user manual and installation instructions - biasi plus he... · user manual and installation...

Wall hung, fanflue, roomsealed, high efficiency gas boiler

User manual andInstallation instructions

Riva Plus HEModels G.C. Appl. No.

M296.24SM/C 47-583-24 CoMbI boIlERM296.28SM/C 47-583-25 CoMbI boIlER

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Congratulations on your choice.

Riva Plus HE are condensing high efficiency sealed chamber fan flue gas boilers. They are fully electronically controlled and have electronic ignition.The materials they are made of and the control systems they are equipped with give you safety, a high level of comfort and energy savings to allow you to get the greatest benefit out of independent heating.Riva Plus HE allow a higher efficiency by reducing the flue gas temperature such that the water vapour formed during the combustion is condensed out.This allows a gain of useful heat that otherwise would be lost.

Biasi UK Ltd is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety, efficiency and performance.Benchmark is managed and promoted by the Heating and Hot water Industry Council. For more information visit www.centralheating.co.uk.

DANGER: The indications marked with this symbol must be observed to pre-vent accidents of mechanical or generic origin (e.g.: Injuries or bruises).

DANGER: The indications marked with this symbol must be observed to pre-vent accidents of electric origin (electrocution).

DANGER: The indications marked with this symbol must be observed to pre-vent the risk of fire or explosion.

DANGER: The indications marked with this symbol must be observed to pre-vent accidents of heat origin (burns).

ATTENTIoN: The indications marked with this symbol must be observed to prevent malfunctioning and/or damage to materials of the appliance or other objects.

ATTENTIoN: The indications marked with this symbol is important informa-tion that must be carefully read.

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Remember that...

The manual must be read thoroughly, so that you will be able to use the boiler in a safe and sensible way; must be carefully kept. It may be necessary for reference in the future.

The lighting up must be carried out by competent and responsible engineer. The manufacturer

• disclaim all liability for any translations of the present manual from which incorrect inter-pretation may occur;

• cannot be held responsible for non-observance of instructions contained in this manual or for the consequences of any procedure not specifically described.

Please ensure that the installer has fully completed the Benchmark Checklist on the inside back pages of the installation instructions supplied with the product and that you have signed it to say that you have received a full and clear explanation of its operation. The installer is legally required to complete a commissioning checklist as a means of complying with the appropriate Building Regulations (England and Wales).All installations must be notified to Local Area Building Control either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer who should, on receipt, write the Notification Number on the Bench-mark Checklist.This product should be serviced regularly to optimise its safety, efficiency and performance. The service engineer should complete the relevant Service Record on the Benchmark Checklist after each service.The Benchmark Checklist will be required in the event of any warranty.

Using the boiler...

before lighting the boiler you are advised to have a Gas Safety Registered Engineercheck that the installation of the gas supply

• is gas-tight;• is of the correct gauge for the flow to the boiler;• is fitted with all the safety and control devices required by the current Regulations.

Ensure that• check with the Installer that he has connected and terminated the pressure relief valve

in a manner which allows safe discharge. The manufacturers are not responsible for damage caused by opening of the pressure relief valve and consequent escape of wa-ter, if this is not connected and terminated.

• the installer has connected the condensate outlet to a suitable drain pipe.

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on detecting the smell of gas:• don’t operate any electrical switches, the telephone or any device that may produce

sparks;• open the windows and doors at once to create a draught of air which will purge the area;• shut off the gas cocks;• get the assistance of a qualified person. Emergency telephone number Tel 0800 111999.

Do not touch the appliance with parts of the body that are wet or damp and/or bare feet. Do not block or modify the condensate outlet and pipework. In case of structural work or maintenance near the exhaust duct and/or fume exhaust

devices or their attachments, turn off the appliance. On completion of the work, have a professionally qualified person check their efficiency.

Repairs (under guarantee) must be carried out only by a Biasi an approved engineer, us-ing genuine spare parts. Thus do no more than switching off the boiler yourself (see the instructions).

Your boiler allows heating up of water to a temperature less than boiling point;• must be connected to a central heating system and/or a hot water supply system, com-

patible with its performance and output;• can be used only for those purposes for which it has been specially designed;• must not be touched by children or by those unfamiliar with its operation;• must not be exposed to weather conditions.

During the operation it is quite normal that the boiler produces a white plume of conden-sation vapour from the flue terminal. This is due to the high efficiency of the appliance and may be particularly evident with low outdoor temperatures.

Safe handling of substances

Biasi products are manufactured in accordance with ISO 9001 and do not, and will not, contain any hazardous materials or substances such as asbestos, mercury or C.F.C.’s. The appliance packaging does not contain any substances, which may be considered a hazard to health.

When handling or lifting always use safe techniques• keep your back straight, bend your knees, don't twist.• move your feet, avoid bending forwards and side way sand keep the load as close to your

body as possible.

Where possible transport the boiler using a sack truck or other suitable trolly.Always grip the boiler firmly, and before lifting feel where the weight is concentrated to estab-lish the centre of gravity, repositioning yourself as necessary.

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Combustion chamber panelsMaterial: mineral fibresKnown hazards - Some people can suffer reddening and itching of the skin. Fibre entry into the eye will cause foreign body irritation, which can cause severe irritation to people wearing contact lenses. Irritation to respiratory tract.Precautions - Dust goggles will protect eyes. People with a history of skin complaints may be particularly susceptible to irritation. High dust levels are only likely to arise following harsh abrasion. In general, normal handling and use will not present high risk, follow good hygiene practices, wash hands before, touching eyes, consuming food, drinking or using the toilet.First aid - Medical attention must be sought following eye contact or prolonged reddening of the skin.

Thermostat / Temperature gaugeDescription - Sealed phial and capillary containing liquid.Known hazards - irritating to skin, eyes and throat. Vapour is harmful. Inflammable -do not extinguish with water.Precautions - Do not incinerate. Avoid contact with broken/leaking phials. Do not purposely puncture.First aid - medical attention must be sought following eyes/skin contact, wash with clean water.

Sharp EdgesCaution should be taken when handling the boiler to avoid sharp edges on the boiler.

boiler installation and commissioning tips

The installation must be carried out by a qualified Gas Safety Registered Engineer who will be responsible for observing the current Regulations and the completion of the Benchmark Gas Boiler System Commissioning Checklist, located at the back of this User manual.

Installing the boiler...

Do not forget to remove the transit caps and plugs from the boiler connections these are fitted to every boiler.

Keep the boiler clear of dust during installation and in particular do not allow any dust or debris to enter the top of the boiler where the flue connection is made. It is recommended that you put a dust sheet over the top of the boiler until you are ready to make the flue

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connection. Because every boiler is fired and tested live at the factory, a small amount of water re-

mains within the boiler. It is possible for this water to initially cause the pump to seize. It is therefore recommended that the pump rotor be manually turned to free its rotation before turning the boiler on.

Remember to release the auto air purge before filling the boiler. See the instructions to identify the location of this device.

This boiler allows to control the flow temperature of the central heating system at very low levels. In case of underfloor heating system a temperature limiting device (e.g. a safety thermostat) is recommended to stop the boiler in case that the water temperature exceeds the design temperature.

You are strongly advised to to the British Standard BS 7593-2006 Code of practice,flush out the system both cold and hot in order to remove system and installation debris.

It is also sensible to initially fire and commission the boiler before connecting any external controls such as a room thermostat. By following this procedure if you have a subsequent problem this method if you have a subsequent problem following the addition of an exter-nal control you can eliminate the boiler from your fault analysis.

If the boiler is fitted with a digital programmer, when setting the times for automatic opera-tion, remember that for every “ON” time there must be an “OFF” time to follow and that on every occasion you enter a time you must also indicate which days that you want the boiler to follow the timed settings.

Some products incorporate an anti cycling time delay. It is normal when first switching the boiler on for the boiler to operate on heating for a few seconds then switch off. After 3 - 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally. The igni-tion delay cycle does not prevent normal operation of the boiler to provide d.h.w.

If you are in any doubts as to the installation or operation of the boiler please read the instruction manuals thoroughly and then if necessary contact Biasi UK for advice and as-sistance.

Guarantee conditions. The guarantee registration form must be returned within 30 of purchase, failure to comply will invalidate the guarantee.

Please remember that if you are in any doubt about the installation of this product you can contact our Technical Helpline on tel. 01922 714 600.

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TAblE oF CoNTENTS1 APPlIANCE DESCRIPTIoN. . . . . . . . . . . . . 8

1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3 Isolation valves . . . . . . . . . . . . . . . . . . . . . . . . . . 81.4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . 91.5 Operation lights . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 INSTRUCTIoNS FoR USE . . . . . . . . . . . . 102.1 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.2 Refilling procedure . . . . . . . . . . . . . . . . . . . . . . 102.3 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.4 C.h. circuit temperature . . . . . . . . . . . . . . . . . . .112.5 D.h.w. temperature . . . . . . . . . . . . . . . . . . . . . . 122.6 Extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . 132.7 Built in time switch A . . . . . . . . . . . . . . . . . . . . . 132.8 Built in time switch B. . . . . . . . . . . . . . . . . . . . . 15

3 USEFUl ADVICE. . . . . . . . . . . . . . . . . . . . 183.1 Central Heating. . . . . . . . . . . . . . . . . . . . . . . . . 183.2 Frost protection. . . . . . . . . . . . . . . . . . . . . . . . . 183.3 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . 183.4 Periodic maintenance . . . . . . . . . . . . . . . . . . . . 183.5 External cleaning . . . . . . . . . . . . . . . . . . . . . . . 183.6 Operational faults . . . . . . . . . . . . . . . . . . . . . . . 19

4 TECHNICAl INFoRMATIoN. . . . . . . . . . . 214.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.2 Main diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3 Technical data mod. M296.24SM/C . . . . . . . . . 244.4 Technical data mod. M296.28SM/C . . . . . . . . . 274.5 Hydraulic specifications . . . . . . . . . . . . . . . . . . 304.6 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . 30

5 GENERAl REQUIREMENTS . . . . . . . . . . 315.1 Related documents. . . . . . . . . . . . . . . . . . . . . . 315.2 Location of appliance . . . . . . . . . . . . . . . . . . . . 315.3 Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.4 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.5 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.6 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.7 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . 335.8 Water circulation (c.h.) . . . . . . . . . . . . . . . . . . . 345.9 Domestic water . . . . . . . . . . . . . . . . . . . . . . . . . 355.10 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . 365.11 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . 36

6 INSTAllATIoN . . . . . . . . . . . . . . . . . . . . . 376.1 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.2 Precautions for installation . . . . . . . . . . . . . . . . 37

6.3 Installing the bracket. . . . . . . . . . . . . . . . . . . . . 386.4 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . 386.5 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.6 Mounting the boiler . . . . . . . . . . . . . . . . . . . . . . 396.7 Fitting the flue system. . . . . . . . . . . . . . . . . . . . 396.8 Choice of flue . . . . . . . . . . . . . . . . . . . . . . . . . . 406.9 Electrical connections . . . . . . . . . . . . . . . . . . . . 426.10 External frost protection . . . . . . . . . . . . . . . . . . 44

7 CoMMISSIoNING . . . . . . . . . . . . . . . . . . . 457.1 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . 457.3 Gas supply installation . . . . . . . . . . . . . . . . . . . 457.4 Filling the d.h.w. system . . . . . . . . . . . . . . . . . . 457.5 Initial filling of the system . . . . . . . . . . . . . . . . . 457.6 Condensate pipe and traps . . . . . . . . . . . . . . . 467.7 Lighting the boiler . . . . . . . . . . . . . . . . . . . . . . . 477.8 Checking the gas pressure at the burner . . . . . 477.9 Checking the burner ignition . . . . . . . . . . . . . . . 487.10 Checking the ignition device . . . . . . . . . . . . . . . 497.11 Checking the flue system . . . . . . . . . . . . . . . . . 497.12 Checking the condensate drain pipe . . . . . . . . 497.13 Instructing the user . . . . . . . . . . . . . . . . . . . . . . 49

8 GAS CoNVERSIoN . . . . . . . . . . . . . . . . . 518.1 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . 539.1 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539.2 Dismantling the external panels . . . . . . . . . . . . 539.3 Emptying the d.h.w. system . . . . . . . . . . . . . . . 539.4 Emptying the c.h. system . . . . . . . . . . . . . . . . . 539.5 Combustion analysis check . . . . . . . . . . . . . . . 549.6 Cleaning the primary heat exchanger. . . . . . . . 549.7 Checking the pressurisation in the expansion

vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549.8 Cleaning the burner . . . . . . . . . . . . . . . . . . . . . 549.9 Checking the flue . . . . . . . . . . . . . . . . . . . . . . . 549.10 Drain pipe inspection . . . . . . . . . . . . . . . . . . . . 549.11 Visual inspection of appliance . . . . . . . . . . . . . 549.12 Gas pressures and tightness . . . . . . . . . . . . . . 559.13 Water inhibitor concentration . . . . . . . . . . . . . . 55

Gas boiler system commissioning check-list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Service record . . . . . . . . . . . . . . . . . . . . . 59

Abbreviations used in the manual:C.h. = Central heatingD.h.w. = Domestic hot waterD.c.w. = Domestic cold wate

Appliance category: II2H3+ (Gas G20 20 mbar, G30 29 mbar, G31 37 mbar)Country of destination: United Kingdom (Gb) Ireland (IE)This appliance conforms with the following EEC directive:Gas Directive 2009/142/CEBoiler Efficiency Directive 92/42/CEEElectromagnetic Compatibility Directive 2004/108/CELow Voltage Directive 2006/95/CEThe manufacturer, in the continuous process to improve his products, reserves the right to modify the data expressed in the present documentation at any time and without prior notice.The present documentation is an informative support and it can not be considered as a contract to-wards third parties.

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APPlIANCE DESCRIPTIoN

1 APPlIANCE DESCRIPTIoN

1.1 overviewThe model and serial number of the boiler are printed on bottom right side.

Fig. 1.1

1

2

3

1 Case front panel2 Control panel3 Control panel cover

1.2 Control panel4 C.h. circuit temperature and pressure

gauge5 Time switch (c.h. control)6 Lock-out signal lamp7 Lockout reset button

8 Function selector and c.h. temp. control knob

9 D.h.w. temperature control knob10 Appliance operation lights

1.3 Isolation valves

Provide for the installation of a stop valve on the D.c.w. inlet pipe.

Fig. 1.2

16 15 14 13

12 11

11 Condensate drain pipe12 C.h. return valve13 D.c.w. inlet valve14 Gas inlet valve15 D.h.w. outlet pipe16 C.h. flow valve

10 9 8 7 6 5 4Fig. 1.3

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APPlIANCE DESCRIPTIoN

1.4 Technical dataFor detailed technical data see sections "Technical Data" on pag. 24 or pag. 27.

1.5 operation lightsThree lights (10 in Fig. 1.3) give detailed in-dication regarding the operation of the boiler.The following table gives the relationship between each of the possible light combina-tions and their meaning.

A short pulse every 4 sec-onds: stand-by condition

position.Anti-freeze system active1 second pulse every 2 seconds: normally op-erating boiler. Function selector in or po-sition

C.h. operation

D.h.w. operation

Frost protect operation

D.h.w. operationExcessive temperature on primary circuit

If the lights combination observed is not included in the above table a fault may be indicated.Reference should be made to the following table.In this case switch off the boiler, as de-scribed in section "Extinguishing" to page 13 and call a competent and responsible Service Engineer.

Faulty c.h. temperatureprobe NTC

Faulty d.h.w temperatureprobe NTC

Faulty flue temperatureprobe NTC

Faulty primary circuit(no water or low c.h.pressure)

Faulty primary circuit(absence of flow)

Faulty air pressure sen-sor

lack of burner ignition (no ignition signal from the full sequence ignition device)

Safety thermostat lock out

Flue temperature probe NTC lock out

Flame detection error

other faults

lack of power supply orfauly electr. control p.c.b.

Meaning of symbols:

lamp oFF

lamp oN

Flashing lamp, alone or simultane-ously with an other lampFlashing lamp, alternate with another lamp

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INSTRUCTIoNS FoR USE

2 INSTRUCTIoNS FoR USE

2.1 Warningsbiasi UK ltd support the benchmark ini-tiative. The benchmark Checklist is locat-ed at the back of this manual and should be completed by the Installing/Commis-sioning Engineer and handed over to the User for future reference by other visiting Engineers. Also included is the Service Interval Record card that should be com-pleted by the Service Engineer following the annual service maintenance of the boiler and system.All Gas Safe Registered Installers carry a Gas Safe ID card, and have a registration number. both should be recorded in your benchmark Checklist. You can check your Installer is registered by calling Gas Safe direct on 0800 408 5500, or go on line at www.GasSafeRegister.co.uk.

In order to guarantee safety and correct op-eration, it is essential that all the tests are carried out by a competent and responsible service engineer before lighting up the boiler.The tests are described in the installation in-structions in section 7 commissioning.Ensure that the c.h. circuit is regularly filled with water (even if the boiler is only used for d.h.w. supply) checking that the pressure indicated on pressure gauge 4 is not lower than that shown in Fig. 2.2.If the pressure reading on the pressure gauge is below that shown in Fig. 2.2, then the system will require topping up. A filling loop is normally provided by the Installer for this purpose.

If you are in any doubt regarding this pro-cedure you are advised to contact your Installer or an Approved Engineer.

This appliance is provided with a built in anti-freeze system that operates the boiler when the temperature is below 5 °C.Therefore, when the boiler is not lit or used in cold weather, with consequent risk of freezing do not switch off the boiler at the fused spur isolation switch or close the gas inlet cock.When you do not expect to use the boiler for a long period and the boiler is not to be used for frost protection then follow the in-structions given in section "Extinguishing" to page 13.

2.2 Refilling procedure• Isolate the boiler from the electrical supply

at the fused spur. Reconnect the filling loop as demonstrated in Fig. 2.1.

Fig. 2.1

Controlvalve

Double check valve

Temporaryconnection

Supply pipe(cold water

inlet) Control valveC.h. return pipe

• Open the valves of the filling loop and watch the gauge until it reaches normal fill-ing pressure as shown in Fig. 2.2.

Fig. 2.2

Normal fillingpressure

4

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• Close the valves and remove the filling loop.

If you experience any difficulty with the operation of the boiler, switch off the boil-er immediately at the fused spur isolation switch and contact your Installer or an approved Service Engineer.

Air introduced into the boiler during this fill-ing process will vent through the automatic air purger fitted to the boiler. You may also find it necessary to vent air from your radia-tor circuit using your radiator key, however be aware that excessive venting will cause the pressure in the system to drop.Always ensure that the pressure gauge is set at the required pressure.

2.3 Ignition• Check that the valves located in the lower

part of the boiler are open Fig. 2.3.

Fig. 2.3open position

• Turn on the electricity supply to the boil-er switching on the fused spur isolation switch. The appliance operation light 10 (Fig. 2.4) will flash every 4 seconds (stand-by condition).

• If the boiler is to be used for c.h. and d.h.w, position the function selector 8 as in Fig. 2.4. The appliance operation light 10 will

flash every 2 seconds (operating boiler).

Fig. 2.410 8

• If d.h.w. supply only is required, position the function selector 8 as in Fig. 2.5. The appliance operation light 10 will flash every 2 seconds (operating boiler).

Fig. 2.510 8

2.4 C.h. circuit temperatureThe output temperature of c.h. water is ad-justable from a minimum of about 40°C to a maximum of about 85°C (Fig. 2.6), by turning the function selector (8).Adjustment of c.h. output on the boiler is au-tomatic.The greatest output pre-set in the factory can, however, be reduced in level according to actual system requirements; this does not affect the maximum output in d.h.w. opera-tion.Such adjustments must be carried out by a qualified person; therefore we advise you to contact your installer or Service Agent.Adjustment of the boiler temperature alters

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the gas flow at the burner according to the thermal demand in the system. So it is usual to see the burner lit at the minimum level for more or less long periods.

Fig. 2.6

Minimum

Maximum

AdjustmentIn order to achieve optimal settings for econ-omy and comfort, we recommend adjusting the operating temperature of the c.h. water according to the outside temperature, posi-tioning the knob as follows:

Fig. 2.7

From 5 to 15 °Cbetween

- 5 and +5 °C

lowerthan - 5 °C

Your qualified installer will be able to recom-mend the most suitable adjustment for your system.The temperature and pressure gauge (4, Fig. 1.3 on page 8) will allow you to check that the set temperature is obtained.

2.5 D.h.w. temperatureThe temperature of the d.h.w. leaving the

boiler can be varied from a minimum of about 35°C to a maximum of about 55°C (Fig. 2.8), by turning the temperature control knob 9.

Fig. 2.8

Minimum

Maximum

Adjustment of the d.h.w. temperature is com-pletely separate from that of the c.h. circuit.The adjustment system integrated within the boiler automatically controls the flow of gas to the burner in order to keep the tempera-ture of d.h.w. delivered constant, between the limits of maximum and minimum output.Where the demand is at a low level or with the temperature set to the minimum, it is nor-mal to see a cycle of lighting and extinguish-ing of the burner when running.

AdjustmentIt is advisable to adjust the d.h.w. tempera-ture to a level commensurate with the de-mand, minimising the need to mix with cold water. In this way, the automatic control fa-cilities will be fully exploited.Moreover, where the amount of limescale present in the water may be particularly great, not exceeding the position in Fig. 2.9 of the d.h.w. temperature control knob 9 cor-responding to about 50°C (Fig. 2.9),mini-mises annoying incidences of scale deposits and clogging.

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Fig. 2.9

In these cases, however, it is advisable to install a small water treatment device or sof-tener. With such a device you should avoid periodic descaling.Consequently, the d.h.w. heat exchanger will keep its performance consistent for a longer period of time with resulting gas savings.If the demand for d.h.w. is so great as to pre-vent reaching a high enough temperature, have the appropriate output limiting valve installed by your installer or an Authorised Service Engineer.

2.6 ExtinguishingTo turn the boiler off set the function selector 8 to the position shown in Fig. 2.10.The appliance operation light 10 will flash every 4 seconds.

Fig. 2.1010 8

When you do not expect to use the boiler for a long period:• Switch off the electricity supply to the boil-

er, by means of the fused spur isolation

switch.• Shut off the gas supply cock 14 and the

valves for the water circuits fitted under the boiler (Fig. 2.11).

• Empty the water circuits, if necessary, as shown in section General access and emptying hydraulic circuits in the service manual.

Fig. 2.1114 Closed position

2.7 built in time switch AThe boilers are equipped with a built in elec-tronic time switch (5, Fig. 1.3 on page 8) which controls the c.h. operation.

Fig. 2.12

G

F E D C b

A

H

Display and control panel:A Mode selector switchb Reset buttonC Enter button

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D Increase “+” setting buttonE Decrease “-” setting buttonF On-off buttonG Time displayH ON-OFF display

Setting the current timeNote: with a new unit or when the reset but-ton B has been pressed and the selector switch A is to the position, the time display G is flashing.Set the mode selector switch A to the posi-tion and press the buttons D or E until the current time appears in the display G.The clock starts by moving the switch A to the AUTo position.Setting example shown in Fig. 2.13:Current time 16.30.

Fig. 2.13

A

Setting the switching time20 memory locations are available, corre-sponding to 10 on-off sequences.Set the mode selector switch A to the C1 po-sition.The symbols shown in Fig. 2.14 appears in the display.

Fig. 2.14

A

Press the buttons D or E to set the desired ON time. Press the “enter” button C to con-firm the setting and to continue programming the OFF time.Set the OFF time as explained above for the

ON setting and confirm by pressing the “en-ter” button C. Proceed in the same way for other settings.Setting example shown in Fig. 2.15:I ON time 7.45.J OFF time 10.30.

Fig. 2.15I J

Activating the timed settingsSet the mode selector switch A to the AUTo position shown in Fig. 2.16.The current time appears in the display. The ON-OFF display H indicates the current state of operation (according to the settings).

Fig. 2.16

A

Note: when the mode selector switch A is in the AUTo position and the boiler is switched off at the fused spur isolation switch, the display H indicates only the OFF state. The other indications are blanked.

Reading the timed settingsSet the mode selector switch A to the C1 po-sition. The symbols shown in Fig. 2.14 ap-pears in the display.Press the “enter” button C. Each time the button is pressed the display shows the de-tails of the next setting.

Changing or deleting the timed settingsSet the mode selector switch A to the C1 po-sition. The symbols shown in Fig. 2.14 ap-pears in the display.

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Press the “enter” button C until the display shows the setting to be modified or deleted.The time setting can be modified now by pressing button D or E and the operation can be switched on or off by pressing the button F.To delete a time set press the button D or E until the symbols shown in Fig. 2.14 appears in the time display G.The new settings are memorized by moving the switch A to a different position.

Manual operationThe operation of the time switch can be forced on or off constantly or for a timed pe-riod.To force constantly on or off the timer op-eration set the mode selector switch A to the TIMER position. The symbols shown in Fig. 2.17 appears on the display.

Fig. 2.17

The operation can be switched permanently on or off by pressing the button F and leaving the switch A in the TIMER position. To force a timed delay on or off operation, set the mode selector switch A in the TIMER position.Set the time delay by pressing the button D or E and the operation can be forced on or off by pressing the button F.The time delay can be set within the follow-ing ranges:1 to 23 hours with steps of 1 hour1 to 27 days with steps of 1 day.

The time delay setting is activated by moving the switch A to the AUTo position.The ON-OFF display H flashes indicating

that the current state of operation has been forced.To delete the timed delay setting, set the mode selector switch A in the TIMER posi-tion, press the button D or E until the sym-bols shown in Fig. 2.17 appears in the dis-play and then set the mode selector switch A to the AUTo position.Setting example shown in Fig. 2.18:forced ON state for 4 hours.

Fig. 2.18

ResettingTo completely reset the timer, press the reset button with a pointed object (pencil).CAUTIoN: pushing the reset button will completely erase the settings as well as all the data, including the current time.

2.8 built in time switch bThe combiboilers are equipped with a built in electronic time switch which controls the c.h. operation.

Fig. 2.19

G

F E D C b

A

H

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Display and control panelA Mode selector switchb Reset buttonC OK buttonD Increase “+” setting buttonE Decrease "-” setting buttonF On-off buttonG Time displayH ON-OFF display

Setting the current timePress repeatedly the button A until the dis-play shows the symbol .Press the buttons D or E until the current time appears in the display G.The clock starts by pressing the button A to show the symbol AUTo.Setting example shown in Fig. 2.20:Current time 16.30, day Thursday.

Fig. 2.20

A

Setting the switching time28 memory locations are available, corre-sponding to 14 on-off sequences.Press repeatedly the button A until the dis-play shows the symbol C1.The symbols shown in Fig. 2.21 appears in the display.

Fig. 2.21

A

Press the buttons D or E to set the desired ON time. Press the “OK” button C to confirm the setting and to continue programming the OFF time.

Set the OFF time as explained above for the ON setting and confirm by pressing the “OK” button C. Proceed in the same way for other settings.Setting example shown in Fig. 2.22:K ON time 7.45.l OFF time 10.30.

Fig. 2.22K l

Activating the timed settingsThe current time appears in the display. The ON-OFF display H indicates the current state of operation (according to the settings).

Fig. 2.23

A

Note: when the display shows the symbol AUTo and the boiler is switched off at the fused spur isolation switch, the display H in-dicates only the OFF state. The other indica-tions are blanked.

Reading the timed settingsPress repeatedly the button A until the dis-play shows the symbol C1 (Fig. 2.21).The symbols shown in Fig. 2.21 appears in the display.Press the “OK” button C. Each time the but-ton is pressed the display shows the details of the next setting.

Changing or deleting the timed settingsPress repeatedly the button A until the dis-play shows the symbol C1 (Fig. 2.21).The symbols shown in Fig. 2.21 appears in

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the display.Press the “OK” button C until the display shows the setting to be modified or deleted.The time setting can be modified now by pressing button D or E and the operation can be switched on or off by pressing the button F.To delete a time set press the button D or E until the symbols shown in Fig. 2.21 appears in the time display G.The new settings are memorised by pressing the button A.

Manual operationThe operation of the time switch can be forced on or off constantly or for a timed pe-riod.To force constantly on or off the timer op-eration press repeatedly the button A until the display shows the symbol TIMER. The symbols shown in Fig. 2.24 appears on the display.

Fig. 2.24

A

The operation can be switched permanently on or off by pressing the button F and leaving the display shows the symbol TIMER.To force a timed delay on or off operation, press repeatedly the button A until the dis-play shows the symbol TIMER.Set the time delay by pressing the button D or E and the operation can be forced on or off by pressing the button F.

The time delay can be set within the follow-ing ranges:1 to 23 hours with steps of 1 hour1 to 27 days with steps of 1 day.

Press the button A until the display shows the symbol AUTo.The ON-OFF display H flashes indicating that the current state of operation has been forced.To delete the timed delay setting, press re-peatedly the button A until the display shows the symbol TIMER, press the button D or E until the symbols shown in Fig. 2.25 appears in the display and then press the button A un-til the display shows the symbolAUTo.Setting example shown in Fig. 2.25:forced ON state for 4 hours.

Fig. 2.25

A

Note: If during manual operation, power sup-ply turns off, timer must be set again follow-ing previous steps.

ResettingTo completely reset the timer, press the reset button with a pointed object (pencil).

CAUTION: pushing the reset button will completely erase the settings as well as all the data, including the current time.

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USEFUl ADVICE

3 USEFUl ADVICE

3.1 Central HeatingFor reasonably economical service install a room thermostat. Never shut off the radia-tor in the area where the room thermostat is installed. If a radiator (or a convector) does not heat up, check that no air is present in it and that its valve is open. If the ambient temperature is too high, do not alter the radiator valves. Reduce the central heating temperature in-stead by means of the room thermostat and the function selector (8 in Fig. 3.1).

Fig. 3.1

8

3.2 Frost protectionThis appliance is provided with a built in anti-freeze system that operates the boiler when the temperature is below 5 °CTherefore, when the boiler is not lit and used in cold weather, with consequent risk of freezing do not switch off the boiler at the fused spur isolation switch or close the gas inlet cock.

3.3 Condensate drainThe condensate drain must not be modi-fied or blocked. Blockage of the condensate drain, caused by debris or freezing, can cause automatic shutdown of the boiler. If freezing is suspected and the pipe run is accessible an attempt may be made to free

the obstruction by pouring hot water over the exposed pipe an cleaning any blockage from the end of the pipe.If this fails to remedy the problem the assis-tance of a Gas Safe registered installer or in IE a competent person should be sought.

3.4 Periodic maintenanceFor efficient and continuous operation of the boiler, it is advisable to arrange mainte-nance and cleaning by an Authorised Ser-vice Centre Engineer, at least once a year. During the service, the most important com-ponents of the boiler will be inspected and cleaned. This service can be part of a main-tenance contract.

In particular, you are advised to have the following checks carried out: • primary heat exchanger;• domestic hot water heat exchanger; burn-

er;• exhaust fume duct and flue;• pressurisation of the expansion tank;• filling up of the central heating circuit;• bleeding of air from the central heating

system;• general check of the appliance’s opera-

tion.

3.5 External cleaningbefore carrying out any clean-ing, disconnect the appliance from the electrical mains, using the fused spur isolation switch fitted adjacent to the appliance.

To clean the external panels, use a cloth soaked in soapy water. Do not use solvents, abrasive powders or sponges.

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USEFUl ADVICE

Do not carry out cleaning of the appliance and/or its parts with readily flammable sub-stances (for example petrol, alcohols, naph-tha, etc.).

3.6 operational faultsIf the lock-out signal lamp comes onThis indicates that the safety lock-out 6 (Fig. 3.2) has stopped the boiler.To re-start the boiler, it is necessary to press the boiler reset button 7 (Fig. 3.2).

Fig. 3.27 6

For the first lighting up and following main-tenance procedures for the gas supply, it may be necessary to repeat the resetting operation several times so as to remove the air present in the pipe work.After five consecutive resetting attempts the reset button is inhibited. To restore its func-tion it is necessary to switch the boiler off and on from the electrical mains, using the fused spur isolation switch fitted adjacent to the appliance.Safety lock-out may occur even in case of a blockage of the condensate drainage (e.g. plugged drain pipe). It is advisable to check the condensate drainage pipe and traps for cleanness.

In this case and in case of per-sistent lock-out call a compe-tent and responsible Service Engineer.

If noises due to air bubbles are heard during operation...You should check that the pressure on the temperature and pressure gauge (Fig. 2.2 on page 10) is not below the correct setting.If required, top up the system correctly, as described in the section "Refilling proce-dure" to page 10.Bleed any air present in the radiators, if nec-essary.

If the pressure on the temperature and pressure gauge has gone down...It is necessary to top up the appliance with water again, so as to raise the pressure to an adequate level as described in the sec-tion "Refilling procedure" to page 10. If top-ping up with water has to be done very fre-quently, have the system checked for leaks.

If water comes out of the pressure relief valveCheck on the temperature and pressure gauge that the pressure in the central heat-ing circuit is not close to 3 bars. In this case, temperature rise in the circuit can cause the pressure relief valve to open. So that this does not happen and to de-crease the pressure to a normal value, it is advisable to vent some of the water in the appliance through the bleed valves present in the radiators.

If in time, a reduction in domestic hot water supply is observed...The likely causes may be impurities caught in the domestic hot water flow switch filter or limescale deposited in the domestic hot wa-ter heat exchanger. It is advisable to have the appliance cleaned out by an Authorised Service Centre Engineer.

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USEFUl ADVICE

If water should occasionally leak from the boiler...Shut off the valves positioned under the boiler (Fig. 2.11 on page 13) and call an Au-thorised Service Centre Engineer.

If the left appliance operation light 10 (Fig. 3.3) flashes very quickly the boiler is detecting a fault.

Fig. 3.310 8

In this case or in case of prob-lems other than those men-tioned here, switch off the boil-er, as described in section "Extinguishing" to page 13 and call a competent and responsi-ble Service Engineer.

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TECHNICAl INFoRMATIoN

4 TECHNICAl INFoRMATIoN

4.1 overview

Fig. 4.1

20 22

42

38 39

31 26

40

30 28

19

23

37

29 27 25

41

21 17

36

18

24 35

43

44

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4.2 Main diagram

Fig. 4.2

11 Condensate drain pipe12 C.h. return valve13 D.c.w. inlet valve14 Gas inlet valve15 D.h.w. outlet pipe16 C.h. flow valve17 Fan

18 Air pressure sensor test points19 Air pressure sensor20 Flue temperature probe NTC21 Condensing heat exchanger22 Safety thermostat23 C.h. temperature probe NTC24 Main circuit drain valve

50

51

21

41

17 19

28

38 36

29

14 12

47

11

16

46

13 15

25

26

40

23

35

33

31

49

48

37

42

44

20

22

45

34

32

24

30

39

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25 Condensate trap26 Automatic air purger valve27 Pump vent plug28 Pump29 C.h. pressure relief valve30 D.h.w. flow switch31 Modulation gas valve32 Modulation operator33 Gas valve outlet pressure test point34 Gas valve inlet pressure test point35 D.h.w. temperature probe NTC36 Three-way diverter valve37 D.h.w. heat exchanger38 Primary circuit pressure switch39 Combustion chamber over heat40 Flame-detecting electrode41 Burner42 Ignition electrode43 Combustion chamber44 Primary heat exchanger45 C.h. expansion tank46 By-pass valve47 Fan pressure connection48 Domestic water circuit filter49 D.h.w. flow limiter50 Flue outlet pipe51 Air intake pipe

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4.3 Technical data mod. M296.24SM/C

Heat input

Nominal net (A) (ch - dhw)kW 25,0

BTU/h 85304

Nominal gross (B) (ch - dhw)kW 27,8

BTU/h 94687

Minimun net (A) ch - dhwkW 7,5

BTU/h 25591

Minimun gross (B) ch - dhwkW 8,3

BTU/h 28406

Useful output

Maximun (ch - dhw)kW 24,4

BTU/h 83256

Minimun (ch - dhw)kW 7,3

BTU/h 24909

Maximun condensing (ch - dhw)kW 26,3

BTU/h 89739

Minimun condensing (ch - dhw)kW 7,8

BTU/h 26615

Central heating

Min/Max flow temperature settings* °C 50-85

Minimum return temperature °C 40

Maximum pressurekPa 250

bar 2,5

Minimum pressurekPa 30

bar 0,3

Available head (in 1000 l/h)kPa 25

bar 0,25

Seasonal effiency G20 % 88,0

Seasonal effiency G30 G31 (C) % 89,0

* to the minimum useful output

Domestic hot water

Min/Max temperature settings °C 35 - 55


bar 10


bar 0,3

Flow rate minimun l/min 2,5

Flow rate 30° rise (D) l/min 11,6



Gas supply pressures

Gas Pa mbar

Natural G20

Nom 2000 20

Min 1700 17

Max 2500 25

Butane G30

Nom 2900 29

Min 2000 20

Max 3500 35

Propane G31

Nom 3700 37

Min 2500 25

Max 4500 45

1 mbar approximately equals 10 mm H2O

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Max. gas pressures at the burner

Natural G20Pa 1340

mbar 13,4

Butane G30Pa 2760

mbar 27,6

Propane G31Pa 3550

mbar 35,5

Min. gas pressures at the burner

Natural G20Pa 140

mbar 1,4

Butane G30Pa 280

mbar 2,8

Propane G31Pa 350

mbar 3,5

Ignition gas pressures at the burner

Natural G20Pa 850

mbar 8,5

Butane G30Pa 2110

mbar 21,1

Propane G31Pa 2700

mbar 27,0


Gas rate maximum - ch dhw

Natural G20 m3/h 2,65

Butane G30 kg/h 1,97

Propane G31 kg/h 1,94

Gas rate minimum - ch dhw




Gas restrictors references N° Ø mm /100

Natural G20 12 120

Butane G30 12 77

Propane G31 12 77

Electrical data

Voltage V~ 230

Frequency Hz 50

Power consumption W 140

Protection degree IPX4D

External fuse rating A 3

Internal fuse rating A N° 2 - 2 AF

Flue design

Boiler type

C12 C32 C42 C52 C82

ø Coaxial mm 60/100

ø Twin split pipes mm 80/80

ø Roof mm 80/125

Nominal heat flow rate (A) (E) kW 25,0

Exhaust temperature (E) °C 60

Mass flow rate (E) kg/s 0,0128

Flue gas figures

Nominal heat input (A) (E) kW 25,0

CO2 content with gas G20 % 7,9

O2 content with gas G20 % 6,8

CO content with gas G20 ppm 27,0

Exhaust temperature (E) °C 60,0

NOx class 2,0

Weighted NOx ppm 94

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Co2 contents - ch dhw



CO2 content with gas G 30 G31 % 9,1

Minimum heat input (A) (E) kW 7,5


CO2 content with gas G30 G31 % 4,5

Other specifications

Height mm 803

Width mm 400

Depth mm 350

Weight (dry) kg 42,5

Water volume in the boiler (up to 1 bar) l (kg) 1,4

(A) referred to the net calorific value at 15°C and 1013,25 mbar: G20 = 34,02 MJ/m3 - G31 = 46,34 MJ/kg(B) referred to the gross calorific value at 15°C and 1013,25 mbar: G20 = 37,78 MJ/m3 - G31 = 50,37 MJ/kg(C) The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calcu-lated have been certified by a notified body.(D) Values subject to tolerance(E) Values refer tests with a 1 m flue working at the nominal heat input

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4.4 Technical data mod. M296.28SM/C

Heat input

Nominal net (A) (ch - dhw)kW 29,0

BTU/h 98952

Nominal gross (B) (ch - dhw)kW 32,2

BTU/h 109837

Minimun net (A) ch - dhwkW 8,7

BTU/h 29686

Minimun gross (B) ch - dhwkW 9,7

BTU/h 32951

Useful output

Maximun (ch - dhw)kW 28,3

BTU/h 96564

Minimun (ch - dhw)kW 8,4

BTU/h 28662

Maximun condensing (ch - dhw)kW 30,6

BTU/h 104411

Minimun condensing (ch - dhw)kW 9,1

BTU/h 31050

Central heating

Min/Max flow temperature settings* °C 50-85

Minimum return temperature °C 40


bar 2,5


bar 0,3

Available head (in 1000 l/h)kPa 25

bar 0,25

Seasonal effiency G20 % 88,0

Seasonal effiency G30 G31 (C) % 89,0

* to the minimum useful output

Domestic hot water

Min/Max temperature settings °C 35 - 55


bar 10


bar 0,3

Flow rate minimun l/min 2,5




Gas supply pressures

Gas Pa mbar

Natural G20

Nom 2000 20

Min 1700 17

Max 2500 25

Butane G30

Nom 2900 29

Min 2000 20

Max 3500 35

Propane G31

Nom 3700 37

Min 2500 25

Max 4500 45


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Max. gas pressures at the burner

Natural G20Pa 1330

mbar 13,3

Butane G30Pa 2780

mbar 27,8

Propane G31Pa 3550

mbar 35,5

Min. gas pressures at the burner

Natural G20Pa 140

mbar 1,4

Butane G30Pa 260

mbar 2,6

Propane G31Pa 350

mbar 3,5

Ignition gas pressures at the burner

Natural G20Pa 850

mbar 8,5

Butane G30Pa 2110

mbar 21,1

Propane G31Pa 2700

mbar 27,0


Gas rate maximum - ch dhw




Gas rate minimum - ch dhw




Gas restrictors references N° Ø mm /100

Natural G20 14 120

Butane G30 14 77

Propane G31 14 77

Electrical data

Voltage V~ 230

Frequency Hz 50

Power consumption W 150

Protection degree IPX4D

External fuse rating A 3

Internal fuse rating A N° 2 - 2 AF

Flue design

Boiler type

C12 C32 C42 C52 C82

ø Coaxial mm 60/100

ø Twin split pipes mm 80/80

ø Roof mm 80/125

Nominal heat flow rate (A) (E) kW 29,0

Exhaust temperature (E) °C 60

Mass flow rate (E) kg/s 0,0147

Flue gas figures



O2 content with gas G20 % 6,8

CO content with gas G20 ppm 26,0

Exhaust temperature (E) °C 60,0

NOx class 2,0

Weighted NOx ppm 90

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Co2 contents - ch dhw



CO2 content with gas G 30 G31 % 9,1

Minimum heat input (A) (E) kW 8,7


CO2 content with gas G30 G31 % 4,3

Other specifications

Height mm 803

Width mm 400

Depth mm 350

Weight (dry) kg 44

Water volume in the boiler (up to 1 bar) l (kg) 1,5

(A) referred to the net calorific value at 15°C and 1013,25 mbar: G20 = 34,02 MJ/m3 - G31 = 46,34 MJ/kg(B) referred to the gross calorific value at 15°C and 1013,25 mbar: G20 = 37,78 MJ/m3 - G31 = 50,37 MJ/kg(C) The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calcu-lated have been certified by a notified body.(D) Values subject to tolerance(E) Values refer tests with a 1 m flue working at the nominal heat input

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4.5 Hydraulic specificationsThe hydraulic specifications in Fig. 4.3 rep-resent the pressure (available head for the central heating system) as a function of the flow rate.The load loss due to the boiler has already been subtracted.

Fig. 4.3

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0 200 400 600 800 1000 1200 14000

10

20

30

40

kPa bar

l/h

60

50

output with thermostat cocks shut offThe boiler is equipped with an automatic by-pass valve (46on page 23), which protects the condensing primary exchanger.In case of excessive reduction or total blockage of water circulation in the cen-tral heating system owing to closure of the thermostatic valves or system component cocks, the by-pass valve ensures a mini-mum flow of water through the primary heat exchanger.

4.6 Expansion vesselNote: this boiler is designed for opera-tion only in a sealed central heating sys-tem.The height difference between the pressure relief valve and the highest point in the sys-tem may be 10 m at most.For greater differences, increase the pre-load pressure in the expansion vessel and the system, when cold, by 0.1 bar for each additional 1 m.For 24 Kw and 28 Kw

Fig. 4.4

Capacity l 6,0

Pre-load pressurekPa 100

bar 1,0

Maximum volume of water in the system * l 94

* Where conditions are:• Average maximum temperature of the

system is 85 °C• Initial temperature when filling up the sys-

tem is 10 °C

For systems with volumes greater than 94l, an additional expansion vessel must be pro-vided.

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GENERAl REQUIREMENTS

5 GENERAl REQUIREMENTS

benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commis-sioned and serviced in accordance with the manufacturer’s instructions by com-petent persons and that it meets the re-quirements of the appropriate building Regulations. The benchmark Checklist can be used to demonstrate compliance with building Regulations and should be provided to the customer for future ref-erence. Installers are required to carry out in-stallation, commissioning and servic-ing work in accordance with the bench-mark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.

our Company supports the benchmark initiative. The benchmark Checklist is located at the back of this manual and should be completed by the Installing/Commissioning Engineer and handed over to the User for future reference by other visiting Engineers. Also included is the Service Interval Record card that should be completed by the Service Engineer following the annual service maintenance of the boiler and system.For Ireland (IE), it is necessary to com-plete a “Declaration of Conformity” to

indicate compliance to I.S.813.2002.This appliance must be installed by a competent person in accordance with the Gas Safety (installation & Use) Regu-lations.

5.1 Related documentsThe installation of this appliance must be in accordance with the relevant requirements of the current Gas Safe (Installation & Use) Regulations, the Local Building Regula-tions, the current I.E.E. Wiring Regulations, the Regulations and by-laws of the local wa-ter undertaking, and in Scotland, in accord-ance with the Building Standards (Scotland) Regulation. Health and safety document n° 635 ”Electricity at work regs.”.It should also be in accordance with the Brit-ish Standard Codes of Practice:In Ireland (IE). The installation must be carried out by a Competent Person and in-stalled in accordance with the current edi-tion of I.S.813.2002 “Domestic Gas Installa-tions” the current Building Regulations and reference should be made to the current ETCI rules for electrical installations.

5.2 location of applianceThe appliance may be installed in any room or internal space, although particular atten-tion is drawn to the requirements of the cur-rent I.E.E. Wiring Regulations, and in Scot-land, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combined appliance in a room containing a bath or shower.For Ireland (IE), reference should be made to the current edition of I.S.813.2002 and the current ETCI rules for electrical instal-

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lations.

Where a room-sealed appliance is in-stalled in a room containing a bath or shower, any electrical switch or appli-ance control, utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

The location must permit the provision of an adequate flue and termination.For unusual locations special procedures may be necessary and BS 6798 gives de-tailed guidance on this aspect.A compartment used to enclose the appli-ance must be designed specifically for this purpose. This appliance is not suitable for external installation.

5.3 Flue systemThe provision for satisfactory flue termina-tion must be made as described in BS 5440 part 1. For Ireland (IE), refer to I.S.813.2002.The appliance must be installed so that the flue terminal is exposed to external air.It must not be installed so that the terminal discharges into an other room or space as an outhouse or lean-to. It is important that the position of the terminal allows a free passage of air across at all times.The terminal should be located with due regard for the damage or discoloration that might occur to building products in the vicin-ity.In cold and/or humid weather water vapour may condense on leaving the flue terminal; the effect of such ”steaming” must be con-sidered.Pluming may easily occur at the terminal. Where possible, terminal position which

could cause a nuisance should be avoided.The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig. 5.1.

Fig. 5.1

A

BC

EF

G

I

JK L

MN

H

I

O

P

QD

I

II

Terminal position mmA Directly below the window or

other opening 300b Below gutters, soil pipes or

drain pipes 75C Below eaves 200D Below balconies* 600E Below car port roof NOF From vertical drain pipes and

soil pipes 150G From internal corners** 450H From external corners 300I Above ground or balcony lev-

el*** 300J From a next door boundary 2500K From a terminal facing a termi-

nal 2500l From an opening in the car port

(e.g. door, window) into dwell-ing NO

M Vertically from a terminal in the same wall 1500

N Horizontally from a terminal in the same wall 300

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GENERAl REQUIREMENTSo Above the roof pitch with roof

slope less than or equal to 30° 350o Above the roof pitch with roof

slope more than 30° 600P From wall face 600Q From, above or to side of an

opening 300

* Wherever practicable to do so, the flue should be extended beyond the perim-eter of the balcony

** Consideration should be given to adding protection against condensate to the ad-jacent structure

*** Wall terminals with horizontal discharge less than 2.5 m from a car parking space and less than 2,1 m above the ground.

Wall terminals less than 2,1 m above the ground with horizontal discharge of the flue products across a public footway, or a frequently used private access route, or a patio (hard surface area).

5.4 Gas supplyThe Gas meter is connected to the service pipe by the local gas region or a local gas region contractor.If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliance when they are in use at the same time.Pipework must be of adequate size. Pipes of a smaller size than the boiler inlet con-nection should not be used.Installation pipes should be fitted in accord-ance with BS 6891 and the complete instal-lation should be tested for tightness.For Ireland (IE), refer to I.S.813.2002.

5.5 Air supplyThe room in which the boiler is installed does not require a purpose provided air vent.

5.6 VentilationIf installed in a cupboard or compartment, it is not necessary to provide additional venti-lation for cooling for this particular product. However consideration must be given to clearance requirements for maintenance (section "Precautions for installation" to page 37) and under no circumstances must stored articles be allowed to come into con-tact with the boiler or flue pipe.

5.7 Condensate drainEnsure that the condensate discharge com-plies with the national or local regulations in force. The condensate pipe must be fitted in accordance with Building Regulations.Drain pipe material should be resistant to acid as the condensate is slightly acid with a pH less than 6.5. The boiler includes a trap (25on page 23) that prevents the combus-tion products entering the drain.The boilers incorporate a condensate trap with a 75 mm seal to comply with BS 6798: 2008.The schematic diagrams of possible con-nections are given in Fig. 5.2 and Fig. 5.3. The length of the condensate pipe should be kept to a minimum, any external pipe should not be more than 3 m in 32 mm pipe and insulated to prevent freezing.

To avoid condensate being trapped:• the drain pipe should be run with a fall of

at least 2.5° (45 mm/m) away from the boiler;

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• the number of bends and joints should be kept at minimum.

The drain pipe should be adequately fixed to prevent pipe sagging.If a part of the drainpipe runs externally this part should be kept as short as possible and protected to reduce the risk of freezing.

Fig. 5.2

Connection of condensate drainage pipe tointernal soil and vent stack.

Dimensions in mm

450

A

Condensate drain

b

C D

A Boilerb Internal soil and vent stackC InvertD 450 mm up to three storeys

Fig. 5.3Dimensions in mm

Connection of condensate drainage pipedownstream of a sink waste trap

ACondensate drain

E

F

A BoilerE SinkF Open end of condensate drainage pipe

direct into gully below grating but above water level

5.8 Water circulation (c.h.)Detailed recommendations are given in BS 6798, BSEN 12828: 2003, BSEN 12831: 2003 & BSEN 14446: 2004; the following notes are given for general guidance.For Ireland (IE), refer to I.S.813.2002.

PipeworkThe return temperature must not be lower of 40°C. Copper tubing to BSEN 1057 is rec-ommended for water pipes. Jointing should be either with capillary soldered or with compression fittings.Where possible pipes should have a gradi-ent to ensure air is carried naturally to air release points and water flows naturally to drain taps.The appliance has a built-in automatic air release valve, it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air.Except where providing useful heat, pipes should be insulated to prevent heat loss and to avoid freezing.Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

by-passThe appliance includes an automatic by-pass valve which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system due to the closing of thermostatic valves or cock-type valves within the system.

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The by-pass is calibrated to assure a mini-mum flow of 200-300 lts/hr through the main heat exchanger.If you are installing a system that includes thermostatic radiator valves (TRV) and/or small bore (8-10 mm) it may be necessary to fit an external by-pass to facilitate correct operation of the boiler.The fitting of an external bypass helps to prevent and limit system noise.

Air release pointsThese must be fitted a tall high points where air will natural collect and must be sited to facilitate complete filling of the system.

Expansion vesselThe appliance has an integral sealed ex-pansion vessel to accommodate the in-crease of water volume when the system is heated. Refer to Fig. 4.4 on page 30 for its technical data.If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity.

Mains water feed: central heatingThere must be no direct connection to the mains water supply even through a non re-turn valve, without the approval of the Local Water Authority.

Mains water feed: hot water supplyThe domestic section of the boiler is de-signed to withstand an internal domestic water pressure of 10 bar. Where it is likely that the mains domestic water pressure may exceed 5 bar, it is possible due to internal “water hammer” effects that the pressure within the domestic system can increase to a level in excess of the 10 bar limit.

In these circumstances it is therefore rec-ommended that a 3 bar pressure reducing valve be fitted to the incoming mains wa-ter supply and a mini expansion vessel in-stalled on the domestic circuit.These devices will protect the boiler and the domestic system from damage due to ex-cessive domestic water pressure.

FillingA method for initially filling the system and replacing water lost during servicing must be provided and it must comply with local water authority regulations.The correct method is shown in Fig. 5.4.The temporary connection must be re-moved immediately after filling.

Fig. 5.4

Temporaryconnection

Control valve

Control valve

Double check valve

Supply pipe(cold water inlet)

C.h. return pipe

The installer should ensure that no leaks ex-ist either inside the boiler or on the system as frequent filling of the system could cause premature scaling of the heat exchanger.

5.9 Domestic waterThe domestic water installation must be in accordance with the relevant recommenda-tions of BS 5546. Copper tubing to BS EN 1057 is recommended for water carrying pipework and must be use for pipework car-rying potable water.For Ireland (IE), refer to I.S.813.2002.

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5.10 Water treatmentC.h. circuitWhere a new boiler is fitted to a new sys-tem with either plastic or copper pipes, it is important the system is fully flushed, on completion, to ensure flux residues, swarfs, oils and other installation debris is removed.Where a new boiler is fitted to an existing system, it is important the debris from the existing system is fully removed in order to ensure the efficiency of the new appliance is maintained.Details on flushing procedure are given in the section "Initial filling of the system" to page 45 of this manual.

D.h.w. circuit (scale protection)In areas where the water is ’hard’ (i.e. more than 200 ppm total hardness as defined by BS 7593: 2006 Table 2) it is recommended that a proprietary scale-reducing device is fitted into the boiler cold supply, within the requirements of the local water company.

5.11 Electrical supplyWarning, this appliance must be earthedExternal wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regula-tions and any local regulations which apply.Reference should be made to the current ETCI rules for electrical installations.For Ireland (IE), refer to I.S.813.2002.The boiler is supplied for connection to a 230 V~ 50 Hz supply. The supply must be fused at 3A.The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance by the use of a fused spur isolation switch. Its installation permits a complete switching off in the con-

ditions of the overvoltage category III. Alter-natively it can be used a 3A fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363.The point of connection to the electricity supply must be readily accessible and adja-cent to the appliance, except where the ap-pliance is installed in a bathroom, this must then be sited outside the bathroom.

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6 INSTAllATIoN

6.1 WarningsThe use of gas appliances is subject to statutory control; it is essential to observe the current regulations and laws in force (see also chapter 5). The appliance must discharge combustion products directly outside or into a suitable ex-haust duct designed for this pur-pose. Combustion products must be discharged using origi-nal flue kits only, since they are integral parts of the boiler.

For LPG, the appliance must also conform with the requirements of the distributors and comply with current Regulations and laws in force.The safety relief valve and the condensate drain must be connected to a suitable drain, or discharge in a safe manner.

The electrical wiring must conform with cur-rent Regulations, in particular:• The boiler must be earthed using the cor-

rect bonding clamp.• Adjacent to the boiler a fused spur isola-

tion switch must be installed which permits a complete switching off in the conditions of the overvoltage category III.

Refer to section "Electrical connections" to page 42 in this chapter for the electrical con-nections.

In no circumstances will the manufac-turer be held responsible if the warnings and instructions contained in this manu-al have not been complied with.

6.2 Precautions for installationThe following prescriptions must be respected for installa-tion:

• The boiler must be fixed to a strong wall.• The dimensions for the exhaust fume duct

(detailed in section "Choice of flue" to page 40) and the correct procedures for installing the duct, depicted in the instruc-tion leaflet included with the flue kit, must be complied with during installation.

• To allow maintenance procedures it is necessary to leave the minimum gaps in-dicated in Fig. 6.1.

Fig. 6.1

25 25

All measures are in mm

250

200

• When installing the boiler in a cupboard, cover or alcove allow at least 50 mm per-manent clearance from the front face of the boiler. Also ensure sufficient clearance to allow free access for servicing and the lowering of the front control panel.

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• If the boiler is installed outside, cover the appliance to protect it against the ele-ments and add some special anti-freeze (neutralised) to the c.h. system.

• Before installing the boiler on an existing c.h. system, flush it out thoroughly be fore fitting the boiler, so as to remove muddy deposits.

It is advisable to equip the system with a sediment filter, or use a water-treatment product in the circulating water.The latter option in particular, not only cleans out the system, but also has an anti-corrosive effect by promoting formation of a protective skin on metal surfaces and neu-tralising gases present in the water. We recommend the use of a suitable univer-sal inhibitory to protect the c.h. system from corrosion.

6.3 Installing the bracketPrecautionsBefore mounting the bracket, check that the dimensions for fitting the exhaust fume duct are complied with (refer to the leaflet includ-ed with the flue kit, packed separately).Utilise the paper template supplied with the boiler to determine the fixing position for the bracket and boiler. Securely mount the bracket to the wall using appropriate fixings suitable for the type of wall construction and capable of supporting the total (wet) load. Refer to the weight given in the technical data tables specific for each model.

6.4 overall dimensionsThe boiler respects the following dimen-sions:

Fig. 6.2

ø80 ø80

ø100

400

20047245

196

803

700

35115 142

16

31

6060

100 257

20056 25 46 56

50

73

350

198

Boilerfront

A

A

b

b

C

C

D

J

E F G H

I

A Flue outlet / air intake pipe (co-axial)b Flue outlet pipe ø 80 mm (twin kit)C Air intake pipe ø 80 mm (twin kit)D Electric connections areaE C.h. flowF D.h.w. outletG GasH D.c.w. inletI C.h. returnJ Condensate drain connection area

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6.5 Joints

Functions Pipe sizes (o.d)

Gas, c.h. return, c.h. flow ø 22D.c.w. inlet ø 15D.h.w. outlet ø 15Pressure relief valve ø 15Condensate drain ø 25 (plastic)sizes in mm o.d.

6.6 Mounting the boiler• Take the protective caps off the boiler

pipework.• Thoroughly clean the connections.• Mount the boiler on its bracket.• Fix the c.h. valves A and gas cock B (¾”) to

the boiler using the ¾” gaskets (Fig. 6.3).• Fix the ø 22 mm pipes C (c.h. circuit) to the

c.h. valves A and the ø 22 mm pipe D (gas) to the cock B using the ¾” gaskets.

• Repeat the above procedure for the d.c.w. inlet utilising the ½” cold water inlet valve J, the ø 15 mm copper tail E with its con-nection nut and two ½” gaskets.

• Fix the ø 15 mm copper tail F with the ½” connection nut and a ½” gasket.

Fig. 6.3A

Ab

C

C

D

J

EF

• Connect the pipe G (Fig. 6.4) from the pressure relief valve to the safety dis-

charge pipework.• Fit the condensate drain 11 (Fig. 6.4) in the

air brake connected to the drainage pipe-work. See also section "Condensate drain" to page 33.

Fig. 6.4

G 11

6.7 Fitting the flue systemRefer to the assembly instructions contained within the chosen flue kit packaging for the correct assembly and installation.In general, it has to be taken in considera-tion that the horizontal sections of the flue pipe must have an horizontal sloping not less than 1.5 deg. (25 mm per metre) to-wards the boiler.In the standard horizontal flue kit the flue pipe is angled within the air duct therefore the air duct must be horizontally installed.

Fig. 6.5If one or more extensions have to be used they must be adequately supported so that

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there is no sag in the flue pipe and a mini-mum fall of 1,5 deg. (25 mm per metre) over the whole length towards the boiler is en-sured.Before fitting the flue system, ensure that the flue gasket shown in Fig. 6.5 (given with the boiler) is fitted to the boiler.

6.8 Choice of flueThe following flue kits are available for con-necting to the boiler:

Standard horizontal flue kit (Fig. 6.6 A)

Fig. 6.6

B

A

C45°

90°

Type C13

Co-axial 60/100 mm - nominal length 1 mThis kit is normally supplied with the boil-er and can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow. Minimum length required is 0.3 m. Maximum equiva-lent length of 2,7 metres (for M296.24SM/C and M296.28SM/C) can be achieved utilis-ing extensions. This flue system can only be used to discharge horizontally, it is not designed to enable termination in the verti-cal plane.

Vertical kit with 90° elbow (Fig. 6.6 b)Co-axial 60/100 mm.Supplied with a straight flanged adapter a co-axial elbow and a co-axial pipe with terminal, this kit allows for a vertical rise of 0,5 m from the boiler. In all circumstances the flue terminal must discharge horizon-tally and the equivalent flue length must not exceed 2,7 metres (for M296.24SM/C and M296.28SM/C).

Elbows 45° & 90° (Fig. 6.6 C)Coaxial 60/100 mm.Elbow kits enable the standard flue kits to be offset to overcome obstructions or ensure the correct clearances for the flue terminal. Each elbow used in addition to the standard flanged elbow reduces the overall accept-able length of the flue system as follows:

For the elbow of 45° loss 0,5 mFor the elbow of 90° loss 1 m

Twin pipe kits ø 80 mm (Fig. 6.7 - Fig. 6.8)

Fig. 6.7

Type C12

Various twin (split) pipes kits and optional accessories (elbows) are available to assist in the termination of the flue where the boiler is installed in a location remote to an outside

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wall.These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses. Consequently it is pos-sible to extend the flue system to a greater distance than that provided by the standard horizontal co-axial flue.

If either an additional 45° or 90° accessory elbow is used then the maximum permissi-ble length of either pipe must be reduced by 0.90 m or 1,65 m respectively.

Fig. 6.8

Type C52

90°=---1,65 m

45°=---0,90 m

Type C42

Type C82

N.B: The air intake and the flue outlet must not terminate on opposite sides of

the building.Two restrictors with different size are supplied with the twin pipe kit and have to be installed between the boiler and the air intake adapter (Fig. 6.9).

Fig. 6.9

Air intake adapter

Restrictor

Gasket

For the correct use of the restrictors with twin pipes refer to the table:.For M296.24SM/C, M296.28SM/CEquivalent length(air duct + flue duct)

Restrictor

Between 1 and 15 m ø 50 mmMore than 15 m up to 30 m ø 55 mm

Vertical- roof kit (Fig. 6.10)This kit allows vertical termination of the flue pipe through the roof. The kit is 1.2 min length. Extension pieces (Co-axial) are also available which allows the flue system to be extended to a total overall maximum permis-sible length.Optional 45° and 90° elbow scan be used to offset the flue route. Each additional elbow reduces the overall acceptable length of the flue system as follows:

For the elbow of 45° loss 0,5 mFor the elbow of 90° loss 1 m

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Fig. 6.10

90°=---1 m

45°=---0,5 m

max =8,5 m

ø 125

Type C32

Pluming kit (Fig. 6.11) (Fig. 6.11)Co-axial ø 60/100 mm + vertical part ø 60 mm (flue outlet).This kit allows the combustion air to be sucked up and expel the burnt gases directly to the outside through a telescopic co- axial flue (450-950 mm).

Fig. 6.11

90°=---1 m

45°=---0,5 m

90°=---0,85 m

45°=---0,65 m

ø 60 mm

ø 60/100 mm

Type C52

In the last section, the fumes are expelled through a vertical section.Extensions and elbows can be added to ex-tend the kit’s length.The chart of Fig. 6.12 gives the allowable

dimensions of the ducts “a” and “b” of Fig. 6.11.

Fig. 6.12

”a” vertical length (m)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8”b” horizontal length (m)

Allowed values

Each additional elbow reduces the overall acceptable length of the flue system as fol-lows:45° (60/100 mm) reduce length by 0,5 m.90° (60/100 mm) reduce length by 1 m.45° (60 mm) reduce length by 0,65 m.90° (60 mm) reduce length by 0,85 m.

6.9 Electrical connections• Remove the front panel of the case (see

the section 9.2 in this manual).• Remove the screws K (Fig. 6.13).• Loosen the screws L.

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Fig. 6.13

K

l

• Remove the side panels or move the low-er part of the side panels as indicated in Fig. 6.14 and pull the control panel. When completely pulled out, the panel can rotate 45° downwards to facilitate the operations on the internal parts.

Fig. 6.14

• Loosen the screws M and remove the ser-vice panel (Fig. 6.15).

Fig. 6.15

M

For the electrical connection to the boiler use electric wire switch conform to the cur-rent regulations, with flexible cord, each core having a cross section area not less than 0,75 mm2.

• Connect the electrical supply flexible cord coming from the fused spur isolation switch to the power supply terminal block of the boiler (Fig. 6.16) keeping the same connections for the live (brown wire) and the neutral (blue wire). External 3 A fuse or fused plug with same current rating is rec-ommended. Do not connect live wires to terminals to which the room thermostat must be connected.

• Connect the earth wire (yellow/green).

Connection of a room thermostatThe room thermostat must be connected to the terminal block situated next to the con-trol panel.

When connecting any type of external control, the link N in Fig. 6.16 must be removed.

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Fig. 6.16

N

• Connect the room thermostat between ter-minals 1 and 3 as shown in Fig. 6.17.

Do not connect live wires to ter-minals to which the room ther-mostat must be connected.

Fig. 6.17

13

Power supplyterminal block

External controlsterminal block

TL N

Roomthermostat

• Route the electrical supply flexible cord and the external control flexible cord as illustrated in Fig. 6.18. Lock the flex-ible cords in place with the flexible cord clamps.

Fig. 6.18

To the fusedspur isolationswitch

To the externalcontrol device

6.10 External frost protection• Connect the frost thermostat between

terminals 1 and 2 as shown in Fig. 6.19. Do not connect live wires to terminals to which the room thermostat must be connected.

Fig. 6.19

Power supplyterminal block

External controlsterminal block

T

Room thermostat

T

Frost thermostat

L N

32 1

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CoMMISSIoNING

7 CoMMISSIoNING

7.1 WarningsThe commissioning of this boiler and system must only be undertaken by a professionally qualified person in ac-cordance with the requirements of the Gas Safe Installation and Use Regula-tions and be approved by Gas Safe.

Ensure that the benchmark Checklist is satisfactorily completed during the com-missioning process. The Checklist is located at the end of this manual. This manual should be handed to the User following completion of the installation and commissioning process. Failure to comply with these requirements may in-validate the manufacturers guarantee.

For Ireland (IE), it is necessary to com-plete a “Declaration of Conformity” to indicate compliance to I.S.813.2002.

7.2 Electrical installationPreliminary electrical system checks to en-sure electrical safety shall be carried out by a competent person. i.e. polarity, earth con-tinuity, resistance to earth and short circuit.If a fault has occurred on the appliance the fault finding procedure should be followed as specified in the service manual.

7.3 Gas supply installation• Inspect the entire installation including the

gas meter, test for tightness and purge, all as described in BS 6891; For Ireland (IE), refer to I.S.813.2002.

• Open the gas cock 14 (Fig. 7.1) on the ap-pliance and check the gas connector on

the appliance for leaks.

Fig. 7.1

14 open position

7.4 Filling the d.h.w. system• Close all hot water draw-off taps.• Open the cold water inlet valve.• Slowly open each draw-off tap and close

it only when clear water, free of bubbles, flows out.

7.5 Initial filling of the system• Open the c.h. flow and return valves.• Remove the front panel of the case (sec-

tion "Dismantling the external panels" to page 53).

• Unscrew the cap on the automatic air purger valve 26 in Fig. 7.2 one full turn and leave open permanently.

Fig. 7.2

27

26

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• Gradually open stopcock at the filling point connection to the c.h. system until water is heard to flow; do not open fully.

• Open each radiator air vent starting at the lowest point of the system and close it only when clear water, free of bubbles, flows out.

• Purge the air from the pump by unscrew-ing the pump plug 27 (Fig. 7.2); release the pump shaft by turning in the direction indicated by the arrow on the information plate.

• Replace the pump plug.• Continue filling the system. The actual

reading should ideally be 1,3 bar and not less than 0,3 bar.

• Close all air release valves on the c.h. system.

• Inspect the boiler and the system for wa-ter soundness and remedy any leaks dis-covered.

• Cold flush the system to remove any loose particles and any system debris be-fore starting the boiler for the first time

The flushing procedure must be in line with bS7593:2006 Treatment of Water in d.h.w. c.h. Systems.When the installation and second fill-ing are completed turn on the c.h. sys-tem and run it until the temperature has reached the boiler operating tempera-ture. The system must then be immedi-ately flushed through.This procedure must be repeated twice more.During this operation we highly recom-mend the use of a c.h. flushing detergent in the quantities as specified by the ap-propriate manufacturer, whose function it is to dissolve any foreign matter which may be in the system.

The above operation could save the in-validation of your boilers guarantee and will also prevent problems which you may experience in the future if an inhibi-tory is not used.

7.6 Condensate pipe and trapsThe full length of the condensate pipe should be check for leaks.The boiler has a built-in condensate trap provided with a ball valve that prevents the escape of combustion products when the trap is empty.

It is however recommended that any oth-er trap in the drain system is correctly filled with water before to run the boiler.

Fill the built in condensate trap by removing the flue elbow and pouring a cupful of water into the flue outlet (Fig. 7.3).

Fig. 7.3

An alternative, to the removal of the flue el-bow, pour the water through the flue sam-pling point (Fig. 7.4)

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Fig. 7.4

Sampling points Flue exhaust

7.7 lighting the boilerSome products incorporate an anti cycling time delay. It is normal when first switch-ing the boiler on for the boiler to operate on heating for a few seconds then switch off. After 3-4 minutes has elapsed the boiler will then re ignite and operate perfectly normal-ly. The ignition delay cycle does not prevent normal operation of the boiler to provide d.h.w.

If external controls are fitted (e.g. Timeclock, room thermostat) ensure they ”call for heat”.• Turn on the electricity supply to the boil-

er, switching on the fused spur isolation switch. The appliance operation light 10 will flash every 4 seconds.

• Turn the function selector 8 as in Fig. 7.5. The appliance operation light 10 will flash every 2 seconds.

Fig. 7.510 8 7 6

The boiler will now go through an ignition sequence and the burner will light.

If during the ignition attempt period the boiler fails to light, the full sequence control p.c.b. will go to lockout and the lock-out sig-nal lamp 6 will appear.To reset the boiler press and release the boiler reset button 7.

7.8 Checking the gas pressure at the burner

This boiler has been factory tested to the highest quality control standards.The maximum and minimum gas pres-sures are already set during this quality control process however the checking procedure must be followed to ensure maximum operating efficiency from the boiler.

• Remove the front panel of the case (see section "Dismantling the external panels" to page 53) and the sealed chamber lid.

• Loosen the internal screw 33 (Fig. 7.6) on the Outlet Pressure Test Point of the Gas Valve and connect a pressure gauge us-ing a suitable hose.

• Set the d.h.w. and c.h. temperature con-trol knobs to their maximum position. If external controls are fitted (e. g. Time-clock, room thermostat) ensure they ”call for heat”.

• Switch on the boiler and open at least one hot water tap fully.

• Check the maximum gas pressure and compare the value on the gauge with the value indicated in the sections "Technical Data" on pag. 24 or pag. 27 (gas pres-sures at the burner), accordingly with the model of boiler installed.

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• Check the maximum gas flow at the gas meter and compare the value indicated in the sections "Technical Data" on pag. 24 or pag. 27 (gas rate), accordingly with the model of boiler installed.

• Switch off the boiler.• Disconnect the gas modulator coil by re-

moving the electrical connector A (Fig. 7.6).

Fig. 7.6

A 33

• Switch on the boiler.• Check the minimum gas pressure and

compare the value on the gauge with the value indicated in the sections "Technical Data" on pag. 24 or pag. 27 (gas pres-sures at the burner), accordingly with the model of boiler installed.

• Switch off the boiler and re-connect the electrical connector A to the modulator coil.

• Switch on the boiler.• Check that the boiler lights up uniformly. If

not refer to section “Ignition gas pressure adjustment” of the Service Manual for the necessary adjustment procedures.

• Switch off the boiler, turn off the hot water tap(s) and disconnect the pressure gauge.

• Reassemble the sealed chamber lid and the front panel of the case (see "Disman-tling the external panels" to page 53).

If the maximum and minimum gas pres-sures measured above are not in accord-ance with the technical data (sections "Technical Data" section pag. 24 or pag. 27) then adjustment will be necessary. A full explanation of the gas pressure ad-justment procedure is given in the Gas Valve section of the service manual. If maximum and/or minimum gas pres-sures are adjusted then the ignition gas pressure must be checked and adjusted if necessary.

Important: after the gas pressure checks and any adjustment operations, all of the test points and adjustment devices must be sealed. Replace the adjustment pro-tection cap.

7.9 Checking the burner ignition• Turn the boiler OFF.• Open the gas valve outlet pressure test

point 33 (Fig. 7.6) and connect the gauge.• Turn the boiler ON positioning the control

selectors 8 in the positions as shown in as in Fig. 7.7 and ensure that the timer selec-tor switch and room thermostat, if fitted, are set to “heat demand”.

Fig. 7.710 8

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• Watch the gauge and check to see if the ignition pressure registered corresponds to the values as given in the Technical Data. Turn off the boiler and reignite it by turning the function selector 8 to the OFF position and then back to that indicated in Fig. 7.7.

• Repeat this process two to three times leaving 30 second intervals between each ignition. Check the ignition pressures and visually check that the burner lights uni-formly and in a controlled manner.

• If the burner ignition is not uniformly con-trolled then checks should be made to: - the flue installation and termination. - that the flue gasket as shown in Fig. 6.5 on page 39 is in place.

- that the burner and injectors are clean. - that the boiler is set for the correct gas used (see "GAS CONVERSION" to page 51).

• If the ignition pressure recorded is not as indicated in the Technical Data then refer to section “Ignition gas pressure adjust-ment” of the Service Manual for the nec-essary adjustment procedures.

Important: after the gas pressure checks and any adjustment operations, all of the test points must be sealed and replace the adjustment protection cap.

7.10 Checking the ignition deviceWith the burner on high flame close the gas cock.After three ignition attempts (within about three minutes), the lock-out signal lamp 6on page 8 must appear.To reset the boiler press and release the boiler reset button 7on page 8.

7.11 Checking the flue systemThe flue system should be visually checked for soundness. Check all clamps, gaskets and fixing are secure and tight.Ensure that the flue terminal is sited cor-rectly in accordance with the flue fitting in-structions and Fig. 5.1 on page 32 of this manual.To carry out a combustion check refer to the instructions given in the section "Combus-tion analysis check" to page 54.Reference figures are given in the "Techni-cal Data" section page 24 of this manual (Flue gas figures).

7.12 Checking the condensate drain pipe

Check the soundness and integrity of the condensate drain pipe.Verify the cleanness and correct filling of the condensate traps.

7.13 Instructing the userHand over this combined User & Installation manual and the Service manual to the end user and explain how to use the unit in both c.h. and d.h.w. modes.

Take the User step by step through the light-ing instructions.Show the User how to switch off the appli-ance quickly and indicate the position of the electric supply isolator.Explain the proper use and adjustment of all system controls; this will ensure the great-est possible fuel economy.Explain the function and use of the function selector.Explain and demonstrate the function of time and temperature controls (if fitted).

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Explain how to turn off the appliance for both short and long periods and advise on the precautions necessary to prevent dam-age should the appliance be inoperative when freezing conditions may occur.Fill in the details required on the Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee registration.Finally, advise the User that, for continued safe and efficient operation, the appliance must be serviced by a competent person at least once a year.

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8 GAS CoNVERSIoN

8.1 WarningsThe commissioning of this boiler and system must only be undertaken by Safe-ty Registered Engineer,qualified to work on Liquefied Gas Petroleum Gas (LPG)

Components used to adapt it to the type of gas available must be genuine parts only.

8.2 ProceduresCheck that the gas cock fitted under the boiler is turned off and the appliance is switched off at the mains isolating spur.

Fig. 8.1

14 Closed position

• Remove the front panel of the case (see the section General access and emptying hydraulic circuits in the service manual).

• Take off the lid of the sealed chamber.• Take the front panel of the combustion

chamber off and remove the burner (41on page 23). See section Ignition and detec-tion electrodes in the service manual for detailed instructions.

• Carry out the conversion for the type of gas, replacing the burner injectors cor-rectly.

• Re-assemble the burner, the front panel of the combustion chamber.

• Switch on the appliance at the mains iso-lating spur.

• Turn the boiler OFF positioning the func-tion selector 8 as indicated in Fig. 8.2.

Fig. 8.210 8

• Disconnect the electrical connectors of the C.h. temperature probe NTC 23 in Fig. 8.3

Fig. 8.3

23

• Keep pressed the reset button 7 for about 10 seconds until the lock-out signal lamp 6 blinks.

• Connect the electrical connectors of the C.h. temperature probe NTC 23 in Fig. 8.3.

• Press the reset button 7 repeatedly (4 times) until the lamps 10 give the indica-tion as in Fig. 8.4 (gas type mode).

Fig. 8.4

Where: lamp oFF

lamp oN

At this step it is possible to visualize the cur-

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rent setting by keeping the reset button 7 pressed for more than 5 seconds. The lamps 10 will flash a number of times correspond-ing to the setting of the knob 9 in Fig. 8.5.

Fig. 8.5

NATURAL

4L.P.G.

9

Gas typeSetting No.

GAS1

Gas supply

Position of knob 9

Approx. Max cur-rent through the modulator device

Natural gas

1 125 mA

L.P.G. 4 165 mA

Fig. 8.6

• To change the setting turn the knob 9 on a position corresponding to the gas used as shown in Fig. 8.5. By turning the knob 9, the lock-out signal lamp 6 blinks quickly (2 per seconds) indicating that the setting has changed and must be memorised.

• To memorize the setting keep pressed the reset button 7 for about 5 seconds until the lamps 10 briefly blinks simultaneously.

• Open the gas cock (14 in Fig. 8.7).• To reset the boiler to the normal operation

turn it ON by the function selector 8 on the desired operation and checking the igni-tion pressure and that the burner lights up uniformly. In any case, the boiler automati-cally resets to its normal operation after 10 minutes.

Factory setting = Natural gas (as illustrated)

Fig. 8.714 open position

• Calibrate the gas valve according to the instructions given in the service manual, section Modulating gas valve-Adjustment.

• Re-assemble the lid of the sealed cham-ber.

• Replace the self-adhesive label indicating the type of gas, and the gas pressures to which the appliance has been set with the label included with the conversion kit. The label is placed on the botton of the appli-ance.

• Replace the adjustment protection cap.• Replace the front panels of the case.

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9 MAINTENANCE

9.1 WarningsThe procedures detailed in this chapter must be carried out only by a Gas Safety Registered Engineer.Thus you are advised to contact an Author-ised Service Agent.For Ireland (IE), the servicing work must be carried out by a competent Person.For efficient and continuous operation of the boiler you are advised to have, at least once a year, maintenance and cleaning done by an Approved Service Engineer.Isolate the appliance from the electricity supply by turning off the fused spur isola-tion switch adjacent to the appliance and turn off the gas cock, before carrying out any procedures, whatsoever, for cleaning, maintenance, opening or dismantling boiler panels.

9.2 Dismantling the external panels

Front panel• Loosen the three screws A (Fig. 9.1).• Lift and remove the panel.

Fig. 9.1

Sampling pointFlue exhaust

Sampling pointAir

A

Side panels• Loosen the screws B. Bring the bottom

of the panels away from the boiler and lift them, freeing them from the top hooks (Fig. 9.2).

Fig. 9.2

b

9.3 Emptying the d.h.w. system• Turn off the d.c.w .inlet isolating valve and

turn on the hot water taps and any drain cocks.

9.4 Emptying the c.h. system• Close the c.h. isolating valves.• Open the central heating drain cock (24

in Fig. 9.3).

Fig. 9.3

24

• A small quantity of water will remain in the d.h.w. heat exchanger after draining.

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If the boiler is being drained to prevent freezing, the d.h.w. heat exchanger must be removed and inverted to drain fully or an antifreeze solution added.

9.5 Combustion analysis checkIf it is necessary to carry out a combustion analysis remove the plugs indicated in Fig. 9.1.Reference figures are given in the sections "Technical Data" on pag. 24 or pag. 27 (Flue gas figures).

9.6 Cleaning the primary heat exchanger

• Take off the front of the case.• Take off the removable front of the sealed

chamber and the front panel of the com-bustion chamber.

If you notice dirt on the fins of the primary heat exchanger (44on page 23):• Cover the sloping surfaces of the burner

(41on page 23) entirely in a protective layer (sheets of newspaper or similar).

• Brush out the primary heat exchanger (44on page 23) with a bristle paintbrush.

9.7 Checking the pressurisation in the expansion vessel

Empty the central heating systemas de-scribed in section "Emptying the c.h. sys-tem" to page 53 and check that the expan-sion vessel pressure is not less than 1 bar. See also section "Expansion vessel" to page 30.If the pressure is lower, take steps to correct the pressure level

9.8 Cleaning the burnerThe sloping and multi-gas type burner (41on page 23) does not need special main-tenance, but it is sufficient to dust it with a bristle paintbrush.To reach the burner:• Take off the front of the case.• Take off the removable front of the sealed

chamber and the front panel of the com-bustion chamber.

• Brush out the burner with a bristle paint-brush.

9.9 Checking the flueHave the integrity of the flue outlet pipe (50on page 23) air intake pipe (51on page 23), checked periodically, the air pressure sensor* (19on page 22) and the efficiency of the flue safety circuit checked at least once a year.* For details see the section Fan and air pressure sensor in the service manual.For all the above maintenance operations it is advisable to call an approved Service Engineer.

9.10 Drain pipe inspectionCheck the soundness and integrity of the condensate drain pipe.Verify the cleaness and correct filling of the condensate traps.

9.11 Visual inspection of applianceVisually inspect all water joints, seals and connections for any evidence of leakage and retighten, grease or replace them as necessary.

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9.12 Gas pressures and tightnessCheck appliance for gas tightness. Recheck operational pressures and adjust as neces-sary as described in section "Checking the gas pressure at the burner" to page 47.

9.13 Water inhibitor concentrationWhere chemical products are used the level of water treatment should be checked on an annual basis and re treated after full or par-tial drain down.

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Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

If yes, and if required by the manufacturer, has a water scale reducer been fitted?

Condensing Boilers only

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted? Yes

service recordIt is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

service ProviderBefore completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

Always use the manufacturer’s specified spare part when replacing controls.

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Operative ID No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.


Comments:

Signature:

service 1 service 2

service 3 service 4

service 5 service 6

service 7 service 8

service 9 service 10

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

If yes, and if required by the manufacturer, has a water scale reducer been fitted?

Condensing Boilers only

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted? Yes

*1796215484*17962.1548.4 0312 60A5 UK

biasi UK ltdCommercial RoadLeamore Enterprise ParkWALSALL

WS2 7NQ

Sales Tel. 01922 714600Tech. Service Tel. 01922 714636www.biasi.co.uk

16/012012

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