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FINEST PLATINUM
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE GIVEN TO THE USER
0086
EC 0087/BO/33
G.C. Appliance No. 47-260-02 (Finest Platinum)
G.C. Appliance No. 47-260-03 (Finest Platinum Propane)
PREMIUM PERFORMANCE COMBI BOILER
CONTENTS
CONTENTS
1
GENERAL DESCRIPTION
2
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . .1
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1
Appliance overall dimensions . . . . . . . . . . . . . . . . . . . .1
Concentric air/flue duct specifications . . . . . . . . . . . . . .2
Exploded diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3
INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . .6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Statutory requirements . . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Flue terminal position . . . . . . . . . . . . . . . . . . . . . . . . . .7
Ventilation requirements . . . . . . . . . . . . . . . . . . . . . . . .7
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Central heating system . . . . . . . . . . . . . . . . . . . . . . . . .7
Domestic hot water systems . . . . . . . . . . . . . . . . . . . . .8
Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4
INSTALLING THE APPLIANCE . . . . . . . . . . . . . . . . . . . . .10
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . .10
Preparing the wall . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mounting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Service connections . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pressure relief valve connection . . . . . . . . . . . . . . . . . .12
Air/flue duct installation . . . . . . . . . . . . . . . . . . . . . . .12
Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5
COMMISSIONING AND TESTING . . . . . . . . . . . . . . . . . .17
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Filling the water system . . . . . . . . . . . . . . . . . . . . . . .17
Commissioning the appliance . . . . . . . . . . . . . . . . . . .18
DHW flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Ignition lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .18
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Other features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
User’s instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6
ROUTINE SERVICING INSTRUCTIONS . . . . . . . . . . . . . . .20
7
INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . .22
7.1
Functional flow diagram . . . . . . . . . . . . . . . . . . . . . . .22
8
8.1
8.2
8.3
8.4
8.5
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Diagnostic indicator LEDs . . . . . . . . . . . . . . . . . . . . . . .23
Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DHW fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Central heating fault finding . . . . . . . . . . . . . . . . . . . .24
9
REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . .24
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9.19
9.20
Combustion chamber insulation . . . . . . . . . . . . . . . . . .24
Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Ignition and detection electrodes . . . . . . . . . . . . . . . . .24
Gas control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Diverter valve actuator . . . . . . . . . . . . . . . . . . . . . . . .25
PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
CH micro-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
DHW flow switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Draining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .26
CH/O’heat and DHW thermistors . . . . . . . . . . . . . . . . .26
DHW heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .26
Water flow regulator . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .27
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . .27
10
SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
11
SUPPLEMENTARY INSTRUCTIONS
FOR VERTICAL FLUE SYSTEMS . . . . . . . . . . . . . . . . . . . .29
1
INTRODUCTION
The Halstead Finest Platinum and Finest Platinum Propane are fully
automatic, wall mounted, fan-assisted, balanced flue gas combination
appliance for use with natural gas (G20) and LPG (G31). They incorporate a
microprocessor based, fully modulating gas control system with direct burner
ignition. The appliances incorporate a domestic hot water (DHW) pre-heat
feature which can automatically adjust to the user’s habitual requirements. Thus
during long stand still periods, eg overnight, no pre-heat is provided.
The Halstead Finest Platinum features an attractive white stove enamelled
casing with an inset control panel. The flue elbow and air ducts are also white
stove enamelled to give a clean, attractive appearance to the Installation.
Central heating (CH) output is fully modulating with a range 14.6 kW
(49,747 Btu/h) to 24.9 kW (85,000 Btu/h). DHW output is also fully
modulating with a maximum of 32.2 kW (110,000 Btu/h) - nat gas, 29.3 kW
(100,000 Btu/h) - propane. The appliance always gives priority to DHW
demand.
The appliances are supplied with a standard telescopic concentric air and flue
duct system suitable for flue lengths of up to 820 mm (32in). The duct
assembly is connected to the boiler via a turret which can exit the boiler in any
horizontal direction. Extension ducts may be fitted in accordance with and up
to the maximum dimensions stated in these instructions.
A vertical outlet kit is also available for installations where an outside wall is
not accessible and it is desired to fit the kit ‘through the roof’. Installation using
the standard flue kit is described in the main text of these instructions and
supplementary instructions at the rear of this booklet describe installation
involving the vertical outlet kit. NO OTHER FLUE KITS OR EXTENSIONS
MAY BE USED WITH THESE APPLIANCES.
The appliances can be installed from inside the room without access to the
external wall provided that a wall liner is fitted and that the wall thickness is
less than 0.5 m (19 in). The wall liner is available as an optional extra. See
section 4 for further details. (Note: If the vertical outlet kit is to be used, access
to the roof is necessary).
The appliances are designed for use with sealed primary water systems and
incorporates a circulating pump, diverter valve assembly, pressure gauge, flow
switch, safety valve and system expansion vessel. A separate DHW expansion
vessel is not required. Isolation valves are fitted to the service connections and
an automatic heating by-pass is fitted to maintain an adequate flow rate
through the boiler.
If thermostatic radiator valves are installed it is recommended that one radiator
is fitted with lockshield valves (normally in the bathroom) to allow pump
overrun circulation. Internal frost protection is fitted as standard equipment.
The boiler may be used with any certified mains voltage room thermostat. An
electro-mechanical 24 hour time clock is fitted as standard.
NOTE: British Standard BS7593: 1992 stresses the importance of
cleansing and flushing of the system to ensure it continues to run
efficiently with the minimum of maintenance necessary. Halstead
Boilers fully support this professional approach and recommend
that the system is cleansed with an effective chemical cleanser
and protected long term with a suitable inhibitor. Such products
are available from Fernox and Sentinal.
Gas Consumer Council
The Gas Consumer Council (GCC) is an independent organisation which
protects the interests of gas users. If you need advice, you will find the
telephone number in your local directory under ‘Gas’
2.1
2
TECHNICAL SPECIFICATIONS
GAS CATEGORIES AND
APPLIANCE CLASSIFICATION
MODE
The appliance is certified to comply with the requirements of EN 483 and
EN 625 for use in GB and IE (Great Britain and Ireland) using the
following gas categories:
Finest Platinum: I2H (G20 with a governed gas supply at 20 mbar (8
in.wg) inlet pressure).
Finest Platinum Propane: II2H3P (G31 [Propane] with a regulated supply at
37 mbar (14.9 in.wg) inlet pressure)
The appliance classification (as defined in EN 483) may be any of the
following depending on the chosen flue option: C12 or C32.
2.2
RATE
Central Max
Heating Min.
DHW Max
Min.
OUTPUT
kw
(Btu/h)
INPUT
Net
kw
24.9
14.6
32.2
9.0
(85000)
(49,747)
(110000)
(30844)
27.4
16.4
35.7
10.7
(Btu/h)
INPUT
Gross
kw
(Btu/h)
(93455)
(55,957)
(121740)
(36577)
30.4
18.2
39.6
11.9
(103725)
(62098)
(135115)
(40603)
CH
DHW
2.4
BURNER
PRES
mbar
(in.wg)
9.0
3.0
15.5
1.0
(3.61)
(1.2)
(6.23)
(0.4)
(102.3 ft3/h)
Max. gas rate (after 10 mins operation i.e. hot)
2.90 m3/h
Min. domestic hot water flow rate
2.1 l/min
(0.46 gpm)
Design domestic hot water performance
13.2 l/min (2.9 gpm) raised 35°C
Specific DHW flowrate (EN625)
15.4 l/min
Max. domestic hot water temperature
60 °C
Max. mains water inlet pressure
10 bar
(146 psi)
Min. mains water inlet pressure for operation
0.3 bar
(4.4 psi)
Min. mains water inlet pressure for max heat output
1.0 bar
(14.6 psi)
Max. gas rate (after 10 mins operation i.e. hot)
3.77 m3/h
(133 ft3/h)
HALSTEAD Finest Platinum Propane
As natural gas appliances except where stated below
365mm
200mm
.
(Btu/h)
INPUT
Gross
kw
(Btu/h)
24.9
14.6
29.3
9.0
(85000)
(49,747)
(100000)
(30844)
27.4
16.4
32.4
10.7
(93455)
(55,957)
(110480)
(36577)
29.8
17.8
35.2
11.7
(101678)
(60734)
(120068)
(39750)
1.35 mm Ø x 13
0.90 mm Ø x 13
1 litre
0.5 bar
3.0 bar
49.1 kg
37.3 kg
50.1 kg
230V 50Hz
Fuse at 3A
T4H 4A 250V
190 W
80 °C
176°F
8l
18.3 g/s
18.8 g/s
155 °C
145 °C
5.6 ± 6% (0.002 ± 10%)
6.8 ± 6% (0.001 ± 10%)
7.5 ± 8% (0.008 ± 50%)
7.4 ± 8% (0.003 ± 50%)
15 mm compression
22 mm compression
22 mm compression
15 mm compression
15 mm compression
15 mm tail
•
200mm
. .
•
.
•
5mm •
NOTE:
10mm for normal
operation 450mm for
installation and servicing
760mm
(6.83)
(2.33)
(9.40)
(0.92)
GENERAL SPECIFICATIONS
1(b)
100mm
.
(in.wg)
17.0
5.8
23.4
2.3
MINIMUM CLEARANCES
Gas
CH flow
CH return
DHW inlet
DHW outlet
Pressure relief valve outlet
. 100mm DIA.
.
BURNER
PRES
mbar
(39.6 ft3/h)
Max. gas rate (after 10 mins operation i.e. hot)
1.12 m3/h
Min. domestic hot water flow rate
2.1 l/min
(0.46 gpm)
Design domestic hot water performance
12.0 l/min (2.6 gpm) raised 35°C
Specific DHW flowrate (EN625)
14.0 l/min
Max. domestic hot water temperature
60 °C
Max. mains water inlet pressure
10 bar
(146 psi)
Min. mains water inlet pressure for operation
0.3 bar
(4.4 psi)
Min. mains water inlet pressure for max heat output
1.0 bar
(14.6 psi)
Max. gas rate (after 10 mins operation i.e. hot)
1.33 m3/h
(47.0 ft3/h)
.
.
.
210mm
INPUT
Net
kw
CONNECTION SIZES
OVERALL DIMENSIONS AND
MINIMUM CLEARANCES
1(a) .
.
(Btu/h)
Main burner injector (NG)
Main burner injector (Propane)
Total water capacity
Minimum CH system pressure (static head) – Cold
Maximum CH system pressure (static head) – Hot
Empty weight
Max. lift weight
Total weight (full)
Electrical supply
Internal fuses
Maximum power consumption
Max. CH flow temperature
Integral expansion vessel capacity
Flue products mass flow rate (NG)
Flue products mass flow rate (Propane)
Average flue gas temperature (NG)
Average flue gas temperature (Propane)
CO 2 value (CO)% (max CH output) (NG)
CO 2 value (CO)% (max CH output) (Propane)
CO 2 value (CO)% (max DHW value) (NG)
CO 2 value (CO)% (max DHW value) (Propane)
The Seasonal Efficiency is 80.5 %, The efficiency value is used in the UK
Government Standard Assessment (SAP) for energy rating of dwellings.
1
kw
Minimum clearances for installing and servicing the appliance refer to Fig. 1(b) below.
GENERAL
2.5
OUTPUT
GENERAL
2.3
HALSTEAD Finest Platinum
CH
DHW
Central Max
Heating Min.
DHW Max
Min.
PERFORMANCE DATA
The Seasonal Efficiency is 78.7 %, The efficiency value is used in the UK
Government Standard Assessment (SAP) for energy rating of dwellings.
MODE
RATE
•
•
SEE
NOTE
••
5mm
900mm
.
.
•
455mm
.
.
200mm
•
1
CONCENTRIC AIR/FLUE DUCT SPECIFICATIONS
2.5
The appliance is supplied complete with a standard telescopic flue
kit. This comprises a standard duct and a terminal duct and can be
used for flue lengths between 506 mm and 820 mm without cutting
the ducts. To use terminal duct for flue length between 300 and 506
mm the ducts need cutting. Avoid swarf and sharp edges to maintain
telescopic function
The following additional concentric kits are available as optional
extras.
These optional kits may be used with the standard flue kit to
produce an extensive range of flue options. Examples are
illustrated in Figures 2 and 3. Variations upon these illustrations
may be used providing that the following rules are strictly obeyed.
a) The maximum/minimum permissible allowable length of the flue
system is:
Extension duct (each extension extends the flue length by up to
767 mm)
90° Extension Elbow (Allows an additional bend in the flue and
has an ‘equivalent length’ of 767 mm.) This elbow is mechanically
different from the flanged elbow supplied as standard with the
appliance, but has the same equivalent length of 767 mm.
45° Extension Elbow Allows an additional bend in the flue and
has an equivalent length of 384 mm.
Vertical Turret Socket For use with elevated horizontal flues and
vertical cowls.
2
Vertical Roof Terminal For use where an external wall is not
available. For installation details, refer to Supplement 1 at the rear of
this booklet.
Horizontal flue terminal (Right and Left) - maximum 2500 mm (99 in)
Horizontal flue terminal (Rear)
- maximum 2000 mm (79 in)
Horizontal flue terminal
- minimum 300 mm (12 in)
Vertical flue terminal
- maximum 4000 mm (158 in)
Vertical flue terminal
- minimum 565 mm (22 in)
b) The standard terminal must always be fitted horizontally. The vertical
terminal must always be used if a vertical outlet is required.
c) The flue must only terminate in a horizontal or vertical position.
However, 90° flue elbows may be used to drop the height of
the flue system by 500 mm.
SPECIFICATION FOR STANDARD AND SIDE HORIZONTAL FLUES
(Refer to section 2.6(b) for maximum allowable lengths)
•
2(a)
‘L’
‘L’
•
•
•‘R’
•
Fig 2a - Standard flue assembly using either
side or rear outlet.
L measured from the centre line of boiler flue outlet to
outside wall face = max 820 mm
R measured from the centre line of boiler flue outlet to rear
of boiler = 201 mm
•
‘S’
•
S measured from the centre line of boiler flue outlet to side
of boiler = 226 mm
(Allow for minimum clearance of 5 mm at side of boiler)
No flue restrictors should be used if the flue
length exceeds 620 mm.
•
‘L(ii)’
2(b)
•
‘L(i)’
•
Fig 2b - Standard flue assembly with
optional straight extensions using either
side or rear outlet
Maximum flue length ‘L(i)’ (measured from the boiler
outlet centre line to the outside wall face).
Finest Platinum = 2500mm (99in)
Maximum flue length ‘L(ii)’ (measured from the boiler
outlet centre line to the outside wall face).
Finest Platinum = 2000mm (79in)
2
d) The flue system must use either a flanged elbow or a vertical
flue turret socket at the entry/exit to the appliance.
e) All joints must be correctly made and secured in accordance
with the installation instructions.
Additional instructions for flue systems incorporating a vertical
outlet (Fig. 3) are given in the supplements at the rear of this
booklet.
Installation instructions for installing the appliance with a standard
flue and straight extension ducts (Fig. 2) are included in the main
text of these instructions (section 4.7).
3
SPECIFICATION FOR VERTICAL FLUE SYSTEMS
180mm
•
••
•
•
1045mm
max
•
•
•30mm
••
•
767mm
•
•
•
4000 mm
max
•
767mm
•
L
•
767mm
•
•
425mm
•
•
••
•
•
Fig 3(a) Vertical flue assembly with:
Vertical turret socket, standard duct, vertical
roof terminal and extension(s) where required.
•
ROOF LINE
100/60mm TO
118/80mm DIA
ADAPTOR
100/60mm DIA
EXTENSION DUCT
Fig 3(c) Vertical flue assembly
and dimensions
3(a)
BALANCED FLUE
ROOF TERMINAL
430mm
100/60mm DIA
EXTENSION DUCT
100/60mm DIA
EXTENSION DUCT
STANDARD DUCT
VERTICAL
SOCKET
50mm
a
•
‘L’ measured from the top of the boiler casing to
the underside of the air cowel. Maximum
allowable length of L = 4000 mm
•
3(b)
b
Fig 3(b) - Offset vertical flue
‘a’ measured from the boiler centre line to the centre line of
the extension elbow
‘b’ measured from the centre line of the extension elbow to
the underside of the air cowl
Maximum allowable length of a + b = 2400 mm
•
3
6
4
EXPLODED DIAGRAM (for key no. references see spare parts catalogue)
Drawing amended June 03
7
HYDRAULIC CIRCUIT
AUTOMATIC AIR VENT
EXPANSION
VESSEL
PUMP
Heating
Return
Filling Loop
Overheat
Stat
Heating
Flow
DHW
out
3 bar
Pressure
Relief Valve
Cold
Water IN
Plate Heat
Exchanger
PRESSURE
GAUGE
CENTRAL HEATING MODE
By-Pass
AUTOMATIC AIR VENT
EXPANSION
VESSEL
PUMP
Heating
Return
Overheat
Stat
DHW
out
Filling Loop
Heating
Flow
3 bar
Pressure
Relief Valve
Cold
Water IN
Plate Heat
Exchanger
PRESSURE
GAUGE
By-Pass
DOMESTIC HOT WATER MODE
5
3.1
3
INSTALLATION REQUIREMENTS
STATUTORY REQUIREMENTS
8
FLUE TERMINAL POSITION
•
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1996 (AS AMENDED)
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI Registered
Installer. It must be carried out in accordance with the relevant
requirements of the:
Gas Safety (Installation and Use) Regulations
The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Current I.E.E. Wiring Regulations
Where no specific instructions are given, reference should be made to
the relevant British Standard code of Practice.
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.
It should also be in accordance with the relevant recommendations in
the current editions of the following British Standards and Codes of
Practice: BS5449, BS5546, BS5440:1, BS5440:2, BS6798,
BS6891, Institute of Gas Engineer document IGE/UP-7, BS7074
(expansion vessel), BS5482 (propane installations) and IS813 for IE.
A
•
•
BOILER LOCATION
•
b) This position MUST allow for a suitable flue system and terminal
position. The boiler must be installed on a flat vertical wall which
is capable of supporting the weight of the appliance and any
ancillary equipment.
c) If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the British Gas publication ‘Guide
for Gas Installations In Timber Frame Housing’, Institute of Gas
Engineers document IGE/UP-7. If in doubt, advice must be
sought from the Local Gas Supplier.
6
d) The appliance is approved to a protection rating of IP20.
Therefore if the appliance is to be installed in a room containing
a bath or a shower, any electrical switch or control utilising
mains electricity must be so situated that it cannot be touched by
a person using the bath or a shower. Attention is drawn to the
requirements of the current BS7671 (I.E.E Wiring Regulations,
and in Scotland the electrical provisions of the Building
regulations applicable in Scotland.
•F
• •
D,N
J
•
•
K
• •
•
A•
E
•
•• •
G
•
K
M
•
••
B,C
•
•
•
F
••
F
•
•
•
L
• ••
L
K
•
•
K
•
•G
•
•
SPECIAL REQUIREMENTS FOR A
VERTICALLY BALANCED FLUE
•
Q
•
300mm
MIN.
•
•
P
• •
•
430 mm
MIN.
•
•
•
R
O
O
•
•
•
Position Minimum
spacing
A
The following limitations MUST be observed when siting the boiler:
a) The boiler is not suitable for external installations. The position
selected for installation should be within the building, unless
otherwise protected by a suitable enclosure, and MUST allow
adequate space for installation, servicing and operation of the
appliance, and for air circulation around it (Section 2.3 and
3.4).
•
H,I
•
•B,C
•
•
G
IMPORTANT NOTE: Manufacturer’s instruction must NOT be
taken in any way as overriding statutory obligations.
3.2
C
•
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
Directly below and above an openable 300mm
window,air brick, or any other
ventilation opening
Below gutter, drain/soil pipe
75mm
Below eaves
200mm
Below a balcony
200mm
From vertical drain pipes and
150mm
soil pipes
From internal or external corners
300mm
Above adjacent ground or
balcony level
300mm
From a surface facing the terminal
600mm
Facing terminals
1200mm
From opening (door/window) in
1200mm
carport into dwelling
Vertically from a terminal on the
1500mm
same wall
Horizontally from a terminal on the 300mm
same wall
Adjacent to opening
300mm
Below carport
600mm
From adjacent wall
300mm
From adjacent opening window
1000mm
From another terminal
600mm
Minimum height
300mm
12in
3in
8in
8in
6in
12in
12in
24in
48in
48in
60in
12in
12in
24in
12in
40in
24in
12in
3.3
FLUE TERMINAL POSITION
Detailed recommendations for flue installation are given in BS
5440:1. The following notes are for general guidance.
a) The boiler MUST be installed so that the terminal is
exposed to the external air.
b) It is important that the position of the terminal allows free
passage of air across it at all times.
c) It is ESSENTIAL TO ENSURE that products of combustion
discharging from the terminal cannot re-enter the building,
or any other adjacent building, through ventilators,
windows, doors, other sources of natural air infiltration, or
forced ventilation/air conditioning.
d) The minimum acceptable dimensions from the terminal to
obstructions and ventilation openings are specified in Fig.8.
e) If the terminal discharges into a pathway or passageway
check that combustion products will not cause nuisance and
that the terminal will not obstruct the passageway.
f) Where the lowest part of terminal is fitted less than 2000 mm
(78 ins) above the ground, above a balcony or above a
flat roof to which people have access, the terminal MUST
be protected by a purpose designed terminal guard
(optional extra; Part No.951505).
g) The air inlet / flue outlet duct MUST NOT be closer than
25mm (1in) to combustible material.
h) In certain weather conditions the terminal may emit a
plume of steam. This is normal but positions where this
would cause a nuisance should be avoided.
3.4
VENTILATION REQUIREMENTS
Detailed recommendations for air supply are given in BS 5440:2.
The following notes are for general guidance.
a) It is not necessary to have a purpose provided air vent in the
room or internal space in which the appliance is installed.
b) If the boiler is to be installed in a wall cupboard permanent
air vents are required for cooling purposes in the cupboard at
both high and low levels. Both air vents must communicate
with either the same internal room / space or be on the same
wall to external air. Each air vent communicating with another
room or internal space must have a minimum effective area
of: 362 cm2 (56 in2)
d) An existing meter and/or pipework should be of sufficient
size to carry the maximum boiler input plus the demand
of any other installed appliance. (BS 6891: 1988).
A minimum of 22 mm dia. pipework is required to
within 1 metre of the appliance gas cock.
e) Natural gas appliances: The governor at the meter
must give a constant outlet pressure of 20 mbar (8 in.wg)
when all appliances on the system are running.
Propane appliances: The regulator must give a
constant outlet pressure of 37 mbar (14.9 in.wg) when all
appliances on the system are running.
f) The gas supply line should be purged. WARNING: Before
purging open all doors and windows, also extinguish any
cigarettes, pipes, and any other naked lights.
g) The complete installation must be tested for gas soundness
.
3.6
a) This appliance is designed for connection to sealed central
heating water systems. Refer to Fig. 11 for a typical system
design.
b) A sealed system must only be filled by a competent person.
c) The available pump head is given in Fig. 9.
d) A minimum heating flow rate corresponding to a heating
differential of 15°C must be obtained at all times.
e) An automatic heating bypass is fitted within the appliance.
However if thermostatic radiator valves are fitted, a radiator
must be fitted with two lockshield valves.
f) The following paragraphs outline the specifications of the
items fitted to the boiler.
PUMP
The available head shown in Fig. 9 is that in excess of the
appliance hydraulic resistance, i.e. that available for the system.
9
GAS SUPPLY
a) The Gas Supplier should be consulted at the installation
planning stage in order to establish the availability of an
adequate supply of gas.
b) An existing service pipe MUST NOT be used without prior
consultation with the Gas Supplier.
c) A gas meter can only be connected by the Gas Supplier or by
their contractor.
Bth/hr.
85,000
75,000
65,000
50,000
kW
25.0
22.0
19.0
14.7
2m HEAD
Flow rate
17.9 l/m
17.9 l/m
17.9 l/m
17.9 l/m
∆t°C
20.0
17.6
15.3
11.8
6
Available Head Metres
3.5
AVAILABLE PUMP HEAD
7
If the ventilation is direct to air from outside the building, the
necessary areas quoted above may be halved.
If the cupboard or compartment height is 2000 mm
min then NO purpose made ventilation is required.
CENTRAL HEATING SYSTEMS
5
4
3
2
1
0
2
4
6
8
10
12
14
Flow Rate ltr/min
16
18
20
22
7
10
ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
FLEXIBLE HOSE UNION
TEMPORARY CONNECTION
To be removed immediately after filling
•
•
STOP
VALVE
•
•
•
DOUBLE
CHECK
VALVE
ASSEMBLY
MAINS WATER
SUPPLY
•
STOP
VALVE
MAINS
WATER SUPPLY
•
•
HEATING SYSTEM
RETURN
CISTERN &
OVERFLOW
METHOD B
RECOMMENDED AND APPROVED METHOD FOR
FILLING A CLOSED CIRCUIT IN A HOUSE.
(R24-2a WATER REGULATIONS GUIDE)
The table below shows the maximum system volume that the
integral expansion vessel can sustain under different charge
pressure conditions. If the system volume exceeds that shown, an
additional expansion vessel must be fitted and connected to the
heating system primary return pipe as close as possible to the
appliance. If an extra vessel is required, ensure that the total
capacity of both vessels is adequate. Further details are available
in the current issues of BS5449 and BS6798.
NOTE: If the pressure gauge indicates 2.65 bar or greater when
the appliance is at maximum temperature with all radiators in
circulation an extra expansion vessel is required.
PRESSURE GAUGE A pressure gauge is situated on the
appliance control panel. This can be viewed by lowering the
bottom front panel.
PRESSURE RELIEF VALVE A pressure relief valve set at 3 bar
(43.5 psi) is supplied with the appliance.
Total water content of system
using 8ltr. (1.54gal) capacity expansion
vessel supplied with appliance
0.5
7.3
0.75
11
1.0
14.5
1.5
21.8
96ltr
84ltr
73ltr
50ltr
21gal
18gal
16gal
11gal
For systems having a larger
0.0833 0.093 0.109 0.156
capacity multiply the total system capacity
in litres (gallons) by the factor to obtain the
total minimum expansion vessel capacity required litres (gallons)
3.7
8
PRESSURE PUMP
& REDUCING VALVE
IF REQUIRED
•
EXPANSION VESSEL
EXPANSION VESSEL REQUIREMENTS
Vessel charge and initial
bar
system pressure
psi
•
DOMESTIC HOT WATER SYSTEM
a) Check that the mains water pressure is sufficient (as stated in 2.4
“General Specification”) to produce the required DHW flow rate,
but does not exceed the maximum DHW pressure (10 bar). If
necessary, a pressure reducing valve must be fitted to the mains
supply before the DHW inlet connection.
b) The final 600mm (24in) of the mains supply pipe to the boiler
must be copper.
c) Avoid long DHW pipe runs and several hot water draw off points
d) Insulate the Hot water pipes if accessible to minimise the heat
losses within the pipes to keep the water hot longer.
e) A domestic hot water regulator is fitted within the group set to
control the maximum water flow rate. This may be removed to
Note:
The appliance has a built in
filling loop
STOP
VALVE
•
HEATING
SYSTEM
RETURN
•
obtain higher flow rates. Higher flow rates will not damage
the appliance but may reduce the water temperature below an
acceptable level.
f) If the appliance is installed in an area where the temporary
hardness of the water supply is high, say over 150ppm, the
fitting of an in-line scale inhibitor may be an advantage.
Consult the Local Water Supplier if in doubt.
g) For specific information relating to fittings (eg. Showers,
Washing Machines etc) suitable for connection in the DHW
circuit, consult the Local Water Supplier. However the
following information is given for guidance:
DOMESTIC HOT/COLD WATER SUPPLY TAPS AND
MIXING TAPS. All equipment designed for use at mains
water pressure is suitable.
SHOWERS & BIDETS. Any mains pressure shower or bidet
complying with the Local Water Undertaking bylaws is suitable.
h) Consider IRN 116 and Byelaw 90 + 91. Ensure that necessary
action have been carried out to account for thermal expansion of
water. If thermal expansion is not provided then high water
pressure may result in damaging to fittings and devices.
3.8
ELECTRICITY SUPPLY
a) Wiring external to the appliance must be in accordance with
the current l.E.E. Wiring Regulations (BS 7671) for electrical
installation and any local regulations which apply.
b) The mains cable must be at least 0.75mm2 (24/0.2mm)
PVC Insulated to BS6500 table 16.
c) THIS APPLIANCE MUST BE EARTHED. (Failure to provide
a satisfactory Earth connection will result in appliance
malfunction)
d) The method of connection to the mains supply must facilitate
complete electrical isolation of the appliance. Either a 3A
Fused three pin plug and unswitched shuttered socket outlet,
both complying with BS1363, or a 3A fused double pole
switch having a 3mm contact separation in both poles and
serving only the boiler (and its external controls) may be used.
3.9
EXTERNAL CONTROLS
The appliance may be used with any certificated mains voltage
room thermostat as described in section 4.
11
TYPICAL SYSTEM DESIGN
PRESSURE RELIEF VALVE
OUTLET TO DRAIN
APPLIANCE
•
GAS SUPPLY
CH FLOW
DOMESTIC HOT
WATER OUT
MAINS WATER IN
CH RETURN
RADIATOR WITH
2 LOCKSHIELD VALVES
IN OPEN POSITION
••
••
•
•
•
•
DOMESTIC HOT
WATER
•
DOMESTIC COLD
WATER
PRESSURE REDUCING
VALVE IF REQUIRED
BS STOP VALVE
(FIXED SPINDLE)
MAINS WATER
•
•
•
•
DRAIN COCK
AT LOWEST POINT(S)
OF SYSTEM
Note: The boiler incorporates an automatic bypass, hence no other
system bypass is necessary. However, it is recommended to fit TRV’s on
all radiators except in rooms with a room thermostat.
9
4
INSTALLING THE APPLIANCE
Before installing the appliance, check that the chosen location is
suitable (section 3.2) and that the requirements for flue position
(section 3.3) and minimum clearances (Fig. 1b) are satisfied.
4.1
UNPACKING THE APPLIANCE
The appliance and standard flue kit are supplied in a single box.
In addition, various optional flue kits are available as described in
section 2.6. If the appliance is to be installed without access to
an external wall, a wall liner kit is also required.
Unpack and check the contents:
• Complete boiler
• Standard flue kit
e) Drill the four fixing holes using an 8 mm drill and insert the wall
plugs provided.
f) Enter the top two fixing screws ONLY into the wall plugs, leaving
10 mm proud.
g) Hang the wall mounting plate on the screws. Hook the piping
frame onto the two bottom locating tabs of the wall mounting
plate. Refer to Fig. 12.
h) Enter the bottom two fixing screws into the wall plugs and tighten
up all four screws.
12
MULTIFUNCTIONAL BOILER CHASSIS
• Paper wall mounting template
MARK POSITION OF TOP & SIDES
• Wall mounting plate
TOP LOCATING TABS
• Piping frame
• Installation and Servicing Instruction
• User’s Instructions
• Benchmark book
•
•
•
•
•
•
• Hardware pack containing:
50mm x No 10 wood screws – 4 off
Wall plugs – 4 off
WALL FIXING HOLES
22 mm copper compression elbows – 2 off
15 mm copper compression elbows – 2 off
Manual Handling Note: During the appliance installation
it will be necessary to employ caution and assistance
whilst lifting, as the appliance exceeds the recommended
weight for a one man lift.
WALL MOUNTING
PLATE
•
Take care to avoid trip hazards, slippery or wet surfaces.
4.2
BOTTOM LOCATING TABS
PREPARING THE WALL
a) Fix the paper template in the required position (ensuring that
the necessary clearances are achieved). Ensure squareness by
hanging a plumbline
FIXING HOLES
b) Mark the position of the wall mounting plate fixing holes (4).
Select one from each group. Refer to Fig. 12.
c) Mark the position of the flue outlet. For side flue installation
extend the flue centre line on to the side wall. Refer to Fig.18.
Remove the paper template.
d) Cut the hole in the wall for the air/flue duct (preferably with a
core-boring tool). The hole must be horizontal and not be less
than 100 mm in diameter.
10
If the hole is not accessible from outside, its minimum diameter
must be sufficient to allow insertion of the wall liner (130 mm,
51/4in). The wall liner is available as an optional extra and must
be sealed in position with mortar (or equivalent). It is
recommended that the flue assembly slopes slightly downwards
away from the boiler.
•
•
•
•
•
PIPING FRAME
If required, service connections may be made now
before mounting the boiler – Refer to section 5.
NOTE: Pipe work may be routed from
above or below the boiler as required.
13
DETERMINING THE POSITION OF THE
• AIR/FLUE DUCT HOLE
•
13(a) REAR FLUE
95mm
•
•
200mm
POSITION OF DUCT HOLE
•
225mm
•
•
•
13(b) SIDE FLUE
95mm
•
•
225mm
•
POSITION OF WALL
MOUNTING PLATE
•
•
14
SERVICE
CONNECTIONS
FILLING
LOOP
CENTRAL
HEATING
RETURN
SERVICE
CONNECTION
PIPES NOT
SUPPLIED
•
MAINS WATER IN
•
DOMESTIC
HOT WATER
OUT
•
•
•
GAS SUPPLY
CENTRAL
HEATING
FLOW
•
•
•
•
•
•
295mm •
340mm •
355mm •
420mm •
30mm
95mm
230mm
4.3
•
• DRAIN POINT
•
MOUNTING THE BOILER
Refer to Fig 15
a) Lift the boiler into position using the lifting points shown in
Fig 15. Position the top of the boiler approximately 10 mm
above the top of the wall mounting plate and use the side
wings on the plate to locate the boiler in a horizontal
direction. Then carefully lower the boiler, ensuring that the two
top locating tabs are securely engaged.
b) Locate and tighten the water valves to the boiler. (Seals are
prefitted) Using the fittings supplied in the hardware pack:
c) Connect the central heating system to the boiler flow and
return isolating valves.
PRESSURE
RELIEF
•
•
•
•
d) Connect the mains water supply to the boiler DHW inlet
isolating valve.
e) Connect the DHW supply pipe to the boiler DHW outlet
connection.
4.4
SERVICE CONNECTIONS
Commission the central heating system as described in section 5.1
and then proceed to Section 4.5.
11
GAS CONNECTION
4.5
Refer to Fig 14.
Extend a gas supply pipe of not less than15 mm OD copper to the
boiler and connect to the gas service cock.
Note:
Natural Gas: A working gas pressure of 20 mbar (8 in wg) should
be available at the boiler inlet with the boiler firing at full DHW output.
Propane: A working gas pressure of 37 mbar (14.9 in wg) should
be available at the boiler inlet with the boiler firing at full DHW output.
15
MOUNTING THE BOILER
SIDE WINGS
LOCATING TABS
•
•
•
4.7.1
PREPARING THE AIR/FLUE DUCTS
a) Measure the required flue length as shown in Figure 16.
Refer to section 2.5 to determine whether any extension
kits are required. Installations using only the standard ducts
or standard ducts with straight extensions are described in
this section. Installation instructions for all other flue
systems are described in the supplements at the rear of this
booklet.
b) Fit the external sealing ring to the terminal and assemble
the air/flue ducts as shown in Figure 17. The standard
duct is always used at the entry/exit to the boiler and the
sliding (telescopic) terminal is always slid into the end of
the standard or extension duct (where appropriate).
c) Achieve the correct flue length using Figure 18 as a guide.
Note that the flue length is measured to the inside of the
external wall sealing ring. In most cases it will be possible
to achieve the required flue length without cutting the
ducts, however where necessary the plain ends of the
extension ducts may be cut. Never cut the swaged
end, and always ensure that the cut is square and free of
burrs or debris. The minimum overlap of the telescopic
section is 50mm (2 in).
d) Assemble the flue using Figure 19 as a guide. It is
important that the steps are carried out in the order stated
in Figure 19. When securing the ducts in position always
drill two 3.3 mm diameter holes in each extension air duct
joint and use the self tapping screws provided to secure
each joint.
•
NOTE IT IS ESSENTIAL THAT THE TERMINAL IS FITTED THE
CORRECT WAY UP See Fig 17 (i.e. rainshield at the top).
16
LIFTING POINT
4.6
12
TOTAL FLUE LENGTH FROM
FLUE OUTLET CENTRE TO
OUTSIDE WALL FACE:
•
= LENGTH
PRESSURE RELIEF VALVE
PIPE CONNECTION
The safety valve is located at the bottom RHS of the boiler.
Connect a copper discharge pipe of not less than 15 mm diameter to
the safety valve outlet.
The pipe should be positioned so that the discharge of water or
steam can be noticed, but cannot create a hazard to the occupants
of the premises or damage electrical components or wiring.
4.7
MEASURING THE EXACT FLUE LENGTH
L
WALL
•
AIR FLUE DUCT INSTALLATION
If the wall thickness is less than 800mm (31 in) the air/flue duct
may be fitted without access to the external wall providing that the
optional wall liner is used. (This is necessary to seal any cavity
and to allow the sealing ring to pass through from inside but still
open and provide an adequate seal). The wall liner is a tube
diameter 130mm with a wall thickness of 0.8mm.
L
FAN OUTLET
EXTERNAL
Dia. 60mm
••
•
17
AIR/FLUE DUCT ASSEMBLY
TOP
•
EXTERNAL SEALING
RING
•
•
Ensure the “O” ring
(fitted in the flanged
end of the flue elbow
only) is located correctly.
•
EXTENSION DUCT(S)
Fits Over Duct
•
STANDARD DUCT
Fits Outside Elbow
•
18
STANDARD
TERMINAL
Fits Inside Duct
ACHIEVING THE CORRECT FLUE LENGTH
•
MAX. 319mm
TOP
•
MIN. OVERLAP
50mm (2in)
L
•
•
•
•
•
•
•
425mm
76mm
••
•
17mm
•
INSIDE EDGE OF
EXTERNAL SEAL IN
POSITION ON AIR
DUCT
767mm
EXTENSION
•
13
19
1
ASSEMBLING THE FLUE SYSTEM
SLIDE EXTERNAL SEALING RING UP TO FLUE TERMINAL
•
L
•
INTERNAL
SEALING
RING
•
•
•
•
•
•
•
2 STANDARD DUCT
Push ducts fully over elbow
and drill two 3·3mm dia.
holes. Secure with self
tapping screws
4.7.2
3 EXTENSION
Push extension duct
(if required) over standard
duct, engage fully.
Drill two 3·3mm dia. holes
and secure with
self-tapping screws
FLUE RESTRICTOR
20
A flue restrictor (47 mm Ø NG, 43 mm Ø propane) is supplied with the
appliance for use only if the horizontal flue length does not exceed 620
mm, if a vertical flue is fitted refer to supplement 1 for further guidance
on the use of flue restrictors.
Drill and screw
telescopic
overlap
5 STANDARD
TERMINAL
Slide telescopic
section to achieve
length ‘L’
4
Check terminal
is correctly
aligned
(see Fig. 27)
FLUE RESTRICTOR LOCATION
(Do not disturb if extension ducts are to be fitted)
FLUE RESTRICTOR
•
If any extensions ducts or additional elbows etc are to be used, proceed
to section 4.7.3.
If only the standard flue components (i.e those packed in the same
carton as the appliance) are to be used fit the restrictor as follows:
6
•
APPLIANCE TOP
a) Note the position of the flue restrictor ring. This is fitted on top of
the appliance and is secured by the air pressure switch bracket screws
(fig 24). Loosen the air pressure switch screw by 1/2 turn only, to
release the ring and tighten the two screws.
b) Fit the restrictor ring inside the flue elbow bottom as shown in figure
25 ensuring that it is the correct way round.
22
FITTING THE FLUE RESTRICTOR
RESTRICTOR
NOTES
1) Failing to fit the restrictor when installing the appliance with a
standard flue system will not provide optimum performance.
2) Fitting the restrictor on horizontal flue system incorporating
extensions or additional bends and fitting a restrictor on
vertical flues greater than 2300 mm will adversely affect
performance and may constitute a safety hazard.
14
3) Failure to comply with these instructions will invalidate the appliance
Certification and therefore may contravene the appropriate EC
legislation and local statutory requirements.
90° ELBOW
•
•
•
•
FAN
ALUMINIUM
FAN OUTLET
4.7.3
INSTALLING THE AIR/FLUE DUCT
FROM INSIDE THE ROOM
Wall thickness up to 800 mm (31in) only.
a) Push the terminal through the wall liner taking care to
ensure that the terminal is the correct way round and the
external wall sealing ring does not become dislodged.
b) Pull the flue system towards the boiler to seat the external
sealing ring against the outside wall and secure the elbow
to the boiler using the two screws provided.
21
c) Finally use the internal sealing ring to make good the
internal hole, and check that the terminal is correctly
located on the outside wall (Where possible this should
be visually checked from outside the building.) Figure 26
shows a view of the flue system, correctly installed.
d) Assemble as shown in Figure 26
INSTALLING THE FLUE SYSTEM FROM
INSIDE THE ROOM
INTERNAL WALL
SEALING RING
130mm Dia.
HOLE WITH
WALL LINER
•
•
TOP
•
•
•
EXTERNAL
WALL
SEALING
RING
FIBRE
SEAL FITTED
2 ALIGN ASSEMBLED
FLUE SYSTEM ELBOW TO
APPLIANCE AND SECURE
3 SLIDE INTERNAL
WALL SEALING RING TO
WALL TO FORM
A GOOD SEAL
1 INSERT
ASSEMBLED FLUE
SYSTEM FROM
INSIDE THE ROOM.
EXTERNAL WALL
SEALING RING
OPENS
•
4.7.4
INSTALLING THE AIR/FLUE DUCT
FROM OUTSIDE THE BUILDING
(Flue hole diameter 100mm - wall liner not necessary)
a) Secure the flue elbow with seal to the appliance using
4 screws.
d) Pull the flue system towards the boiler to seat the
external sealing ring against the outside wall and secure
the air duct to the elbow using the two screws provided.
b) Fit external wall sealing ring over flue and then from
outside the building, push the flue system through the
wall taking care to ensure that the terminal is the
correct way around.
e) Finally use the internal sealing ring to make good the
internal hole. Check that the external wall sealing ring
is correctly located, on the outside wall from outside the
building.
c) Fit the internal wall sealing ring over the inside end of
the flue, then fit the air duct to the elbow, drill and
secure with the two screws.
Figure 27 shows a view of the flue system, correctly
installed.
15
23
INSTALLING THE FLUE SYSTEM FROM OUTSIDE THE BUILDING
1 FIT ELBOW
(AFTER SETTING CORRECT
LENGTH AND ALIGNMENT)
100mm
Dia. HOLE
INTERNAL WALL
SEALING RING
•
•
•
TOP
•
•
EXTERNAL
WALL
SEALING
RING
•
4 REFIT AND SECURE
ELBOW TO AIR DUCT,
THEN TO APPLIANCE
3 SLIDE INTERNAL
WALL SEALING RING
OVER AIRDUCT. PUSH
AGAINST THE WALL TO
FORM A GOOD SEAL
2 INSERT FLUE
LENGTHS FROM
OUTSIDE THE
ROOM. ENSURE
EXTERNAL WALL
SEALING RING
FORMS A GOOD
SEAL
•
FIBRE SEAL FITTED
4.8
WIRING INSTRUCTIONS
Connect the electricity supply and external controls (using suitable
mains cable) as follows:
Wire the cable(s) into the appropriate connections in the electrical
plug provided (Figure 28). Live supply to L1, Neutral and Earth as
indicated. Check that L2 and L3 are linked.
To provide correct cable retention, fit the piece of tubing supplied
over the cable as it passes through the clamping arrangement. The
cable will be held in position as the plug cover is fitted.
If a room thermostat is to be fitted remove the red link between L2
and L3 and connect the thermostat across these terminals. Any
external controls fitted must be rated at 230V 50Hz and have voltfree contacts.
NOTE: Assuming that the appliance is to be
commissioned immediately after installation it is not
necessary to fit the casing panels at this stage.
16
24
ELECTRICAL CONNECTIONS
Note: If room
thermostat is to be
fitted remove the link
and connect room
thermostat across
L2 and L3.
(rear view)
5
COMMISSIONING AND TESTING
Before commissioning the appliance, the whole gas installation
including the meter MUST be purged and tested for gas tightness
in accordance with BS 6891: 1988.
IMPORTANT: Open all doors and windows, extinguish naked
lights, and DO NOT SMOKE whilst purging the gas line.
Before commencing the commissioning procedure, ensure that the
gas service cock is turned on, the electricity supply is isolated, and
that the DHW and CH pipework is complete.
25
FILLING THE WATER SYSTEMS
5.1
A special feature of the Finest and Finest Gold is that the water
systems can be completely filled prior to fitting the boiler. It is
recommended that this procedure is followed even when the boiler
is to be fitted immediately after filling the system.
Fill the water systems by following the procedure detailed below
Fig 25, steps 1 to 5.
COMMISSIONING THE WATER SYSTEM
•
•
•
•
•
CENTRAL
HEATING
RETURN
Note: It is recommended, where possible, to flush the
CH system without the boiler fitted, to avoid debris
and flux blocking the plate heat exchanger.
1) Check that the CH flow and return isolating valves are in the
open position.
2) Fill the system with water using one of the approved
methods described in section 3.6 to about 2.0 bar. Vent
the system via the radiator valves and system air vents in
accordance with normal practice. Ensure that all system
air vents are closed.
NOTE: The boiler is supplied with a filling loop and fittings.
3) Check the system for soundness.
4) Check the operation of the pressure relief valve (Fig. 32) by
rotating the plastic head anticlockwise 1/4 of a turn and
checking that water is discharged. Ensure that the valve
seats correctly and does not leak. If the valve leaks or is
stuck closed replace it.
5) Drain the entire system to flush out any debris, and refill to
0.2 bar above the system design pressure (between 0.5 and
1.5 bar) by repeating the above procedure. Follow the
COLD
WATER IN
FILLING
LOOP
VALVE
CH
DRAIN
CENTRAL
HEATING
FLOW
commissioning procedure described below, then repeat this
instruction with the system hot. It is recommended that the
system is cleaned with a recognised system cleaner such as
Fernox or Sentinel.
6) Open the DHW inlet valve and open and close each hot
water tap in turn to clear all the air from the pipes and
the boiler.
7) Remove the pump vent cap to bleed any air from the pump.
Using a screwdriver, rotate the pump shaft. Replace the cap.
Note: When bleeding the pump, the flow switch, situated
beneath the pump, must be protected from water leakage, either
by covering it or temporarily removing it from the manifold –
Refer to section 9.10.
8) If the filling loop has been used, disconnect it from the system.
9) Prior to lighting the boiler to check the gas rates, the Central
Heating and Boiler system should be checked for circulation
by running the boiler and pump with the gas turned off, to
ensure no air locks occur.
Boiler may go into ignition lock-out and require resetting.
17
5.2
COMMISSIONING THE APPLIANCE
Refer to Fig. 25
Note: If, at any time during the commissioning procedure, it is required
to prevent the boiler from modulating, set the CH temperature control
knob to the Service position.
a) Check that the gas supply is turned ON and the gas service cock is
OPEN.
b) Slacken the screw in the burner pressure test point and connect a
suitable manometer. Refer to Fig. 30.
c) Set the DHW and CH temperature control knobs fully anticlockwise to the standby positions.
d) Turn on the electrical supply and set the ON/OFF switch to ON (I).
The Reset LED will briefly show red, then blue, then extinguish.
The fan will start briefly and then stop.
The LEDs 1-4 (yellow) will illuminate briefly.
e) Turn the DHW temperature control knob to the desired temperature
position and fully open any DHW tap. LED 1 will show yellow
(Economy mode). The ignition sequence will commence and
when flame is detected the Reset LED will show blue.
If the burner fails to light after five attempts, ignition lock-out occurs.
In this event the Reset LED will show RED.
To re-set the appliance and initiate a further ignition sequence,
press the Reset button.
Note: If the Reset LED show RED, to establish the cause press and hold
the Reset button for three seconds. The Reset LED will flash RED and
the error code will be displayed via the LED’s 1-4.
f) After ignition, allow the boiler to run for at least 10 minutes and
check that the burner pressure is as stated on the data badge ±10 %.
(Nat. gas 15.5 mbar 39.6 kW or 135115 Btu/h gross heat input,
Propane 23.4 mbar or 120068 Btu/h). The DHW burner pressure
is factory set and should not require adjusting. If the burner pressure
is low, check that the appliance has not started to modulate (This will
occur if the DHW flow rate is low. If modulation is suspected, open
all DHW taps to maximise the flow and re-check the burner
pressure). If it is necessary to adjust the burner pressure the method
is described in section 9.5 ‘Gas valve replacement’.
Note: To select Comfort DHW control, ie with pre-heat, turn the
DHW temperature control knob fully clockwise and then back to the
desired temperature setting. LED 2 will then illuminate and LED 1
extinguish.
27
g) Close the DHW tap and ensure that the burner goes out (BLUE
light off) and the pump stops after an over-run period of 5 minutes.
h) Ensure that the room thermostat (if fitted) is calling for heat.
Turn the clock override switch to the ‘I’ position Turn the CH
temperature control knob to the ‘+’ position.
The boiler will perform a series of self-checks, light and then
go to minimum rate burner pressure(Nat. gas 3 mbar, propane
5.8 mbar). After ignition, the burner pressure will remain at this
for about ten minutes, before ramping up to the factory set burner
pressure, or to a modulated value if the system is hot.
The Reset LED will show BLUE and LEDs 3 and 4 will show
YELLOW.
i) Set the clock to the desired times by setting the tabs.
j) Slide the clock override switch to the 'timed' position and
check the operation of the clock and room thermostat (If fitted)
Caution: With the CH temperature control knob in the Service position,
the boiler will fire continuously at full output and LEDs 3 and 4 will flash.
This setting is for the convenience of the Service Engineer ONLY.
5.3
DOMESTIC HOT WATER FLOWRATE
A flow regulator is supplied factory fitted to the appliance to ensure that
no adjustment is necessary. Should the mains flow rate be below the
minimum required, it is possible to remove the flow regulator from the
appliance as instructed in section 9. The nominal pre-adjusted flow rate
may vary by ± 5 % due to factory tolerances and mains water pressure
fluctuation.
5.4
FINAL CHECKS
a) Turn both the DHW and CH temperature control knobs to standby.
b) Turn the appliance on/off switch to the off (o) position, remove
the manometer and tighten the burner pressure test point screw.
Re-light the burner and test for gas tightness.
c) Fit the boiler casing as described and illustrated in Figure 28: Fit each
side panel with two screws at the top and bottom of each panel. Position
and fit controls cover in place using screws provided. Ensure it hinges
correctly. Fit the front panel in position using locating studs and ensure
correctly seated by pressing.
d) Set the heating and hot water controls to the required settings.
Ensure that the clock override switch is in the timed position and check
that the time clock is set at the desired time periods. Set the room
thermostat (if fitted) to the required setting.
FASCIA PANEL AND CONTROLS
Service Function
Economy/Comfort
Error Code LED (1&2)
••
DHW Economy/
Comfort Switch
24hr Clock
Pressure
Gauge
•
•
• •
•
BURNER (Blue)
LOCK-OUT (Red)
LED and
Reset Button
•
CH Error Code
Indicator (3&4)
•
Mains ON/OFF
Switch
CH Temp.
Control
CLOCK OVERRIDE
SWITCH (Heating only)
= Continuous ON
= Timed
= OFF
ARROW
INDICATES
CURRENT TIME
•
•
DHW
Temperature
Control
•
18
TABS OUT
= ON PERIOD
TABS IN
= OFF PERIOD
•
•
5.5
IGNITION LOCKOUT
In the event of failure during an ignition sequence, (5 attempts) the
Reset LED will show steady RED. By pressing and holding the Reset
button 3 seconds the Reset LED will flash RED and LEDs 1 to 4 will
display the error code (0011). To Reset the appliance and initiate a
further ignition attempt, press the Reset button.
NOTE: In the event of failure during normal running, the Reset LED will
show steady RED.
To access the relevant error codes, press the Reset button for three
seconds. The Reset LED will flash RED. To reset the appliance press the
Reset button.
5.6
OVERHEAT THERMOSTAT
The appliance is fitted with an overheat thermostat (integral with the CH
control thermistor). In the event of overheating, the boiler will go to lockout
and the Reset button show steady RED if the error codes are accessed the
LED 4 (Code 0001) will illuminate. Allow the boiler to cool, then press the
Reset button to clear.
5.7
FROST PROTECTION
The appliance is fitted with a frost protection device. In the event of very
cold conditions, the pump may operate and the boiler light for a few
minutes to protect the appliance and system from potential frost damage.
This can only function if the gas and electricity supplies are maintained and
the ON/OFF switch on the appliance is left ON. (1) The clock can be
switched to the OFF setting.
5.8
OTHER FEATURES
The following additional features are included in the appliance
specification:
ANTI-CYCLE DEVICE: When the appliance cycles on its central heating
control thermostat, a slow cycle device operates. The timer (set to 3 mins) is
activated after the end of burn cycle to prevent rapid cycling of the burner.
ANTI PUMP SEIZURE DEVICE:
Providing that a power supply is maintained and the appliance ON/OFF
switch is ON, the pump will operate for at least 20 seconds every 23 hours
(regardless of heat demand) to prevent pump seizure during periods where
the appliance is not used.
WATER FLOW SWITCH:
This device prevents the burner from firing if there is inadequate water flow
through the main heat exchanger.
DHW PRE-HEAT:
DHW Comfort selected: With no demand for DHW the boiler will fire
periodically for a few seconds to maintain the DHW plate heat exchanger in
a heated condition. This feature will automatically adjust to the user’s habitual
requirements. Thus during long periods of no DHW draw-off, eg overnight, no
pre-heat is provided. DHW Economy selected: No pre-heat is provided.
5.9
e) Explain the function of the boiler overheat thermostat, and how to re-set it.
Emphasise that if cut-out persists, the boiler should be turned off and the
installer or service engineer consulted.
f) Stress the importance of an annual service by a registered heating
engineer.
g) The electrical mains supply to the appliance must remain ON and the
ON/OFF switch must be left ON for the frost protection circuit to operate.
5.10
BOILER LOGBOOK
A logbook is supplied with this appliance to record installation and
commissioning details and to make future servicing of the appliance
easier.
This logbook forms part of the industry's Benchmark code of practice for
the installation, commissioning and servicing of central heating systems.
Please ensure that the logbook is fully completed and left with the
customer for future reference, along with Users Instructions and this
Installation and Servicing Instruction manual.
5.11
CONVERSION INSTRUCTIONS
Appliance conversion from one gas group to another is only possible for
category II2H3P appliances; these may be converted between Propane
and natural gas by use of conversion kits. the kits comprise the following.
Propane to Natural Gas - Kit Number: 955095
• Main Burner Injectors 1.35 mm Ø x 13
• Gas Control Valve
• Boiler Chip Card Nat. Gas
• Flue Restrictor Ring 47 mm Ø
• Data Badge (Nat. Gas)
• Conversion Instructions
Natural Gas to Propane
• Main Burner Injectors 0.9 mm Ø x 13
• Gas Control Valve
• Boiler Chip Card Propane
• Flue Restrictor Ring 43 mm Ø
• Data Badge (Propane)
• Conversion Instructions
Instructions on how to convert the appliance is given in the conversion
instructions supplied with these kits. However, particular attention should
be given to the fitting of flue restrictors and to the use of the Boiler Chip
card.
For further information contact: Halstead Boilers Ltd, Service Help Line,
01926 834 834
28
FITTING THE CASING PANELS
USERS INSTRUCTIONS
Upon completion of commissioning and testing the system, the installer must
instruct the user in how to operate the appliance by drawing the user's
attention to the following.
a) Give the 'Users Instructions' to the householder and emphasise their
responsibilities under the 'Gas Safety (Installation and Use) Regulations or
rules in force.
b) Explain and demonstrate the lighting and shutdown procedures.
c) Advise the householder on the efficient use of the system, including the
use and adjustment of all system controls for both CH and DHW.
d) Advise the user of the precautions necessary to prevent damage to the
system, and to the building, in the event of the system remaining
inoperative during frost conditions.
FIT BALL STUDS TO
FRONT PANEL
3 HOLES ON
EACH SIDE PANEL
WILL HAVE RUBBER
GROMMETS FITTED
BY THE INSTALLER
19
6
ROUTINE SERVICING
6.1
MAIN BURNER ASSEMBLY
Refer to Figs. 29 and 30
a) Remove the casing front panel. Refer to Fig. 31.
b) Remove the sealed chamber front panel (4 screws).
c) Remove the combustion chamber front panel (9 screws). Take
care not to damage the insulation.
Do not attempt to light the burner with Front Panel removed.
d) Remove the two securing screws and lower the controls fascia
panel.
e) Disconnect the three leads from the spark and detection
electrodes and disengage the grommets from the combustion
chamber bottom panel.
f) Remove the 4 screws securing the burner to the gas manifold
and slide the burner out of the combustion chamber.
g) Inspect, and if necessary clean the main burner ports using a soft
brush or vacuum cleaner. Do not use a wire brush or any
abrasive material.
LOCATION OF
SERVICEABLE
COMPONENTS
FAN ASSEMBLY BASE
PLATE SCREWS
BURNER INJECTOR
Check that the injectors fitted in the gas manifold are free from dirt and
debris. If necessary, clean the injector orifices carefully using a soft
brush or vacuum cleaner. Do not use a wire brush or any abrasive
material.
It is not necessary to remove the injectors. If there are signs of
injector(s) being blocked please call the Halstead Service Department.
6.3
IGNITION AND DETECTION ELECTRODES
a) Inspect the ignition and detection electrodes in situ. If necessary,
clean using a soft brush. If either the electrode or the ceramic
insulation show signs of damage or wear, replace the
electrode(s).
b) Check that the alignments of the ignition and detection
electrodes are correct. Refer to Fig. 34. Adjust by carefully
bending the tip of the electrode rod whilst supporting the base of
the rod. Do not put any pressure on the ceramic insulation.
FAN ASSEMBLY
6.4
a) Remove combustion chamber front panel. Refer to 6.1.
b) Carefully disconnect the two electrical leads from the fan.
c) Disconnect the air pressure switch sensing pipes from the fan,
noting their positions
d) Remove the fan assembly by unscrewing the three screws,
lowering the assembly and lifting it forwards.
e) Inspect the fan assembly (especially the impeller and the venturi)
for dirt, damage, or signs of wear. If necessary clean the
impeller and/or venturi using a soft brush or vacuum cleaner.
Spin the impeller and check that it rotates freely, without noise,
and without imbalance. If there is any sign of deterioration or
damage, replace the fan.
•
•
•
29
6.2
•
To ensure continued efficient operation of the appliance, it is
recommended that it is checked and serviced as necessary at regular
intervals. The frequency of servicing will depend upon the particular
installation conditions and usage, but in general once a year should
be adequate. It is the law that any service work must be carried out
by a competent person, such as British Gas or other CORGI
registered personnel.
The boiler incorporates a flue sampling point on the top panel in
front of the flue outlet. If the service engineer has suitable equipment
to analyse the flue gas, the plastic cap may be removed and a 6mm
inside diameter sample tube fitted. Check CO2 /CO values and
compare with figure stated in section 2.4. Do not forget to replace
the plastic cap after use. Before commencing any service operation,
ISOLATE the mains electrical supply, and TURN OFF the gas supply
at the main service cock.
Service the appliance by following the full procedure detailed below:
•
AIR PRESSURE
SWITCH & PIPES
FAN ASSEMBLY
AUTO AIRVENT
IGNITION ELECTRODES
COMBUSTION CHAMBER
FRONT PANEL FIXING
SCREWS (9)
DETECTION ELECTRODE
BURNER
••
•
•
•
OVERHEAT THERMOSTAT
PRESSURE RELIEF
VALVE
•
•
•
PRESSURE
GAUGE
CONTROL PANEL
•
•
20
GAS COCK
•
•
GROUP SET
GAS CONTROL VALVE
•
•
PUMP
CONTROL
BOX
6.5
AIR PRESSURE SWITCH PIPES
Check that the pressure switch sensing pipes are not blocked or
damaged. It is not necessary to remove the air pressure switch
which is not adjustable and does not require any servicing.
30
BURNER REMOVAL
6.7
GENERAL
NOTE: Safe handling of substances.
Care should be taken when handling the boiler insulation panels,
which can cause irritation to the skin. No asbestos, mercury or
CFCs are included in any part of the boiler or its manufacture.
a) Check that the combustion chamber insulation is not
damaged.
b) Clean the inside of the sealed chamber using a soft brush or,
preferably, a vacuum cleaner.
c) Check that the sealed chamber front panel seal is intact and in
good condition. Replace if necessary.
d) Always wear a protective mask when cleaning the appliance.
6.8
RE-ASSEMBLY
Re-assemble all components in reverse order, but do not swing the
fascia panel back into position or fit the casing front panel until
servicing has been completed.
When re-fitting the burner, it is essential to ensure that it is level
and that it is correctly assembled into the injector. Refer to Fig. 30.
Check that all joints and seals are correctly fitted.
Note that fan polarity is immaterial.
6.9
31
ELECTRODE ALIGNMENT
DETECTION ELECTRODE
(flame sensor)
IGNITION ELECTRODE
a) Slacken the screw in the burner pressure test point and
connect a suitable manometer. Refer to Fig. 31.
Turn on the gas and electricity supply and light the boiler as
described in section 5.2
b) Check the operation of the appliance in both CH and DHW
modes. Ensure that the DHW maximum and minimum burner
pressures after ten minutes running are as stated on the data
badge.
c) Remove the manometer and tighten the sealing screw. Re-light
the appliance and test for gas soundness.
6.10
•
12.2
•
•
20.0
2.5 ± 0.5
HEAT EXCHANGER
Inspect the heat exchanger from both above and below the fins. If
necessary, clean the fins with a soft, non-metallic brush.
SEALED WATER SYSTEMS
a) Check the operation of the pressure relief valve as described
in section 5.1.
b) Check the correct operation of the pressure gauge by noting
the reading when cold and check that the pressure increases
with temperature. Replace the gauge if readings are suspect.
c) Check that the system is at its original (cold) design pressure.
If necessary, re-pressurise the system as described in section
5.1 and search for and rectify any leaks causing loss of water.
d) In case of heavy pressure fluctuations during the heat and cool
down cycle, check the pre-charge pressure of the expansion
vessel. If the air pressure is less than 0.75bar recharge vessel
with an air pump.
6.11
6.6
RE-COMMISSIONING
FINAL CHECKS
a) Swing the fascia panel into the upright position and secure
with the two screws.
b) Re-fit the front casing panel. Refer to Fig. 28.
c) Return all appliance and external controls (if fitted) to their
original settings.
21
7
INTERNAL WIRING DIAGRAMS
7.1 : FUNCTIONAL FLOW WIRING DIAGRAM
22
8.1
8
FAULT FINDING
Detailed procedures for replacing faulty components are described in
section 9 (Parts Replacement).
GENERAL
Before looking for a fault condition, check that:
• The mains electrical supply is turned on.
• The clock and/or room thermostat (if fitted) are calling for heat
(CH 'faults' only)
• The gas service cock is open.
• The CH and DHW isolation cocks are open.
• The system is at design pressure.
Before attempting any electrical fault finding, always conduct the
preliminary electrical system checks as described in the Instructions
for the British Gas Multimeter, or other similar instrument.
On completion of any service or fault finding operation involving
making or breaking electrical connections, always check for EARTH
CONTINUITY, POLARITY and RESISTANCE TO EARTH.
● = LED ON
For further information contact: Halstead Boilers Ltd.,
Service Help line : 01926 834834
DIAGNOSTIC INDICATOR LED’S
8.2
FASCIA PANEL
The Reset LED shows steady RED in a lockout condition.
To access the error codes, press the Reset button for three
seconds and the LED will begin to flash.
For fault finding, refer to the diagnostic chart shown below,
together with the notes given in sections 8.3, 8.4 and 8.5
IGNITION FAULT FINDING
8.3
In the event of the boiler failing to light, refer to the
Diagnostics Chart.
● = LED OFF
LED CODE
1 2 3 4
FAULT
REASON
ACTION
●●●●
Water pressure switch inoperative
Low water pressure
● ●●●
Lockout flame signal
No flame signal on ignition,
or loss of signal during
operation
●●●●
Erroneous APS signal
Missing or defective APS signal
●●●●
Overheat thermostat activated
Boiler temperature > 105°C
●●●●
No DHW temperature control
Defective DHW sensor
●●●●
5 sec flame signal after burner is switched off
Defective gas valve
●●● ●
●●●●
●● ●●
●●●●
●●●●
BCC error
Activate BCC
Error in power supply
CRC error
Safety system failure
Wrong/missing BCC
New BCC, press reset to activate
Low mains voltage
Internal Eprom data error
Failure of internal self checking system
• Check water pressure (> 0.5 bar)
• Check CH pump/ expansion vessel
• Check switch
• Check detection electrode/lead
• Check gas supply
• Check gas valve and lead
• Check PCB/spark generator
• Check APS
• Check pipe connections for blockage
• Check fan
• Check PCB
• Check flue condition
• Check CH/O’heat thermistor
• Check wires to sensor
• Check no air is in CH system
• Check PCB
• Check pump
• Check DHW sensor
• Check wires to sensor
• Check gas valve and lead
• Check PCB
• Burner off
• Burner off
• Check mains voltage
• Check PCB
• Check PCB
•
•
DHW TEMP
CONTROL
•
PRESSURE
GAUGE
LED 4
RESET & burner/
lock-out LED
CH TEMP
CONTROL
•
•
•
•
CLOCK
LED 3
• •
LED 2
•
LED 1
FACIA PANEL
ON/OFF
SWITCH
23
8.4
DHW FAULT FINDING
8.5
When the hot water tap is turned on, the controls should carry out
a set of start up checks followed by an ignition sequence. Refer to
section 5.2
If the control has powered up correctly but does not respond to a
DHW demand.
Check operation of fan and air pressure switch. Check if Red LED
on DHW flow switch is on or off. If off, check DHW hall effect
sensor and condition of sanitary flow detector in hydraulic group
set. If on, check wires to flow switch, check DHW thermistor and
wires. If fan, air pressure switch, DHW flow switch, thermistor
and wires are OK replace PCB.
Guidance notes (Refer to section 7.1):
If DHW temperature heavily fluctuates during a long draw off and
occasionally goes to an overheat Lock-out condition, check the
secondary plate heat exchanger for debris and replace.
9
COMBUSTION CHAMBER
INSULATION
The design of the appliance is such that the combustion chamber
insulation should not require replacement unless mechanically
damaged. It is recommended that to prevent dust, the insulation is
dampened prior to removal.
a) Remove the retaining screw and lift off the casing front panel.
Refer to Fig.28
b) Remove the sealed chamber front panel (4 screws).
c) Remove the combustion chamber front panel (9 screws).
The front insulation may now be replaced, but to replace the side and
rear insulation, the heat exchanger must be removed. Refer to section X
d) Fit the new insulation and re-assemble in reverse order.
e) Ensure that all joints and seals are correctly re-fitted and recommission the system (if necessary) using the procedure in
section 5.1.
It is recommended that a protective mask is worn when
changing or handling the insulation material.
9.2
24
Upon a demand for Central Heating, (closure of the time switch and
room thermostat, if fitted) , the controls should carry out a set of start up
checks, followed by an ignition sequence. Refer to Section 5.2.
If the control has powered up correctly but does not respond to a CH
demand. Check voltage between pin 2 plug X1A (orange wire) and
pin 2 X13 (blue wire). If 0V ac, check room thermostat and clock. If
230 V ac, check operation of fan and air pressure switch. Check
operation of gas valve. If room thermostat clock, fan, air pressure
switch and gas valve are OK replace PCB.
Guidance notes (Refer to section 7.1):
1) Whenever a CH demand is removed, either by the timer, the room
thermostat or the boiler internal temperature control, an anti cycle mode
is initiated which prevents the boiler from firing in CH mode for 3
minutes. Ensure that the control is not in this mode by removing power
from the control and restoring it after a delay of 10 seconds.
PARTS REPLACEMENT
Before commencing any service operation, ISOLATE the mains electrical
supply and TURN OFF the gas supply at the main service cock.
It is the law that any service work must be carried out by a registered
person.
9.1
CENTRAL HEATING FAULT FINDING
FAN ASSEMBLY
Refer to Fig. 29
a) Ensure supply voltage is isolated.
b) Remove the casing front panel, sealed chamber panel and
combustion chamber panel. Refer to section 9.3
c) Carefully disconnect the two electrical leads from the fan.
d) Disconnect the air pressure switch sensing pipes from the fan,
noting their position.
e) Remove the fan assembly (3 screws) and withdraw the
assembly by lowering and lifting it forwards.
f) Fit the new fan assembly and re-assemble in reverse order.
Ensure that all joints and seals are correctly re-fitted. (Polarity is
immaterial on the fan connections.)
9.3
BURNER
a) Remove the casing front panel. Refer to Fig. 31
b) Remove the sealed chamber front panel (4 screws).
c) Remove the combustion chamber front panel (9 screws). Take
care not to damage the insulation.
d) Lower the controls front cover panel and remove the two
securing screws and lower the controls fascia panel.
e) Disconnect the three leads from the spark and detection
electrodes and disengage the grommets from the combustion
chamber bottom panel.
f) Remove the four screws securing the burner to the gas
manifold and slide the burner out of the combustion chamber.
g) Transfer the ignition and detection electrodes to the new
burner and check their alignment. Refer to Fig.34.
h) Fit the new burner and reassemble in reverse order. Ensure
that all joints and seals are correctly re-fitted.
9.4
IGNITION & DETECTION ELECTRODES
Refer to Fig. 29
a) Ensure supply voltage is isolated. Remove the burner. Refer to
section 9.3.
b) Fit the new ignition and /or detection electrode(s) and check
that both electrodes are aligned as detailed in Fig.34.
c) Re-assemble in reverse order. Ensure that all joints and seals
are correctly re-fitted.
9.5
9.5.1
MULTIFUNCTIONAL GAS CONTROL
GAS CONTROL REPLACEMENT
Refer to Figs. 32 and 35
a) Ensure supply voltage is isolated.
b) Lower the controls front cover panel and remove the casing
front panel. Refer to section 9.3
c) Remove the two retaining screws and lower the controls
fascia panel.
d) Release the screw and unplug the electrical lead from the
gas control.
e) Disconnect the two electrical leads from the Modureg.
f) Ensure that the gas supply is turned OFF and remove the four
socket screws securing the gas service cock to the gas control.
g) Remove the four screws securing the gas outlet flange to
the gas control.
h) Withdraw the gas control from the boiler.
i) Fit the new control and re-assemble in reverse order, ensuring
that the ‘O’ rings are correctly fitted.
32
MULTIFUNCTIONAL GAS CONTROL
Modureg
Gas outlet flange
Electrical lead
DHW Burner
pressure adjuster
•
•
•
•
•
Burner pressure
test point
9.5.2
•
Inlet pressure
test point
•
Gas service cock
GAS CONTROL BURNER PRESSURE
SETTING PROCEDURE
Refer to Figs. 32
a) Connect a suitable manometer to the burner pressure test
point. Turn on the gas supply.
Check for gas tightness taking the precautions described in
section 5 and re-commission the appliance in accordance with
section 5.3.
Note: It is only possible to set the DHW heat inputs because the
CH heat inputs are electronically set by the control.
A 2mm and 3mm Allen key are required for this adjustment.
a) Turn the DHW temperature control knob fully clock-wise to the
Comfort position and fully open any DHW tap to ensure that
the boiler fires at full rate.
b) Remove the cap from the pressure adjuster and insert the Allen key.
c) Turn the small diameter shaft clockwise to increase, or anticlockwise to decrease the burner pressure. Set to 15.5 mbar
(6.2 in wg) Nat. Gas, 23.4 mbar (9.4 in wg) Propane.
d) Disconnect one of the low voltage electrical leads from the
Modureg to reduce the rate to minimum.
e) Turn the large diameter shaft clockwise to increase, or
anti-clockwise to decrease the burner pressure. Set to 1.0
mbar (0.4 in wg) Nat. Gas, 2.3 mbar 0.92 in wg Propane.
f) Reconnect the Modureg lead and replace the adjuster cap.
g) Close the DHW tap and ensure that the burner is
extinguished and the pump stops after a brief overrun
period. Remove the pressure gauge and tighten pressure
test point screw, open the DHW tap to re-light the burner
and test for gas tightness screw.
h) Close the DHW tap, re-assemble in reverse order and ensure the
plastic cap is refitted and a blob of paint re-applied to seal it.
9.6
AIR PRESSURE SWITCH
Refer to Fig. 29
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and sealed chamber front
panel. Refer to section 9.3.
c) Disconnect the sensing pipes from the pressure switch.
Note that the short pipe from the flue gas sampling point is
connected to the rear (-ve) connection on the pressure switch.
d) Disconnect the electrical leads from the pressure switch, noting
their positions.
e) Remove the two securing screws and withdraw the switch from
the boiler.
f) Fit the new pressure switch and re-assemble in reverse order,
referring to the wiring diagrams (section 7) if necessary.
9.7
DIVERTER VALVE ACTUATOR
Refer to Fig. 33
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
c) Unplug the electrical lead from the actuator.
d) Withdraw the retaining clip to release the actuator from the
head of the diverter valve.
e) Fit the new actuator and re-assemble in reverse order.
9.8
PCB
Refer to Fig. 29 and 33
a) Ensure supply voltage is isolated.
b) Lower the controls front panel and lower the control fascia
panel. Refer to section 9.3.
c) Unplug the electrical leads from the PCB. Refer to section 7.
d) Remove the PCB plastic cover.
e) Unclip the PCB and withdraw.
f) Carefully remove the three control knobs, noting their position
and fit onto new PCB.
g) Fit the new PCB and re-assemble in reverse order. Ensuring
control knobs are free to move and reset button operates.
33
PCB HOUSING
Electrical
Connectors
Securing
Screws
NG/Propane
chip card
•
•
25
9.9
CH MICROSWITCH
Refer to Fig. 34
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
c) Withdraw the retaining spring clip to release the microswitch
assembly from the spindle
d) Remove the three screws securing the halves of the plastic
housing and slide the microswitch forwards to release it from
the housing.
e) Disconnect the electrical leads from the micro switch.
f) Fit the new micro switch and re-assemble in reverse order.
9.10
DHW FLOW SWITCH (Hall Effect)
Refer to Fig. 34
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
c) Draw the switch forward to unclip it from the brass manifold.
d) Disconnect the electrical lead from the switch.
e) Fit the new switch and re-assemble in reverse order.
Note: The Hall effect magnet is housed within the DHW sanitary
flow detector and should not normally need replacement.
9.11
TIME CLOCK
Refer to section 7.2.
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
c) Unplug the four electrical leads from the back of the clock.
d) Remove the four retaining screws and withdraw the clock from
the control panel.
e) Fit the new clock and re-assemble in reverse order.
9.12
DRAINING THE BOILER
To replace components in sections 9.13 to 9.21 it is necessary to
drain the boiler and/or the DHW circuit. There may be some
slight water spillage, so electrical components should be
protected.
Refer to section 5.
a) CH: Close the CH flow and return isolating valves. Attach a
hose to the drain point and open the drain valve.
b) DHW: Close the cold water inlet valve and open all DHW
taps to empty the DHW circuit.
9.13
26
CH/OVERHEAT OR
DHW THERMISTORS
Refer to Fig. 34
a) Ensure supply voltage is isolated.
b) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
c) Isolate the boiler from the system. Refer to section 5:
DHW thermistor: Close the cold water inlet valve and open all
DHW taps to empty the DHW circuit.
CH/O’Heat thermistor: Close the boiler flow and return isolating
valves and drain the boiler’s CH circuit, refer to section 9.12.
d) Disconnect the electrical lead from the thermistor.
e) Unscrew the thermistor from the manifold.
f) Fit the new thermistor and re-assemble in reverse order.
Ensure that the copper washers are correctly fitted to provide
a sealed joint.
g) Re-commission the system. Refer to section 5.
9.14
DHW HEAT EXCHANGER
Refer to Fig. 34
a) Remove the casing front panel and lower the controls fascia
panel, refer to section 9.3.
b) Remove boiler bottom panel, refer to section 9.14.
c) Drain both the boiler and DHW circuits, refer to section 9.12.
d) Remove the two spring clips securing the bypass pipe and pull
out the pipe.
e) Remove the two socket screws securing the heat exchanger to
the water manifolds and push the heat exchanger downwards
to release it.
f) Remove the water flow regulator, noting its position and
orientation.
g) Fit the water flow regulator to the new heat exchanger.
h) the new heat exchanger and re-assemble in reverse order.
i) Re-commission the heating and hot water systems. Refer
to section 5.
9.15
WATER FLOW REGULATOR
Refer to Fig. 34
a) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
b) Remove the DHW heat exchanger. Refer to section 9.14.
The plastic regulator is located in the top LH entry port of the
heat exchanger
c) Fit the new regulator, ensuring that it is the correct way round.
d) Re-assemble in reverse order and re-commission the DHW
circuit. Refer to section 5.
9.16
PUMP
Refer to Fig. 34
a) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
b) Drain the boiler. Refer to section 9.12.
c) Remove the pump terminal box cover and disconnect the
electrical leads.
d) Either undo the two pump unions and remove the entire pump
(using new sealing gaskets), OR remove the four socket screws
and remove the pump head only.
e) Fit the new pump (or pump head) and re-assemble in
reverse order.
f) Re-commission the system. Refer to section 5.
9.17
9.20
PRESSURE RELIEF VALVE
MAIN HEAT EXCHANGER
Refer to Fig. 34
Refer to Fig. 29
a) Remove the casing front panel and lower the controls fascia
panel. Refer to section 9.3.
a) Remove the casing front panel. Refer to Fig. 31
b) Drain the boiler. Refer to section 9.12.
e) Remove the combustion chamber front panel (9 screws). Take
care not to damage the insulation.
c) Undo the two union connections and remove the valve.
d) Fit the new valve and re-assemble in reverse order.
f) Remove the two securing screws and lower the controls fascia
panel.
e) Re-commission the system. Refer to section 5.
9.18
b) Remove the sealed chamber front panel (4 screws).
g) Disconnect the three leads from the spark and detection
electrodes and disengage the grommets from the combustion
chamber bottom panel.
PRESSURE GAUGE
Refer to Fig. 29
a) the casing front panel and lower the controls fascia panel.
Refer to section 9.3.
h) Remove the four screws securing the burner to the gas
manifold and slide the burner out of the combustion chamber.
b) Drain the boiler. Refer to section 9.12.
i) Close the CH flow and return isolating valves and drain the
appliance.
c) Disconnect the pressure gauge capillary from the water manifold.
j) Disconnect the plastic pipe from the automatic air vent.
d) Disengage the pressure gauge from the fascia panel, and
remove the gauge.
k) Bend the retaining clips down and carefully remove the LH
combustion chamber insulation panel to reveal an access hole
to the heat exchanger union connections.
e) Fit the new pressure gauge and re-assemble in reverse order.
l) Using a suitable spanner, undo the heat exchanger union
connections from inside the combustion chamber.
f) Re-commission the system. Refer to section 5.
9.19
m) Lift the heat exchanger clear of the two pipes and remove by
sliding it forwards.
AUTO AIR VENT
Refer to Fig. 29
a) Remove the casing front panel and sealed chamber front
panel. Refer to section 9.3.
b) Drain the boiler. Refer to section 9.12.
n) Transfer the automatic air vent to the new heat exchanger.
o) Fit the new heat exchanger and re-assemble in reverse order.
Ensure that all joints and seals are correctly re-fitted and recommission the system using the procedure in section 5.1.
c) Disconnect the plastic pipe from the top of the air vent, and
unscrew the vent from the heat exchanger header.
d) Fit the new air vent and re-assemble in reverse order.
e) Re-commission the system. Refer to section 5.
34
WATER HOUSING GROUP SET
DHW THERMISTOR
PUMP
SECURING
SCREWS (2)
CH MICROSWITCH
CH THERMISTOR AND
OVERHEAT THERMOSTAT
DHW
FLOWSWITCH
ACTUATOR
PRESSURE RELIEF VALVE
PLATE HEAT
EXCHANGER
27
10
Key
G C Part
No.
1
1
2
3a
3b
4
5
5
6
7
8
9
10a
10b
11
12
13
14
15
16
17
18
19
19a
20
21
22
34
SHORT PARTS LIST
Description
No
off
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
BURNER (Nat gas)
BURNER (Propane)
MANIFOLD SET(Nat gas)
IGNITION ELECTRODE L/H
IGNITION ELECTRODE R/H
DETECTION ELECTRODE
GAS CONTROL (Nat gas)
GAS CONTROL (Propane)
PCB
AIR PRESSURE SWITCH
FAN ASSEMBLY
DHW FLOWSWITCH (Hall effect Sensor)
CH/O’HEAT THERMISTOR
DHW THERMISTOR
MAIN HEAT EXCHANGER
DHW HEAT EXCHANGER
PRESSURE RELIEF VALVE
AUTO AIR VENT
PRESSURE GAUGE
PUMP 6M
MICROSWITCH ASSEMBLY
WATER FLOW REGULATOR
DIVERTER VALVE ELECTRONIC ACTUATOR & CLIP
DIVERTER VALVE SERVICE KIT
EXPANSION VESSEL
HEATING CLOCK
BCC (Boiler control Chip)
SHORT PARTS LIST
3b
2
3a
Makers
Pt No.
700563
700562
700564
500620
500621
500622
500632
500636
988455
500592
601012
500641
550530
500590
450984
451011
450987
450908
450961
851213
500593
300717
500642
500643
450986
600520
500637
4
5
1
9
7
10a
8
6
10b
14
11
13
12
17
16
19
20
15
21
22
18
28
11
SUPPLEMENT 1
Supplementary instructions for flue systems with a
vertical outlet.
Vertical flue terminal length - max 4000mm (158 in)
min 565 mm (22 in)
IMPORTANT: The equivalent flue length must not
exceed 4000mm'
Extension duct (each extension extends the flue length by up to
767 mm)
90° Extension Elbow (Allows an additional bend in the flue and
has an ‘equivalent length’ of 767 mm.) This elbow is mechanically
different from the flanged elbow supplied as standard with the
appliance, but has the same equivalent length of 767mm.
45° Extension Elbow Allows an additional bend in the flue and
has an equivalent length of 384 mm.
NOTE: FLUE RESTRICTOR
A flue restrictor (Ref No. VF 90) is supplied with the
boiler kit. This MUST ONLY be fitted to the boiler if the
equivalent vertical flue height is to be 2300 mm or
less. For fitting instructions refer to Fig 22. The flue
restrictor supplied with the appliance must not be used
and should be discarded.
a) Read the installation requirements and flue specifications
described in section 3.
b) Follow the installation procedure described in section 4 up to
section 4.7 (but making the necessary hole(s) in the
ceiling/roof instead of the wall). Use the following instructions
in place of section 4.7.
c) Measure the vertical distance from the top of the boiler case to
the roof line (Fig. 3). Use this length to calculate the number of
extension ducts required.
d) Starting at the boiler, fit the vertical socket, standard duct and
extensions required. Then fit the adaptors. Ensure that they are
in line (level).
e) Now working from outside fit the balanced flue roof terminal,
ensuring the roof flashing and sealing components are secured
to the roof.
f) Ensure the inner and outer ducts are correctly fitted to the
adaptor.
Note: All the joints should be secured using the selftapping screws supplied.
29
Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex C09 2EX.
Telephone: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588.
Service Helpline: 01926 834834. Training: 01926 834838.
Email: sales@halsteadboilers.co.uk or service@halsteadboilers.co.uk or training@halsteadboilers.co.uk
Website: www.halsteadboilers.co.uk
Halstead Boilers is continuously improving its products and may therefore change specifications without prior notice.
The statutory rights of the consumer are not affected.
HB 9/03-750985
SERVICE HELPLINE: 01926 834834 TRAINING: 01926 834838
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