm,

nuts

hood

fan motor

is fitted,

into

case

by retightening the

is fitted,

previous

their

boiler controls.

gas

seconds a

pilot

and selcctor

electricity

and

switch to CONT, if a

light and after a

burner

is fitted,

using a small amount of

covering

and

Ensure

Fig.

see

securing the

cover

impellor

and

temporarily

position

set the

sett"ings.

will

click

is

turned off every time the

ensure that the

s*'itche s

gas

from the

position

and

reconnect

-

and securc

main

heat

in the

secure

that the

19.
bottom

bottom

supply

supplies to the boiler.

be

second

left hand

front

ensuring that

flue

assembly and

reconnect it

burner setting

the boi-ler and

over

fixing

to the correct time

clock

off

HIGH.
heard

or

s€t

are

way

burner

with two

pilot

the

grommet

hood.

with

two screws

screw.

the

and

programmer
The automatic

indicating

the

sc'

clock

to their

jointing

in the base of the chassis.

flange.

screws

supply

on the elecrode

corner of

the

reconnect

to the

pressure

push

boiler

that

gas

main

main

is

set

previous

compound.

previously

to the

the

chassis.

burner stud

previously

the

wiring

and

back

to engage the

(do

not

thermostat switch set to

is fitted

ignition

the start

solenoid

burner

to the

correct

scttings.

removed.

pilot

assembly

Enswe that

locates in

removed.

fan wires

centre.

replace

rotate

and check that all system

sequence

gas

solenoid

will

is

off.

time

Note: The

lead is htted

the

(the

gas

the

fixing

dial anti-clockwise)

the

will

has

and the

open

The ignition

(do

40

gas

and

to the bumer air

pilot

the

bracket. Secure

polarity

valve

cover

pins

O:

The fan will start

start.

opened, the

main

sequence is automatically

not

rotate

Si injr:ctor

valve.

supply and electrode

of

the

and

on

the chassis side

controls are calling

burner

the dial

uses a

guide.

with four screws

wires

is not

inner

case.

programme

the

and

and after a

ignition

sparks

will light.

anti-clockwise)

sealing washer.

Check that the spark

lead

are

behind

one wing

and

important).

into

case.

the

and

selector

for heat.

purge

will

also be heard.

activated when

and

that

Secure

period

the

20. REPLACEIIIENT
WARNING:
supply. Slide
IMPORTANT:
checks of controls.

20.1 To replace
Remove

l.

2. Disconnect
Withdra* tlre

3.
chassis).

4.

Undo
Insert a new

5.

chassis),
Ensure
mounting box.
Replace any

6.
Remove

7 .

in

Fig.

Replace

8.
Replace

9.

10. Refer

Before

off

fre outer and

the securing

through

that the

the two screws securing the

19.
the
the

to the lightrng

commencing

bottom

the

Al*a; s test for

spark

the

tlre electrode

electrode

nut

electrode and

the side of

large

winng

pilot

shield

inner

case,

OF PARTS

*ork

se t

the boiler thermostat switch to

cover and

electrode - see

inner

lead from

lead through the

remove

and

secure with

grommet

connectors removed from the

and

programmer

instructions,

turn off

gas

soundness after completing

Fig.

cases as described

ignition

the

the electrode

nut.

the

is fitted to

secure

board mounting

circuit

pilot

with

facia

or

section

gas

the

19.

circuit

Pass the

burner

the

shield.

screws.

two

panel

19. Light

in

circuit board.

board

Lift

supply

section

from

circuit

18.1,

mounting

pilot

the

elecrode

box and connect
guide

air

board

off the

,wiring

the boiler

Allow

O.

gas

at

the

any

lead

pilot

centre

service

exchange

paras

See section

box and the clamping bracket

assembly.

behind the clamping bracket

and the small

replace

and

shield

and outer case.

replace

and

cock.
gas

of

carrying

4.

I

o

20.6.

it

to the

circuit board.

grommet

the

circuit

and check that the

bottom

the

the boiler to cool

components and carry out

(bouom

(bottom

is

fitted in

board mounting

spark

cover.

the side of

gap

isolate

and

left hand

left hand

plate.

is

3.0 to

the electricity

functional

corner

corner of the

circuit

the

4.0 mm

as

the

of

board

shown

Page

15

l0.l To replece the

I R-,.mov€ the

l. Remove the screw securing

Remove

3.

4.

Undo the tubing

5. Remove the
Fit a new injecor and

6.
Replace

7 .

the clamp.
Refer

8.
replace
Replace the outer case.

9.

10. Refer

the clamping bracket

the
the

to

the

to the

pilot injector

outer

pilot

clamping
commissioning

gas

lighting instructions,

inner

and

nuts

and disconnect

injector from

reconnect

bracket - bottom

valve

cover, inner

-

Fig. 19.

see

cases as described

gas

the

instructions,

valve cover

which recains

pilot

the

pilot

the

the

assembly,

pilot

left hand

section

programmer

case,

section

supply.

19.

the

Light the

in

section

lift off

and
pilot

supply and electrode

supply,

see

see Fig. 19.

corner of the chassis.

15. Light
or facia

boiler

paras

18.1,
the cover.

Fig. 19, from both

pilot

the

panel

replace

and

4.

I to

lead

the

Ensure that the

and

check the

wiring

and

the bottom

the botmm left hand

at

pilot

assembly and

pilot

supply

flame,

test the

centre.

cover.

corner of the chassis.

gas

valve.

and electrode

pilot

supply

for

lead

gas

are

behind

soundness,

20.3 To
l. Remove the outer

2. Remove

3.

4.

5. Undo the tubing

6. Remove the

7.

8.

9. Fit a new

10. Remove the
I l. Replace the

12. Refer

13.

14. Refer

20.4 To
Note:

L Remove

2. Remove the

3.

4.

5.

6.

replace

the screw securing the
Remove
Undo the securing

Remove
Remove the remaining screw

spark

the clamp.
replace

Replace

Remove the
burner
Using a

Ifaprogrammerisfitted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginstructions,section
the
case,

Replace the

the clamping bracket which

the

gap

the

to

the

the
the lighting insrucdons, section 19. Light

to

replace

The

burner

the outer

injector. Note: The 40

new

pilot

and

prognrmmer

pilot

the

pilot
two screws

pilot

is

3.0
uppermost

clamping bracket - boaom
commissioning

gas

outer

the burner.

burner

pilot

'O'

check

outer

burner - see

inner

and

nut

nuts

injector

burner and secure

4.0 mm

to

valve

case.

fitted may be either Furigas

and inner

as

assembly and

ring in the burner

the

or facia

case and

cases as described

gas

and remove the elecrode

and disconnect

from

the

securing the

securing the

with two screws. Replace

shown in

as

screw

securing the

instructions,

cover, inner

described

flame,

case,

cases as described

in

main

injector

Si

test the

panel and wiring

bottom

Fig.l9.

in

section

valve

cover

and

retains

pilot

the

pilot

assembly, see

pilot

Fig. 19.

left

section

programmer

section

bumer

uses a

manifold flange fit

pilot

cover.

pilot

the

from

supply, see

shield and
pilot

burner and

pilot

burner and

hand

corner

15.

Light the

the boiler

(silver)

in

section

paras

18.1,
injector

and main burner supplies

centre.

and

sealing washer.

paras

18.1,

lift

off the cover.

supply and elecrode lead

pilot

the

Fig. 19,

Fig. 19.

lift

off

the

remove

tlre

replace

the

of

chassis.

pilot

or facia

or Bray

panel

and replace

18.1,

8

17,

to

fit to

the

tlre burner and

I o 4.

assembly.

from

both the

pilot

shield.

pilot

the

pilot

injector,

pilot

the

Ensure

and check

wiring

and

the bottom

(blue)

either

paras

I

4.

to

new

burner. Use a small

reassemble

gas

for

the bottom left hand

at

pilot

assembly and

burner.

pilot

supply

and spark

shield

securing

that the

may

soundness

pilot

the flame, test the

centre.

be

used as a

as described in section 18.3,

it

with

supply and electrode

pilot

cover.

replacement

amount of

replace

and

corner

gas

valve.

electrode.

two screws.

lead

for

supply

for

jointing

gas

compound

valve

cover, inner

of

the chassis.

Check that the

are behind

gas

soundness,

the other.

paras

2

to 9.

l5.Light

on

the

20.5 To replace
Three

thermostats are

paint,

brown

I . Remove the

2. Disconnect

3. Unscrew the

4.

Ensure
Reconnect

5.
device, a brown and
page
Replace

6.

7

Refer

.

the
the

8. Replace

that the

20.
the

to the

boiler

'Lo'

thermostat
the bottom

the

the two

the two

off and on

Page 16

'Hi'

the

'Lo'

outer and

fixing

mounting

inner

lighting instructions,

'Lo'

or

mounted on the right hand

thermostat

wires from

screws and

wires. The

yellow

qrse,

when

switches the

cover.

thermostats.

with white

inner cases as

the thermostal
remove

plate

is

clean,

polarity

wire

to

programmer

section 19.

the boiler thermostat switch

boiler

described

the

fit

of

these

'Hi'

the

facia

or

off and on.

(flow)

pipe

from

the

paint

and

in section

thermostal
the new

wires is not important. Ensure

thermostat and a white

panel

Light

overheat

the

18.

thermostat

wiring

is

centre

set to

,

the boiler and allow it to heat

cut-off device

paras

I

,

and secure in

and
and

HIGH.

heat

exchanger.

4.

I

o

position.
that

yellow

wire

outer

case.

Set the boiler thermosrar switch to

The'Hi'

grey

with

to the

grey
'Lo'

the two

up. Check

thermostat

paint.

*

irt's

rmostat.

the

rhar the

go

'Hi'

is marked

to

overheat cut-off

the

wiring diagram

See

thermostat switches

LOW

and check that

with

'see

To replace

20.6
ignition

The
behind

Remove

l.

wiring

2. If

centre
the
From underneath

3.
screw

and

disengage

circuit

facia

the

the screw

centre.

programmer

a

slide

and

panel.

facia

securing

carefully

the

4. Disconnect
wiring

two
Carefully

5.
with a
Reassemble

6.
Refer to

7.
To replace

20,7

Ensure

l. Remove

18.1,

Remove the

2.

the
Disconnect

3.
terminal
not
(pilot)
(main)

4. Remove
in section
Remove

5.
side
sure
Remove

6.
Disconnect

7.
Remove

8.
Withdraw

9.

10.

Using
to the
of the

Do

remove the

new

the

the

that

the

paras

cover.

from the

importantbut

solenoid

solenoid).

tlre

20.6.

the one

wiring

of the

the

that

the
the

the

new

boiler

chassis.

replace the

not

ignition

the

panel

board

circuit

is

programmer.

or

securing

is fitted, unplug

programmer.

out the

ignition

the

back.

it at the

lower the

rear

wiring connector

the

connectors

mounting

fixing.

from the

circuit

one.

in reverse order.
lighting

the
gas

outer

I

to

screw

the

instructions,

gas

valve

suPPlY

and

4.
securing

push-on

is

inner

gas valve.

red and blue

the

white

the

and

wiring

See

ignition

'tag;

the

,O'

in reverse

circuit

securing

screw

anO

centre

rear of

at the

pilor

3

bracket

supply

socket screws

mm

clamping
eight

gas valve and discard

in

rings

the

order.

gas valve cover

board

positioned on the

front of the

the

programmer

the

programmer

If a

mounting

board

circuit

Remove

board

'see

tfte two

plate

from

rear of

from

section

Fig.2l.

withdrawing

front,

the

the circuit

the

19. Light

off.

described

as

cases

gas valve cover and

the

unscrew

terminals

board

wittrOraw

and

polarity

(The

must

wires

wires to the

blrck

and

diagram,

page20.

mounting

mountingplatebox

the

ne box.

located

the box

is

which retains

the

both

from

securing

'O'

the

service

cock and

Ensure that

this stage.

at

the

ll. Ifaprogrammerisf,itted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginstruclions,section

pitoi

ttre

burner

the

12. Replace

anO

setring

the

theflame,iestthepilotsupply

check

pressure, replace the

outer

case and

bottom

cover.

gas

20.

Fig.

of the

side

wiring

plug

screws

elecnode

the

board,

mounting

in section

tle

of these

go

the

o

plate

as described

The screw

in

the

pilot

the

gas valve

the

in

rings

manifold

burner

pilot

supply

connections

valve

cover,

wiring

and

centre

from the

fitted, slide

is not

plate

slacken

securing

it

it fonvards

lead

Fig'

see

pillan

and

boiler and

the

lift off

earth

wires is

inlet

outlet

the

to

is

accessible

on

out

cut

and electrode

supply

pilot

and

gas valve

service

the

flanges

and electrode

and

inner

centre

Mounting
oox

plate

lower the

wiring

out

one

the

front

the

at

and

to

the

slightly

20'

replace

replace

-
from

the

assembly.

(four

cock

side

the

to

and

of

Take care

(both

lead

the bottom

beneath
the

lead

service

burner

'O'

are

the box.

wiring centre

the

at

cock

manifold

rings are

behind

cover.

bottom

not to lose

and

the same
the clamp

Fig.20

Fig.21

Note: When

before

hand corner

left

pilot injector,

the

to the burner

four

flanges.

size)

in

the

gas valve inletandoutletconnections

programmer

case,

or

facia

panel and

Fan,

refitting the box

replacing

the

manifold)'

reassemble

bottom

forgas

wiring

left

soundness, check

centre.

pressure

@@

make

fixing screw'

chassis.

of the

Fig. l9'

see

valve

new

the

hand

corner

l5.Light

replace

To

20.E
Remove

l.

2. Remove
Unscrew

3.

4.

Screw

Replace

5.
Ifaprogrammerisfitted,temporarilyreconnectittothewiringcentre.Refertothecommissioninginsfictions,sectionl5.Light

6.

boiler,

the

facia

or
Replace

7.

the burner

outer and

the
the burner assembly

injector

tlre

replacement

in a

burner assembly

the

test the

panel

and

outer case and

the

injector.

inner cases

from

injector

pilot

and

wiring

centre.

as described

as described

manifold.

the

using

as described

burner supplies

main

botlom

cover'

in

section

a small

in

section

in

section

18.1,

amount

18.3,
gas

for

paras I

18.1,
paras

jointing

of

paras 2

soundness

4.

to

U'

8 to

compound.

9'

to

replace the

and

Note: The

gas valve

40 Si

inlcctor use

inner

cover,

s a sealing

progfammer

case,

Page

washer.

17

20.9

To replace

l.

Remove

2.

Disconnect the
valve.

go

must
(main)

3.

Carefully

(fhe polarity

solenoid).

gas

a
screw

the

push-on

to the inlet

prise

out the

solenoid and its mounting

4.

Position

the

new

solenoid

order.

5. Refer
bottom

20.10

To replace

pump

The
above

the wiring

l.

Remove

2.

Remove

3. Remove
next

to

with

thermostaL

4.

Disconnect

lighting

to the

cover.

overrun

the

outer and

ignition

the

one

the

wiring

the

the

the

thermostat is

centre.

screw

centre underneath

three wires

brackeL

5. Fit

6. Connect

7. Refer

new

the

thermostat

the three wires

n the

lighting
cover.
Allow

8.
run for

the boiler to

15 minutes.

5 to

the

-

gas

Fig. 22.

see

valve

cover and

valve

solenoid

securing

terminals and unscrew

of these wires is not important

(pilot)

solenoid

See wiring

retaining

bracket,

into

instructions,

pump

oyerrun

inner

control box as

securing the

and the white

diagram,

page20.

clip from

seeFig.22.

the mounting

section

thermostat

situated at

cases

described in

as

described

pump

behind the solenoid

bracketand

19. Light

tbe

overrun thermostat mounting

tlre chassis.

remove

and

to the mounting

to the

instructions,

heat

up

fully

thermostat,

then

the

two

bracket

see

section 19. Light

switch it

lift

the

off

the

terminal

earth

but the red

and blue wires

and black wires

and

reassemble

the boiler

-

see Fig.

bottom right

section

in

section 20.6.

and replace

23.
hand

18.1,

Carefully withdraw

screws

securing the thermostat

and secure with

Fig.

23 and reassemble

the

boiler

and

off at the

programmer

cover.

lift

gas

the

outlet

off the

from

to the

in reverse

the

corner of the

4.

I

to

bracket situated

the

bracket

two screws.

in reverse

replace

or

extemal

chassis

complete

the

to

order.

the

bottom

conrrols and

Yellow

lead

check

Mounting

Fig.22

(2)

Fig.23

that the

bracket

overrun

thermostat

pump

continues

Brown

(3)

lead

ro

20.11 To replace
Note: It is
injector
Ensure
l.

Remove

2.

Remove

extremely unlikely

pilot

and

that the

the
the

24. Discard

3.

Carefully

4.

Replace

remove

the

pilot

the

supply are

gas

supply

gas

valve

five

screws securing

gasker

the

ttre

rear

cover
screws.
Replace

5.
cover or the
Turn

6.
using

7. Refer

gas

for

8. If

programmer

a

9. Apply

instructions,

10.

Refer

wiring

and

gas

valve

the

inner

and

gas

on

the
a suitable
to the

supply

leak

detecting

commissioning

soundness.

is fitted

suitable leak

a

section

l9

to the commissioning instructions,

centre.

11. Replace the outer case

20.l2To replace
L Remove the

2.

Unplug the

3. Slide out

4.

Slide the

5. Connect

the
new

the

6. Refer m the

7.

Set

Replace

8.

programmer

the

the bottom

programmer (if

the

screw

securing

programmer

programmer

progmmmer
programmer
lighting

instructions, section

clock o the correct time

cover.

-

filter

as described in

pilot

using a

in reverse

that the

clear

is

off.

filter,

see Fig. 24.

pilot

and

the

section 20.7.

rear

the

see Fig.24

gasket

new

order

section 20.7,

to

outer cases.

and test the

servibe cock to

fluid.

instructions,

temporarily reconnect it

detecting fluid

around

and light the main

and

bottom cover.

fitted).

front

the

plug

from

inlo the

plug

from

of the

wiring

the

the control

control box, and

wiring

to the

filter *ill

filter is

cover

become

still suspect

plate

and

and replace with

and secure

by evenly

but do

gas

valvejoint

section 15. Light

to the wiring

gas

the

burner.

section l5

wiring

valve

Test

the

and

cenuc

replace

centre.

box.

push

centre,

close the

19. Light
and

the boiler

switches to

the

blocked. If

proceed

carefully

remove

a new one.

tightening the five

not

replace

for

pilot

the

nrre.

ce

rear co','er

gas valve

the

carefully

and

fully home.

wiring

and check

their

the

follows:

as

it,

see Fig.

gas

the

gas

soundness

and check

and $c'

rL-ar

cover

las

gas valve

lower

iL

cenre and

the controls.

previous

pilot

valve

flame

tre

valve

and

rcsr ric

outlet

connection. Refer

and outlet conneclion

cover,

inner case,

secure in

posiuon

prcgrammer

with

settings.

I-ig.24

pilot

for

supply

gas

connections

to

the

soundness.

facia

or

the fixing screw.

lighting

panet

Page

I8

To replace

20.13
The

l. Remove the outer

2.

3. Remove the

4.

5.

6. Reconnect the
7 . Refer to

8.

flow

air

Carefully

screws to

these

a

Using

washers

fibre

Reconnect the

Replace

the air

pressure

disconnect the

screws securing the

two

insulate

pressure

new

are used.

wires

flexible

lighting instructions, section

the

the bottom cover.

pressure

flow

switch

and inner

is

flexible

the

switch

to the

tube and

pressure

switch.

situated at

cases as

tube

pressure

pressure

(supplied

switch from the

switch.

reassemble

the top

described

from

with mounting bracket) secure the mounting

19. Light

right hand

in

section

pressure

the

mountirig

switch

flue

wiring

See

in

reverse ordcr.

the boiler

corner of the chassis to

paras

18.1,

switch and

hood.

diagram

and check

I

to

disconnect

bracket to the

page

20.
that the

4.
the three

flue hood. Note: There

pressure

right

the

wires

bracket to the

switch

allows

the fan.

of

noting their

,

are two

flue hood. Ensure

position.

fibre washers

main burner to light.

the

on

that the two

2A,MTo replace the

l. Remove

2. Reassemble in reverse ordcr using the
Refer to the

3.
on and off

4. Replace

20.15

l. Remove the outer and

2. Remove the bumer as dcscribed
Remove the two

3.

4. Remove

chamber

5. Slide

6. Slide

7. Fit a

Reassemble in

8.

of
Ifaprogrammerisfitted,temporarilyreconnectittotlewiringcentre.Refertothecommissioninginstructions,section l5.Light

9.

the boiler,

10. or

10. Replace the outer

20.16

Ensure that the system

care

Take
and its connecting

L Remove the outer and

2. Remove the burner as described in

Remove

3.

4.

Remove
the

5. Undo
it

6. Reassemble

at

7. Fill and

Ifaprogrammerisfitted,temporarilyreconnectittothewiringcenue.Refertothecommissioninginstructions,secLron

8.

tle boiler, test the

or
Replace

9.

the outer

the bottom cover.

To replace

the

to clear

out $e

the

out

panel,

ne*'

the chassrs.

panel

facia

To replace the heat

when

the
the four screws

heat exchanger

littings

the

from

the

bouom left

the

vent

panel

facia

the

fan

motor and

inner

case,

lighting instructions, section 19. Light

respectrvely.

the combustion chamber

innc'r cases

nurs sccuring

four scrc*s

the

front rnsulation

side

tuo

lower

reverse

test

the

and

case

removing

pipes.

nuts securing

two

securing

pipes.

in

reverse order using a new

hand

the system.

pilot
wiring

and

ourcr

case and bottom

(two

heat

exchanger

panels

edge

order.

pilot

and

wiring

centre.m cover.

and
exchanger.

is

drained.

the

inner

(two

remove.

and

the

corner of the chassis.

and

centre.

impellor

case

and

as

in

section 18.1,

flue hood to

the

each side)

panel

and carefully

remove

and

first and

Ensure

main

burner

bottom

heat exchanger

cover.

cases

as

section 18.1,

the flue hood

each side) securing

inlet

and

main

burner supplies for

cover.

assembly.

the fan

new assembly.

insulation.

described

securing

remove.

and

the

push

back

that the

described in

pilot

supplies for

as

outlet

heat

motor

the boiler and check that the

in

section 18.1,

paras

the combustion chamber and disengage the tie

replace

panel

rear

into

supply and electrode

even

section

paras

ul the

fte combustion chamber. Carefully lower

pipes

exchanger. Ensure

impellor

and

to 17.

8

the combustion chamber

with a new

pulling

by

position.

gas

soundness and

with

the

18. I

17.

8 to

combustion chamber

to the heat exchanger

gas

soundness

assembly as

paras

forwards

in

Slide

paras

,

that the

drained

and

system

4.

I to

one.

new

two
lead

are

replace

4.

I to

and disengage the tie rods.

and

pilot

replace

described in

fan

switches on and off

the

fo

chassis. Carefully

at the top then

panels.

side

behind the clamp

gas

the

there will

carefully

supply

lower

and electrode lead are

gas

the

section I 8.1

rods.

lifting

out

the bottom

at

valve

cover,

still be

valve

water in

the combustion chamber

heat

the

cover, inner case,

paras

,

the main

as

lower

inner

case,

the heat exchanger

exchanger ro

behrnd rhe

I to 6.

burner cycles

the combustion

left hand

corner

progmmmer

to

clear

disengage

clamp

l5.Light

programmer

Page

19

WIRING

21.
Illustrated wiring

a.

c0t0uR

ilOTE:
lf

swilched live

Bemove link HW
fined terminal

DIAGRAMS

diagram

v

c00E

-

b

blue

-

bk

black

br - brown

-

g

green

-

gy

grey

-

0

orange

Apollo

prog,ammer

to terminal

to

CH OFF

the

with Apollo

Fan

Motor

-

pk

pink

p - purple

-

Y

violet

r-red

w - white

y - yellow

-

g/y

green

is not

litted, remove

0l{.

Oil when

fitting erternal controls. lf an Apollo

is live

when HOT

programmer.

yellow

and

WATER

link

HW lo 0t{ and connecl a

is selected.

'Lo'Thermostat

programmer

is

'Hi

Overheat
cut

Pump overrun
Thermostat

Thermostat

gY

ofl devtce

br

l'

t

b,-,i

4

f..u'l ( lc

I >LVV

Ir

|

$t.a

MNI
+

'

?
NH

L

gv

6-waySocket
for Apollo
Programmer

'(

>

--

*l

lgnition

Crrcu,t

Board

Boiler

Terminal

Block

,,',{"

i

M",^,

Pumn

Earthin
Stud

L't

.

-c

l,

{

{

L

L-\vL

i
F

F
HL

jarthrng

Screw

Twice

Once

Cont

3-way

Suppressor

High

o

Low

3-way

Apollo

Programmer

Switch

Switch

6-w plug

I

I
I

I

Page 20

lr*

ott

I

Hw&cH

I

L-

3-r/ay Swrtch

Clock

I
I

I

J

Functional flow wiring

b.

Pump
0v!rrun
Thermd,

diagram

*'ithout

programmer.

lli

Therm6tit

Lo Thermostal

3

I

=

Spark
Ilarne

c(3)

electroder
sensot

Pressure

Switch

L.I

Nc(1)

MN

L2

PN
FN

N

cot

b

bk

br

g

gY

0

pk

ouR

-

blue

-

black

-

brown

-

gleen

-

grey

-

orange

-

pink

c00E

-

p

purple

v - violel

r-red

-

w

while

-

y

yellow

g/l green

and

yellow

\0'[

'a

programmer

rs not frtted,

hnk HW

to

0N to be removed

and

a switched live

connected

to lennrnai

-']^.

Page

2I

c. Functiooal

flow wiring

Pump
0verrun
Therm6t

diagram

l

with

Apollo programmer.

HW

oN

5s

Hr

Thermoslal

Cl6k

Thermostal

Lo

KEJ.-

a->-J

SWay
Swrlch

CH OFF

N0TE:

Link

HW-0tl

,"r1

I

Stiark

=

I

anre

Pump

I

is removed

when

L3

c(3)

eleclrode

sensor

any exlernal

PL

Pressure

Swttch

controls

ML

I rlrl

lj'l

1_I{]]l

hoard

are

fitted

L1

MN

L2

PN

FN

N

.+l

>al

c0r.0uR

bk

b

blue

-

bk

black

-

br

brown

g

green

-

gy

orey

-

o

orange g/l

pk

pink

c00E

Pg

rr;

-D

\

-

p

-

v

r-red

w

Y

purple
violet

white
yellow
green

Marns

and

N

yellow

Page

22

CF

C;;

r,',

SETECTOP

'

S//-'-

,

22. FAULT

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Page 23

24.

SHORT

LIST

SPARE

PARTS

Ke1 No.

I
l0
l3

2l
22
22
23
23
35
36
31

43

50
50
50
5l
5l
5l
52
53
55
56
6
72
76

ll5

r28
r29

o

52

GC

3327rr
377 000

323 342
323
323
323
323 344
395 880
382397
382373
384208
382

382

398

398329
323
386 532
381
377 M2
323 36r
386
359
31104,6
332
386 608

ee

ry

43

No.

405
343
406

422

423
316

468
702

756

2rl
12r

Description

Outer case
Inspection
Plastic door
Combustion chamber
Combustion chamber
Combustion
Combustion
Combustion chamber
Overheat

'Hi'thermostat
'Lo'thermostat

Pump overrun thermostat

Burner
Burner - 40Si
Burner
Main injector,
Main injector,Cat2S
Main

Main injector washer
Pilot burner
Pilot injecor,56142A

Spark

Burner'O'ring
Gas
Gas

Ignition
Fan

Air flow

l-ol

10

L-j

-

r=-1-

u

36

window

chamber
chamber

cut-off device

-

30Si

-

50Si

Cat

injector,

electrode and

valve

valve'O'ring

assembly

Cat

PCB

pressure

76

'F]

,-l

L-l

-- Fr

assembly

insulation
insulation
insulation
insulation
insulation

16

size
size

16

size

-

40Si

lead

switch

h{

dh

37

35

800 - 30Si

1000
1400

c

66

(sides)
(front)
(front)
(rear)
(rear)

-

40Si

-

50Si

V

@

-

30Si

-

40Si,

-

30Si

-

40Si,

w

13

72

@

129

50Si

50Si

o

o

il"rilH

115

Qty.

I
I

2
2

1
I

I

I
I
I
I

I
I
I
I

I
I
I
I

I
I

I
I
I
I

2

I
I
I

a8

q

53

Part No.

402A2r93
402A2476

402C3081

402Cr04
402C105
402Cr78
402Cr4r
402Cl8l

4025 1498

4025 l 14
4025 I l5
402S088

40252510

4025322r

402525

40253239

Q395A1003

45004108-005

402A2525

402S098

vR470081034

4m-mrc-7-32

40252240

l l

402S067
307S527

402Cs32

309S374
309S503

Page 25

Eastern Avenue,

Telephone: 091

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482

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Heating

Tyne &

Telex: 53265 MYSEAS

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Telefax: 091

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