InstallationInstallationInstallationInstallationInstallation& Servicing& Servicing& Servicing& Servicing& ServicingInstructionsInstructionsInstructionsInstructionsInstructions

THESE INSTRUCTIONSTO BE RETAINEDBY USER

41

Contents

Design principles and operating sequence Page1.1 Principle components 21.2 Mode of operation (at rest) 21.3 Mode of operation (heating) 21.4 Mode of operation (DHW) 21.5 Safety devices 2

Technical data Page2.1 Central heating 32.2 Domestic hot water 32.3 Gas pressure 32.4 Expansion vessel 32.5 Dimensions 32.6 Clearances 32.7 Connections 32.8 Electrical 32.9 Flue details 32.10 Efficiency 32.11 Pump duty 42.12 Appliance 4

General requirements (UK) Page3.1 Related documents 53.2 Location of appliance 53.3 Gas supply 53.4 Flue system 53.5 Air supply 53.6 Water circulation 53.6.1 Pipework 63.6.2 Automatic by-pass 63.6.3 Drain cocks 63.6.4 Air release points 63.6.5 Expansion vessel 63.6.6 Filling point 63.6.7 Low pressure sealed system 63.6.8 Frequent filling 63.7 Electrical supply 63.8 Showers 63.9 Mounting on a combustible surface 73.10 Timber framed building 73.11 Inhibitors 7

Installation Page4.1 Delivery 84.2 Contents 84.3 Unpacking 84.4 Preparation for mounting the appliance 84.5 Fitting the flue 84.5.1 Concentric horizontal flue 84.5.2 Concentric vertical flue 94.6 Connecting the gas and water 104.6.1 Gas 104.6.2 Flow and return 104.6.3 Cold water inlet 104.6.4 Hot water outlet 104.6.5 Safety valve 104.6.6 Condense pipe 104.7 Electrical connections 114.7.1 Casing removal 114.7.2 Appliance terminal block 114.7.3 Connecting the mains (230V) input 11

Commissioning Page5.1 Gas supply installation 125.2 The heating system 125.3 Initial filling of the system 125.4 Initial flushing 125.5 Filling the hot water system 125.6 Pre-operation checks 125.7 Initial lighting 125.7.1 Checking burner pressures 125.8 Final flushing of the heating system 125.8.1 Inhibitors 125.9 Setting the boiler operating temperature 125.9.1 Setting the DHW temperature 135.10 Setting the system design pressure 135.11 Regulating the hot water 135.11.1 Changing the flow restrictor 135.11.2 Regulating the central heating system 135.12 Final checks 135.13 Instructing the user 13

Servicing instructions Page6.1 General 146.2 Routine annual servicing 146.3 Replacement of components 146.4 Component removal procedure 146.5 Pump assembly 146.6 Safety valve 156.7 Automatic air release valve 156.8 Water pressure switch 156.9 Pressure gauge 156.10 Primary thermistor 156.11 High limit thermostat 156.12 PCB 156.13 Gas valve 156.14 Integral time switch 166.15 Electrode, burner thermostat, burner & injectors 166.16 Flue fan 176.17 Main heat exchanger 176.18 Air pressure switch 176.19 Flow restrictor 176.20 DHW flow switch 186.21 DHW heat exchanger 186.22 Valve actuator 186.23 Divertor valve cartridge 186.24 DHW thermistor 186.25 Automatic by-pass 186.26 DHW non-return valve 186.27 Expansion vessel 186.27.1 Expansion vessel removal (with sufficient clearance above) 186.27.2 Expansion vessel removal (with insufficient clearance above) 196.28.1 Latent heat collector 196.28.2 Dismantling the latent heat collector 196.29 Condense trap removal 19

Checks, adjustments and fault finding page7.1 Checking appliance operation 207.2 Appliance mode of operation 207.2.1 Selector switch in the OFF position 207.2.2 Selector switch in the hot water only position 207.2.3 Selector switch in the heating & hot water position 207.2.4 Appliance functions 207.2.5 DHW mode 207.2.6 Heating mode 217.3 Checking & adjusting burner pressure 227.3.1 Setting the maximum burner pressure 227.3.2 Setting the minimum burner pressure 227.3.3 Setting the minimum CH output 227.4 Combustion analysis test 227.5 Checking the expansion vessel 237.6 External faults 237.6.1 Installation faults 237.7 Electrical checks 237.7.1 Earth continuity test 237.7.2 Short circuit check 237.7.3 Polarity check 237.7.4 Reversed polarity or supply fault 247.7.5 Resistance to earth check 247.8 Fault finding 247.8.1 Replacing the main PCB 247.9 Fault codes 247.10 Fault finding 25-30

Wiring diagrams Page8.1 External wiring 318.2 Typical control applications 318.3 Room thermostat 318.4 Other controls 31Functional diagram 32

Exploded diagrams PageTable 1-5 33-37

L.P.G. instructions Page10.1 Related documents 4010.2 Technical data 4010.3 Converting the appliance gas supply 4010.4 Gas supply 4010.5 Gas supply installation 4010.6 Checking & adjusting burner pressure 4010.6.1 Setting the maximum burner pressure 4010.6.2 Setting the minimum burner pressure 40

1

INTRODUCTION

Fig.1 General Layout

1 Diverter valve motor2 Discharge valve3 Domestic hot water heat exchanger4 Safety valve5 Pump6 Pressure switch7 Auto air vent (AAV)8 Electrode9 Main burner10 Main heat exchanger11 Latent heat collector12 Flue gas analysis test point13 Flue outlet14 Air intake15 Differential pressure switch16 Silicone pressure tube (-)17 Silicone pressure tube (+)18 Fan assembly19 CH NTC sensor20 Combustion chamber21 High limit thermostat22 Expansion vessel23 Condensate pressure switch24 Ignition transformer25 Condense trap26 Modulator coil27 Gas valve28 DHW flow switch

29 Pressure gauge30 DHW position31 Mode selector switch32 Fault indicator led33 CH position34 Timeclock

The Sabre HE range of appliances is comprised of 2models of high-efficiency combination boiler with inputsto heating & DHW of 25, 29 & 35kW respectively. Eachappliance - by design - incorporates electronic ignition,circulating pump, expansion vessel, safety valve, pres-sure gauge and automatic by-pass.

The Sabre HE range is produced as room sealed, cat-egory II2H3P appliances, suitable for internal wall mount-ing applications only. They are provided with a fan

powered flue outlet with an annular coaxial combustionair intake that can be rotated - horizontally - through 360degrees for various horizontal or vertical applications.The Sabre HE range is approved for use with C12 & C32type flue applications.These appliances are designed for use with a sealedsystem only; consequently they are not intended for useon open vented systems

Fig. 1

29 30 31 33 3432

2

SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

Fig. 2

1.1 PRINCIPLE COMPONENTS● A fully integrated electronic control board fea-

turing electronic temperature control, anti-cy-cle control, pump over-run, LED fault indicator,full gas modulation.

● Low-water-content, copper heat exchanger.● Electronic ignition with flame supervision.● Integral high-head pump.● Fan.● Air pressure switch.● Expansion vessel.● Water pressure switch.● Two-stage gas valve.● Pressure gauge.● Safety valve.● Condense switch.

1.2 MODE OF OPERATION (at rest)When the appliance is at rest and there are norequests for heating or DHW, the following func-tions are active:● Frost-protection system: the frost-protection

system protects the appliance against the riskof frost damage. Should the temperature of theappliance fall to 5 °C, the boiler will function inthe heating mode at minimum power until itreaches 35 °C.

● Anti-block function: the anti-block function ena-bles the pump and divertor valve actuator, to beenergised for short periods, when the appli-ance has been inactive for more than 19-hours.

1.3 MODE OF OPERATION (Heating)When there is a request for heat via the time clockand/or any external control, the pump and fan arestarted, the fan will then prove the air pressureswitch. At this point an ignition sequence isenabled.

Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Once suc-cessful ignition has been achieved, the electroniccircuitry increases the gas rate to 75% for aperiod of 15 minutes. Thereafter, the boiler’soutput will either be increase to maximum ormodulate to suit the set requirement.

When the appliance reaches the desired tem-perature the burner will shut down and the boilerwill perform a three-minute anti-cycle (timer de-lay).

When the request for heat has been satisfied theappliance pump and fan may continue to operateto dissipate any residual heat within the appli-ance.

1.4 MODE OF OPERATION (DHW)When there is a request for DHW via a hot wateroutlet or tap, the pump and fan are started, the fanwill then prove the air pressure switch. At thispoint an ignition sequence is enabled.

Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Once suc-cessful ignition has been achieved, the electroniccircuitry increases the gas rate to maximum orwill modulate output to stabilise the temperature.

In the event of the appliance exceeding thedesired temperature the burner will shut downuntil the temperature drops.

When the request for DHW has been satisfied theappliance pump and fan may continue to operateto dissipate any residual heat within the appli-ance.

1.5 SAFETY DEVICESWhen the appliance is in use, safe operation isensured by:● A water pressure switch that monitors system

water pressure and will deactivate the pump,fan and burner should the system water pres-sure drop below the rated tolerance.

● A high limit thermostat that over-rides the tem-perature control circuit to prevent or interruptthe operation of the burner.

● An air pressure switch that requires the fan toprove operation before the gas valve is ener-gised.

● A pressure switch that interrupts the operationof the appliance if the condense pipe becomesblocked.

● A safety valve which releases excess pressurefrom the primary circuit.CH

returnCHflow

DHWoutlet

Domestic coldwater inlet

safety valve

automaticby-pass

divertervalve motor

pump

AAV

expansionvessel

latent heatcollector

flueoutlet

airintake

pressureswitch

main heatexchanger

CH NTCsensor

mainburner

gas valve

DHW heatexchanger

DHW tempera-ture sensor

waterpressureswitch

DHW nonreturn valve

DHWflow switch

3

SECTION 2 TECHNICAL DATA

Ref. Condition 15 °C , 1013,25 mbar, dry gasNOTE: L.P.G. data refer to section 10

25 29 35

2.1 Central heating

Heat input (kW) 25.00 29.00 34.80

Maximum heat output@ 80/60 °C (kW) 24.35 28.30 33.93

Minimum heat output@ 80/60 °C (kW) 14.25 14.28 14.04

Maximum heat output@ 50/30 °C (kW) 25.90 29.93 36.05

Minimum heat output@ 50/30 °C (kW) 14.85 14.75 14.55

Minimum working pressure 0.5 bar 0.5 bar 0.5 bar

Maximum working pressure 3.0 bar 3.0 bar 3.0 bar

Minimum flow rate 350 l/h 350 l/h 350 l/h

2.2 Domestic hot water

Maximum output (kW) 25.00 29.00 34.80

Minimum output (kW) 9.50 9.90 9.90

Flow rate (35 °C rise) 10.2 l/min 11.9 l/min 14.3 l/min

Maximum inlet pressure 6.0 bar 6.0 bar 6.0 bar

Minimum inlet working pressure 0.15 bar 0.15 bar 0.15 bar

Minimum flow rate 2 l/min. 2 l/min. 2 l/min.

2.3 Gas pressures

Inlet pressure G20 20.0 mbar 20.0 mbar 20.0 mbar

Maximum burner pressure 9.40 mbar 9.20 mbar 10.10 mbar

Minimum burner pressure (central heating) 3.50 mbar 2.70 mbar 2.10 mbar

Minimum burner pressure (domestic hot water) 1.50 mbar 1.20 mbar 1.00 mbar

Gross rate (central haeting, max - min) 2.64 - 1.59 m3/h 3.07 - 1.59 m3/h 3.68 - 1.59 m3/h

Injectors size 12 x 1.35 mm 14 x 1.35 mm 16 x 1.35 mm

2.4 Expansion vessel

Capacity 8 litres 10 litres 10 litres

Maximum system volume 76 litres 76 litres 76 litres

Pre-charge pressure 1.0 bar 1.0 bar 1.0 bar

2.5 Dimensions

Height 780 mm 780 mm 780 mm

Width 400 mm 450 mm 500 mm

Depth 332 mm 332 mm 332 mm

Dry weight 40 kg 44 kg 46 kg

2.6 Clearances

Sides 12 mm 12 mm 12 mm

Top 150 mm from casing or 25 mm above flue elbow, whichever is applicable

Bottom 150 mm 150 mm 150 mm

Front 600 mm 600 mm 600 mm

2.7 Connections

Flow & return 22 mm 22 mm 22 mm

Hot & cold water connections 15 mm 15 mm 15 mm

Gas 15 mm 15 mm 15 mm

Safety valve 15 mm 15 mm 15 mm

Condense 21 mm 21 mm 21 mm

2.8 Electrical

Voltage 230V/~ 50hz 230V/~ 50hz 230V/~ 50hz

Power consumption 153 W 153 W 153 W

Internal fuse 2 A 2 A 2 A

External fuse 3 A 3 A 3 A

2.9 Flue details (concentric)

Maximum horizontal flue length (60/100mm) 4.5 m 4.0 m 1.85 m

Maximum vertical flue length (60/100mm) 5.5 m 5.0 m 2.85 m

2.10 EfficiencySEDBUK 86.9 Band “B” 86.7 Band “B” 86.4 Band “B”

4

2.11 PUMP DUTYFig. 3 shows the flow rate available - after allowing for pressure loss through the appliance - for systemrequirements. When using this graph, apply only the pressure loss of the system. The graph is based on a20 ºC temperature differential.

Fig. 4

SECTION 3 GENERAL REQUIREMENTS (UK)

Fig. 3Litres Per Hour (x100)

Res

idu

al h

ead

(x

100

mb

ar)

25 - 29 35

Litres Per Hour (x100)

Res

idu

al h

ead

(x

100

mb

ar)

Key Location Minimum distance

A Below an opening (window, air-brick, etc.) 300 mmB Above an opening (window, air-brick, etc.) 300 mmC To the side of an opening (window, air-brick, etc.) 300 mmD Below gutter, drain-pipe, etc. 75 mmE Below eaves 200 mmF Below balcony, car-port roof, etc. 1200 mmG To the side of a soil/drain-pipe, etc. 150 mmH From internal/external corner or boundary 300 mmI Above ground, roof, or balcony level 300 mmJ From a surface or boundary facing the terminal 1200 mmK From a terminal facing a terminal 1200 mmL From an opening in the car-port into the building 1200 mmM Vertically from a terminal on the same wall 1500 mmN Horizontally from a terminal on the same wall 300 mmP From a structure to the side of the vertical terminal 500 mmQ From the top of the vertical terminal to the roof flashing As determined by the fixed collar

of the vertical terminal

2.12 ApplianceNOx 94 ppm - 166 mg/kWh 92 ppm - 162 mg/kWh 89 ppm - 156 mg/kWhCO (max-min) 80 ppm - 80 ppm 100 ppm - 60 ppm 100 ppm - 130 ppmCO2 (max-min) 6.75 - 3.90 % 7.05 - 3.50 % 6.7 - 2.3 %CO/CO2 ratio (max) 0.001 to 1 0.001 to 1 0.001 to 1CO/CO2 ratio (min) 0.002 to 1 0.002 to 1 0.006 to 1

25 29 35

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300

first speed

second speed

third speed

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

6,0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

first speed

second speed

third speed

5

This appliance must be installed by a competentperson in accordance with the Gas Safety (Instal-lation & Use) Regulations.

3.1 RELATED DOCUMENTSThe installation of this boiler must be in accord-ance with the relevant requirements of the GasSafety (Installation & Use) Regulations, the localbuilding regulations, the current I.E.E. wiringregulations, the bylaws of the local water under-taking, the Building Standards (Scotland) Regu-lation and Building Standards (Northern Ireland)Regulations.It should be in accordance also with any relevantrequirements of the local authority and the rel-evant recommendations of the following BritishStandard Codes of Practice.

3.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current I.E.E.wiring regulations and in Scotland, the electricalprovisions of the Building Regulations, with re-spect to the installation of the appliance in a roomor internal space containing a bath or shower.

When an appliance is installed in a room orinternal space containing a bath or shower, theappliance or any control pertaining to it must notbe within reach of a person using the bath orshower.The location chosen for the appliance must per-mit the provision of a safe and satisfactory flueand termination. The location must also permit anadequate air supply for combustion purposesand an adequate space for servicing and aircirculation around the appliance. Where the in-stallation of the appliance will be in an unusuallocation special procedures may be necessary,BS 6798 gives detailed guidance on this aspect.A compartment used to enclose the appliancemust be designed and constructed specificallyfor this purpose. An existing compartment/cup-board may be utilised provided that it is modifiedto suit.Details of essential features of compartment/cupboard design including airing cupboard instal-lations are given in BS 6798. This appliance is notsuitable for external installation.

3.3 GAS SUPPLYThe gas meter - as supplied by the gas supplier- must be checked to ensure that it is of adequatesize to deal with the maximum rated input of allthe appliances that it serves. Installation pipesmust be fitted in accordance with BS 6891.Pipe work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused. The installation must be tested for sound-ness in accordance with BS6891.If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.

3.4 FLUE SYSTEMThe terminal should be located where the disper-sal of combustion products is not impeded andwith due regard for the damage and discolorationthat may occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (see fig. 4).Water vapour will condense on leaving the termi-nal and the effect of such pluming must beconsidered.

BS 5440 PART 1 FLUES

BS 5440 PART 2 FLUES & VENTILATION

BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS

BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES(2ND FAMILY GASES)

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW

BS 6891 LOW PRESSURE INSTALLATION PIPES

BS 7074 PART 1 APPLICATION, SELECTION AND INSTALLATION OF EXPANSION VESSELS ANDANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

If installed less than 2m above a pavement orplatform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to BS 5440 Part 1, when a terminal is sitedless than 1m below a plastic gutter, or less than500mm below a painted surface, a suitable onemetre long heat shield should be fitted.

3.5 AIR SUPPLYThe following notes are intended for generalguidance only.This appliance is a room-sealed, fan-flued boiler,consequently it does not require a permanent airvent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also not re-quired.

3.6 WATER CIRCULATIONDetailed recommendations are given in BS 5449Part 1 and BS 6798. The following notes are forgeneral guidance only.

6

Fig. 5a

3.6.7 LOW PRESSURE SEALED SYSTEMAn alternative method of filling the system wouldbe from an independent make-up vessel or tankmounted in a position at least 1 metre above thehighest point in the system and at least 5 metresabove the boiler (see fig. 5a).The cold feed from the make-up vessel or tankmust be fitted with an approved non-return valveand stopcock for isolation purposes. The feedpipe should be connected to the return pipe asclose to the boiler as possible.

3.6.8 FREQUENT FILLINGFrequent filling or venting of the system may beindicative of a leak. Care should be taken duringthe installation of the appliance to ensure allaspects of the system are capable of withstand-ing pressures up to at least 3 bar.

3.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V@ 50Hz electrical supply; it must be protectedwith a 3-amp fuse. The method of connection tothe mains electricity supply must allow for com-plete isolation from the supply. The preferredmethod is by using a double-pole switch with acontact separation of at least 3mm. The switchmust only supply the appliance and its corre-sponding controls, i.e. time clock, room thermo-stat, etc. Alternatively an un-switched shutteredsocket with a fused 3-pin plug both complyingwith BS 1363 is acceptable.

3.8 SHOWERSIf the appliance is intended for use with a shower,the shower must be thermostatically controlledand be suitable for use with a combination boiler.

3.6.1 PIPEWORKIt is recommended that copper tubing to BS 2871Part 1 is used in conjunction with soldered capil-lary joints.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand that water flows naturally to drain cocks.Except where providing useful heat, pipes shouldbe insulated to avoid heat loss and in particular toavoid the possibility of freezing. Particular atten-tion should be paid to pipes passing throughventilated areas such as under floors, loft spaceand void areas.

3.6.2 AUTOMATIC BY-PASSThe appliance has a built-in automatic by-pass.However it may be necessary to fit an externalbypass should the design of the heating systemrequire such. In any case, the design of thesystem should be such that it prevents boiler‘cycling’.

3.6.3 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all waterpipes connected to the appliance. The draincocks must be manufactured in accordance withBS 2879.

3.6.4 AIR RELEASE POINTSThese must be positioned at the highest points inthe system where air is likely to be trapped. Theyshould be used to expel trapped air and allowcomplete filling of the system.

3.6.5 EXPANSION VESSELThe appliance has an integral expansion vesselto accommodate the increased volume of waterwhen the system is heated. It can accept up to 8litres (25kW) or 10 litres (29 & 35kW) of expan-sion from within the system, generally this issufficient, however if the system has an unusu-ally high water content, it may be necessary toprovide additional expansion capacity (see 6.19).

3.6.6 FILLING POINTAn approved method for initial filling of the systemand replacing water lost during servicing etc. isrequired (see fig. 5). This method of filling mustcomply with the current Water Supply (WaterFittings) Regulations 1999 and Water Bylaws2000 (Scotland).

Fig. 5

control valve

temporaryconnection

control valve

supply pipe

double checkvalve

flow/returnpipe

Make-up vesselor tank

Automaticair-vent

Non-returnvalve

Stopcock

5.0

met

res

min

imum

Heatingreturn

7

3.9 MOUNTING ON A COMBUSTIBLE SURFACEIf the appliance is to be fitted on a wall ofcombustible material, a sheet of fireproof mate-rial must protect the wall.

3.10 TIMBER FRAMED BUILDINGIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance with theInstitute of Gas Engineers publication (IGE/UP/7) ‘Guide for Gas Installations in Timber FrameBuildings’.

3.11 INHIBITORSIt is recommend that an inhibitor - suitable for usewith copper and aluminium heat exchangers - isused to protect the boiler and system from theeffects of corrosion and/or electrolytic action.The inhibitor must be administered in strict ac-cordance with the manufacturers instructions*.

*Water treatment of the complete heating system- including the boiler - should be carried out inaccordance with BS 7593 and the DomesticWater Treatment Association’s (DWTA) code ofpractice.

Fig. 6a

Fig. 6

25kW

35kW30kW

8

Using the template provided, mark and drill a115mm hole for the passage of the flue pipe. Thehole should be drilled level to ensure any con-dense fluid that forms will drain back to the boiler.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropri-ate type and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.

FITTING THE HORIZONTAL FLUE KITCarefully measure the distance from the centre ofthe appliance flue outlet to the edge of the fin-ished outside wall (dimension X). Add 65mm todimension X to give you dimension Y (see fig 7A).Measure dimension Y from the terminal end ofthe concentric flue pipe and cut off the excessfrom the 100mm pipe ensuring any burrs areremoved. Using the cut-off piece of 100mm pipeas a guide, mark and cut the same length of pipefrom the inner 60mm pipe (the 60mm shouldalways project past the 100mm pipe by 30mm).Pass the concentric flue pipe through the previ-ously drilled hole. Fit the flue bend to the boilerflue outlet and insert the concentric flue pipe intothe flue bend ensuring the correct seal is made.Using the clamps, gaskets, and screws supplied,secure the flue bend to the appliance flue spigotand the flue terminal.

NOTEFit the internal (White) trim to the flue assemblyprior to connecting the flue pipe to the bend.

Fig. 7

Boiler

outerclamp

Terminal orextension

Part No. Description Min-Max Length

491 Horizontal flue kit for use with 1000 mmadd. bends & extensions

492 0.5m extension 500 mm493 1.0m extension 1000 mm494 2.0m extension 2000 mm495 45º bend (pair) N/A496 90º bend N/A499 Wall bracket N/A

Horizontal flue terminals and accessories

SECTION 4 INSTALLATION

4.1 DELIVERYDue to the weight of the appliance it may be necessaryfor two people to lift and attach the appliance to itsmounting. The appliance is contained within a heavy-duty cardboard carton. Lay the carton on the floor withthe writing the correct way up.

4.2 CONTENTSContained within the carton is:● the boiler● the wall bracket● appliance template● an accessories pack containing appliance serv-

ice connections and washers● the instruction pack containing the installation

& servicing instructions, user instructions,Benchmark logbook, guarantee registration cardand a 3-amp fuse.

4.3 UNPACKINGAt the top of the carton pull both sides open - donot use a knife - unfold the rest of the carton fromaround the appliance, carefully remove all pro-tective packaging from the appliance and lay theaccessories etc. to one side. Protective glovesshould be used to lift the appliance, the applianceback-frame should be used for lifting points.

4.4 PREPARATION FOR MOUNTING THE APPLI-ANCEThe appliance should be mounted on a smooth,vertical, non-combustible surface, which must becapable of supporting the full weight of the appli-ance. Care should be exercised when determin-ing the position of the appliance with respect tohidden obstructions such as pipes, cables, etc.When the position of the appliance has beendecided - using the template supplied - carefullymark the position of the wall- mounting bracket(see fig. 6) and flue-hole (if applicable).

4.5 FITTING THE FLUEThe top flue outlet permits both horizontal andvertical flue applications to be considered.

4.5.1 CONCENTRIC HORIZONTAL FLUE(For concentric vertical flue, see section 4.5.2).

The appliance flue outlet elbow can be rotatedthrough 360º on its vertical axis. In addition theflue may be extended from the outlet elbow in thehorizontal plane (see 2.9). A reduction must alsobe made to the maximum length (see tablebelow) when additional bends are used.

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre

90º bend 1.0 metre

Reduction for additional bends

9

Using the dimensions given in fig. 9 as a refer-ence, mark and cut a 107mm hole in the ceilingand/or roof.

4.5.1.1 EXTENDING THE FLUEConnect the bend - supplied with the terminal kit- to the top of the boiler using clamp (supplied)see fig. 7. The additional bends & extensions havepush-fit connections, care should be taken toensure that the correct seal is made when as-sembling the flue system. Connect the requirednumber of flue extensions or bends (up to themaximum equivalent flue length) to the flue ter-minal (see fig. 7 & 8).The hole should be drilled level to ensure that anycondense fluid drains back to the appliance.NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension (see fig. 7 & 8). Re-move any burrs, and check that all seals are lo-cated properly. You must ensure that the entireflue system is properly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that will provide satisfac-tory weatherproofing.

Fig. 9

Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre

90º bend 1.0 metre

Reduction for bends

Part No. Description Min-Max Length

490 Vertical flue terminal497 Pitched roof flashing plate N/A498 Flat roof flashing plate N/A492 0.5m extension 500 mm493 1.0m extension 1000 mm494 2.0m extension 2000 mm495 45º bend (pair) N/A496 90º bend N/A499 Wall bracket N/A

Vertical flue terminal and accessories

145

Fig. 8

Fig. 7a “X” + 45 mm = “Y”

125 mm

FLUE RESTRICTOR RING (horizontal flue)To ensure maximum efficiency of the appliance,it may be necessary to fit one of the suppliedflue restrictor rings to the appliance flue outlet(see tables below).

Total flue length Restrictor required

Less than 1.2 metre 82.5mm diameter

Less than 3.0 metres 88mm diameter

Less than 4.5 metres not required

25

Total flue length Restrictor required

Less than 2.0 metres 84mm diameter

Less than 4.0 metres not required

29

Total flue length Restrictor required

Less than 1.85 metres not required

35

4.5.2 CONCENTRIC VERTICAL FLUEThe vertical flue terminal can be connected di-rectly to the appliance flue outlet. Alternatively,an extension or bend can be connected to theappliance flue outlet if desired (see 4.4.2), how-ever if additional bends are fitted, a reductionmust be made to the maximum flue length (seetable below).

FLUE RESTRICTOR RING (vertical flue)To ensure maximum efficiency of the appliance,it may be necessary to fit one of the suppliedflue restrictor rings to the appliance flue outlet(see tables below).

Total flue length Restrictor required

Less than 2.0 metre 82.5mm diameter

Less than 4.0 metres 88mm diameter

Less than 5.5 metres not required

25

Total flue length Restrictor required

Less than 2.8 metres 84mm diameter

Less than 5.0 metres not required

29

Total flue length Restrictor required

Less than 2.7 metres not required

35

10

Fit the appropriate flashing plate to the roof andinsert the vertical flue terminal through the flash-ing plate from the outside, ensuring that the collaron the flue terminal fits over the flashing.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropri-ate type and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.

IMPORTANTThe vertical flue terminal cannot be cut; thereforeit may be necessary to adjust the height of theappliance to suit or use a suitable extension.Connect the vertical flue assembly to the boiler fluespigot using the 60mm & 100mm clips, gaskets &screws (supplied), ensuring the correct seal ismade. The flue support bracket (supplied with thevertical flue kit) can now be fitted.If the vertical flue requires extension/s or addi-tional bend/s, connect the required number offlue extensions or bends (up to the maximumequivalent flue length) between the boiler andvertical flue assembly (see fig. 8).Ensure that any horizontal sections of the fluesystem have a minimum 1º fall back to the boiler(17mm per 1000mm).

NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension (see fig. 8). Removeany burrs, and check that any seals are locatedproperly. You must ensure that the entire fluesystem is properly supported and connected.

4.6 CONNECTING THE GAS AND WATERThe appliance is supplied with an accessory packthat includes service valves.The service valves are of the compression type.The accessory pack contains sealing washers’ etc,for use with the service valves. When connectingpipe work to the valves, tighten the compressionend first then insert the sealing washers beforetightening the valve to the appliance.

NOTEIt will be necessary to hold the valve with onespanner whilst tightening with another

4.6.1 GAS (fig. 6 & 10)The appliance is supplied with a 15mm servicevalve, connect a 15mm pipe to the inlet of thevalve and tighten both nuts.NOTEIt will be necessary to calculate the diameter ofthe gas supply pipe to ensure the appliance hasan adequate supply of gas.

4.6.2 FLOW & RETURN (fig. 6 & 10)The appliance is supplied with 22mm servicevalves for the flow and return connections, con-nect a 22mm pipe to the inlet of each valve andtighten both nuts.

NOTEDepending on system requirements, it may nec-essary to increase the size of the flow & returnpipe work after the service valve connections.

4.6.3 COLD WATER INLET (fig. 6 & 10)The appliance is supplied with a 15mm stopcock,connect a 15mm pipe to the inlet of the stopcockand tighten both nuts.

4.6.4 HOT WATER OUTLET (fig. 6 & 10)The appliance is supplied with a 15mm outletconnection, connect a 15mm pipe to the outletconnection and tighten both nuts.

4.6.5 SAFETY VALVE (fig. 6 & 10)Connect the safety valve connection pipe to thesafety valve outlet and tighten. The dischargepipe must have a continuous fall away from theappliance to outside and allow any water to drainaway thereby eliminating the possibility of freez-ing. The discharge pipe must terminate in aposition where any water - possibly boiling -discharges safely without causing damage orinjury, but is still visible.

4.6.6 CONDENSE PIPE (fig. 6 & 10)During normal operation the boiler produces con-dense which is collected in a trap located in thelower part of the boiler. A flexible pipe (condenseoutlet pipe) is connected to the outlet of the trap.The flexible pipe must be connected to a plasticwaste pipe only. The plastic waste pipe musthave a minimum of a 3º fall towards the drain. Anyexternal run of pipe should be insulated to pre-vent the risk of freezing.

CONNECTING THE CONDENSATE OUTLETGently pull the condense outlet pipe down fromits location inside the boiler until approximately itprotrudes from the underside of the boiler. Con-nect a suitable plastic (not copper) pipe (no lessthan 21mm diameter) to the outlet pipe andensure it discharges in accordance with localbuilding regulations or other rules in force.

Fig. 10

flow return gas DHWoutlet

DHWinlet

condense

safetyvalve drain

11

4.7 ELECTRICAL CONNECTIONSThe boiler is supplied with a 2-metre fly-lead. Thislead can be used for connection to the electricalsupply. Connect the fly-lead to a fused plug orfused isolator in the following way:● brown wire to LIVE supply● blue wire to NEUTRAL supply● green/yellow to EARTH connection.

Insert the supplied 3-AMP fuse into the fusedisolator or fused plug.Should the fly-lead be unsuitable, refer to 4.7.3for details on how to connect the electrical supplydirectly to the boiler.The electrical supply must be as specified insection 3/3A. A qualified electrician should con-nect the appliance to the electrical supply. Ifcontrols - external to the appliance - are required,a competent person must undertake the designof any external electrical circuits, please refer tosection 8 for detailed instructions. ANY EXTER-NAL CONTROL OR WIRING MUST BE SERVEDFROM THE SAME ISOLATOR AS THAT OFTHE APPLIANCE. The supply cable from theisolator to the appliance must be 3-core flexiblesized 0.75mm to BS 6500 or equivalent. Wiring tothe appliance must be rated for operation incontact with surfaces up to 90 ºC.

4.7.1 CASING REMOVALTo gain internal access to the appliance you must firstremove the casing, proceed as outlined below:● locate and unscrew the 3-screws (A) that se-

cure the outer casing to the appliance (see fig.11)

● lift the casing upward to disengage it from thetop locating hooks and then remove

● store the casing and screws safely until re-quired. Re-fit in the reverse order

● gently lower the control fascia until it rests.

4.7.2 APPLIANCE TERMINAL BLOCKThe appliance terminal block is located on theleft side of the control fascia (see fig. 11). Locateand remove the screw that secures the terminalblock cover.

NOTEThe appliance comes with a factory fitted clockto allow basic operation of the boiler. If it is antici-pated that additional controls - such as a room

thermostat - will be required please refer to thewiring diagrams in section 8 for more detailedinformation.

4.7.3 CONNECTING THE MAINS (230V) INPUT (seefig. 12)Lift the terminal block cover as described in 4.7.2.Pass the cable through the cable anchorage point.At the terminal block on the extreme left, thereare 3 terminals from left to right they are:

LIVE - NEUTRAL - EARTH

Connect the supply cable wires (LIVE, NEUTRAL& EARTH) to their corresponding terminals on theappliance terminal block (see fig. 13). Ensure thatthe EARTH wire is left slightly longer than theothers, this will prevent strain on the EARTH wireshould the cable become taut.

The securing screw on the cable anchorageshould now be tightened. This must be donebefore the control fascia is re-fitted in the uprightposition. The appliance casing and screws cannow be re-fitted.

Control panel screws and casing screws

Fig. 11

A

Fig. 12

Fig. 13

12

5.1 GAS SUPPLY INSTALLATIONInspect the entire installation including the gasmeter, test for soundness and purge. Refer to BS6891 for specific instruction.

5.2 THE HEATING SYSTEMThe appliance contains components that maybecome damaged or rendered inoperable by oilsand/or debris that are residual from the installa-tion of the system, consequently it is essentialthat the system be flushed in accordance with thefollowing instructions.

5.3 INITIAL FILLING OF THE SYSTEMEnsure both flow and return service valves areopen, remove appliance casing as described in4.7.1, identify the automatic air release valve andloosen the dust cap by turning the cap anti-clockwise one full turn. IMPORTANT, THEREARE NO MANUAL AIR RELEASE VALVES LO-CATED ON THE APPLIANCE. Ensure all manualair release valves located on the heating systemare closed. Connect the filling loop (not supplied)and slowly proceed to fill the system. As waterenters the system the pressure gauge will beginto rise. Once the gauge has reached 1 BAR closethe filling loop and begin venting all manual airrelease valves, starting at the lowest first. It maybe necessary to go back and top-up the pressureuntil the entire system has been filled. Inspect thesystem for water soundness, rectifying any leaks.

5.4 INITIAL FLUSHINGThe whole of the heating system must be flushedboth cold and hot as detailed in 5.8. Open allradiator or heating valves and the appliance flow& return service valves. Drain the boiler andsystem from the lowest points. Open the drainvalve full bore to remove any installation debrisfrom the boiler prior to lighting. Refill the boilerand heating system as described in 5.3.

5.5 FILLING THE HOT WATER SYSTEMClose all hot water outlets, turn appliance stop-cock to the normal operating position (fully coun-ter clockwise), slowly open each outlet until airhas been expelled and clear water is discharged.Check pipe-work etc. for water soundness.

5.6 PRE-OPERATION CHECKSBefore attempting the initial lighting of the appli-ance, the following checks must be carried out:● ensure all gas service valves from the meter to

the appliance are open and the supply pipe hasbeen properly purged

● ensure the proper electrical checks have beencarried out, (see 7.7) particularly continuity,polarity and resistance to earth

● ensure the 3 AMP fuse - supplied with theappliance - has been fitted

● ensure the system has been filled, vented andthe pressure set to 1 BAR

● ensure the flue system has been fitted properlyand in accordance with the instructions

● ensure all appliance service valves are open.

SECTION 5 COMMISSIONING

5.7 INITIAL LIGHTINGEnsure the electrical supply to the appliance isswitched on. Move the selector switch to theHeating & Hot Water position, ensure the timeclock is switched to an ‘ON’ position and ensureany other external controls (room thermostat forexample) are also calling for heat.The appliance will now operate in the mode asdescribed in 1.2. Should the appliance fail toignite, refer to 5.6 and/or section 7 (faultfinding).

5.7.1 CHECKING THE BURNER PRESSUREAlthough the burner pressure is factory set, it isnecessary to check it during commissioning.Isolate the appliance from the electrical supplyand attach a suitable manometer to the gas valveoutlet test-point (see fig. 14). Light the boiler asdescribed in 5.7, turn the Hot Water temperatureselector to maximum, and open fully a DHWoutlet (preferably the bath), allowing the appli-ance to stabilise. Compare the reading on themanometer with the value described in 2.3. Ifadjustment is required, follow the detailed in-structions in section 7 (7.3).

Once the burner pressure has been checked,close the DHW outlet, isolate the appliance fromthe electrical supply, remove the manometer andtighten the gas valve outlet test nipple.

5.8 FINAL FLUSHING OF THE HEATING SYSTEMThe system shall be flushed in accordance withBS 7593. Should a cleanser be used, it must besuitable for Copper and Aluminium heat exchang-ers. It shall be from a reputable manufacturer andshall be administered in strict accordance withthe manufacturers’ instructions and the DWTAcode of practice.

5.8.1 INHIBITORSSee section 3 “General requirements”.

5.9 SETTING THE BOILER OPERATING TEM-PERATUREThe flow outlet temperature can be adjustedbetween 40 ºC - 80 ºC via the Heating thermostatknob (see fig.1).

Fig. 14

Protectivecap

Outlettest-point

Inlettest-point

13

5.9.1 SETTING THE DOMESTIC HOT WATER TEM-PERATUREThe DHW outlet temperature can be adjustedbetween 40 ºC - 65 ºC via the Hot Water thermo-stat knob (see fig.1).

5.10 SETTING THE SYSTEM DESIGN PRESSUREThe design pressure should be a minimum of 1BAR and a maximum of 1.5 BAR.The actual reading should ideally be 1BAR plusthe equivalent height in metres (0.1 BAR = 1metre) to the highest point in the system abovethe base of the appliance (up to the maximum of1.5 BAR total).N.B. The safety valve is set to lift at 3 BAR/30metres/45 psig.).To lower the system pressure to the requiredvalue, water can be drained from the heatingsystem drain cock or from the boiler drain cock.

5.11 REGULATING THE HOT WATERThe appliance is fitted with a flow rate restrictorthat limits the maximum flow rate that can bedrawn through the appliance.

The restrictor eliminates the need to manuallyadjust the DHW flow rate. However if it is feltnecessary to further increase or decrease theavailable flow rate, spare restrictors are includedin the accessory pack.The spare flow rate restrictors can be fitted toeither increase or decrease the maximum flowrate. The tables above denote the size of restrictorfitted and the spare restrictors supplied in theaccessory pack. Each restrictor is colour-codedto enable identification.

5.11.1 CHANGING THE FLOW RESTRICTORRefer to 6.19 for detailed instruction on changingthe flow restrictor.

5.11.2 REGULATING THE CENTRAL HEATING SYS-TEMFully open all radiator and circuit valves and runthe appliance for both heating and hot water untilheated water is circulating. If conditions are warmremove any thermostatic heads. Adjust radiatorreturn valves and any branch circuit return valvesuntil the individual return temperatures are cor-rect and are approximately equal.

5.12 FINAL CHECKS● ENSURE ALL TEST NIPPLES ON THE AP-

PLIANCE GAS VALVE HAVE BEN TIGHT-ENED AND CHECKED FOR SOUNDNESS.

● ENSURE THE APPLIANCE FLUE SYSTEMIS FITTED CORRECTLY AND IS PROPERLYSECURED.

● ENSURE ALL PIPE WORK IS RE-CHECKEDFOR SOUNDNESS.

● RE-FIT APPLIANCE CASING.● COMPLETE BENCHMARK CHECKLIST.

Complete details of the boiler, controls, installa-tion and commissioning in the Benchmark check-list at the back of this book. It is important thatthe Benchmark checklist is correctly completedand handed to the user. Failure to install andcommission the appliance to the manufacturersinstructions may invalidate the warranty.

5.13 INSTRUCTING THE USERHand over all documentation supplied with thisappliance - including these instructions - andexplain the importance of keeping them in a safeplace.Explain to the user how to isolate the appliancefrom the gas, water and electricity supplies, andthe locations of all drain points.Show the user how to operate the appliance andany associated controls correctly.Show the user the location of the filling valve andhow to top-up the system pressure correctly, andshow the location of all manual air release points.Explain to the user how to turn off the appliancefor both long and short periods and advise on thenecessary precautions to prevent frost damage.Explain to the user that for continued safe andefficient operation, the appliance must be serv-iced annually by a competent person.

9-litre (Orange) 10-litre (Blue) 11-litre (Beige)Spare Fitted Spare

29

11-litre (Beige) 12-litre (Red) 13-litre (Olive)Spare Fitted Spare

35

8-litre (White) 9-litre (Orange) 10-litre (Blue)Fitted Spare Spare

25

14

SECTION 6 SERVICING INSTRUCTIONS

6.1 GENERALTo ensure the continued safe and efficient opera-tion of the appliance, it is recommended that it ischecked and serviced at regular intervals.

To ensure correct and safe operation of theappliance, it is essential that any worn or failedcomponent be replaced only with a genuinespare part.

The frequency of servicing will depend upon theparticular installation conditions, but in general,once per year should be adequate.

It is the law that any servicing work is carried out bycompetent person such as an engineer, an approvedservice agent, British Gas, CORGI registered per-sonnel or other suitably qualified personnel.

The following instructions apply to the applianceand its controls, but it should be rememberedthat the central heating and the domestic hotwater systems would also require attention fromtime to time.

6.2 ROUTINE ANNUAL SERVICINGCheck the operation of the appliance and ensureit functions as described in section 7. Comparethe performance of the appliance with its designspecification. The cause of any noticeable dete-rioration should be identified and rectified withoutdelay.Thoroughly inspect the appliance for signs ofdamage or deterioration especially the flue sys-tem and the electrical apparatus.Check and adjust - if necessary - all burnerpressure settings (see section 7.3).Check and adjust - if necessary - the systemdesign pressure (see section 5.10).Carry out an analysis of the flue gases (see 7.4)and visually check the condition of the entire flueassembly. Compare the results with the appli-ance design specification. Any deterioration inperformance must be identified and rectified with-out delay.Ensure both flue venturis are clean and free fromany debris or obstruction.Ensure the burner, main heat exchanger andlatent heat collector are clean and free from anydebris or obstruction.

6.3 REPLACEMENT OF COMPONENTSAlthough it is anticipated that this appliance willgive years of reliable, trouble free service, the lifespan of components will be determined by factorssuch as operating conditions and usage. Shouldthe appliance develop a fault, the fault findingsection will assist in determining which compo-nent is malfunctioning.

6.4 COMPONENT REMOVAL PROCEDURETo remove a component, access to the interior ofthe appliance is essential. Isolate the appliancefrom the electrical supply and remove the fuse.And when necessary, close all service valves on

the appliance, remove the appliance casing asdescribed in section 4.7.1 and drain the watercontent from the appliance via the drain valvelocated at the front of the hydraulic section usingthe tube provided. Ensure some water absorbentcloths are available to catch any residual waterthat may drip from the appliance or removedcomponent. Undertake a complete commission-ing check as detailed in section 5, after replacingany component. ALWAYS TEST FOR GASSOUNDNESS IF ANY GAS CARRYING COM-PONENTS HAVE BEEN REMOVED OR DIS-TURBED.

6.5 PUMP ASSEMBLY fig. 15Carry out component removal procedure as de-scribed in 6.4.The pump head can be replaced by disconnect-ing the electrical connection at the pump andremoving the 4-Allen screws that secure the headto the pump base. Alternatively, the completepump assembly can be removed as follows:● disconnect the electrical connection from the

pump control box● locate and remove the pressure gauge secur-

ing pin and disconnect the pressure gauge fromthe pump assembly

● locate and remove the expansion pipe securingpin and disconnect the expansion pipe from thepump assembly

● locate and remove the condense pipe locatedbetween the air-chamber and condense trap

● refer to fig. 15, disconnect and remove items A,B & C

● locate and remove securing pin ‘F’ and lift thepump assembly away from the hydraulic sec-tion.

Replace in the reverse order.

6.6 SAFETY VALVE fig. 16Carry out component removal procedure as de-scribed in 6.4.Disconnect and remove the safety valve outletpipe. Locate and remove the safety valve secur-ing pin (B). The safety valve can now be re-moved. Replace in the reverse order.

Fig. 15

A

BC

F

G

15

6.7 AUTOMATIC AIR RELEASE VALVE fig. 15(AAV)Carry out component removal procedure as de-scribed in 6.4.Locate and remove the expansion pipe securingpin and disconnect the expansion pipe from thepump assembly. Locate and remove the AAVsecuring pin (G) and lift the AAV free from thepump assembly.Replace in the reverse order.

6.8 WATER PRESSURE SWITCH fig. 1Carry out component removal procedure as de-scribed in 6.4.Disconnect the 2-wires from the water pressureswitch, taking note of their locations. Locate andremove the pin that secures the water pressureswitch to the flow pipe. Remove the water pres-sure switch from the flow pipe. Replace in thereverse order.

6.9 PRESSURE GAUGE fig. 1Carry out component removal procedure as de-scribed in 6.4.Locate and remove the pressure gauge securingpin and disconnect the pressure gauge from thepump assembly. Locate the spring tabs on thepressure gauge body, push and hold tabs in, toenable extraction of the gauge from its locationon the control panel.Replace in the reverse order.

6.10 PRIMARY THERMISTOR fig. 17Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover andremove the right side air baffle.Disconnect thermistor electrical plug.Using a 13mm spanner slacken and remove thethermistor and sealing washer (1,2) from themain heat exchanger.Replace in the reverse order.

6.11 HIGH LIMIT THERMOSTAT fig. 18Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover.Pull off electrical connections from the high limitthermostat (2), slacken and remove retainingscrews (3).Replace in reverse order.

6.12 PRINTED CIRCUIT BOARD fig. 19Carry out component removal procedure as de-scribed in 6.4.Locate and remove the screws that secure thePCB cover, then remove cover. After carefullytaking note of all wiring connections, disconnectall wiring from the PCB, locate and remove thePCB securing screws (2,3,), remove the requiredPCB (Main or ignition control). Replace in thereverse order.

NOTEEnsure that any replacement PCB has the cor-rect jumper tag configuration, and that the rel-evant gas pressures are correctly set/adjusted(see 7.8.1).

6.13 GAS VALVE fig. 20Carry out component removal procedure as de-scribed in 6.4. The gas valve must be changed ascomplete unit. Disconnect the electrical plug andleads from the gas valve.Slacken and unscrew gas valve inlet and outletconnections (3). Please note, the sealing wash-ers (2) must be discarded and replaced with newsealing washers (2). Locate and remove gasvalve retaining screws on the underside of theboiler if required. The gas valve can now beremoved. Replace in the reverse order. Checkand adjust burner pressure settings. WARNING,A GAS SOUNDNESS CHECK MUST BE CAR-RIED OUT.

Fig. 18

Fig. 17

Fig. 16

B

E

16

6.14 INTEGRAL TIME SWITCH (if fitted)Carry out component removal procedure as de-scribed in 6.4.Locate and remove the PCB cover and securingscrews (fig. 19/19A), locate and remove the timeclock retaining screws, remove time clock. Dis-connect wiring after carefully taking note of allelectrical connections. Replace in the reverseorder.

Fig. 19

6.15 ELECTRODE, BURNER THERMOSTAT,BURNER & INJECTORS fig. 21Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover (2).Locate and remove the 6 screws securing thefront combustion cover (3), pull the cover towardsyou before lifting and disengaging. Disconnectthe electrode lead and burner thermostat fromtheir respective connectors. Ease the electrodesealing grommet from its seating (4). Remove theretaining screw for the burner thermostat andremove the thermostat.

FIG. 22: locate and remove the four screwswhich secure the burner in position (1), gentlyease the burner out of its location. Once theburner has been removed, the electrode retain-ing screw can be removed. Locate the burnerinjectors (2) and remove (if necessary). Replacein the reverse order. Please note, the injectorsealing washers (3) must be replaced if theinjectors have been removed, ensure all sealsare in good condition, taking care to ensure theyare replaced correctly. Replace in the reverseorder.

Fig. 19a

M

M

CLK-1

CLK-4

Fig. 20

Fig. 21 Fig. 22

17

6.16 FLUE FAN fig. 23Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover, gentlypull the cover towards you before lifting anddisengaging. Locate and remove the six screwsthat secure the front combustion cover, thenremove the cover. Disconnect the electrical con-nections and silicone tubes attached to the fan,noting their positions. Locate and remove thescrews (6) that secure the air pressure switchassembly (4 & 5). Locate and remove the screwsthat secure the flue hood and air baffle, discon-nect the flue clip (1) from the fan-flue elbow, andgently ease the fan (3) & flue hood assembly (2)from its location. Locate and remove the fourscrews that secure the fan to the flue hood.Remove the fan to flue elbow. Replace in thereverse order. Ensure all seals are in good con-dition, taking care to ensure they are replacedcorrectly.

6.17 MAIN HEAT EXCHANGER fig. 23/24Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover, gentlypull the cover towards you before lifting anddisengaging. Locate and remove the six screwsthat secure the front combustion cover, thenremove the cover. Remove the air chamber side

panels if necessary by unscrewing the securingscrews. Disconnect the flow and return connec-tions (4,5, fig. 24) on the heat exchanger. Theheat exchanger can now be withdrawn from theappliance. Replace in the reverse order. Ensureall seals are in good condition, taking care toensure they are replaced correctly.

6.18 AIR PRESSURE SWITCH fig. 23Carry out component removal procedure as de-scribed in 6.4.Unclip and remove the air chamber cover, gentlypull the cover towards you before lifting anddisengaging. Locate and remove the two screws(6) holding the air pressure switch to the airchamber. Disconnect the electrical connectionsand silicone tubes (10) attached to the air pres-sure switch, noting their connections/positions.Replace in the reverse order. Ensure all seals arein good condition, taking care to ensure they arereplaced correctly.

6.19 FLOW RESTRICTOR fig. 25Carry out the component removal procedure asdescribed in 6.4.Slacken the cold water inlet pipe (A) at the DHWflow switch and disconnect. Ease the flow restrictor(B) from its seating. Replace in the reverse order.Ensure all seals are in good condition, taking careto ensure they are replaced correctly.

Fig. 23

Fig. 24Fig. 25

�

��

�

�

�

�

�

�

A

B

18

6.20 DHW FLOW SWITCH fig. 25Carry out component removal procedure as de-scribed in 6.4.Disconnect the cold water inlet pipe (A) from theDHW flow switch. Disconnect the wiring to theDHW flow switch. Remove the locking pin fromthe DHW flow switch and lift the DHW flow switchfrom its location. Replace in the reverse order.Ensure all seals are in good condition, taking careto ensure they are replaced correctly.

6.21 DHW HEAT EXCHANGER fig. 16Carry out component removal procedure as de-scribed in 6.4.Before removing the DHW heat exchanger, itmay be necessary to first remove the pumpassembly and condense trap. Locate and re-move the screws (E) that secure the heat ex-changer to the DHW manifolds. Carefully removethe heat exchanger from its location taking carenot to spill any residual water. Replace in thereverse order ensuring that the heat exchanger‘O’ ring seals are correctly inserted into the DHWmanifolds. Ensure all seals are in good condition,taking care to ensure they are replaced correctly.

6.22 VALVE ACTUATOR fig. 26Carry out component removal procedure as de-scribed in 6.4.Remove the locking pin (A) that secures theactuator (B) to the hydraulic manifold. Discon-nect the electrical plug from the actuator. Re-place in the reverse order.

6.23 DIVERTOR VALVE CARTRIDGE fig. 26Carry out component removal procedure as de-scribed in 6.4.Remove the valve actuator as described in 6.22.Remove the cartridge locking pin (C) and - usinga suitable pair of pliers - withdraw the cartridge

Fig. 26

Fig. 26a

assembly. The cartridge assembly is a non-serviceable item and therefore needs to be re-placed if it’s suspected as being damaged orworn. Replace in the reverse order ensuring thatthe seating cam inserts into the locating groovecorrectly (see fig. 26a). Ensure all seals are ingood condition, taking care to ensure they arereplaced correctly.

6.24 DHW THERMISTOR fig. 27Carry out component removal procedure as de-scribed in 6.4.Disconnect the electrical plug. Using a suitablepair of pliers, remove the thermistor locking pin(E) and ease the thermistor (F) from its seating.Replace in the reverse order ensuring the sealingring is in good condition.

6.25 AUTOMATIC BY-PASS fig. 27Carry out component removal procedure as de-scribed in 6.4.Locate and remove the hydraulic cover lockingpin (A) and remove the cover. Using a suitablehooked wire or screwdriver, gently ease the non-return valve (C) from its seating. Ensure all sealsare in good condition, taking care to ensure theyare replaced correctly. Replace in the reverseorder ensuring the cartridge is facing the correctway.

6.26 DHW NON-RETURN VALVE fig. 27Carry out component removal procedure as de-scribed in 6.4.Locate and remove the hydraulic cover lockingpin (A) and remove the cover. Using a suitablehooked wire or screwdriver, gently ease the non-return valve (D) from its seating. Ensure all sealsare in good condition, taking care to ensure theyare replaced correctly. Replace in the reverseorder ensuring the cartridge is facing the correctway.

6.27 EXPANSION VESSEL fig. 1Should the removal and replacement of the ex-pansion vessel be deemed impractical, an exter-nal expansion vessel may be fitted to the returnpipe as close to the appliance as possible.

6.27.1 EXPANSION VESSEL REMOVAL (with suffi-cient clearance above)Carry out component removal procedure as de-scribed in 6.4.Disconnect the flue from the appliance.

Fig. 27

E

F

A

D

C

19

Disconnect the flexible expansion pipe from thevessel. Locate and remove the four screws (A)that secure the vessel top holding plate (B),remove the plate (fig. 28). The expansion vesselcan now be removed. Replace in the reverseorder. Ensure all seals are in good condition,taking care to ensure they are replaced correctly.

6.27.2 EXPANSION VESSEL REMOVAL (with insuf-ficient clearance above)Carry out component removal procedure as de-scribed in 6.4.Disconnect the flexible expansion pipe from thevessel.Disconnect the flue elbow or pipe from the appli-ance flue outlet. Unclip and remove the air cham-ber cover, gently pull the cover towards youbefore lifting and disengaging. Remove the RHside panel of the air chamber. Disconnect thewiring to the fan, pressure switch, primary ther-mistor, overheat thermostat, condense switch &spark electrode, taking note of their locations.Carefully unclip the wires from the air chamberand withdraw the wiring & grommet from the airchamber.Disconnect the outlet gas pipe, the flow & returnpipes and the condense pipe from the air chamber.Locate and remove the 2-screws that secure thelower section of the air chamber. Locate andremove the 2-screws that secure the upper sec-tion of the air chamber. The complete air cham-ber assembly can now be lifted clear from theappliance.Locate and remove the 4-screws that secure thevessel (see fig. 28). The expansion vessel cannow be removed. Replace in the reverse order.Take extreme care when refitting the wiring to theair chamber. Ensure all seals are in good condi-tion, taking care to ensure they are replacedcorrectly.

6.28.1 LATENT HEAT COLLECTOR fig. 29/30Carry out component removal procedure as de-scribed in 6.4.Remove the flue hood and fan assembly asdetailed in 6.16. Disconnect and remove the inlet,outlet and condense pipes from the collector.Unscrew and remove the 3 screws that securethe collector to the air chamber and disconnect

Fig. 28

B

A

the collector from the flue connection. Replace inthe reverse order ensuring all seals are intact andlocated correctly.

6.28.2 DISMANTLING THE LATENT HEAT COLLEC-TORApart from routine servicing or maintenance of thecoil, the latent heat collector is a non-serviceablecomponent, therefore, there is no requirement todisassemble the collector.

6.29 CONDENSE TRAP REMOVAL fig. 31Carry out component removal procedure as de-scribed in 6.4.Disconnect the flexible condense pipe (1) fromthe condense trap. Locate and remove the con-dense pipe locking pin and disconnect the con-dense pipe (2) from the condense trap. Locateand disconnect the condense pressure switchpipe from the condense trap (3). Carefully re-move the condense trap. Replace in the reverseorder.

Fig. 29

Fig. 30

Fig. 31

20

SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING

7.1 CHECKING APPLIANCE OPERATIONWhen carrying out any repairs or servicing to theappliance, the relevant commissioning proce-dure must be undertaken to ensure the continuedsafe operation of the appliance. Particular atten-tion should be made to ensure gas soundness,water soundness and the electrical integrity of theappliance.

7.2 APPLIANCE MODE OF OPERATIONNOTEThere must be sufficient system water pressure(min. 0.5 bar) to ensure the water pressure switchis activated. If there is insufficient system pres-sure the pump and fan will be prevented fromoperating.

7.2.1 SELECTOR SWITCH IN THE OFF POSITIONWhen the selector switch is in the OFF position,the Green LED status indicator will flash every 6-seconds to confirm the appliance is in standbymode. The divertor valve is in the DHW position.The appliance will not respond to any DHW orheating requests.

Active functions:●●●●● frost-protection system●●●●● pump anti-block●●●●● valve actuator anti-block● fan over-run.

7.2.2 SELECTOR SWITCH IN THE HOT WATERONLY POSITIONWhen the selector switch is in the HW onlyposition, the Green LED is illuminated:●●●●● flashing every 6-seconds if no DHW request is

active●●●●● constant during a DHW request.

The divertor valve is in the DHW position. Theappliance will respond to any DHW requests.

Active functions:●●●●● frost-protection system●●●●● pump anti-block●●●●● valve actuator anti-block●●●●● fan over-run.

7.2.3 SELECTOR SWITCH IN THE HEATING & HOTWATER POSITIONWhen the selector switch is in the heating & HWposition, the Green LED is illuminated:●●●●● flashing every 6-seconds if no Heat or DHW

request is active●●●●● constant during a heat or DHW request.

The divertor valve remains in the DHW position ifno heat request is active. The appliance willrespond to any heating or DHW requests.

Active functions:●●●●● frost-protection system●●●●● pump anti-block●●●●● valve actuator anti-block●●●●● fan/pump over-run.

7.2.4 APPLIANCE FUNCTIONS●●●●● Frost-protection: this function is only active

when there are no requests for heating or HW.When the temperature of the primary thermis-tor drops below 5 °C, the valve actuator willmotor to the heating position, whereupon theboiler will operate on minimum power until thetemperature of the primary thermistor reaches35 °C. Thereafter the pump will over-run for 30-seconds.

●●●●● Anti-block cycle: when there has been noheating or HW request for 19-hours, the anti-block cycle is activated. The valve actuator willmotor from the DHW position to the heatingposition and then motor back to the DHWposition. Thereafter the pump will be activatedfor a period of 30-seconds.

●●●●● Fan over-run: should the temperature of theprimary thermistor exceed 78 °C after a heatingor DHW request, the pump and/or fan will runfor a period of 30-seconds.

●●●●● SARA function: the SARA function permitsthe boiler (when the set-point is within theSARA range) to automatically adjust (raise) theheating flow outlet temperature should the roomthermostat contacts remain closed for morethat 20-minutes.

7.2.5 DHW MODE fig. 32With the selector switch in the Heating & HWposition, or HW only position and a DHW outlet isopened, the appliance will operate in the HWmode. The valve actuator will motor to the HWposition (if a heating request was active) and thepump and fan will be active. The operation of thefan causes the air pressure switch to deliver asignal voltage to the control PCB. A slow ignitionsequence is enabled, whereby the current sup-plied to the gas valve modulating coil is progres-sively increased from minimum to maximum overa period of 8-seconds. During this period theignition electrode sparks continuously even if theburner has ignited.

21

NOTEIf the spark/sensing electrode does not senseignition the appliance will then go to lockout.Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Once suc-cessful ignition has been achieved, the electroniccircuitry modulates the appliance output in order toachieve the DHW set-point (the position of theDHW temperature selector) as measured at thesecondary thermistor.When the set-point has been reached, the appli-ance will begin the modulation phase whereby thefan and gas valve will continuously modulate tomaintain the set-point.If the temperature continues to rise and exceedsthe set-point by 5 °C, the burner will shut down untilthe temperature drops to set-point + 4 °C, wherebya new ignition sequence will be enabled.When the request for DHW has been satisfied, theappliance fan may continue to operate to dissipateany residual heat from within the appliance.

7.2.5.1 DHW PARAMETERS

7.2.6 HEATING MODE fig. 33With the selector switch in the Heating & HWposition and the relevant controls (time clock,room thermostat, etc,) are calling for heat, theappliance will operate in the heating mode. Thevalve actuator will motor to the heating positionand the pump and fan will be active. The operation

of the fan causes the air pressure switch to delivera signal voltage to the control PCB. A slow ignitionsequence is enabled, whereby the current suppliedto the gas valve modulating coil is progressivelyincreased from minimum to maximum over aperiod of 8-seconds. During this period the ignitionelectrode sparks continuously even if the burnerhas ignited.

NOTEIf the spark/sensing electrode does not senseignition the appliance will then go to lockout.Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Once suc-cessful ignition has been achieved, the electroniccircuitry allows 75% of the full gas rate through theappliance. After 15 minutes the gas rate is increasedto maximum (100%).When the set-point has been reached (the positionof the heating temperature selector) as measuredat the primary thermistor, the appliance will beginthe modulation phase whereby the fan and gasvalve will continuously modulate to maintain theset-point.If the temperature continues to rise and exceedsthe set-point by 6 °C, the burner will shut down andthe boiler will perform a three-minute anti-cycle(timer delay).A new ignition sequence will be enabled when the3-minute anti-cycle has been performed and thetemperature at the primary thermistor has dropped6 °C below the set-point.

NOTESThe timer delay can be de-activated by the inser-tion of a ‘jumper’ on the PCB at JP1 or by isolatingthe appliance from the electrical supply for 30seconds.Any DHW requests will always have priority overa heating request.When the request for heating has been satisfied,the appliance pump and fan may continue tocirculate to dissipate any residual heat within theappliance.

Fig. 32

RANGE MINIMUM MAXIMUMTemperature (°C) 37.5 60DHW NTC fault ON at 50 °C OFF at 55 °C

Fig. 33

22

7.2.6.1 HEATING PARAMETERS

When the boiler is operating in the SARA range,the Green LED flashes rapidly to signify the SARAfunction is active.

SARA FUNCTIONWhen the heating temperature selector is setwithin the SARA range (SARA sector) the boilerwill automatically raise the heating flow outlettemperature by 5 °C every 20-minutes that theroom thermostat contacts remain in the closedposition or until the boiler reaches the maximumoperating temperature.

7.3 CHECKING AND ADJUSTING BURNERPRESSURE (see fig. 15)Although the burner pressure is factory set, it isnecessary to check it during servicing or if the gasvalve has been removed.Isolate the appliance from the electrical supplyand attach a suitable manometer to the gas valveoutlet test nipple.

RANGE MINIMUM MAXIMUMTemperature (°C) 40 801ST sector 40 55SARA sector 55 652ND sector 65 80

Fig. 34

7.3.1 SETTING THE MAXIMUM BURNER PRESSUREfig. 39Light the boiler as described in 5.7 and comparethe reading on the manometer with the valuedescribed in 2.3. If adjustment is required, re-move the protective cap from the gas valvemodulating coil assembly and turn the outer(10mm) nut clockwise to increase, or counter-clockwise to decrease the burner pressure.NOTEAlways check and/or adjust the minimum andmaximum gas pressures whilst the appliance is inthe HW only mode. Ensure a DHW outlet (pref-erably the bath) is fully open, and that the HWtemperature selector is at maximum.

7.3.2 SETTING THE MIMIMUM BURNER PRES-SURE fig. 34Once the maximum burner pressure has beenchecked and/or adjusted, remove one of the greywires from the modulating coil. Compare thereading on the manometer with the value de-scribed in 2.3. If adjustment is required, turn theinner (red) crosshead screw clockwise to in-crease, or counter-clockwise to decrease theburner pressure, whilst ensuring that the outer(10mm) nut does not move. When checking and/or adjustment has been completed, isolate theappliance from the electrical supply, replace theprotective cap, refit the grey wire to the modulat-ing coil, remove the manometer and tighten theoutlet test nipple.IMPORTANT, A GAS SOUNDNESS CHECKMUST BE CARRIED OUT.

7.3.3 SETTING THE MINIMUM CENTRAL HEATINGOUTPUTTHIS CAN ONLY BE CARRIED OUT AFTERTHE MAXIMUM AND MINIMUM GAS PRES-SURES HAVE BEEN SET.● Isolate the appliance from the electrical supply.● Attach a manometer to the gas valve outlet test

nipple.● Insert a jumper tag at JP2.● Switch the appliance ON in the heating mode.● Turn potentiometer P5 to the minimum position● Adjust potentiometer P4 to the required value

shown in section2.3 (section 10.2 for LPG), i.e.minimum burner pressure (central heating).

● Turn potentiometer P5 back to the maximumposition.

● Isolate the appliance from the electrical supply.● Remove the manometer, tighten the outlet test

nipple, and check for soundness.

7.4 COMBUSTION ANALYSIS TESTA combustion analysis check can easily be car-ried out on the appliance via the test pointslocated on the top of the appliance, however youmust check that the burner pressures are setcorrectly (see 7.3).● Isolate the appliance from the electrical supply

and turn the mode selector switch to the OFF/RESET position.

● Locate and remove the CO test point sealingscrew (see fig. 36).

● Insert the flue gas analyser probe into the testpoint.

● Restore the electrical supply to the appliance● Remove the mode selector knob and turn the

shaft fully clockwise (see fig. 37).Fig. 35

23

● The boiler will now enter the combustion analy-sis mode (CO mode) for a period of 15 minutes,signified by the LED flashing Yellow. Duringthis time, the boiler will remain on full gas.

● Once the flue gas analysis has been made, turnthe shaft back to the required position andreplace the mode selector knob.

● Remove the probe and replace the sealing screw.7.5 CHECKING THE EXPANSION VESSEL

Carry out the component removal procedure asdescribed in 6.4. You must ensure that the boileris completely drained of water.Using a suitable pressure gauge, remove dustcap on expansion vessel and check the chargepressure. The correct charge pressure should be1.0 bar ± 0.1 bar.If the charge pressure is less, use a suitablepump to increase the charge.

NOTEYou must ensure the drain valve is in the openposition whilst re-charging takes place. Replacethe dust cap and carry out the relevant commis-sioning procedure (section 5).

7.6 EXTERNAL FAULTSBefore carrying out any faultfinding or componentreplacement, ensure the fault is not attributable toany aspect of the installation.

7.6.1 INSTALLATION FAULTS

7.7 ELECTRICAL CHECKSAny electrical checks must be carried out by asuitably qualified person.

7.7.1 EARTH CONTINUITY TESTIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between anappliance earth point and the earth wire of theappliance supply cable. The resistance should beless than 1 OHM. If the resistance is greater than1 OHM check all earth wires and connectors forcontinuity and integrity.

7.7.2 SHORT CIRCUIT CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter, carry out a shortcircuit test between the Live & Neutral connec-tions at the appliance terminal strip (fig.12).Repeat above test on the Live & Earth connec-tions at the appliance terminal strip (fig.12).NOTEShould it be found that the fuse has failed but nofault is indicated, a detailed continuity. Check willbe required to trace the fault. A visual inspectionof components may also assist in locating thefault.

7.7.3 POLARITY CHECKWith the appliance connected to the electricalsupply and using a suitable multimeter, carry outthe following voltage tests:●●●●● Connect test leads between the Live & Neutral

connections at the appliance terminal strip(fig.12). The meter should read approximately230V ac. If so proceed to next stage. If not, see7.7.4.

●●●●● Connect test leads between the Live & Earthconnections at the appliance terminal strip(fig.12). The meter should read approximately230V ac. If so proceed to next stage. If not, see7.7.4.

●●●●● Connect test leads between the Neutral &Earth connections at the appliance terminal strip(fig.12). The meter should read approximately 0- 15Vac. If so polarity is correct. If not, see 7.7.4.

Fig. 37

Symptom Possible causesNo ignition Check wiring

Check electrical supplyNo hot water Check hot/cold pipe

work is not reversedNo central heating Check wiring of room thermostat

and/or other external controls

Frequency Faults/StatusON every 0.5-secs Final fault, e.g.:

●●●●● water pressure switch●●●●● condense pressure switch

●●●●● fan/flue problem●●●●● limit thermostat

Solid ●●●●● primary NTC open/short circuit

RED LED

Fig. 36

Air analysisoutlet

Fumes analysisoutlet Frequency Faults/Status

ON every 0.5-secs CO function activeSolid DHW thermistor fault (see 7.2.5.2)

YELLOW LED

Frequency Faults/StatusON every 6-secs At stand-by with no faults

Flashing 8-times a second SARA function activeON every 0.5-secs Temporary fault, e.g.:

●●●●● APS fault●●●●● low water pressure

Solid Active for heat/DHW request

GREEN LED

24

7.7.4 REVERSED POLARITY OR SUPPLY FAULTRepeat the above tests at the appliance isolator,if testing reveals correct polarity and/or supply atthe isolator, re-check wiring and connections be-tween the isolator and the appliance.If tests on the isolator also reveal reversed polar-ity or a supply fault, consult the local electricitysupplier for advice.

7.7.5 RESISTANCE TO EARTH CHECKIsolate the appliance from the electrical supplyand using a suitable multi-meter carry out aresistance test. Connect test leads between theLive & Earth connections at the appliance termi-nal strip (fig.12). If the meter reads other thaninfinity there is a fault that must be isolated, carryout a detailed continuity check to identify thelocation of the fault.

IMPORTANTThese series of checks must be carried outbefore attempting any faultfinding procedures onthe appliance. On completion of any task thatrequired the disconnection and re-connection ofany electrical wiring or component, these checksmust be repeated.

7.8 FAULT FINDINGBefore attempting any faultfinding, the electricalchecks as detailed in 7.7 must be carried out.Isolate the appliance from the electrical supply.Disconnect any external controls such as roomthermostats etc. from the boiler.

7.8.1 REPLACING THE MAIN PCBWhen replacing the main PCB it’s essential thatthe potentiometers are set as follows:● It’s essential that the minimum - central heating

- gas pressure is checked/adjusted as de-scribed in 7.3.3

● P4 - to be used to set/adjust the minimumheating output

● P5 - set at maximum.

EFFECT OF JUMPER TAGS FITTED TO THEMAIN PCB AT:● JP1 - disables DHW function● JP2 - cancels anti-cycle function and initial

heating output (75% of maximum at start up)● JP3 - for LPG boilers only● JP4 - enables DHW temperature stabiliser

function (boiler modulates at set point andremains on minimum power, even if the setpoint is exceeded).

Restore the electrical supply to the boiler andturn the selector switch to the on position. Theboiler should now function as described in sec-tion 7.2. Should the boiler fail to respond, the in-ternal fuses and connectors should be checkedto ensure integrity and continuity. If the boiler stillfails to respond, refer to the detailed faultfindingflowcharts overleaf.

7.9 FAULT CODESWhen the boiler is in a fault condition, the LED isdisplayed in a colour and/or frequency that isrelevant to the fault. To reset the boiler, turn the

Frequency Faults/StatusON every 0.5-secs CO function active

Solid DHW* thermistor fault (see 7.2.5.2)

YELLOW LED

* When there is a fault condition with the DHW thermistor, theappliance will still operate and produce limited hot water. ThePrimary thermistor will control the temperature of the DHWduring this period and the outlet temperature is fixed at 50-55oC.

mode selector switch to the reset position (0) for2-minutes’ then back to the relevant mode ofoperation.If the boiler does not reset, refer to the followingsection and the detailed faultfinding flowchartsoverleaf.

Frequency Faults/StatusON every 0.5-secs Final fault, e.g.:

●●●●● water pressure switch●●●●● condense pressure switch

●●●●● fan/flue problem●●●●● limit thermostat

Solid ●●●●● primary NTC open/short circuit

RED LED

25

7.10.1 FAULT FINDING TEST ‘A’: CHECKING OPERATION OF ELECTRONIC CONTROL BOARD ATSTART UP

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7.10.4 FAULT FINDING TEST ‘B2’: CHECK CONTROL IN DHW MODE

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7.10.5 FAULT FINDING TEST ‘C’: CHECK CONTROL IN C/H MODE

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31

SECTION 8 WIRING DIAGRAMS

8.1 EXTERNAL WIRINGThe appliance comes with a factory fitted clock toallow basic operation of the boiler (fig. 38). Ifexternal controls are to be added to the system,they must be connected to the appliance asshown in the following diagrams. For advice oncontrols that are not featured in this book, pleasecontact the Service & Technical Helpline on0870-264-1220.

8.2 TYPICAL CONTROL APPLICATIONSThe appliance can be used with the followingcontrols:● external single-channel, voltage-free time clocks● programmable room thermostats.

In addition, the appliance can be used in con-junction with a typical ‘S’-Plan system, pleasecontact the technical help line for further de-tailed instruction.

NOTEThis appliance is not suitable for use with ‘Y’-Plansystems.

Fig. 38

8.3 ROOM THERMOSTATShould a room thermostat be required, it must beof the ‘voltage-free’ type, and should be con-nected to the appliance as shown in fig. 39.

8.4 OTHER CONTROLSContact the controls manufacturer and/or thetechnical help line should you require more spe-cific information on the suitability of a particularcontrol.Further guidance on the recommended practicefor the installation of external controls, can befound in CHeSS - HC5/HC6 (www.energy-efficiency.gov.uk).

Fig. 39

factory configuration

32

FUNCTIONAL DIAGRAM

NOTE: L-N-E CONNECTION IS ADVISABLE

Fig. 40

Key

D.H

.W.F

.S.

Dom

estic

hot

wat

er fl

ow s

witc

hP

.S.

Pre

ssur

e sw

itch

P.D

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ress

ure

switc

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igh

limit

ther

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tat

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er th

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.C

onde

nse

pres

sure

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itch

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odul

ator

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anP

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Gas

val

ve s

olen

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. onl

y se

lect

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ettin

g tim

erJP

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atur

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as o

r L.P

.G. s

elec

tor

JP4

Jum

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nabl

e D

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.S

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se 2

AF

33

SECTION 9 EXPLODED DIAGRAMS

POS. DESCRIPTION 25 HE 29 HE

1 Frame assembly 01005403 0100540612 Pressure gauge 2564 256418 Cover assembly 10026202 1002620219 Printed Circuit Board 10022174 1002217420 Printed Circuit Board 10025340 1002534021 Led light guide 10023816 1002381626 Instrumental panel 10025726 1002572627 Control knob 10023937 1002393728 Selection knob 10023936 1002393631 Case 10026203 1002686649 Adapter 10023935 1002393576 Timer 10023938 1002393890 Fuse 3478 3478

226 Edge clip 5128 5128270 Transformer 10021272 10021272300 Wiring harness (clock) 10023840 10023840301 Wiring harness (clock) 10023940 10023940

270

26

20

12

21

27

28

27

226

18

19

76

49

31

226

90

1

300

301

34

POS. DESCRIPTION 25 HE 29 HE

1 Domestic water heat exchanger 8036 80372 Connection 10024640 100246403 Pressure switch 2044 20444 Non return valve 10025056 100250566 By-pass casing 10024641 100246417 By-pass valve 2047 20479 Heating manifold and cartridge 10026508 10026508

10 3 way valve cartridge 10025305 1002530511 Motorized valve 10025304 1002530412 Fixing fork wrench 10025450 1002545013 Fixing fork wrench 10025449 1002544922 Safety valve 10025055 1002505524 Flow governor 10026043 1002498725 Pipe 10027544 1002754426 DHW actuator 10022349 1002234927 Heating cock 1789 178928 Connection 1790 179030 Heating cock 10025733 1002573337 Pipe 10025840 1002584047 By-pass casing cover 10024643 1002464348 Discharge cock 10024646 1002464663 Pipe 10026228 10026228

112 Pressure switch 10027535 10027535201 Washer 5026 5026265 Washer 5236 5236266 Washer 5237 5237288 Washer 6898 6898290 Clip 2165 2165351 Nut 1823 1823353 Nut 1824 1824432 Clip 10024958 10024958433 Clip 10024986 10024986434 Nipple 10024985 10024985435 Connection 10025059 10025059436 Clip 10025062 10025062438 O-Ring 10024988 10024988439 Washer 10025067 10025067441 Clip 10025063 10025063442 O-Ring 10025065 10025065443 O-Ring 10025064 10025064444 Washer 10025066 10025066521 NTC sensor (red O-Ring) 10027351 10027351600 Wiring harness (PCB + ground faston frame, ground faston floz switch pump diverter valve H20

pressure switch condense, pressure switch gas valve (modulator + safety coils) DHW NTC) 10027558 10027558

435

288432

439

1

432

432

47444

44348

290442

6

7

4

435

288 432

441

43622

63

266

266

26

25

24

201

433

288

2

521

433

201

434

37

438

439

433

343

28351

27353

27

353

28

351

290

3

112

30

288

432

438 265

265

265

201

9

10

11

12

13

300

35

POS. DESCRIPTION 25 HE 29 HE

1 Expansion vessel 2204 25732 Flexible pipe 10025188 100251883 Circulation pump 10027571 100275714 Automatic air vent bottle 10025485 100254856 Pipe 10027541 100275667 Pipe 10024312 100241308 Heat exchanger 2381 23789 Pipe 10021041 10021041

10 Pipe 10027542 1002756725 Siphon 10027546 1002754627 Pipe 10027543 1002756843 Condensing unit assembly 01005291 0100529148 Pipe 10024311 1002412949 Pipe 10024313 1002431366 Flexible pipe 10027545 10027545

200 Washer 24 x 17 5023 5023201 Washer 18,5 x 11 5026 5026202 Washer 5041 5041288 O-Ring 6898 6898290 Clip 2165 2165314 Connection 2186 2186370 O-Ring 10023533 10023533371 Clip 10023532 10023532394 O-Ring 10024142 10024142395 O-Ring 10024143 10024143396 Connections kit 01005292 01005292417 Limit thermostat 10024710 10024710520 NTC sensor (red O-Ring) 10027352 10027352532 Washer 10027540 10027540

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36

POS. DESCRIPTION 25 HE 29 HE

1 Air box bottom 10027533 100275622 Ambidx air box side 10024166 100241663 Clip 0442 04424 Burner assembly 10027536 100275645 Spark electrode 10025985 100259859 Burner plate 5172 5172

12 Gas pipe 10027537 1002753713 Gas valve 10025074 1002507414 Gas pipe 10026703 1002670315 Gas cock 10020897 1002089716 Air box cover 10020216 1002021717 Washer 5072 507218 Glass 3139 313919 Flange 4007 400720 Gas valve solenoid 10020838 1002083821 Washer 5905 590527 Hole cap 8084 8084

200 Washer 5023 5023300 N.G. conversion kit 01005225 01005225301 LPG conversion kit 01005407 01005407

1

512

200

13

200

14

1718

19

4

9

200

15

27

21

2

2

21

3

2016

300

301

37

POS. DESCRIPTION 25 HE 29 HE

1 Combustion chamber assembly 10025935 100264062 Combustion chamber back panel 5270 53163 Combustion chamber lateral panel 5271 52714 Combustion chamber front panel 5269 53157 Hood assembly 10024310 10024125

10 Fan 10024035 1002403513 Venturi and pressure tube kit 01005405 0100540516 Clamp for tube 10024126 1002412619 Fan flue connection 10024137 1002413720 Block with combustion analysis check 10026933 1002693323 Brass cap 8086 808625 Pressure differential switch 10020889 10020889

100 Combustion - fan cable (PCB ground faston fan H2O limit thermostat CH

NTC flue pressure switch) 10027559 10027559

23

2019

16

10

7

13

1

2

3

4

3

25

100

38

SECTION 10 L.P.G. INSTRUCTIONS

10.3 CONVERTING THE APPLIANCE GAS TYPETo convert the appliance to another gas type it isnecessary to change the burner injectors andadjust the gas pressures. It is also necessary toensure the jumper tag at JP3 is enabled ordisabled according to the gas type used.● To change the injectors see section 6.● For correct jumper tag configuration see 7.8.

10.4 GAS SUPPLYThe gas supply must be connected to the appli-ance by a competent LPG installer and must beof sufficient size to supply the appliance at itsmaximum output.An existing supply must be checked to ensurethat it is of adequate size to deal with the maxi-mum rated input of this and any other appliancesthat it serves.

10.5 GAS SUPPLY INSTALLATIONThe entire installation including the meter mustbe purged and checked for gas soundness.

10.6 CHECKING AND ADJUSTING BURNER PRES-SURE (see fig. 22)Isolate the appliance from the electrical supplyand attach a suitable manometer to the gas valveoutlet test point.

10.6.1 SETTING THE MAXIMUM BURNER PRES-SURE fig. 35Light the boiler as described in 5.7, fully open aDHW outlet (preferably the bath) and ensure theHW temperature selector is set at maximum.Allow the appliance to stabilise.Compare the reading on the manometer with thevalue described in 10.2. If adjustment is required,remove the protective cap from the gas valvemodulating coil assembly and turn the outer(10mm) nut clockwise to increase, or counter-clockwise to decrease the burner pressure.

BS 6798 INSTALLATION OF BOILERS OF RATED NOT EXCEEDING 60kW

BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS

BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

BS 5440 PART 1 FLUES

BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

10.1 RELATED DOCUMENTS

10.2 TECHNICAL DATAGAS PRESSURES 25 29 35

Inlet pressure 37 mbar 37 mbar 37 mbar

Burner pressure maximum 35.70 mbar 35.50 mbar 35.60 mbar

Burner pressure minimum (heating) 12.80 mbar 10.00 mbar 7.00 mbar

Burner pressure minimum (DHW) 4.90 mbar 4.50 mbar 3.20 mbar

Maximum gas rate 1.94 Kg/h 2.25 Kg/h 2.70 Kg/h

Minimum gas rate 1.16 Kg/h 1.16 Kg/h 1.16 Kg/h

Injectot size (quantity) 12 x 0.76 14 x 0.76 16 x 0.76

SEDBUK (%) 87.7 Band “B” 87.9 Band “B” 87.7 Band “B”

NOx (max - min) PPM 200 - 120 250 - 180 250 - 180

CO (max - min) PPM 90 - 100 100 - 190 80 - 120

CO2 (%) 7.60 - 4.35 8.20 - 4.00 7.70 - 3.10

CO/CO2 ratio (max - min) 0.001 to 1 - 0.002 to 1 0.001 to 1 - 0.005 to 1 0.001 to 1 - 0.004 to 1

10.6.2 SETTING THE MINIMUM BURNER PRESSUREfig. 34Once the maximum burner pressure has beenchecked and/or adjusted, remove one of the greywires from the modulating coil. Compare thereading on the manometer with the value de-scribed in 10.2.If adjustment is required, turn the inner (red)crosshead screw clockwise to increase, or coun-ter-clockwise to decrease the burner pressure,whilst ensuring that the outer (10mm) nut doesnot move. When checking and/or adjustmentand/or adjustment has been completed, isolatethe appliance from the electrical supply, close theDHW outlet, replace the protective cap, refit thegrey wire to the modulating coil, remove themanometer, and tighten the outlet test point.

IMPORTANT, A GAS SOUNDNESS CHECKMUST BE CARRIED OUT.

39

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COLLECTIVE MARK

Heating Services provides after-sales assistanceand Technical advice for Sabre Boilers

Service & Technical Helpline: 0870-264-1220

We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected