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Combitek-F-23-E Manual Ingles
Combitek-F-23-E Manual Ingles
IN WARRANTY
TECHNICAL HELPLINE
01773 828400
THIS IS A CAT II2H3+ APPLIANCE
01773 828100
1
INSTALLATION AND SERVICING INSTRUCTIONS
COMBITEK F 23 E
Note: The boiler serial number is marked on the data label attached to the PCB housing behind the front
lower section. Refer to the ‘Introduction’ section for a description of the basic functions of the boiler. The
‘User’ section describes how to safely operate the boiler.
USER INSTRUCTIONS
INTRODUCTION If the pressure shown on the pressure gauge is less
The Combitek F 23 E is a wall mounted combination than 1.5 bar the system must be filled up.
boiler providing central heating and instantaneous
domestic hot water. Important notice: A central heating system cannot
operate satisfactorily unless it is properly filled with
These instructions should be carefully followed for water and unless the air initially contained in the
the safe and economical use of your boiler. piping systems has been properly bled off. If these
conditions are not satisfied, air noise will occur within
Gas leak or fault the system and the boiler may fail to operate.
If a gas leak or fault exists or is suspected, turn the
boiler and gas supply off and consult the local gas Air in the heating system
company or your Installer/Service provider. Persistent air in the heating system may indicate
leaks in the system or corrosion taking place. Call
In case of power supply failure your Installer/Service provider.
The boiler no longer operates.
As soon as power supply is restored, the boiler will Overheating safety
restart automatically. In the event of problem, the overheat safety device
causes safety shutdown of the boiler. If this happens,
In case of loss of water in the system call your Installer/Service provider.
CAUTION. The boiler is installed as part of a sealed
system which must only be drained and filled by a
competent person.
2
USER INSTRUCTIONS
2 1 24
21
3
20
6
I
19
9
18
8
17
9
0
16
10 6 15
Diagram 1
21
5
To start the boiler
20
6
Switch on using mains switch (4), see diagram 1. I
Place switch (2) in the Summer or Winter position
19
9
18
To stop the boiler
8
Place switch (4) to the Off position (0).
17
9
0
16
10 6
Setting to ‘Summer’ 11
15
3
USER INSTRUCTIONS
CLEANING BOILER CASING
The boiler casing can be cleaned with a damp cloth CAUTION: Do not remove or adjust the casing in any
followed by a dry cloth to polish. way, as incorrect fitting may result in faulty operation.
Do not use abrasive or solvent cleaners. If in doubt, contact your Installer/Service Provider.
INSTALLATION INSTRUCTIONS
INTRODUCTION Accessories
The Combitek F 23 E is a wall mounted combination A range of accessories are available including,
boiler providing central heating and instantaneous vertical flue components. For further information,
domestic hot water. contact you nearest stockist.
Note: this boiler requires no fixing jig and has top
outlet flueing only ( there is no rear flue option ). Gas Safety (Installation and Use) Regulations
In the interests of gas safety, it is the law that ALL gas
The boiler is of the II2H3+ category for use with appliances are installed and serviced in by a
Natural gas (G20). To convert to Butane (G30) or competent person in accordance with the above
propane (G31), the following kit is required. regulations.
Gas conversion kit :part number 86161
Gas leak or fault
The boiler has a fan assisted, balanced, flue which If a gas leak or fault exists or is suspected, turn off the
both discharges the product of combustion to, and boiler and gas supply and consult the local gas
draws the combustion air from, the outside of the company or your Installer/Service Provider.
building.
TECHNICAL DATA
Heat output
(kW) 8,9 10 11 12 13 14 15 16 17 18 19 20 21 22 23,3
(Btu/h) 30387 34142 37557 40971 44385 47799 51214 54628 58042 61456 64871 68285 71699 75113 79552
Heat input
(kW) 11,9 13,2 14,4 15,7 16,9 18,1 19,2 20,4 21,5 22,7 23,8 24,9 26,0 26,9 28,3
(Btu/h) 40678 45130 49332 53481 57579 61627 65626 69575 73477 77333 81142 84906 88913 91713 96602
GAS
G 20 (mbar) 1,3 2,1 2,6 3,0 3,5 4,0 4,5 5,1 5,7 6,3 6,9 7,6 8,3 8,8 9,8
G 30 (mbar) 3,7 5,3 6,3 7,4 8,6 9,8 11,1 12,5 13,9 15,4 17,0 18,6 20,4 21,7 24,1
G 31 (mbar) 4,0 6,3 7,5 8,8 10,2 11,7 13,3 14,9 16,7 18,5 20,3 22,2 24,4 26,0 28,8
4
INSTALLATION INSTRUCTIONS
Pump:
The performance of the pump varies according to the pump bypass setting, see diagram 3.
50
1 2 Open 1/4 turn
heating flow and return
40
2
3 Open 1/2 turn
30 3
4
4 Open 1 turn
20
5 5 Open 2 turns
10
Pom 052
0 500 1000
(10 kPa = 1 m WG) Flow rate through heating system (I/h)
Diagram 3
DIMENSIONS
Clearances
The boiler can be installed with
4
23
623
Hab 271a
Net weight: 41 kg
410 8
Gross weight: 43 kg 37
Diagram 4
5
INSTALLATION INSTRUCTIONS
BOILER SCHEMATIC
23 22
13
19
20
17
12
16
11
10 14
9
3
6 4
21 24
A B C D E
Shy 131b
Diagram 5
6
INSTALLATION INSTRUCTIONS
Ven 060b
H - From an external corner of the building ...... 300 A
B L
D
I - From an internal corner of the building ....... 300 I H
L - From the ground or from another floor ........ 300
M - Between two terminals vertically .................. 1500
N - Between two terminals horizontally .............. 300
Diagram 6
Thermostatic radiator valves are permitted. Gas Safety (Installation and Use) Regulations.
In your interests and that of gas safety, it is the law
A suitable WRC approved filling loop must be fitted that ALL gas appliances are installed and serviced
to enable correct filling of the system. by a competent person in accordance with the
In all cases, it is ESSENTIAL that the system be above regulations.
thoroughly flushed prior to installing the new boiler.
7
INSTALLATION INSTRUCTIONS
Flow restrictor Isolating cock
Boiler connections
A Heating return
B Cold water mains inlet
C Heating flow
D Hot water outlet
E Gas connection Filter
Fibre B
Pla 277
F Safety valve discharge connection washer
Diagram 7b
Pla 275
A B C D E
Diagram 7a
Ø 105
23
Template
857
802
410 8
120 mm
37
BOILER INSTALLATION
65 mm
WALL SIDE
BOILER SIDE
Ins 071a
55 55 57,5 57,5
Diagram 8
8
INSTALLATION INSTRUCTIONS
HORIZONTAL FLUE INSTALLATION
• Fit gasket (H) onto underside of elbow (C) A
• Carefully insert ‘o’ rings (J) into upper and lower
parts of inner elbow
• Fit elbow onto boiler using screws provided (I) B
• Offer flue pipes to elbow, note that pipe (B) should
be inside pipe (A) before connection. Push pipe
(B) into inner elbow socket and connect pipe (A)
with collar (D). Locking clips (E) are used to lock
C D
collar into position.
• Parts (F) and (G) are used to seal brickwork gaps
E F G
if required. If using part (G) to seal inner wall, this
should be placed over flue before installation. I J
H
Pho 422
Calculation of flue cutting lengths
· Measure wall thickness e (mm)
· For side flues, measure distance from inside face of Diagram 9
the side wall to the centre line of the boiler and The flue kit 86285 is 1000 mm long and com-
subtract 205 mm to get dimension a (mm) see prises:
diagram 10. - Outer pipe .................................................... A
· Refere to table 1 for the cutting lenghs of both - Inner pipe ....................................................... B
the inner and outer flue pipes for each of the - Flue elbow ..................................................... C
various flue options available. - Fixing collar ................................................... D
· Important: All flue cutting lengths must be - Locking clips .................................................. E
measured from the terminal end of the flue pipes, - External rubber sealing collar ..................... F
see diagram 11. - Internal flange .............................................. G
· When the dimension x measured on site is greater - Gasket ........................................................... H
than that given in table 1 a flue extension kit will be - Screws .............................................................. I
required, refere to table 2 for details. - 'O' rings ........................................................... J
Table 1
Flue cutting lengths
Table 2 e a a e
Hab 210
Diagram 11
9
INSTALLATION INSTRUCTIONS
VERTICAL FLUE INSTALLATION
A
A .................................................................... Gasket Diagram 12
B ..................................................... Vertical adaptor Show vertical kit adaptor & terminal
C .................................................................... ‘O’ ring
D ....................................................................... Collar
E ...................................................................... Clamp B
F ...................................................................... Screws
G .................................................................. Terminal E
H ...................................................................... Screws F
H
· Fit gasket (C) onto underside of vertical adaptor
(B)..
· Carefully insert ‘O’ ring (A) into vertical adaptor C
inner spigot. D
· Fit adaptor correctly onto fan outlet.
· For flat roof installation, fit flat roof flashing collar
(part no. 85107)
· Fit flue terminal (L) onto roof ensuring flashing
makes a watertight joint.
· For pitch roof installation, fit pitch roof flashing
collar (part no. 85105)
· Fit flue terminal (G) onto roof ensuring flashing
makes a watertight joint.
NOTE: Maximum vertical height with no bends is 4 m.
Diagram 12
10
INSTALLATION INSTRUCTIONS
ELECTRICAL CONNECTION DO NOT INTERRUPT THE MAINS SUPPLY TO THE BOILER
WITH A TIME SWITCH OR PROGRAMMER.
Warning: This boiler must be earthed.
All system components must be of an approved The combitek F 23 E is delivered with 1metre mains
type. supply lead ready connected.
Connection of the whole electrical system and any
heating system controls to the electrical supply must External controls
be through a common isolator. The boiler will work for heating AS DELIVERED without
Isolation should preferably be by a double pole a room thermostat fitted provided the two wires on
switched fuse spur box having a minimum contact the integral external controls connection REMAIN
separation of 3 mm on each pole. The fused spur LINKED TOGETHER (as supplied).
box should be readily accessible and preferably If a room thermostat is required, it must be connected
adjacent to the boiler. It should be identified as to its as shown below and the link must be removed.
use. ANY ROOM THERMOSTAT USED MUST BE OF THE VOL-
A fused three pin plug and shuttered socket outlet TAGE FREE TYPE.
may be used instead of the fused spur box, provided
that: WARNING: ON NO ACCOUNT MUST ANY ELECTRICAL
a) They are not used in a room containing a bath or VOLTAGE BE APPLIED TO EITHER OF THE TERMINALS OF
shower. THE EXTERNAL CONTROLS CONNECTION
b) Both the plug and socket comply with the current WARNING: This boiler must be wired in accordance
issue of BS1363. with these instructions. Any fault arising from incor-
The mains electrical supply must be maintained at rect wiring cannot be put right under the terms of the
all times in order to provide domestic hot water and guarantee.
frost protection
°C
For no external controls
leave wire link (E) in place
sch 228
sch 229
Diagram 13
11
INSTALLATION INSTRUCTIONS
COMMISSIONING
Gas installation
It is recommended that any air is purged from the
supply at the gas inlet test point on the left hand
side of the gas valve, see diagram 14.
mec 117
Diagram 14
Filling the system
Reg 008
Sec 058
Sec 058
Ins 062
Ins 061
12
INSTALLATION INSTRUCTIONS
ADJUSTMENTS
On reaching maximum temperature, the boiler
should be turned off and the system drained as
rapidly as possible whilst still hot.
• Refill system to a pressure of 1.5 bar and vent as
before.
• Restart boiler and operate until a maximum tem-
perature is reached. Shut down boiler and vent
heating system. If necessary, top up heating sys-
tem and make sure that a pressure of 1.5 bar
is indicated on the pressure gauge when system is
COLD.
Des 044
Diagram 15
Gas pressures
The main burner pressure should be checked dur-
ing commissioning to make sure the correct out-
put is obtained. Proceed as follows:
• Shut down boiler.
• Undo screw on burner pressure test point below
sealed combustion chamber and connect a
suitable manometer, see diagram 15.
• Start boiler as described in 'User Instructions'.
• Set boiler thermostat to maximum and check
Reg 056
that any external controls are calling for heat.
• Check that the reading on the gauge matches Diagram 16
that given in 'Technical Data' for the type of gas
being used.
• Adjust the range rating adjuster screw as neces- • Connect a suitable pressure gauge.
sary to obtain the desired input, see diagram 16. • Start boiler as described in 'User Instructions'.
• Shut down boiler. • Check that the inlet pressure reading matches
• Remove manometer, tighten up test point screws that given in 'Technical Data' for the type of gas
and check for gas soundness. being used.
• Using a ball point pen, clearly indicate on the • Shut down boiler.
data label the input the boiler is set to. • Remove pressure gauge, tighten up test point
screws and check for gas soundness.
Note: This adjustment does not affect the domes- • If the gas pressure is incorrect, refer to the Fault
tic hot water output. Finding section in 'Servicing Instructions'.
If measured burner pressure differs greatly from the • If the inlet pressure is below that given, the gas
given figure, check the gas inlet pressure as follows: supply pipework/meter must be checked and any
• Shut down boiler. fault corrected.
• Remove screw from inlet test point on the side of • In the case of an LPG installation, check the stor-
the gas valve, see diagram 14. age tank or cylinder, regulator and pipework.
SAFETY DEVICES
Air flow rate safety device Important notice: A central heating system cannot
If an obstruction, even partial, of the flue occurs, operate satisfactorily unless it is properly filled with
for any reason whatsoever, the built in safety sys- water and unless the air initially contained in the
tem of the boiler will turn the boiler OFF and the piping systems has been properly bled off. If these
fan will continue to run. conditions are not satisfied, air noise will occur
The boiler will be ready to operate when the fault within the system.
has been cleared.
The COMBITEK F 23 E boiler has a built in frost pro-
In case of power supply failure tection device that protects the boiler from freez-
The boiler no longer operates. ing. If the boiler is to be left and there is a risk of
As soon as power supply is restored, the boiler will frost, ensure that the gas and electrical supplies are
be automatically restarted. left connected and the summer/winter switch is in
the position. The frost protection device will light
Overheat safety the boiler when the temperature of the boiler wa-
In the event of a problem, the overheat thermos- ter falls below 6°C. When the temperature reaches
tat causes safety shutdown of the boiler. Should this 16°C, the boiler stops.
occur, reset the thermostat by pressing the red
button. The overheat thermostat is located on the Note: This device works irrespective of any room
RHS of the heat exchanger. thermostat setting and only protects the boiler.
13
INSTALLATION INSTRUCTIONS
SETTINGS
Maximum setting
• Remove one electrical connector from the
modulating gas valve coil.
• Turn the domestic hot water temperature ad-
Reg 013
juster to maximum setting.
Diagram 17
• Remove the protective
cover from the gas valve ad-
juster.
Using a 2 mm Ø rod, press in B A
the spindle in the middle of
screw.
• Turn nut 'B' to obtain the de-
sired pressure, see technical
data.
Mec 121
Minimum setting
This must be done AFTER the
maximum setting.
• Hold nut B to prevent from turning, turn nut 'A' to
obtain the desired pressure, see technical data.
Reg 057
Diagram 18
Bypass
The COMBITEK F 23 E has a built-in bypass. This must
be adjusted according to the requirements of the
system, refer to the flow rate pressure curve (dia-
gram 3). The boiler is supplied with the built-in by-
pass open a half a turn. It is adjusted by turning the
bypass screw (A), see diagram 17. Turn the screw
clockwise to close the bypass.
When using thermostatic radiator valves (TRV's), it
is recommended that an additional, adjustable
bypass of 15 mm minimum diameter is fitted be-
tween the flow and return of the heating circuit,
see diagram 6. Any bypass must be fitted before
system controls.
PCB Settings
The combitek has a switch SW1 on the main PCB
which incorporates two dip switches. Both these dip
switches should normaly be set to the Off position.
14
SERVICING INSTRUCTIONS
ROUTINE CLEANING ANS INSPECTION
To ensure the continued efficient and safe opera-
tion of the boiler it is recommended that it is
checked and serviced at regular intervals. The fre-
quency of servicing will depend upon the particu-
lar installation conditions and usage, but in gen-
eral once a year should be enough.
Des 047
It is the law that any servicing is carried out by a Diagram 19
competent person.
• Unscrew and remove two injector bar retaining
Service Check and Preparation. screws and separate injector bar from burner.
• Operate boiler and check for any faults that • Examine and clean injectors as necessary.
need to be put right. Note: Do not use a wire or sharp instrument on the
• Isolate boiler from the gas and electrical supplies. holes.
• On completion check all gas carrying parts for • Replace burner in reverse order to removal.
soundness with leak detection fluid.
• The maximum domestic hot water flow rate is 12 Heat exchanger
litres/minute. • After removal of burner, examine heat ex-
• Remove boiler casing as follows: changer for any blockages or build up of deposits.
• Clean using soft brush or vacuum cleaner.
Upper front panel Important: Take care not to scratch or otherwise
• Disengage the two 'quarter turn' fasteners by damage painted surface of heat exchanger.
turning the heads of the screws a quarter of a turn
towards the centre of the boiler. Reassembly of parts removed for servicing
• Carefully lower the panel down on its hinge until • Replace all parts in reverse order to removal.
it is horizontal.
• Turn both plastic catches to release upper front Flue system
panel. • Check externally to make sure flue is not blocked.
• Remove upper front panel by pulling forward at • Inspect flue system to make sure all fittings are
the bottom and lifting off. secure.
Note: The upper front panel is retained by a plastic
safety strap, disengage this before removal. Operation of fan
• Switch on electrical supply and turn on gas.
Side panels • Switch boiler On/Off switch to 1 (On).
• From below boiler, unscrew and remove black • Light burner by opening a hot tap.
plastic screws securing side panels to the boiler. • Without upper front panel in place, burner should
• Prise out black plastic inserts and lift panel off be prevented from lighting by air flow detection
boiler. system.
• Refit upper front panel.
Combustion chamber • Check that fan runs when burner is lit and stops
• Loosen two wing nuts on combustion chamber when it goes out.
cover.
• Disengage retaining lugs from holes in either side Cold water inlet filter
of combustion chamber and move rods away to • Drain down hot water circuit of boiler as follows:
clear combustion chamber sides, see diagram 19. • Close isolating valve on cold water inlet connec-
• Unclip two toggle clips holding upper part of tion, see diagram 5.
combustion chamber in place. • Open one or more hot water taps to drain boiler.
• Holding both sides, pull chamber forward to re- • Undo connecting nut from cold water inlet con-
lease it from underside of heat exchanger and out nection to gain access to filter.
of boiler. • Remove restrictor, then filter from cold water in-
• Take care not to damage insulation material on let connection.
inside faces of combustion chamber. • Clean and inspect filter, replace if necessary.
• With both flow restrictor and filter in place, re-
Cleaning the burner connect pipe to inlet connection and tighten.
• Pull off leads to ignition electrode. • Fully open isolating cock on cold water inlet con-
• Pull off lead to flame sense electrode. nection and check for leaks.
• Unscrew and remove screw holding earth lead
to flame sense electrode. Operation of water valve
• Undo main gas supply nut from main burner. • With the Summer/Winter control in the 'Summer'
• Unscrew and remove locking nut from both main position, slowly open a convenient tap until boiler
gas connection and burner pressure tapping point. lights.
• Lift front edge of burner until tapping point and • Measure water flow, it should not be greater than
gas supply connection are free. Remove burner 3,5 litres/minute.
from boiler taking care to retain both fibre washers • If necessary, replace diaphragm.
and seal on gas supply for use on reassembly. • Replace all outer panels.
15
SERVICING INSTRUCTIONS
REPLACEMENT OF PARTS
Sch 228
• Reconnect plug and refit external controls con-
Diagram 20
nection to bracket.
To replace fan
• Disconnect power supply and earth leads to fan.
• Unscrew and remove two fan retaining screws
located at front edge of fan mounting plate.
• Remove fan with mounting plate attached by
pulling forwards and out of boiler.
• Unscrew and remove three screws securing fan
to fan mounting plate.
• Fit replacement fan to mounting plate and se-
cure with screws.
• Fit replacement fan to boiler in reverse order to
removal making sure that mounting plate retain-
Hab 286
ing lugs are properly engaged into flue hood.
• Reconnect power supply and earth leads. Diagram 21
Important: Make sure that fan outlet is correctly fit-
ted into the flue elbow at the top of the boiler. nection cover to PCB cover, see diagram 21.
Before commissioning boiler, remove the two plas- • Open cover and unclip plastic clip securing
tic transit clips from replacement fan. pump cable to lower front panel.
• Pull off pump connector and earth lead.
To replace air pressure switch • Undo and remove four screws securing PCB
• Locate air pressure switch in upper left hand cor- cover to lower front panel.
ner of sealed chamber. • Lift off PCB cover.
• Pull off plastic tube from left hand connection. • Pull off connectors CN6, CN7, CN8 and CN9 on
• Grasp pressure switch and disengage it from PCB.
bracket clips by pulling from the top. • Undo and remove screw holding PCB to lower
• Remove electrical connections from switch. front panel.
• Fit electrical connections to terminals 1 and 3 of • Lifting PCB up slightly on LHS, pull PCB out of elec-
replacement switch. trical connector on ignition PCB. Leave ignition PCB
• Fit replacement switch in reverse order to re- in place.
moval. • Fit replacement PCB in reverse order to removal.
Important: Refit plastic tube to LEFT hand connec- Important: When fitting replacement PCB, ensure
tor (marked P1). that control knob spindle correctly locates into PCB
adjuster slots.
To replace spark generator • Refit connectors and covers in reverse order to
• Locate spark generator on bracket to right hand removal.
side of gas valve.
• Undo and remove screw securing lower termi- To replace ignition PCB
nal cover to bracket and remove bracket. • Gain access to PCB's as described in previous
• Disconnect four leads from spark generator. section.
• Undo and remove screw securing spark genera- • Remove main PCB securing screw as described
tor to bracket and remove spark generator. in previous section.
• Fit replacement spark generator in reverse order • Pull off three electrical connectors on PCB.
to removal. • Lift up ignition PCB, separate from main PCB and
• Reconnect two grey power supply leads and two remove from boiler.
clear ignition leads to spark generator, the polarity • Fit replacement PCB in reverse order to removal.
is not important. • Refit connectors and covers in reverse order to
• Refit lower terminal cover. removal.
16
SERVICING INSTRUCTIONS
• Close isolating valves on flow and return connec-
tions.
It is not necessary to drain entire heating circuit to
carry out this work.
• Gain access to pump connection as described
in 'To replace main PCB'.
• Pull off pump connector and earth lead.
• Pull out retaining clip from telescopic pump out-
let connection and slide connection upwards to
release from pump.
• Undo and remove two fixing screws and remove
Cla 007
pump retaining bracket from front of pump.
• Grasp pump body, lift upward to disengage from Diagram 22
reversing valve and turn pump to right. Remove
pump by pulling forward and over reversing valve
assembly.
• Discard old pump inlet 'O' ring.
• Apply silicone grease to new 'O' ring supplied,
and fit onto inlet connection on replacement
pump.
• Fit replacement pump in reverse order to re-
moval.
Note: Apply silicone grease to pump outlet con-
nection 'O' ring before assembly.
• Refit pump electrical connection.
• Open isolating valves on flow and return con-
nections, refill, vent and pressurise boiler. Check for
leaks.
Des 054
To replace pressure gauge Diagram 23
• Drain down heating circuit of boiler only as de-
scribed in 'To replace pump'.
• Undo and remove screw securing pressure
gauge capillary to front section, see diagram 22.
• Carefully pull capillary from front section.
• Undo and remove two screws securing pressure
gauge to lower front panel and remove gauge.
• Fit replacement gauge in reverse order to re-
moval.
• Fit capillary of new gauge to front section using
new 'O' ring supplied.
• Open isolating valves on flow and return connec-
tions, refill, vent and pressurise boiler. Check for leaks.
Sec 059
Diagram 24
To replace reversing valve assembly
• Remove pressure gauge capillary as described
previously. • Push water valve back to disengage it from re-
• Remove pump as described previously. versing valve.
• Remove microswitch assembly as described pre- • Unclip and remove loss of water pressure switch
viously. from left of reversing valve assembly, see diagram
• Remove retaining clip from LHS pipe connection 24.
on front section of valve and disengage pipe. • From below boiler, undo and remove three
• Unscrew and disconnect heating flow (centre) screws holding reversing valve to bottom plate of
connection at fixing jig. boiler. Remove complete reversing valve assem-
• Remove retaining clip from heating flow pipe bly from boiler.
connection on right of front section. • Undo and remove heating return connecting
• Remove flow pipe from boiler. pipe and hose from rear of reversing valve assem-
• Unscrew and disconnect heating return (left bly. Fit hose to replacement reversing valve assem-
hand) connection at fixing jig. bly.
• Remove retaining clip from expansion vessel pipe • Fit replacement reversing valve into boiler in re-
connection at rear of reversing valve assembly and verse order to removal.
disengage pipe, pushing pipe back and out of re- Note: Use new 'O' rings, retaining clip, filter and
versing valve. washer provided.
• Undo and remove large screw holding water • Unscrew and remove microswitch assembly from
valve to back plate of reversing valve assembly, top of replacement reversing valve assembly to
see diagram 23 allow refitting of water valve.
17
SERVICING INSTRUCTIONS
Note: fit expansion vessel pipe and loss of water
switch to reversing valve assembly before pump,
to ensure that it is correctly located. Apply silicone
grease to all 'O' rings and hoses prior to assembly.
• Open isolating valves on flow and return con-
nections, refill, vent and pressurise boiler. Check for
leaks.
Cla 007
• Remove pipe connections from either side of
reversing valve front section, refer to previous sec- Diagram 25
tion.
• Move short selector lever on front of valve to left
hand position. To replace water valve or diaphragm
• From below boiler, undo and remove single screw • Drain down hot water circuit of boiler only as
holding reversing valve front plate to bottom plate described in 'Routine Cleaning and Inspection'.
of boiler. • Remove microswitch assembly as described pre-
• Undo and remove six screws holding front sec- viously.
tion to rear section of reversing valve, see diagram 25. • Remove clip holding connecting pipe in rear of
• Remove front plate complete with pump bracket water valve. From below boiler, grip clip with long
and then front section from reversing valve, along nosed pliers and pull down.
with rubber sealing gasket. • Using long nosed pliers, slide pipe away from
• Assemble bypass valve provided and fit into hole water valve into brass cold water inlet connection.
in underside of replacement front section. Fit 'U' • Remove clip holding pipe to heat exchanger in
shaped retaining clip. rear of water valve. From front of boiler, gripclip with
Note: Use bypass valve fitted to original front sec- long nosed pliers and pull upwards.
tion for guidance. • Unscrew and remove large screw holding water
• Fit replacement front section, with gasket, to rear valve to back plate of reversing valve assembly,
section. see diagram 23.
• Locate front plate and replace six fixing screws. • Disengage water valve from reversing valve and
Take care to evenly tighten screws ensuring they remove from boiler.
are not cross threaded. Note: When disengaging water valve from heat
• Refit pipe connections to either side of front sec- exchanger pipe, check that non-return valve is not
tion using new 'O' rings provided. Apply silicone held on end of pipe. If so, carefully separate pipe
grease to 'O' rings before fitting. from valve to ensure that small spring and plunger
• Refit pressure gauge capillary in reverse order to do not fly out and are lost.
removal. • To replace diaphragm, undo five screws and
• Ensure short selector lever on front of valve is set separate main components of water valve.
to right hand position. • If white diaphragm cover is to be replaced, sepa-
• Open isolating valves on flow and return con- rate original from water valve end casting and fit
nections, refill, vent and pressurise boiler. Check for replacement cover.
leaks. • Fit replacement diaphragm , making sure that
metal disc FACES diaphragm cover and beaded
To replace loss of water switch edge of diaphragm is correctly fitted in correspond-
• Drain down heating circuit of boiler only as de- ing groove in both cover and plastic housing, see
scribed in 'To replace pump'. diagram 26.
Note: It is not necessary to drain entire heating cir- • Reassemble water valve, evenly tightening five
cuit to carry out this work. screws.
• Pinch plastic cover to release retaing clips and • Fit water valve actuating pin into hole in dia-
remove cover from switch. Pull plug lead from phragm cover, through nose end of valve and and
switch terminals. push in until flush, or slightly below, nose end of
• Remove clip holding switch into left side of re- valve.
versing valve assembly. Note: Apply silicone grease to pin before fitting.
• Pull switch out of reversing valve assembly, see • Refit water valve to boiler, locating nose end into
diagram 24. rear of reversing valve assembly, 'springing' heat
• Fit replacement switch in reverse order to re- exchanger pipe to gain clearance as necessary.
moval, using new 'O' ring provided and aplying sili- Fit large water valve retaining screw but do not
cone grease to 'O' ring before fitting. tighten fully at this stage.
• Reconnect plug to switch terminals. • Apply silicone grease to 'O' ring and fit onto end
• Open isolating valves on flow and return con- of heat exchanger pipe. Fit pipe into water valve
nections, refill, vent and pressurise boiler. Check for by pulling it forward. Make sure that 'O' ring is cor-
leaks. rectly located.
• Whilst holding pipe in rear of water valve, fit re-
taining clip. This should easily clip over pipe and
18
SERVICING INSTRUCTIONS
should NOT have to be forced. If resistance is ex-
perienced, either pipe is not correctly fitted in rear
of water valve or clip is not being fitted properly
through slot between back plate and plastic hous-
ing of water valve. When clip is fitted, check con-
nection by pushing pipe back away from water
valve.
• Refit telescopic connecting pipe to inlet of wa-
ter valve after applying silicone grease to 'O' ring.
Des 058
Fit retaining clip into groove on connecting pipe,
through slot between back plate and water valve Diagram 26
plastic housing. Check connection by pulling pipe.
Make sure that clip is not loose and likely to fall out
at a later date. If in doubt, fit a new clip.
• Replace microswitch assembly.
• Open isolating valve on cold water inlet connec-
tion and check for leaks.
Mec 117
• Pull off clear plastic tube from gas valve to sealed
chamber tapping point. Diagram 27
• Unscrew main gas supply pipe nut on top of gas
valve, releasing spark ignition unit bracket, see dia-
• Pull out clips securing safety valve to non-return
gram 27.
valve.
• From below boiler, unscrew gas valve connec-
• Remove safety valve from boiler
tion between gas valve and isolating cock.
• Fit replacement safety valve in reverse order to
• Unscrew and remove two screws securing gas
removal.
valve to bottom plate of boiler.
Note: Apply silicone grease to 'O' ring before fitting
• Remove gas valve from boiler.
safety valve into non-return valve body.
• Refit replacement gas valve in reverse order to
• Refill boiler, vent and pressurise as described pre-
removal.
viously.
Note: Use new 'O' ring provided between gas valve
and burner supply pipe.
To replace heat exchanger
• Refit electrical connections to replacement gas
• Drain down both heating and hot water circuits
valve as follows:
of boiler only as described previously.
- BLACK leads to modulating coil.
Note: It is not necessary to drain entire heating sys-
- WHITE leads to EV1 and EV2 terminals of main
tem to carry out this work.
solenoid
• Remove combustion chamber cover as de-
- RED lead to COM terminal of main solenoid.
scribed in 'Routine Cleaning and Inspection'.
• Remove two clips from heating connections to
To replace modulating coil
left side of heat exchanger.
• Ensure gas supply is off.
• Remove clip holding pump outlet connection
• Disconnect two black electrical leads from gas
into pump and slide connection up pump outlet
valve modulating coil.
pipe. Pull complete pipe down to disengage from
• Unscrew and remove two screws holding modu-
heat exchanger.
lating coil to gas valve and remove coil from gas
• Remove retaining clip from LHS pipe connection
valve.
on front section of valve and disengage pipe.
• Fit replacement modulating coil in recerse order
• Disengage pipe downwards from heat ex-
to removal.
changer.
• Reconnect electrical leads to replacement coil.
• Unscrew and disconnect two hot water connec-
Note: All boilers are tested and factory set during
tions to right side of heat exchanger.
manufacture. Should it be necessary to reset a gas
• Grasp both sides of heat exchanger and slide
valve, for example after replacement, refer to 'Set-
forwards and out of boiler.
tings'.
• Fit replacement heat exchanger in reverse or-
To replace safety valve
der to removal.
• Drain down heating circuit of boiler only using
Note: Use new sealing washers and 'O' rings pro-
drain point on front of non-return valve (located to
vided.
the right of reversing valve.
• Open isolating valves on flow and return con-
• Disconnect safety valve discharge pipe from
nections, refill, vent and pressurise boiler. Check for
safety valve.
leaks.
19
SERVICING INSTRUCTIONS
To replace expansion vessel left hand side of boiler, see diagram 28.
• Unclip thermistor from pipe.
1 Boiler in place • Pull off electrical connections from thermistor.
Note: The expansion vessel can be replaced with • Fit replacement thermistor in reverse order to re-
the boiler in place provided that there is a mini- moval.
mum clearance of 400mm on one side of the boiler Note: No heat sink compound is required. The po-
and that no vertical pipework passes between larity of the connections is not important.
boiler and wall on that side.
• Drain down the heating circuit of the boiler only To replace overheat thermostat
as described in 'To replace pump'. • Locate the overheat thermostat on the right
Note: It is not necessary to drain entire heating sys- hand side of the heat exchanger.
tem to carry out this work. • Pull off the electrical connections from the ther-
• Remove pump from boiler as described previ- mostat.
ously. • Unscrew and remove two screws holding ther-
• Unscrew pipe connection nut from expansion mostat to heat exchanger.
vessel and disengage pipe from connection. Keep • Fit replacement thermostat in reverse order to
sealing washer. removal, using heat sink compound on the con-
• Whilst supporting weight of vessel, push bottom tact surface of thermostat.
of vessel away from boiler, disengaging threaded • Refit electrical leads, the polarity is not impor-
connection from hole in rear of boiler. Allow vessel tant.
to drop out of its two upper retaining brackets.
• Remove vessel to side of boiler. To replace combustion chamber insulation
• Fit replacement expansion vessel in reverse or- Front section
der to removal ensuring that sealing washer is fit- • Remove combustion chamber from boiler as
ted to vessel pipe connection. described in 'Routine Cleaning and Inspection'.
• Check that vessel charge pressure is 1bar. Cor- • Slide side panels out of combustion chamber
rect if necessary. sides.
• Open isolating valves on flow and return con- • Lift front insulation panel free from retaining lugs
nections, refill, vent and pressurise boiler. Check for and away from cover.
leaks. • Fit replacement panels in reverse order to re-
moval.
2 Boiler removed from wall
• Drain down the heating circuit of the boiler only Rear panel
as described in 'To replace pump'. • Remove burner from boiler as described in 'Rou-
Note: It is not necessary to drain entire heating sys- tine Cleaning and Inspection'.
tem to carry out this work. • Remove clip from base of insulation panel.
• Ensure that gas and electrical supplies to boiler • Pull bottom edge of insulation panel forward,
are turned off. downward and out from behind heat exchanger.
• Disconnect flue from either rear or top of boiler • Fit replacement panel in reverse order to re-
as applicable. moval.
• Disconnect external controls connections, if ap- • Replace burner into boiler in reverse order to re-
plicable. moval.
• Unscrew and disconnect five connections be-
tween fixing jig and boiler. To replace ignition electrode
• Disengage pipe connections. Lift boiler off hang- • Remove combustion chamber from boiler as
ing bracket and place on a convenient working described in 'Routine Cleaning and Inspection'.
surface. • Pull off ignition leads from ignition electrode.
• Remove expansion vessel from boiler as de- • Unscrew and remove two screws holding igni-
scribed in previous section. tion electrode onto burner.
• Fit replacement vessel in reverse order to removal • Fit replacement ignition electrode in reverse or-
and check charge pressure. der to removal.
• Replace boiler on wall, tighten all connections, • Refit ignition leads, the polarity is not important.
gas connection first, ensuring that all sealing wash-
ers, filters and the cold water flow regulator are fit-
ted before tightening.
• Reconnect flue system.
• Open isolating valves on flow and return con-
nections, refill, vent and pressurise boiler. Check for
leaks.
• Reconnect external controls connections, if ap-
plicable.
• Reconnect gas and electrical supplies to boiler.
• Check for gas soundness.
20
SERVICING INSTRUCTIONS
To replace flame sense electrode • Reconnect ignition and flame sense leads to
• Remove combustion chamber from boiler as electrodes. Reconnect earth lead to flame sense
described in 'Routine Cleaning and Inspection'. electrode. The polarity of the ignition leads is not
• Pull off lead from flame sense electrode. important.
• Unscrew and remove screw holding earth lead
to flame sense electrode. To replace burner injectors
• Unscrew and remove screw holding flame sense • Remove burner as described previously.
electrode onto burner. • Remove ignition and flame sense electrodes as
• Fit replacement flame sense electrode in reverse described in previous sections.
order to removal. • Unscrew and remove two screws holding burner
• Refit lead. injector bar to burner and remove injector bar.
To replace burner • Unscrew and remove burner injectors from burner
• Pull off ignition and flame sense leads from elec- bar.
trodes. • Fit replacement injectors to injector bar and
• Remove burner from boiler as described in 'Rou- tighten.
tine Cleaning and Inspection'. Note: make sure that injector size, marked on each
• Remove ignition and flame sense electrodes as injector, is the same as that given in 'Technical Data'.
described in previous sections. • Reassemble burner and replace into boiler in
• Unscrew and remove two screws holding burner reverse order to removal.
injector bar to burner and remove injector bar.
• Asemble replacement burner, supplied in parts, To replace timeclock
as follows: • Gain access to rear of lower control panel as
• Fit burner injectors to injector bar and tighten. described in 'Routine Cleaning and Inspection'.
• Assemble burner elements (14) into front and rear • Unscrew and remove two screws holding
burner supports with securing pins and rods, using timeclock to lower control panel.
original burner for guidance. • Remove PCB cover.
• Fit burner injector bar to burner. • Remove timeclock plug from connection CN7
• Fit ignition and flame sense electrodes to burner. on main PCB.
• Fit replacement burner to boiler in reverse order • Fit replacement timeclock in reverse order to re-
to removal. moval.
21
SERVICING INSTRUCTIONS
SCHEMATIC WIRING DIAGRAM
FA
Ex
Al
EV1
EV2
K4
Pr
FL
14.9
14.8
14.6
14.5
14.4
14.3
14.7
14.2
14.1
13.4
13.1
13.3
13.2
12.2
12.1
8.1
CN 7
8.2
TRA
8.3
8.4
9.2
9.1
6.13
6.14
6.11
6.15
6.12
6.9
6.8
6.6
6.4
6.2
6.3
2.2
2.1
L
CTN
K5
TA
EV3
Ra
SW3
Diagram 29
22
SERVICING INSTRUCTIONS
FAULT FINDING necessary to determine exactly which aspects of the
boiler are working correctly and which are not.
Prior to fault finding, check :
For example:
Inlet gas pressure = 20 mbar
If the domestic hot water works but the heating
Electrical supply = 240 V - 50 Hz
doesn’t, refer to chart No. 1.
Central heating system is pressurised at 1 - 1,5 bar.
If heating works correctly but the hot water doesn’t,
Overheat thermostat on RHS of heat exchanger has
refer to chart No. 2.
not tripped reset if necessary.
IMPORTANT: Always adopt a logical, step by step pro-
Carry out electrical system checks i.e. earth continu-
cedure starting at the beginning of the appropriate
ity, resistance to earth, short circuit and polarity with
fault finding chart.
a suitable meter.
Note : these must be repeated after any servicing or
WARNING. Always isolate the boiler from the electri-
fault finding. Ensure that all external controls are cor-
cal supply before carrying out any electrical replace-
rectly wired and calling for heat.
ment work.
Always check for gas soundness after any service
The fault finding charts will enable the majority of faults
work.
to be diagnosed. To use the charts effectively, it is
NO CENTRAL HEATING
NO
NO Refer to chart n°3
Does pump run ?
YES
NO
Does fan run ? Refer to chart n°4
YES
Is short selector lever on
front of reversing valve in NO
Move to right
right hand position ?
YES
Does burner fire when NO
Refer to chart n°2
a hot tap is opened ?
YES
YES
External controls Internal control
(if fitted) (clock)
YES
Short out external controls Is there
connection on top of YES Rectify wiring continuity across
reversing valve. Does operation faults on terminals 3 and 4
burner fire ? external controls of clock ?
NO NO YES
Remove leaos from boiler Is clock calling for Is wiring between
thermistor. Check its heat ? clock and pcb
NO
resistance according to Replace thermistor connection cn7 ok ?
YES
thermistor value table.
Is thermistor ok ? Replace clock YES
YES Replace
Replace main pcb main pcb
CHART 1
23
SERVICING INSTRUCTIONS
Open hot tap fully. NO HOT WATER PUMP NOT RUNNING
Does burner fire ?
YES
NO Is there 240 v at pump ? Is pump jammed ?
Termistor Values
Temperature (°C) 0 5 10 15 20 25 30 35 40 45 50
nominal resistance (Ω) for NTC 32565 25345 19875 15700 12500 10000 8060 6535 5330 4370 3605
SPARE PARTS
When ordering spare parts, quote the part number and description, stating the appliance model number
and serial number from the data badge.
24 110664A 06/98