British Gas - 330 - free boiler manuals

British Gas - 330 - free boiler manuals
0020008877-04 08.06
Instructions for Use
Installation and Servicing
12373
To b e l e f t w i t h t h e u s e r
British Gas
330
G.C. No. 41-047-75
High Efficiency
Condensing Boiler
Customer Care Line Tel: 0845 600 5100
www.house.co.uk
Contents
The instructions consist of three parts, User, Installation and Servicing Instructions.
The instructions are an integral part of the appliance and must, to comply with the current
issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on
completion of the installation.
CONTENTS
INTRODUCTION
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
MAINTENANCE
INSTRUCTIONS
0020008877-04
DESCRIPTION
SECTION
PAGE No.
Important Information
General Information
3
4
Appliance Safety Devices
Maintenance
Operating the Boiler
5
5
6
Technical Information
Boiler Location and Ventilation
Flue Location and Ventilation
Water System
Installation Preparation
Boiler Fixing
Gas, Water and Condensate Connections
Flue Preparation Telescopic and Standard Flue
Electrical Connections
Commissioning
1
2
3
4
5
6
7
8
9
10
7
9
10
12
14
15
16
18
21
22
Servicing
Fault Finding
Replacement of Parts
Manual Handling
Spare Parts
Declaration of conformity
11
12
13
14
15
16
26
31
35
40
41
43
2
Important Information
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e. smoking, blowlamps, hot air
guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Call
the British Gas Emergency Service telephone number: 0800 111 999.
Sheet Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning,
with particular regard to edges.
Sealed Components
Under no circumstances must the User interfere with or adjust sealed parts.
Gas Category
Control of Substances Hazardous to Health
The boiler is of the I2H category for use only with
G20 Natural Gas.
Under Section 6 of The Health and Safety at Work Act 1974, we
are required to provide information on substances hazardous to
health.
Gas Safety (Installation and Use) Regulations
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
In your own interests and that of safety, it is the Law that ALL
gas appliances are installed by a competent person in
accordance with the current issue of the above regulations.
Insulation Pads / Ceramic Fibre
These can cause irritation to skin, eyes and the respiratory tract.
Testing and Certification
If you have a history of skin complaint you may be susceptible
to irritation. High dust levels are usual only if the material is
broken.
The boiler is tested and certificated for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless approved, in writing, by British Gas.
Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or
going to the lavatory.
Any alteration not approved by British Gas, could invalidate the
certification, boiler warranty and may also infringe the current
issue of the statutory requirements.
If you do suffer irritation to the eyes or severe irritation to the skin
seek medical attention.
CE Mark
This boiler meets the requirements of Statutory Instrument, No.
3083 The Boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
Electrical Supply
Type test for purposes of Regulation 5 certified by: Notified body
0087.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
Product/production certified by: Notified body 0086.
In GB this is BS 7671.
The CE mark on this appliance shows compliance with:
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
The boiler must be earthed.
All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
1. Directive 90/396/EEC on the approximation of the laws of the
Member States relating to appliances burning gaseous fuels.
The boiler must be connected to a permanent 230V ac, 50Hz
supply.
2. Directive 73/23/EEC on the harmonisation of the Laws of the
Member States relating to electrical equipment designed for
use within certain voltage limits.
Connection of the whole electrical system of the boiler, including
any heating controls, to the electrical supply must be through
one common isolator and must be fused 3 Amp maximum.
3. Directive 89/336/EEC on the approximation of the Laws of
the Member States relating to electromagnetic compatibility.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur box
should be readily accessible and preferably adjacent to the
appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363 may be used, provided they are not used in a
room containing a bath or shower.
The colours of three core flexible cable are, blue - neutral, brown
- live, green and yellow - earth.
3
0020008877-04
General Information
General Note
Pluming from flue terminal
This boiler is a wall hung high efficiency condensing boiler,
designed to provide central heating from a fully pumped openvented or sealed water system with a fully indirect cylinder.
Like all condensing boilers this appliance will produce a plume
of condensation from the flue terminal in cool weather. This is
due to the high efficiency and hence low flue gas temperature
of the boiler. It is normal and not a fault indication.
Once the controls are set the boiler operates automatically.
Cleaning
Please read these instructions and follow them carefully for the
correct installation and economical use of your boiler.
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.
Water Treatment
Do not use any form of abrasive or solvent cleaner as you may
damage the paintwork.
In the case of an existing installation, it is ESSENTIAL that prior
to installing the new boiler the system is thoroughly flushed. For
optimum performance after installation of a new system, the
boiler and its associated central heating system should also be
flushed. Flushing should be carried out in accordance with
BS7593: 1992 using a cleanser such as Sentinel X300 or X400,
Fernox Superfloc or Salamander corrosion guard cleaner.
Electrical Supply
If the mains electricity and gas are to be turned off for any long
periods during severe weather, it is recommended that the
whole system, including the boiler, should be drained to avoid
the risk of freezing. Make sure that, if fitted, the immersion
heater in the cylinder is switched off.
For long-term corrosion protection, after flushing, an inhibitor
suitable for stainless steel exchangers should be used, refer to
the current issue of BS 5449 and BS 7593 on the use of
inhibitors in central heating systems. Examples are Sentinel
X100 Fernox or Salamander corrosion guard inhibitor.
We do not recommend filling using artificailly softened water.
If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising MUST
be carried out by a competent person.
Gas Supply
Compartment or Cupboard Installations
NOTE: This appliance is factory set at 18kW output.
If the boiler is fitted into a compartment or cupboard it does not
require ventilation openings.
Do not use the compartment or cupboard for storage.
On completion of the adjustment, the inlet working pressure of
the appliance should be checked to ensure a steady inlet
working pressure of 20mbar is achieved.
Clearances
Thermal Stores
If fixtures are positioned close to the boiler, space must be
left as shown in diagram 2.1. Enough space must also be
left in front of the boiler to allow for servicing.
This appliance is suitable for installation with thermal stores,
however, the appliance should be adjusted to give the maximum
31kW output.
Condensate Drain
IMPORTANT: If the seal on the 'Pmax' potentiometer is broken
the gas supply, without exception, must be capable of delivering
31.3kW input.
The condensate drain, see section 7.3, must not be modified or
blocked.
Manual Handling
IMPORTANT: With regards to the Manual Handling Operations,
1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift, refer to Section 14. for
more information.
0020008877-04
4
Appliance Safety Devices - User Instructions
Electrical Supply Failure Reset Switch
Frost Protection
The boiler will not work without an electrical supply.
The appliance has a built in frost protection programme as long
as the electricity and gas are left switched on.
Normal operation of the boiler should resume when the electrical
supply is restored.
This device operates the burner and system pump when the
temperature inside the boiler falls to 30C.
Reset any external controls, to resume normal operation of the
central heating.
Any other exposed areas of the system should be protected by
a separate frost thermostat.
If the boiler does not resume normal operation turn the mains
reset switch off and on. If the boiler does not resume normal
operation after this the overheat stat may have operated.
Condensate Blockage
As a safety feature the boiler will stop working if the condensate
trap and siphon drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the pipe
external to the house. Release an ice blockage by the use of
warm cloths on the pipe. The boiler should then restart. Contact
your installation/servicing company if the fault persists.
Overheating Safety
In the event of the boiler overheating the safety devices will
cause a safety shutdown. If this happens, call your Installation/
Servicing company.
Maintenance - User Instructions
Servicing
Spare Parts
For the continued efficient and safe operation of the boiler it is
recommended that it is checked and serviced at regular intervals.
The frequency of servicing will depend upon the installation
conditions and usage, but in general, once a year should be
enough.
REMEMBER: When replacing a part on this appliance, use only
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by British Gas.
If this appliance is installed in a rented property in the UK there
is a duty of care imposed on the owner of the property by the
current issue of the Gas Safety (Installation and Use)
Regulations, Section 35.
If replacement parts are required contact British Gas’s own
service organisation using the telephone number on the front
cover of this booklet.
Please quote the name of the appliance, this information will be
on the name badge on the front of the appliance.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
If in doubt seek advice from British Gas’s own service organisation
using the telephone number on the inside front cover of this
booklet.
To obtain service, please contact British Gas’s own service
organisation using the telephone number on the front cover of
this booklet.
Please be advised that the installation engineer on completion
of commissioning and servicing should complete the British
Gas logbook.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on: - 01256 372300.
5
0020008877-04
12359
Operating the Boiler - User Instructions
CONTROL
LIGHT
DIGITAL
DISPLAY
CONTROLS
FASCIA
MAINS RESET
SWITCH
CENTRAL HEATING
WATER TEMPERATURE
CONTROL KNOB
Diagram 1
OPERATION OF THE BOILER
Sealed Water Systems
CAUTION. A sealed water system must be filled and pressurised prior to use.
Only light the boiler when you are sure that the system and boiler have been filled and pressurised.
The pressure should be at least 0.7 bar, anything less than this figure could indicate a leak and you MUST contact your installer
or British Gas's own Customer Care Line using the telephone number on the front cover of this booklet.
All Systems
Check that the electrical supply to the boiler is ON at the external isolator.
Set any remote controls as required.
USER CONTROLS
Do not operate the boiler without water.
● Slide the mains reset switch to the ON position (I).
The control light will illuminate (green) indicating the boiler is lit, diagram 1.
● The temperature of the central heating water can be adjusted by turning the central heating water temperature control knob
to desired setting between
'Max'
'Min' and
'Max', diagram 1.
is approximately 82°C (180°F)
The digital display, diagram 1, shows the temperature of the appliance when the
appliance is running and in standby.
A fault is indicated by a RED flashing control light and flash fault code on digital display.
To Reset
● Slide the mains reset switch to 0. Wait for 5 seconds.
Slide mains reset switch to I.
If the fault persists contact your installer/service provider.
It should be noted that this is a fan flue appliance and fan operation may be heard.
To Turn the Boiler Off
● There is a mains reset switch on the right hand side of the controls fascia.
However, it is preferable to leave the electrical supply on whenever possible to permit
operation of the built-in frost protection and daily pump exercise.
0020008877-04
6
1 Technical Information
1.1 IMPORTANT NOTICE
The Current I.E.E. Wiring Regulations, sixteenth edition.
The boiler is supplied in one carton, which includes a fittings and
documentation pack.
British Standard 7671:2001, requirements for electrical
installations.
This boiler is for use on Natural Gas (G20) as distributed in the
United Kingdom and Ireland and cannot be used on any other
gas.
In IE, the installation must be carried out by a competent
person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for Electrical Installation.
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
In GB the following Codes of Practice apply:
The installation of this boiler must be carried out by a competent
person in accordance the rules in force in the countries of
destination.
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.2 Statutory Requirements
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
1) Central heating system specification (CheSS) and
In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:
2) Controls for domestic central heating system and hot water.
BRECSU.
The manufacturer’s instructions supplied.
Certification
The Gas Safety (Installation and Use) Regulations.
This boiler certificated to the current issue of EN 483 for
performance and safety.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland), The Building
Regulations (Northern Ireland).
It is important that no alteration is made to the boiler, without
permission, in writing, from British Gas.
The Water Fittings Regulations or Water byelaws in Scotland.
RETURN
FLOW
13436
Any alteration that is not approved by British Gas, could
invalidate the warranty and could also infringe the current issue
of the Statutory Requirements.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
334
176
53
CL
48
FLUE
THIS DIMENSION
CAN BE INCREASED
TO 600 MAX.
75
113.5
33
CL
BOILER
610
CONDENSATE
TRAP OUTLET
48
GAS
GAS
54
30
13
73
133
CONDENSATE
TRAP OUTLET
375
Diagram 1.1
7
0020008877-04
1 Technical Information
1.3 Gas Supply
TABLE 1
The gas installation shall be in accordance with the relevant
standards.
TOTAL WEIGHT
33kg
GAS CONNECTION
Rc1/2 (1/2in BSPT)
WATER CONNECTION
22mm. copper
On completion, test the gas installation for soundness using the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
ELECTRICITY SUPPLY
230V~50Hz fused 3A
NOTE: This appliance is factory set at 18kW output.
ELECTRICAL RATING
60W
IMPORTANT: If the seal on the 'Pmax' potentiometer is broken
the gas supply, without exception, must be capable of delivering
31.3kW input.
INTERNAL FUSE RATE
Main PCB 630mAT
In GB this is BS6891.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
If this appliance is to be used with a thermal store it should be
adjusted to the maximum output and the gas supply must be
capable of delivering 31.3kW input.
TABLE 2
On completion of the adjustment, the inlet working pressure of
the appliance should be checked to ensure a steady inlet
working pressure of 20Mbar is achieved.
BURNER
%CO2
Case Off
Case On
9.1 +0.3 -0.3
9.3 +0.3 -0.3
APPROXIMATE GAS RATE
1.4 Technical Data
m3/h
3.31
2.54
1.90
1.59
1.27
0.67
All dimensions are given in millimetres (except as noted).
See diagram 1.1 and Tables 1 and 2.
The data label is positioned on the inner door, refer to
diagram 1.2.The appliance data label must be completed to
indicate the maximum output using the rate indicating label
provided in the literature pack.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is:
Class 'A'.
The value is used in the UK Government's Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated has been certified by Advantica.
ft3/h
117
90
67
56
45
24
12431
OUTPUT
31 kW
24 kW
18 kW
15 kW
12 kW
MINIMUM
2000467001-02
330 HIGH EFFICIENCY CONDENSING BOILER
GC No. 41-047-75
230V~50Hz 60W fused at 3A For use on TYPE : C13,C 33, C53
1.5 Condensate Drain
Manufactured exclusively for British Gas by Glow-worm
Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge
can be made externally into the household drainage system or
a purpose designed soak away, see Section 7.3 for more
details.
WATER CIRCUIT PMS = 3bar
INJECTOR: N/A - DOES NOT APPLY
RANGE RATING
MAX
HEAT INPUT NETT Q = kW
31.3
HEAT OUTPUT NETT Q = kW
31.0
HEAT OUTPUT CONDENSING = kW 34.6
FAN SETTING
47±1
INDICATE SETTING
REFER TO INSTRUCTIONS FOR
ADJUSTMENT METHOD
24.3
24.0
25.9
36±1
EN437 IP X4D
NOx Class 5
0086
87/BP/32
GB
IE
18.2
18.0
20.2
29±1
15.2
15.0
16.0
23±1
MIN
12.1 6.7
12.0 6.3
12.9
19±1
MINIMUM
MODULATION
I2H -G20-20mbar This boiler is intended
exclusively to be installed on a gas supply
with a governed meter
FACTORY
SETTING
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
SERIAL No.
Diagram 1.2
0020008877-04
8
2 Boiler Location and Ventilation
12360
2.1 Boiler Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
5
5
This boiler is suitable for installation in bathroom zones 2 and 3.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules.
600
†
The boiler must be mounted on a flat wall, which is sufficiently
robust to take its total weight, see Table 1. Section 1. Technical
Information.
2.2 Clearances
5
150
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram
2.1.
Additional clearances may be beneficial around the boiler for
installation and servicing.
For flue installations where external access is not practicable,
consideration should be given for the space required to insert
the flue internally, which may necessitate clearance larger than
those specified in diagram 2.1.
20
20
2.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998 and BG Operational Procedures,
Part 19 Building and Kitchen Work, Section 7 - Timber Frame
Constructions.
2.4 Room Ventilation
200
The boiler is room sealed, so when it is installed in a room or
space, a permanent air vent is not required.
2.5 Compartment Ventilation
Due to the high efficiency and hence low casing temperature of
this boiler, cupboard or compartment ventilation is not necessary.
Leave existing air vents.
† A removable compartment door can be
placed at least 5mm in front of the appliance.
MINIMUM CLEARANCE FROM
PERMANENT SURFACES
9
Diagram 2.1
0020008877-04
3 Flue Location and Ventilation
3.1 Flue Options
3.2 Flue Length
This boiler is suitable for concentric Horizontal and Vertical
flues, elevated horizontal and vertical twin, all are fitted onto the
top of the boiler.
The maximum permissable horizontal flue length is 10 metres
plus the flue terminal, this can be achieved by use of the
accessories, however should an additional 90o or 2 x 45o elbows
be used then the length MUST be reduced by 1metre.
These instructions describe the use of the standard and
telescopic horizontal flues.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least 2.5o
44mm/metre to allow condensate to run back into the boiler and
out via the drain.
The instructions for all other flues will be contained in their
packs.
The flue can be installed from inside the building, when access
to the outside wall face is not practicable.
75 min. to 540 max.
WALL THICKNESS
87min
13162
13161
The diagrams 3.1 to 3.4 describe the lengths achievable without
the use of extensions or elbows.
208 min. to 413 max.
WALL THICKNESS
87min
112
112
176
176
OUTSIDE
WALL FACE
BOILER
MOUNTING WALL
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.
TOP REAR FLUE - STANDARD
Diagram 3.1
87min
A
239
136
CL
FLUE
239
A
OUTSIDE
WALL FACE
A
Max. distance from outside Min. distance from outside
wall face to min clearance. wall face to min clearance.
LH - 458mm
LH/RH - 75mm
RH - 561mm
0020008877-04
Max flue length 589mm
20mm
min.
clearance
INTERNAL
SURFACE
TOP SIDE FLUE - STANDARD
Diagram 3.3
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
Max flue length 717mm
20mm
min.
clearance
OUTSIDE
WALL FACE
TOP REAR FLUE - TELESCOPIC
13388
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
87min
BOILER
MOUNTING WALL
13389
OUTSIDE
WALL FACE
136
CL
FLUE
INTERNAL
SURFACE
A
Max. distance from outside Min. distance from outside
wall face to min clearance. wall face to min clearance.
LH - 330mm
LH - 125mm
RH - 433mm
RH - 228
Diagram 3.2
TOP SIDE FLUE - TELESCOPIC
10
Diagram 3.4
3 Flue Location and Ventilation
3.4 Terminal Position
The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 3.5. Dimensions shown are measured from
edge of terminal.
Only one dimension from the minimum clearance should be
applied, all others should be to the nominal clearance.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from the
flue outlet. This should be taken into consideration when
selecting the position for the terminal.
NOTE: If necessary it is permitted to increase the terminal
protrusion through the outside wall to greater than the minimum
dimension of 87mm but no more than 600mm, see diagram 1.1.
F
B
the building regulations, but they may need to be increased to
avoid wall staining and nuisance from pluming depending on
site conditions.
300
300
300
300
ABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS
C
3.5 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
HORIZONTALLY TO AN OPENING,
D
E
‡
F
G
AIR BRICK, OPENING WINDOWS
300
300
BELOW GUTTER, DRAIN/SOIL PIPE
25
75
BELOW EAVES
25
200
BELOW A BALCONY OR CAR PORT
25
200
If a terminal guard is required, it must be positioned to provide
minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
The guard should be plastic coated similar to that shown in
diagram 3.6.
FROM VERTICAL DRAIN PIPES AND
*
H
H
SOIL PIPES
25
75
FROM INTERNAL/EXTERNAL CORNERS
25
300
300
300
A suitable guard is manufactured by:
Tower Flue Components
TO A BOUNDARY ALONGSIDE THE
TERMINAL
I
Morley Rd.
Tonbridge
ABOVE ADJACENT GROUND OR
BALCONY LEVEL
J
* and J* See diagram 3.5 . These dimensions comply with
H
Min. Nom.
mm mm
DIRECTLY BELOW AN OPENING,
AIR BRICK, OPENING WINDOWS
*
K
L
‡
See diagram 3.5 . Carports or similar extensions
300
300
FACING THE TERMINAL
600
600
FACING TERMINALS
1200
1200
Kent
TN9 1RA
FROM SURFACE OR A BOUNDARY
Size: 280mm x 280mm x 270mm.
TERMINAL GUARD
FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING
1200
1200
M
VERTICAL FROM A TERMINAL
1500
1500
N
HORIZONTALLY FROM A TERMINAL
300
300
12325
A
‡
and L
of a roof only, or a roof and one wall, require special consideration
with respect to any openings, doors, vents or windows under the
roof. Care is required to protect the roof if made of plastic
sheeting. If the carport comprises of a roof and two of more
walls, seek advice from the local gas supply company before
installing the boiler.
SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION
HORIZONTAL FLUES
‡
VERTICAL FLUES
P
FROM ANOTHER TERMINAL
600
600
Q
ABOVE ROOF LEVEL
300
300
R
FROM ADJACENT OPENING WINDOW
1000
1000
S
FROM ADJACENT WALL TO FLUE
300
300
Diagram 3.5
Diagram 3.6
11
0020008877-04
4 Water System
4.1 Draining Tap
4.5 Bypass
A draining tap must be provided at the lowest point of the
system, which will allow the entire system and hot water system
to be drained.
A system bypass will be required fitted at least 1.5 metres away
from the boiler, refer to the current issue of the central heating
system specifications (CHeSS).
Draining taps shall be to the current issue of BS 2879.
4.6 Water Treatment
4.2 Safety Valve
In the case of an existing installation, it is ESSENTIAL that prior
to installing the new boiler the system is thoroughly flushed. For
optimum performance after installation of a new system, the
boiler and its associated central heating system should also be
flushed. Flushing should be carried out in accordance with
BS7593: 1992 using a cleanser such as Fernox or Salamander
products.
A safety valve need not be fitted to an open-vented system.
4.3 Pump
The pump should be fitted on the flow pipe from the boiler and
have isolating valves each side.
A variable duty pump should be set to give a temperature
difference of no greater than 200C between the flow and return,
with the thermostat set at “MAX”, which is about 800C, to give
a flow rate as shown in table 3.
For long-term corrosion protection, after flushing, an inhibitor
suitable for stainless steel exchangers should be used, refer to
the current issue of BS 5449 and BS 7593 on the use of
inhibitors in central heating systems. Examples are Fernox or
Salamander products.
See chart for pressure loss of the boiler, diagram 4.1.
High resistance microbore systems may require a higher duty
pump.
4.7 Open (Vented) Water System
4.4 Flow Rate
The boiler must be supplied from an unrestricted water supply
taken from a feed and expansion cistern situated at a maximum
height of 27 metres (90ft) above the boiler.
If it is necessary to alter the flow rate, the system can be fitted
with a lockable balancing valve in the main flow or return pipes
shown as valve “A” in diagram 4.3. The flow rate through the
boiler must not be allowed to fall below that given in Table 3.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
12430
450mm
MIN.
HEIGHT
Open (vented) system.
Recommended
relationship between
pump, cold feed and vent.
9235
It is important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 4.2.
IMPORTANT Flow and Return Pipe Sizes.
Heating circuit flow and return pipes should be sized as follows.
Upto 18 kW 22mm. over 18 kW 28mm.
22mm (MIN.) VENT
FEED AND
EXPANSION CISTERN
15mm (MIN) COLD FEED
Diagram 4.1
PUMP
Table 3. Flow Rate
OUTPUT
18
31
MINIMUM FLOW RATE
773.8 litres/hr (12.9litres/min)
1289 litres/hr (21.5litres/min)
BOILER
This is equal to 20oC differential acros the appliance.
0020008877-04
HEATING
CYLINDER
1000mm
MIN.
FLOW
RETURN
15mm (MIN.)
AUTOMATIC BY-PASS
150mm MAX.
Diagram 4.2
12
12999
4 Water System
Diagram 4.3
4.8 Combined Feed and Vent
4.12 Safety Valve
For combined feed and vent, a 22mm pipe must be fitted in
accordance with BS 5449.
A safety valve must be fitted to a sealed system.
4.9 Domestic Hot Water Cylinder
It shall be preset, non-adjustable with a lift pressure of 3 bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
The drain from the safety valve must be routed outside the
building, must not discharge above an entrance or window or
any type of public access area, be clear of any electrical fittings
and positioned so that any discharge can be seen.
The domestic hot water cylinder must be of the double feed fully
indirect coil type.
Thermal Stores
4.13 Expansion Vessel
This appliance is suitable for installation with thermal stores,
however, the appliance should be adjusted to give the maximum
31kW output.
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7074 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see the diagrammatic layout, diagram 4.3 unless laid
down differently by the manufacturer.
4.10 Domestic Hot Water System - unvented
General - All domestic hot water circuits, connections, fittings
must be in accordance with the relevant standards and water
supply regulations.
The expansion vessel volume depends on the total water
system volume and the initial system design pressure. For any
system an accurate calculation of vessel size is given in the
current issue of BS5449 and BS7074 Part 1.
For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulations Guide.
Example: For an initial design pressure of 0.7 bar, the minimum
total vessel volume required is 0.063 x Total System Volume.
For IE: The current edition of I.S.813 "Domestic Gas Installations".
NOTE: A higher initial design pressure requires a larger volume
expansion vessel.
Where a storage system will not have a vent to atmosphere the
installation must comply with the building regulations and local
Water Company bylaws, see also the current issue of BS5546
and BS6700.
Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1, for IE refer to the current edition of
I.S.813 "Domestic Gas Installations".
If fitting to an existing system the local authority should be
informed.
The charge pressure must not be less than the static head of the
system, that is, the height of the highest point of the system
above the expansion vessel.
4.11 Sealed water Systems
The installation must comply with the appropriate requirements
of the current issue of BS4814, BS5449, BS6759, BS6798 and
BS7074 Part 1 and 2.
See diagram 4.3 for a suggested layout.
13
0020008877-04
4.14 Pressure Gauge
SUPPLY
PIPE
A pressure gauge with a set pointer and covering at least 0 to
4 bar (0 to 60 lb/in2) shall be fitted permanently to the system in
a position where it can be seen when filling the system.
4.15 Domestic Hot Water Cylinder
BOILER
11680
4 Water System
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
CONTROL
VALVE
The domestic hot water cylinder must be of the double feed fully
indirect coil type. It must be suitable for working at a gauge
pressure of 0.35 bar above the safety valve setting.
DOUBLE
CHECK
VALVE
4.16 Water Make-up
FLOW
Provision should be made for replacing water loss from the
system using a make up bottle mounted in a position higher than
the top point of the system, connected through a non-return
valve to the return side of either the heating circuit or the hot
water cylinder.
HEATING
CIRCUIT
Alternatively, provision for make up can be made using a filling
loop.
4.17 Filling a Sealed Water System
RETURN
TEMPORARY
CONTROL HOSE CONNECTION
VALVE UNION
DRAIN
POINT
Provision for filling the system at low level must be made, see
diagram 4.4. There must be no permanent connection to the
mains water supply, even through a non-return valve.We do not
recommend filling using artificially softened water.
HOSE
UNION
Diagram 4.4
5 Installation Preparation
IMPORTANT: With regards to the Health and Safety Manual
Handling requirements, two persons shall be required to lift the
appliance, refer to manual handling on page 4.
SECURING
SCREW (2 OFF)
Lift the boiler out of the carton
RETAINING
LUG
(2 OFF)
12296
5.1 Appliance Pack
NOTE: The fittings pack and the flexible condensate outlet pipe
are located in the base polystyrene packing under the boiler
base and the bottom cover is located at the back of the boiler.
Remove both and put to one side.
Remove the polystyrene end packing pieces then carefully lay
the boiler on its back, remove the two front casing panel
securing screws and lift off the panel from two retaining lugs,
see diagram 5.1.
Remove the transit packaging behind the front panel and
discard.
FRONT CASING
PANEL
Carefully place front panel and screws to one side.
5.2 Wall Template
Diagram 5.1
Remove the wall template from the documentation pack and
place in the desired position on a flat wall, giving due consideration
to boiler clearances, see Section 2.2, and the flue you are fitting.
0020008877-04
14
5 Installation Preparation
12046
5.3 Flue Hole Cutting
(44mm/metre)
The standard horizontal flues are designed with an internal
fall of 44mm/metre towards the boiler for disposal of condensate.
If the standard flue length alone is being used then the flue hole
of diameter 105mm can be cut in the position marked on the wall
template.
WALL
TEMPLATE
176
900
For standard side flues the horizontal flue centre line on the
wall template should be extended to the side wall, and the
vertical centre of the flue hole marked at 176mm from the back
wall.
Ø 125
For installations with external access, a 105mm diameter core
drill can be used.
For installations with internal access only a 125mm diameter
core drill should be used.
When using extension pipes with the horizontal rear flue, a core
drill size of 125mm should be used to allow the extension pieces
to slope at 44mm/metre (2.50) towards the boiler.
EXTENDED SIDE FLUE
(Standard Flue type 'B' shown)
For extended side flues the flue hole centre should be
determined by extending the dashed inclined line on the template
to the side wall. This dashed line is drawn at 44mm/metre (2.50)
rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of the
flue should then be marked at 176mm from the back wall, see
diagram 5.2.
Diagram 5.2
To allow for the flue passing through the wall at this angle a
125mm hole should be drilled irrespective of internal or external
installation.
If necessary remove the wall template whilst drilling the flue
hole.
6.1 Hanging Bracket Fixing
WALL
TEMPLATE
If previously removed, reposition the wall template over the flue
hole and mark the position of the fixing holes for the hanging
bracket, see diagram 6.1.
12047
6 Boiler Fixing
Mark and drill the fixing holes and secure the hanging bracket,
which is supplied in the polystyrene pack.
NOTE: Due to the varied site conditions we do not supply fixings
and advise that the installer should supply those which are
suitable.
HANGING
BRACKET
6.2 Boiler Fixing
IMPORTANT: With regards to the Manual Handling Operations,
1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift, refer to Manual Handling
section on page 4.
Lifting the boiler into position, lean the top of the boiler slightly
to the wall and position just above the hanging bracket. Lower
the boiler slowly and engage onto the hanging bracket.
Make good the final connections.
WALL PLUG
(4 OFF)
SCREW No12 x 50mm
(4 OFF)
15
Diagram 6.1
0020008877-04
12934
7 Gas, Water and Condensate Connections
GAS SERVICE
COCK SHOWN IN
OPEN POSITION
UNION CONNECTOR
GAS SERVICE
COCK LINER
SPIGOT
GAS
SERVICE
COCK
FLEXIBLE
CONDENSATE
OUTLET PIPE
GAS
SUPPLY
PIPE IN
CONDENSATE DRAIN
CONNECTION
9244
7.1 Gas Connection
Diagram 7.1
Before connection check the supply of local gas.
Heating circuit flow and return
pipes should be sized as follows.
Up to 18 kW 22mm.
over 18 kW 28mm.
Compression is the
recommended fixing
for servicing. (not supplied)
The gas supply can be connected from below, see diagram 7.1.
or through the wall at the rear of the boiler.
Refer also to section 1.2 and 1.3.
The whole of the gas installation, including the meter, should be
inspected, tested for soundness and purged in accordance with
the document IGE/UP/1B.
7.2 Water Connections
Provision is made for the water connections to be made from
above the boiler, see diagram 7.2. The position is shown on the
wall template.
FLOW
Flush out the domestic hot water and the heating systems
before connecting to the boiler.
RETURN
7.3 Condensate Drain Connection
The condensate drain connection is at the rear of the boiler, see
diagram 7.1. A flexible condensate outlet pipe is supplied loose
in the base polystyrene packaging. The 900 end of the flexible
condensate outlet pipe should be used to fit onto the spigot, to
discharge condensate to a drain. The drain pipe 22mm to
25mm OD. non corrosive plastic pipe should have a fall of at
least 2.50 away from the boiler.
Diagram 7.2
Condensate should, if possible be discharged into the household
internal drainage system. If this is not practicable, discharge
can be allowed into the external household drains or a purpose
designed soak away, refer to diagram 7.3.
It is recommended that any external condensate drain pipe is
preferably of 32mm diameter, to prevent freezing in adverse
weather conditions.
The condensate is discharged periodically in ‘slugs’ by siphonic
action.
It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a 75mm high trap inside the
boiler. Fitting an extra trap may cause the boiler siphon to work
incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
0020008877-04
16
INTERNAL SOIL
AND VENT STACK
13000
7 Gas, Water and Condensate Connections
EXTERNAL SOIL
AND VENT STACK
BOILER
BOILER
EXTERNAL
MAX. 3M
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
Internal Soil and Vent Pipe
External Soil and Vent Pipe or Rainwater Pipe
SINK
(CONSTITUTES
AIR BREAK)
BOILER
EXTERNAL LENGTH
OF PIPE 3M MAX.*
Ø22mm MIN.
OPEN END OF PIPE
DIRECT INTO GULLEY
BELOW GROUND BUT
ABOVE WATER LEVEL
BOILER
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
Internal Termination into Combined Sink Waste
*NOTE: FOR EXTENDED
PIPE RUNS 32mm DIA.
PIPE SHOULD BE USED.
External Termination to a Gulley or Hopper
EXTERNAL LENGTH OF PIPE
3M MAX.
Ø22mm MIN.
TERMINATION FROM APPLIANCE.
GROUND
(either/or)
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
BOILER
500mm MIN.
SINK
SEAL
25mm MIN.
Ø100mm
PLASTIC TUBE
300mm
MIN.
BOTTOM OF
TUBE SEALED
OPEN END OF PIPE DIRECT INTO
GULLEY BELOW GROUND LEVEL
BUT ABOVE WATER LEVEL.
LIMESTONE CHIPPINGS
HOLE DEPTH
400mm MIN.
Internal Termination Downstream of
Sink Waste
2 ROWS OF 3 x 12mm HOLES AT
25mm CENTRES 50mm FROM
BOTTOM OF TUBE. HOLES TO
FACE AWAY FROM HOUSE.
External Termination into Soakaway
NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5
44mm FOR EVERY 1M.
o
Diagram 7.3
17
0020008877-04
8 Flue Preparation Telescopic and Standard Flue
Additional flue accessories are available to suit your site
conditions, see diagram 8.2.
8.1 Flue Components
Top Outlet Horizontal Concentric Flue Packs:
A2043600 Horizontal telescopic flue pack.
A2043400 Standard horizontal flue pack.
SEALING
TAPE (telescopic only)
12841
The components supplied in the Standard and Telescopic kit
are shown in diagram 8.1.
FLUE
ELBOW
SECURING
COLLAR
SCREW x 4
SCREW x 2
SCREW x 2
SEALING
COLLAR
GASKET
(fitted)
SCREW x 1
TELESCOPIC
TERMINAL ASSEMBLY
SEALING
COLLAR
Diagram 8.1
12842
STANDARD
TERMINAL ASSEMBLY
45o Bend
2000460485
(2off)
90o Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460482
VERTICAL
FLUE
ADAPTOR
A2024600
2m
EXTENSION
2000460483
0020008877-04
Diagram 8.2
18
8 Flue Preparation Telescopic and Standard Flue
8.2 Flue Length
8.3 Preparation
Top Rear flue - Standard - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 8.3. If the measurement 'Y' exceeds 652mm,
then the appropriate length of extension pipe is required. The
minimum dimension is 187mm to suit a 75mm min wall thickness.
Telescopic:
The Telescopic Flue system MUST NOT be cut.
Adjust the flue to your required length "Y", ensure the air duct
seams line up mark the securing hole position in the air duct.
Drill a 3mm diameter hole at this position, take care not to pierce
the inner flue duct. Secure with screw provided and tape the
joint, see diagram 8.5.
Top Rear flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 8.3. If the measurement 'Y' exceeds 525mm,
then the appropriate length of extension pipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
Standard:
Separate the flue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 8.6.
Top Side flue - Standard - with the flue elbow temporarily fitted,
measure the distance from the outside wall to the butt joint, see
diagram 8.4. If the measurement 'Y' exceeds 652mm, then the
appropriate length of extension pipe is required. The minimum
dimension for Lhd is 270 and Rhd 167 to suit a minimum wall
thickness of 75mm.
The duct cutting lengths are shown in diagram 8.6.
The air duct should be cut at the opposite end to the terminal
fixing.
The terminal plastic flue duct MUST be cut at the opposite end
to the catch.
Top Side flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, see diagram 8.4. If the measurement 'Y' exceeds 525mm,
then the appropriate length of extension pipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
The plastic flue duct extensions MUST be cut at the opposite
end to seal.
The cut ducts must be de-burred and all filings and debris
removed.
12806
12929
NOTE: If you require to lubricate the seals to ease installation,
please do not use a mineral oil based grease, we would
recommend the use of water.
L
12847
Diagram 8.5
Diagram 8.3
13160
TOP REAR FLUE
AIR DUCT
L
13mm
TERMINAL
CATCH
FLUE DUCT
L + 11mm
TOP SIDE FLUE
Diagram 8.6
Diagram 8.4
19
0020008877-04
8 Flue Preparation Telescopic and Standard Flue
NOTE: If the air and flue ducts have been correctly cut to the
instructions given in section 8.2, the rubber sealing collar should
fit flush with the outside wall, check this.
8.4 Flue Fitting (Telescopic and Standard)
Fit the rubber sealing collar behind the locating lugs on the flue
terminal, see diagram 8.7.
RUBBER
SEALING
COLLAR
Secure the flue elbow in position on top of the boiler with four
torque headed screws supplied.
INTERNAL TRIM RING
COLLAR
13157
Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.
Push the flue assembly into the wall, externally or internally,
initially until the end of the assembly protrudes a short way from
the inside face of the wall. This will enable the internal trim ring(if
required) to be positioned and allow the flue duct to be drawn
back into the flue elbow.
DRILL AND
SCREW
Draw the flue assembly from wall and engage the flue duct into
the elbow and butt fit between the air duct and flue elbow.
Enure alignment of the terminal.
Fit the collar into position, mark through two of the pre drilled
holes in the collar. Remove collar and drill two 3mm diameter
holes in the elbow, take care not to pierce the inner flue duct.
Fit the collar and secure with screws provided, see diagrams
8.8 standard rear, 8.9 telescopic rear, 8.10 standard side and
8.11 telescopic side.
OUTSIDE
WALL FACE
BOILER MOUNTING
WALL FACE
13158
12977
Diagram 8.9
INTERNAL TRIM RING
COLLAR DRILL
AND
SCREW
RUBBER
SEALING
COLLAR
CL
FLUE
OUTSIDE
WALL FACE
INTERNAL TRIM RING
COLLAR
INTERNAL TRIM RING
COLLAR DRILL
AND
SCREW
13159
RUBBER
SEALING
COLLAR
Diagram 8.10
13156
Diagram 8.7
DRILL AND
SCREW
RUBBER
SEALING
COLLAR
CL
FLUE
OUTSIDE
WALL FACE
OUTSIDE
WALL FACE
BOILER MOUNTING
WALL FACE
Diagram 8.8
0020008877-04
Diagram 8.11
20
WARNING: This boiler must be earthed.
RETAINING
SCREWS (2)
This appliance must be wired in accordance with these
instructions. Any fault arising from incorrect wiring cannot be
put right under the terms of the guarantee.
12953
9 Electrical Connections
All system components must be of an approved type.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on each
pole. The fused spur box should be readily accessible and
preferably adjacent to the boiler. It should be identified as to its
use.
A fused three pin plug and shuttered socket outlet may be used
instead of a fused spur box provided that:
a) They are not used in a room containing a fixed bath or
shower.
CONNECTION
BOX
b) Both the plug and socket comply with the current issue of
BS1363.
13113
The mains electrical supply must be maintained at all times in
order to provide domestic hot water.
Diagram 9.1
Do not interrupt the mains supply with a time switch or
programmer.
9.1 External controls (Mains Voltage)
Important: If a replacement supply cable is required it must be
purchased. Part No. S1008600.
Ensure that a separate external controls cable and pump supply
cable are fed to the boiler.
Refer to wiring diagram in section 12.
The boiler is fitted with a connection box located at the base of
the boiler into which all connections are made.
To gain access to the connection box remove the two retaining
screws indicated in Diagram 9.1 and carefully lower and pull
forward the box to reveal the terminal strip inside.
Remove the test cable from the terminal strip and discard.
Connect both the mains supply and switched live from the
external controls (room thermostat and, if applicable, frost
thermostat) into the marked terminals as shown in diagram 9.2.
If a room thermostat is not fitted, then the connecting link must
be fitted between terminals 1 and 2, see diagrams 9.2 and 12.2.
Connect the pump supply into the marked pump terminals as
shown in diagram 9.2.
Observe all terminal markings and colour codes as shown in
diagram 12.2.
NOTE: The boiler incorporates a pump overrun thermostat.
Only feed the pump from the marked terminals in the connection
box on the boiler, not from a separate supply.
Ensure that all flexible cords are routed through the strain relief
cable glands on the inlet of the connection box.
Refit the connection box to the underside of the boiler using the
two retaining screws.
Diagram 9.2
21
0020008877-04
9 Electrical Connections
9.2 Electrical connections - testing
9.3 Pump Connection
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cable.
Ensure that a separate pump supply cable is fed to the boiler,
see diagram 9.2.
2. Test the earth continuity and short circuit of cables.
Remove connection box, see diagram 9.1.
Route the pump supply cable through the strain relief cable
gland, connect to the connection box as shown in diagram 9.2.
Refer to diagram 12.1 for wiring colour code.
3. Test the polarity of the mains.
Refit the connection box to the underside of the boiler using the
two retaining screws.
10 Commissioning
Please ensure the British Gas logbook is completed and left
with the user.
10.2 Sealed Systems
Fill the system until the pressure gauge registers the
recommended pressure. Clear any air locks and check for
leaks.
10.1 Preliminaries - All Systems
Remove the casing panels, see diagram 10.1.
Release the cold water to the initial design pressure.
A competent person in accordance with the current issue of
BS6798 should carry out commissioning.
RANGE RATING TABLE 4
Make sure that the system has been thoroughly flushed out with
cold water.
BURNER
%CO2
Refill the system with water, making sure that all the air is
properly vented from the system and pump, diagram 10.2
shows vent point.
OUTPUT
31 kW
24 kW
18 kW
15 kW
12 kW
Before operating the boiler check that all external controls are
calling for heat. Do not operate the boiler without water.
Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.
CASING
PANEL
FAN
SETTING
47
36
29
23
19
9.1 +0.3 -0.3
9.3 +0.3 -0.3
APPROXIMATE GAS RATE
m3/h
3.31
2.54
1.90
1.59
1.27
ft3/h
117
90
67
56
45
12361
Drain the entire system rapidly whilst hot, using the drain tap at
the lowest part of the system. Following completion of the hot
flush, add inhibitor to the system.
Case Off
Case On
INNER
CASING
PANEL
SECURING
SCREW (2 OFF)
SECURING
SCREWS
Diagram 10.1
0020008877-04
22
10 Commissioning
Ensure external controls are calling for heat. The boiler should
fire automatically.
10.3 Preparation for Lighting
Isolate the boiler from the mains electrical supply.
Allow the boiler to fire for a minimum of 60 seconds and then,
using an electrical screwdriver, rotate the ‘service’ potentiometer
fully clockwise, see diagram 10.5. This will allow the digital
display to indicate the ‘flashing’ fan speed on the appliance
fascia.
Test for gas soundness and purge air from the gas supply. Turn
on the gas service cock, slot in line with the length of the valve,
see diagram 7.1.
10.4 Initial Lighting
In the fully clockwise position the display should be indicating
the maximum fan speed of the appliance which is factory set to
18kW.
The lighting procedure of the boiler is fully automated.
Check that all external controls are calling for heat. If an integral
programmer is fitted check that it is correctly programmed and
if necessary overridden to provide heat.
Use 'Pmax' potentiometer to adjust the fan speed to the number
corresponding to the maximum output required, see table 4.
To adjust to 24 or 31kW output the security seal on the 'Pmax'
potentiometer must be broken for access and adjustment.
Ensure that the water temperature control knob is turned OFF
(
).
Rotate the 'service' potentiometer fully anti-clockwise so that
the digital display indicates the water temperature.
Turn on the mains electrical supply and the mains reset switch
to (I) on the controls fascia.
Turn the water temperature control knob to (
Check the gas rate, refer to Section 10.6.
) MINIMUM.
Close the fascia panel and replace the chassis front, inner
casing panel, front casing panel and fit the bottom cover , see
diagram 10.6.
The fan should start and after a few seconds the ignition will
commence
If the burner fails to light the fan will stop. Initially this may be due
to air in the gas supply line. The boiler will automatically have
three attempts at ignition.
10.6 Testing - Gas (Natural Gas only)
Refer to Table 4 for Burner CO2 levels. Should any doubt exist
about the gas rate, check it using the gas meter test dial and
stop watch at least 10 minutes after the burner has lit, making
sure that all other gas burning appliances and pilot lights are off.
If necessary turn the mains reset switch to the off position (O),
then back to the on position (I) and the boiler will restart.
After the boiler has lit, allow to warm at MINIMUM temperature
setting to purge any air from the system.
The gas valve is factory set for natural gas (G20) and should
need no adjustment. It should be checked that the supply
pressure is 20mb when the boiler is firing at full rate. This can
be achieved by checking the inlet pressure at the pressure test
point on the gas valve shown in diagram 10.3 using range rating
table 4.
NOTE: If the appliance is operated above MINIMUM on initial
lighting, there is a possibility that the overheat stat will trip, this
is due to air in the system having not been purged. See diagram
10.4 for overheat thermostat/reset switch.
Disconnect pressure gauge.
Once the system has been purged of air turn the central heating
knob to the desired temperature.
Note that the burner pressure cannot be measured at the gas
valve as it is altered by the suction of the fan and modulated
according to demand.
The appliance will then continue to fire until the user controls are
satisfied.
Replace inner casing panel and casing panel.
NOTE: After first power up the firing sequence for central
heating changes. After one minute stabilisation time the boiler
will ramp slowly to full rate rather than going immediately to full
rate. This is an adaptive feature to cope with small system
requirements.
10.7 Testing - Heating System
Check that all remote controls are calling for heat. The boiler will
fire automatically. Fully open all radiator valves, flow control
valve ‘A’ and bypass valve ‘B’, see diagram 4.3.
10.5 Range Rating
Balance the radiators as required and if fitted adjust valve ‘A’ to
give the required system differential. Turn off all radiators that
can be shut off by the user and check to see if less than the
maximum differential allowed of 200C can be achieved across
flow and return.
NOTE: This appliance is factory set at 18kW output.
IMPORTANT: If the seal on the 'Pmax' potentiometer is broken
the gas supply, without exception, must be capable of delivering
31.3kW input.
Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.
On completion of the adjustment, the inlet working pressure of
the appliance should be checked to ensure a steady inlet
working pressure of 20Mbar is achieved.
Drain the entire system rapidly whilst hot, using the drain tap at
the lowest part of the system. Fill and vent the system as
described previously in section 10.1.
The appliance data label must be completed to indicate the
maximum output using the rate indicating label provided in the
literature pack.
Lock or remove the handles from controls valve ‘A’ to prevent
unauthorised adjustment.
NOTE: This appliance is suitable for installation with thermal
stores, however, the appliance should be adjusted to give the
maximum 31kW output.
10.8 User Controls and Options
The mains reset switch is used to restart the boiler after a fault
condition has occurred, i.e. ignition failure.
To Adjust to 24 or 31kW:
The water temperature control knob allows the user to set the
desired temperature.
Remove casing panel, see diagram 10.1.
With the power off and the appliance cold, unclip the controls
fascia and hinge it down to reveal the potentiometers on the rear
of the User interface, see diagram 10.5. Take care not to allow
the fascia to drop down and damage the wiring.
Temperature Display
The digital display normally shows the operating temperature
of the unit.
Turn on the electrical supply.
23
0020008877-04
10.9 Pump Exercise Program
OVERHEAT
THERMOSTAT /
RESET SWITCH
After a power cut or every 24 hour in frost setting/summer mode
the pump will run for one minute to prevent it from sticking. This
will also occur during normal operating if there is no demand for
more than 24 hours
10.10 Frost Protection
11404
10 Commissioning
FLOW
PIPE
The boiler has a built in frost protection programme as long as
the electricity and gas are left switched on.
This device operates the burner and system pump when the
temperature inside the boiler falls to 30C.
When the temperature inside the appliance reaches 10°C the
burner will shut down and after a short period the pump will stop.
This device primarily protects the boiler. Any other exposed
areas of the system should be protected by a separate frost
thermostat.
RETURN
PIPE
OVERHEAT
THERMOSTAT
FLOW
PIPE
RETAINING
LATCHES
12372
FLOW
THERMISTOR
11404
Diagram 10.4
VENT POINT
OFFSET
ADJUSTMENT
USER
INTERFACE
PMAX
POTENTIOMETER
AND SECURITY SEAL
12357
CONTROLS
FASCIA
Diagram 10.2
12412
RETURN
THERMISTOR
THROTTLE
THE
BROKEN
SEAL IS
ST,
IF THE
PPLY MU N,
GAS SU
PTIO
T EXCE
ING
WITHOU OF DELIVER
PABLE
TPUT
BE CA
31kW OU
GAS
VALVE
ELECTRICAL
PLUG
WARNING
LABEL
PRESSURE TEST
POINT
Diagram 10.3
0020008877-04
SERVICE
POTENTIOMETER
POTENTIOMETERS
24
Diagram 10.5
10 Commissioning
12377
10.11 Instruct the User
Instruct and demonstrate the lighting procedure and advise the
user on the safe and efficient operation of the boiler.
Instruct on and demonstrate the operation of any heating
system controls.
Advise the user on the use and maintenance of any scale
reducer and pass on any relevant instructional documents.
Advise that to ensure the continued efficient and safe operation
of the boiler it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will depend upon
the installation conditions and usage, but in general, once a
year should be enough.
Draw attention, if applicable, to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any property
containing a gas appliance.
STEP 1
It is the Law that any servicing is carried out by a competent
person.
Advise the user that, like all condensing boilers this appliance
will produce a plume of condensation from the flue terminal in
cool weather. This is due to the high efficiency and hence low
flue gas temperature of the boiler.
Advise the user of the precautions necessary to prevent damage
to the system, boiler and the building, in the event of the heating
system being out of use during frost or freezing conditions.
Advise the user that the permanent mains electrical supply
SHOULD NOT be switched off, as the built in frost protection
and pump saver program would not be operable.
Reminder, leave these instructions and the British Gas logbook
with the user.
10.12 Completion
STEP 2
Adjust the boiler temperature control and any system controls
to their required settings. In addition it is necessary to complete
the British Gas logbook.
NOTE: Scottish Gas only. Remove the British Gas badge from
the front casing panel. Replace with the Scottish Gas badge
supplied in the fixing pack.
Testing Flue Gases: If any doubt exists that the flue products
are not exhausting correctly, investigate by use of a gas
analyser (FGA).
For IE, it is necessary to complete a "Declaration of Conformity"
to indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.
STEP 3
BOTTOM COVER
25
Diagram 10.6
0020008877-04
11 Servicing
IMPORTANT NOTES:
1. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year
should be enough.
2. It is the Law that any servicing is carried out by a competent person.
3. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the
gas supply should be turned off at the gas isolation valve.
4. When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by
British Gas.
5. On completion of sevicing the "Benchmark" log book should be completed.
11413
11.1 General Inspection
Prior to servicing carry out an initial inspection of the following:
1. Condition of case and flue.
2. Flue terminal for obstructions.
11490
3. Electrical supply connections.
4. Water connections.
5. Gas connection.
6. System pressure.
11.2 Functional Checks
With the appliance operational carry out the following functional
checks:
1. Check the combustion, preferably with a flue gas analyser as
described in section 11.8. If a flue gas analyser is not available
remove the outer and inner case, see diagram 10.1, and taking
care not to touch any components, check the flame picture
through the viewing window, diagram 11.1.
VIEWING
WINDOW
Should the flame show signs of lift, sooting or appear yellow
then it will be necessary to service the burner, if the servicing
does not correct the condition, then proceed to the combustion
test described in section 11.8.
2. Measure the gas rate during operation. If the gas rate is lower
than the minimum gas rate the burner will require servicing.
Should the combustion measurement or flame and gas rate be
correct, then it is not necessary to remove the burner assembly
for a service.
Diagram 11.1
11.4 Spark Electrode
11.3 Servicing
Disconnect the electrode lead and two securing screws.
Withdraw the spark electrode carefully from the combustion
chamber, see diagram 11.4 and 11.6.
All routine servicing requirements can be achieved by the
removal of the front panel and inner panel and chassis front
only.
Inspect the tips for damage.
Before commencing with a service or replacement of parts. The
boiler should be isolated from the electrical supply and the gas
supply should be turned off at the gas service cock, see
diagrams 11.2 and 11.3.
Clean away any debris and check the spark gap is 3.5 to 4.5
mm.
Check the electrode gasket for signs of damage and replace if
necessary.
Unless stated otherwise parts are replaced in the reverse order
to removal
0020008877-04
If the burner is not to be serviced continue from section 11.9.
26
SEALING
GROMMET
12952
12295
11 Servicing
GAS PIPE BRACKET
SECURING SCREW
CONDENSE
TRAP
UNION NUT
GAS SERVICE
COCK
STEP 1
GAS
SUPPLY PIPE IN
11410
Diagram 11.3
SPARK GAP
3.5 to 4.5mm
STEP 2
SPARK
ELECTRODE
GASKET
SECURING
SCREW
2 OFF
STEP 3
EARTH LEAD
BOTTOM COVER REMOVAL
Diagram 11.4
Diagram 11.2
27
0020008877-04
11.5 Burner
9247
11 Servicing
CHASSIS
FRONT
NOTE: IF THE FUNCTIONAL CHECKS DID NOT INDICATE
POOR COMBUSTION THEN IT IS NOT NECESSARY TO
SERVICE THE BURNER.
The following procedure will require that you replace the burner
door seal and nyloc nuts.
Disconnect the gas supply at the gas service cock.
SECURING
SCREW
(4 OFF)
NOTE: DO NOT DISCONNECT AT THE GAS VALVE.
Remove the two gas pipe bracket securing screws from
underside of inner case, see diagram 11.3.
Drop down the control panel into the service position.
Remove the four screws from the chassis front, see diagram
11.5.
Remove the chassis front by pulling it out at the top from its
retaining slots.
NOTE: When replacing chassis front panel ensure the bottom
fits behind lip.
CONTROL PANEL
SERVICE POSITION
Diagram 11.5
Disconnect the electrical leads from the fan.
SPARK
ELECTRODE
PLUG
Remove the five combustion chamber burner door securing
nuts, see diagram 11.7, these should be discarded and replaced
with the new nylocs nuts supplied in the burner door seal kit.
EARTH
LEAD
12453
Disconnect the gas valve electrical plug at the gas valve, see
diagram 11.6.
Gently remove the fan, gas valve and burner assembly from the
combustion chamber complete with the gas pipe bracket and
seal.
Clean the burner with a soft brush taking great care not to
damage the front insulation. DO NOT use wire or sharp
instruments to clean the holes of the burner.
Inspect the burner for any signs of damage.
Removal of the burner is not necessary during a normal service,
see diagram 11.7.
NOTE: IF THE BURNER HAS TO BE REMOVED IT WILL
REQUIRE A NEW GASKET WHEN REFITTED, REFER TO
DIAGRAM 11.8.
Remove and discard the burner door seal and replace with new
see diagram 11.7.
NOTE: When replacing ensure that the sealing grommet,
situated below the gas valve is correctly re-seated
11.6 Combustion Chamber and Heat
Exchanger.
FAN
ELECTRICAL
LEAD
Refer to diagram 11.7.
Remove loose debris from combustion chamber using a soft
brush and vacuum cleaner. Carefully flush by spraying water
any remaining debris through the condensate trap (Ensure the
water is kept away from electrical components).
Diagram 11.6
11.7 Condensate Drain
The condensate drain does not normally need removing during
servicing.
To flush the condensate drain carefully pour water into the heat
exchanger and check that water flows freely to drain.
If the condensate drain becomes blocked refer to section 13.16
for removal.
0020008877-04
GAS VALVE
ELECTRICAL PLUG
28
13495
11 Servicing
SECTION THROUGH
BURNER DOOR SHOWING
POSITION OF SEAL
COMBUSTION
CHAMBER
SEAL
NYLOC
SECURING
NUTS
(5 OFF)
FAN
BURNER
GAS
VALVE
GAS PIPE BRACKET
AND SEAL
113438
Diagram 11.7
BURNER
BURNER
DOOR
SECURING
SCREW (4)
GASKET
Diagram 11.8
29
0020008877-04
11 Servicing
Once the appliance has been reassembled (apart from the front
and inner casing panels) connect a flue gas analyser to the
sample point on the flue elbow, see diagram 11.9.
12372
11.8 Combustion Check
RETAINING LATCHES
Turn on the gas service cock, see diagram 11.3.
With the power off and the appliance cold, unclip the controls
fascia and hinge it down to reveal the potentiometers on the rear
of the User interface, see diagram 11.10. Take care not to allow
the fascia to drop down and damage the wiring.
Turn on the electrical supply.
Ensure external controls are calling for heat. The boiler should
fire automatically.
Allow the boiler to fire for a minimum of 60 seconds and then,
using an electrical screwdriver, rotate the ‘service’ potentiometer
fully clockwise, see diagram 11.10. This will allow the digital
display to indicate the ‘flashing’ fan speed on the appliance
fascia.
CONTROLS
FASCIA
This should correspond to the range rated output of the boiler,
as indicated on the boiler data label. If the appliance is set to
18kW and the security label on the Pmax potentiometer is intact
this is the maximum output for the boiler. If the seal is broken the
output should be taken as 31kW, with an adequate gas supply,
see Range Rating Table 4, in section 10.
12357
USER
INTERFACE
Carry out a performance test, the CO2 level should be 9.1% ±
0.3.
If adjustment is necessary, refer to section 13.5, Replacement
of Parts.
Turn the service potentiometer back fully anti-clockwise to
return the boiler to normal operation, close the front fascia panel
and replace the cap on the sampling point.
11.9 Inner Casing Panel Seal Check.
Refer to diagram 11.11.
Check the condition of the seal, replace as required.
MIN.
To replace remove the old seal, thoroughly clean the casing
surfaces. Fit the new seal, it is supplied to the correct length.
SERVICE
POTENTIOMETER
MAX.
11.10 Completion
Diagram 11.10
FLUE ELBOW
FRONT
CASING
PANEL
INNER
CASING
PANEL
12370
13379
The Benchmark log book should be completed.
VERTICAL FLUE
ADAPTOR
COMBUSTION
ANALYSER
SAMPLE POINT
SEAL
Diagram 11.11
Diagram 11.9
0020008877-04
30
12 Fault Finding
9247
12.1 Important Notes
Before trying to operate the boiler make sure that :
• All gas supply cocks are open and that the gas supply has
been purged of air.
RETAINING
STRAP
• There is a permanent mains supply to the boiler.
• There is a heating demand from the external controls.
Always check for gas soundness after any service work.
12.2 Electrical Testing
Should there be any doubt about the voltage supply to any of the
components, it is possible to carry out a simple electrical test.
Important. On completion of the Service/Fault Finding tasks
which have required the breaking and remaking of the electrical
connections the earth continuity, polarity, short circuit and
resistance to earth checks must be repeated using a suitable
multimeter.
RETAINING
SLOT
To carry out the electrical test, gain access, as follows:
CONTROL PANEL
Diagram 12.1
Hinge down the control box and remove Torx screws and
unhook the rear panel, refer diagram 12.1.
Refer to the Wiring diagram 12.2 and fault finding charts
diagrams 12.3 and 12.4.
31
0020008877-04
12933
12 Fault Finding
Diagram 12.2
0020008877-04
32
12191
12 Fault Finding
Diagram 12.3
33
0020008877-04
12188
12 Fault Finding
Diagram 12.4
0020008877-04
34
13 Replacement of Parts
13.1 Important Notes
13.5 Gas Valve
When replacing a part on this appliance, use only spare parts
that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy
parts that have not been clearly authorised by British Gas.
For access, refer to section 13.1.
Replacement of parts must be carried out by a competent
person.
Before removing the gas valve note its position on the fan.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
Remove the three securing screws, which fix the gas valve,
plastic swirl plate to the venturi on the fan.
Before replacing any parts the boiler must be isolated from the
mains electric supply and the gas must be turned off at the
service cock on the boiler, see diagrams 11.2 and 11.3.
Remove the gas valve.
Remove the gas supply pipe from the gas valve.
Unless stated otherwise parts are replaced in the reverse order
to removal.
When refitting the gas valve take care as it can be fitted more
than one way.
After replacing any parts always test for gas soundness and if
necessary carry out functional test of the controls.
After assembly test for gas soundness and purge in accordance
with the current issue of BS6891 or in IE, the current edition of
I.S.813 "Domestic Gas Installations".
For replacement of parts, remove the casing panels and chassis
front panel of the boiler, see diagrams 10.1 and 11.5 .
Once the appliance has been reassembled (apart from the front
and inner casing panels) the gas valve may require adjustment.
Connect a CO2 combustion analyser to the sampling point on
the flue elbow, see diagram 11.8.
Remove the two screws on the underside of the front casing,
then undo the two screws on the front of the inner front panel
and lift off. Remove the four screws from the chassis front
panel, then remove it by pulling it out at the top from its retaining
slots.
Turn on the gas service cock, see diagram 11.3.
With the power off and the appliance cold, unclip the controls
fascia and hinge it down to reveal the potentiometers on the rear
of the User interface, see diagram 11.10. Take care not to allow
the fascia to drop down and damage the wiring.
NOTE: When replacing chassis front panel ensure the bottom
fits behind the lip.
The side panels can be hinged sideways to aid replacement of
parts.
Turn on the electrical supply.
Undo and remove the three screws securing each side panel to
the boiler, two at the front and one at the top.
Ensure external controls are calling for heat. The boiler should
fire automatically.
NOTE: The following replacement parts in sections 13.5 to 13.9
will require the removal of the burner door assembly. This will
require that you replace the burner door seal and nyloc nuts.
Allow the boiler to fire for a minimum of 60 seconds and then,
using an electrical screwdriver, rotate the ‘service’ potentiometer
fully clockwise, see diagram 11.10. This will allow the digital
display to indicate the ‘flashing’ fan speed on the appliance
fascia.
13.2 Spark Electrode
For access, refer to section 13.1.
This should correspond to the range rated output of the boiler,
as indicated on the boiler data label. If the appliance is set to
18kW and the security label on the Pmax potentiometer is intact
this is the maximum output for the boiler. If the seal is broken the
output should be taken as 31kW, with an adequate gas supply,
see Range Rating Table 4.
Remove the spark plug lead, earth lead and two securing
screws. Withdraw the spark electrode carefully from the
combustion chamber, see diagram 11.4.
13.3 Igniter Unit
For access, refer to section 13.1.
If adjustment proves necessary then proceed as follows:
Remove ignition lead and electrical connections, see diagram
13.4.
Any adjustment to the gas valve should only be carried out by
a competent person.
Remove igniter unit by removing two securing screws, see
digram 13.4.
Refer to diagram 10.3.
Adjust the CO2 with the throttle to 9.1% + 0.3 - 0.3.
(Rotate anti-clockwise to increase).
13.4 Ignition Lead
Rotate the ‘service’ potentiometer fully anti-clockwise. Hold it
in this position for about 5 seconds before rotating the service
potentiometer clockwise to the mid-point or 3 o’clock position.
The fan should reduce to 1200 rpm which will flash ‘12’ on the
digital display.
For access, refer to section 13.1.
Refer to diagram 11.6.
Pull the spark plug style connector off the spark electrode and
the spade connector connected to the igniter unit.
Check the CO2 value which should be 9.1% + 0.3 - 0.3.
If adjustment of the CO2 at minimum rate is required, it is very
coarse so carefully adjust the CO2 with the offset adjustment to
9.1%, see diagram 10.3.
Rotate the ‘service’ potentiometer fully clockwise, see diagram
11.10, and recheck the combustion, which should be 9.1% +
0.3 -0.3.
Turn the service potentiometer back fully anti-clockwise to
return the boiler to normal operation, close the front fascia panel
and replace the cap on the sampling point.
35
0020008877-04
13.6 Fan
11485
13 Replacement of Parts
GAS
MANIFOLD
For access, refer to section 13.1.
Remove electrical plug.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
SECURING
SCREW
(2)
Remove the gas valve as described in the relevant parts of
section 13.1.
Remove the venturi plate secured with three screws and
remove the two screws securing the fan to the gas manifold, see
diagram 13.1.
FAN
Check the gasket and replace if necessary.
13.7 Burner
VENTURI
PLATE
For access, refer to section 13.1.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
SECURING
SCREW (3)
Remove the four screws that secure the burner.
Diagram 13.1
WASHER
13.8 Front Insulation
11412
NOTE: THE BURNER WILL REQUIRE A NEW GASKET
WHEN REFITTED.
For access, refer to section 13.1.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
Remove burner as per section 13.7.
Remove spark electrode, see section 13.2.
NOTE: THE BURNER WILL REQUIRE A NEW GASKET
WHEN REFITTED.
SECURING
SCREW
13.9 Rear Insulation
For access, refer to section 13.1.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
REAR
INSULATION
Remove securing screw and washer in the centre of the
insulation and withdraw insulation, see diagram 13.2.
HEAT
EXCHANGER
13.10 Viewing Window
Diagram 13.2
Refer to diagram 13.3.
FIBRE
WASHER
Remove circlip.
GLASS
11413
For access, refer to section 13.1.
Remove steel washer.
Remove glass.
Remove fibre washer.
Replace in reverse order.
CIRCLIP
STEEL
WASHER
Diagram 13.3
0020008877-04
36
13.11 Heat Exchanger
FLOW AND RETURN
PIPE NUTS
Refer to Manual Handling section on page 4.
SECURING SCREWS
AND CLAMPS (3 OFF)
12453
13 Replacement of Parts
For access, refer to section 13.1.
Refer to section 11.5 for removal of the fan, gas valve and
burner assembly.
Drain the boiler.
Remove the clip securing the clear condense pipe to heat
exchanger.
ELECTRICAL
CONNECTION
Pull to remove the clear condense pipe out of the bottom of the
heat exchanger.
IGNITION
LEAD
Undo the two nuts of the flow and return pipes from the heat
exchanger, see diagram 13.4.
Move the pipes away from the heat exchanger.
IGNITER
UNIT
Loosen the three heat exchanger securing screws and clamps
(two at the top and one at the bottom) to remove the heat
exchanger, see diagram 13.4.
Diagram 13.4
Remove clear condense pipe connector from bottom of heat
exchanger.
11602
CAUTION: There will be water in the heat exchanger.
FLUE HOOD
13.12 Flue Hood
For access, refer to section 13.1.
Remove heat exchanger as per section 13.11.
Remove the two securing screws and pull the flue hood down
and away from the flue hood bracket and flue elbow, see
diagram 13.5.
FLUE HOOD
BRACKET
13.13 Heating Flow Thermistor
For access, refer to section 13.1.
Refer to diagram 13.6.
Remove the electrical connections from the thermistor.
Remove the retaining clip from the flow pipe.
SECURING
SCREWS
Remove the thermistor from the retaining clip.
Note that the polarity of the wiring to thermistors is unimportant.
Diagram 13.5
13.14 Heating Return Thermistor
Refer to diagram 13.6.
HEATING FLOW
THERMISTOR
Remove the electrical connections from the thermistor.
OVERHEAT
THERMOSTAT
11404
For access, refer to section 13.1.
Remove the retaining clip from the flow pipe.
Remove the thermistor from the retaining clip.
FLOW
PIPE
Note that the polarity of the wiring to thermistor is unimportant.
13.15 Overheat Thermostat
For access, refer to section 13.1.
Refer to diagram 13.6.
Remove the electrical connections from the overheat thermostat.
Remove the retaining clip from the flow pipe.
Remove the overheat stat from the retaining clip.
NOTE: When fitting new thermostat, please ensure that it is
located correctly onto the flat area of the pipe and the retaining
clip is secure.
RETURN
PIPE
HEATING RETURN
THERMISTOR
37
Diagram 13.6
0020008877-04
13.16 Condensate Trap and Siphonic Drain
12962
13 Replacement of Parts
SIPHON
ADAPTER
Refer to diagram 13.7.
Remove the clips securing the flexible tubes to the adapter by
twisting the clips slightly to disengage the clip jaws from each
other.
Remove flexible tubes from adapter.
FLOAT
Lift off the adapter.
Remove the drain connection downstream of the condense
trap.
CONDENSATE TRAP
AND SIPHONIC DRAIN
Remove the two condense trap securing screws. Lift up and
carefully remove the condense trap taking care not to spill any
water which may be left in the unit. As the unit is lifted remove
the flexible pipe on the outlet.
SCREW
Remove any solids found.
Before removing the float note it's orientation.
Remove the float to clean it.
Flush water through the trap to remove any remaining solids.
Check for any debris in the outlet pipe of the condensate drain
and clean as necessary.
Reassemble and refit the condensate trap.
IMPORTANT: Please remove spigot bung before fitting
condensate drain connection.
Using a suitable container, flush the heat exchanger until the
water appears clear in the container.
Reassemble adapter.
SPIGOT
BUNG
(remove
and discard)
Refer to section 11.9.
13.18 Access to Switches, User Interface and
230v controls Interface
For access, refer to section 13.1.
SPIGOT
Diagram 13.7
SWITCH COVER
Release the front of the controls fascia by carefully prising up
the two retaining latches, see diagram 11.10.
12220
13.17 Inner Casing Sealing Panel
Do not allow the front of the fascia to swing down and be loosely
held by the electrical connections to the mains reset switch and
user interface. Either remove the connections or support the
fascia.
13.19 Mains Reset Switch
Refer to section 13.18 for access.
Remove electrical leads.
ELECTRICAL
CONNECTIONS
Lift the switch cover.
Remove switch, see diagram 13.8.
SWITCH
0020008877-04
38
Diagram 13.8
13 Replacement of Parts
12300
13.20 User Interface
Refer to section 13.18 for access and diagram 13.9.
Remove electrical plug.
Remove the three securing screws.
230V
CONTROLS
INTERFACE
BOARD
Withdraw the board.
When replacing the board refer to instructions supplied with
replacement PCB and the appliance data label for indicated
maximum output, see Section 10.5 Range Rating.
13.21 230V Controls Interface
SECURING
SCREWS
For access, refer to section 13.18.
Disconnect the electrical connection from the 230V controls
interface board and the electrical connection from the main
PCB, see diagram 13.9.
Remove the 230V controls interface retaining screw.
Remove the 230V controls interface board.
Diagram 13.9
11420
USER INTERFACE BOARD
When ordering spare parts, contact British Gas's own service
organisation using the telephone number on the inside front
cover of this booklet.
MAIN PCB
Please quote the name of the appliance and serial number, to
be found on the data label, see diagram 1.2.
If ordering from British Gas also quote the G.C. number of the
part.
13.22 Main PCB
For access, refer to section 13.1
Hinge down the control box, see diagram 13.11.
Remove TORX screws and unhook the rear panel.
Remove the electrical connections to the PCB.
Prise back the two PCB retaining clips and withdraw the PCB,
see diagram 13.10.
When refitting the rear panel ensure the leads are not trapped.
13.23 Fuse - Main PCB - Control Box
FUSE
RETAINING CLIPS
For access, refer to section 13.22.
Diagram 13.10
The fuse is located at bottom right hand side of the PCB, see
diagram 13.10.
9247
13.24 Control Box
For access refer to section 13.21.
RETAINING
STRAP
Remove relevant plugs and connectors, refer to wiring diagram
12.2.
Withdraw grommets and leads so they are hanging loose.
Unthread the retaining strap and remove the control box by
drawing it outwards away from its retaining slots, see diagram
13.11.
RETAINING
SLOT
CONTROL PANEL
Diagram 13.11
39
0020008877-04
14 Manual Handling
are used – keep back straight – bend using legs. Keep load as close to
body as possible. Always use assistance if required. Dispose of
packaging in a responsible manner. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp edges and
ensure good grip when handling appliance outside packaging.
General recommendations when handling.
Clear the route before attempting the lift. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Keep load as close to
body as possible. Do not twist – reposition feet instead. If 2 persons
performing lift, ensure co-ordinated movements during lift. Avoid
upper body/top heavy bending - do not lean forward/sideways.
Recommend wear suitable cut resistant gloves with good grip to
protect against sharp edges and ensure good grip. Always use assistance
if required.
Positioning of Appliance for Final Installation – no obstructions.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm grip
on front and sides of appliance, lift upwards, ensure stable balance
achieved and lift upwards to position in place on bracket. Ensure safe
lifting techniques are used – keep back straight – bend using legs - when
lifting load from floor level. Do not twist – reposition feet instead. Keep
boiler as close as possible to body throughout lift to minimise strain on
back. Ensure co-ordinated movements to ensure equal spread of
weight of load. Always use assistance if required. Recommend wear
suitable cut resistant gloves with good grip to protect against sharp
edges and ensure good grip when handling appliance.
Removal of carton from delivery van.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Always use
assistance if required.
Positioning of Appliance for Final Installation – above worktop,
foreseeable obstructions etc.
Carriage of carton from point of delivery to point of installation –
ground floor.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm grip
on front and sides of appliance, lift upwards, onto worktop if practicable.
Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain firm grip at front
and sides/base of boiler. Ensure co-ordinated movements during 2
person lifts to ensure equal spread of weight of load. Ensure safe lifting
techniques are used – keep back straight – bend using legs - when lifting
load from floor level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise strain on back.
Avoid upper body/top heavy bending - do not lean forward/sideways.
Always use assistance if required. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp edges and
ensure good grip when handling appliance.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Clear the
route before attempting the lift. If removing boiler from truck straddle
the load and tilt forwards to facilitate secure grip. Ensure safe lifting
techniques are used – keep back straight – bend using legs. Do not twist
– reposition feet instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use assistance if
required.
Carriage of carton from point of delivery to point of installation – first
or higher floor, cellar.
Positioning of Appliance for Final Installation – within compartment
etc. restricting installation.
Recommend 2-person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Avoid
upper body/top heavy bending - do not lean forward/sideways. Clear
the route before attempting the lift. If removing boiler from truck
straddle the load and tilt forwards to facilitate secure grip. Ensure safe
lifting techniques are used – keep back straight – bend using legs. Do
not twist – reposition feet instead. Take care to avoid trip hazards,
slippery or wet surfaces and when climbing steps and stairs. Always
use assistance if required.
Recommend 2 persons lift appliance to position into place, space
permitting. Fit bracket securely onto wall before lifting appliance into
position. Obtain firm grip on front and sides of appliance, lift upwards,
onto worktop if practicable. Ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons positioning onto
bracket obtain firm grip at front and sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure equal spread of
weight of load. If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler. Ensure safe lifting techniques are
used – keep back straight – bend using legs - when lifting load from floor
level. Do not twist – reposition feet instead. Keep boiler as close as
possible to body throughout lift to minimise strain on back. Always use
assistance if required. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and ensure good grip
when handling appliance.
Carriage of carton from point of delivery to point of installation –
roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during lift.
Avoid upper body/top heavy bending - do not lean forward/sideways.
Clear the route before attempting the lift. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend 1 person to be
in roofspace to receive the appliance and other person to be below to
pass up and support appliance. Ensure safe lifting techniques are used
– keep back straight – bend using legs. Keep load as close to body as
possible. Always use assistance if required. It is assumed safe access,
flooring and adequate lighting are provided in the roof space. It is
recommended a risk assessment of the roof space area be carried out
before moving the appliance into the area to take into account access,
stability of flooring, lighting and other factors, and appropriate measures
taken.
Positioning of Appliance for Final Installation – in roof space restricting
installation.
Recommend 2 persons lift appliance to position into place, space
permitting. Fit bracket securely onto wall before lifting appliance into
position. Obtain firm grip on front and sides of appliance, lift upwards,
ensure stable balance achieved and lift upwards to drop into place onto
bracket. If 2 persons positioning onto bracket obtain firm grip at front
and sides/base of boiler. Ensure co-ordinated movements during 2
person lifts to ensure equal spread of weight of load. If 1 person
positioning onto bracket recommend obtain firm grip supporting base
of boiler. Ensure safe lifting techniques are used - keep back straight
– bend using legs - when lifting load from floor level. Do not twist –
reposition feet instead. Keep boiler as close as possible to body
throughout lift to minimise strain on back. Always use assistance if
required. Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip when handling
appliance. It is recommended a risk assessment of the roof space area
be carried out before moving the appliance into the area to take into
account access, stability of flooring, lighting and other factors, and
appropriate measures taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep
working area clear. Recommend cut base end of carton and open
carton flaps, then tilt boiler forwards from its side onto its base and
remove carton by sliding up over the boiler. Ensure safe lifting techniques
0020008877-04
40
15 Spare Parts
Part No.
Description
GC No
1
801645
Fan assembly
E84024
2
801637
Spark electrode
E83999
3
801655
Igniter unit
E84015
4
2000802452
Gas valve assembly
H20596
5
801722
Heating flow and return thermistor (2)
E84003
6
801724
Overheat stat
E83996
7
2000802731
Main P.C.B.
H27-795
8
2000802779
Mains Reset Switch
H20701
9
2000802751
User interface
H20600
10
2000801702
Burner
E84249
11
2000801923
230V Controls Interface
E84018
12375
Key No.
6
5
3
2
8
10
4
1
7
9
11
Diagram 14.1
41
0020008877-04
0020008877-04
42
16 Declaration of Conformity
Name and Address of the
manufacturer:
Vaillant Industrial UK Ltd.
Nottingham Road
Belper, Derbyshire DE56 1JT
Identification of product:
Condensing wall-hung heating boiler
Appliance type:
British Gas/Scottish Gas 330 - BG 330
The appliance types satisfy the essential requirements of the relevant directives and Standards:
Designed and built to CE-type examination
certificate:
90/396/EEC including amendments
"Directive on the approximation of the law of the
member states relating to appliances burning
gaseous fuels“
PIN no: 87BP32
92/42/EEC including amendments
"Directive of efficiency relating to boiler burning
gaseous fuels“
Designed and built according to European
Standards:
73/23/EEC including amendments
”Directive on the harmonization of the laws of
Member States relating to electrical
equipment designed for use within certain voltage
limits"
89/336/EEC including amendments
"Directive on the approximation of the law of the
member states relating to electromagnetic
compatibility “
EN 483
EN 677
EN 60335-1
EN 60529
EN 50165
EN 55014
EN 61000-3-2
EN 61000-3-3
Any change to the appliance and/or any use not according to the instructions will lead to the
invalidation of this Declaration of Conformity
Program Manager
S. Keeton
Certification Manager
A. Beardsley
Vaillant …..05
Belper 01/02/05
43
0020008877-04
Manufactured by Glow-worm exclusively for British Gas.
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
www.glow-worm.co.uk
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
0020008877-04
44
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