CaprizPlus
Installation and Servicing
Models
24 G.C. No. 47-157-19
28 G.C. No. 47-157-20
12
11
10
9
8
15
mode
17
4
19
2
18
bar
3
0
4
16
5
3
6
14
7
13
2
1
22
21
20
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
23
www.heatline.co.uk
24
High Efficiency Condensing Combination Boilers
1
reset
Guarantee Registration
Thank you for installing a new Heatline appliance in your home.
Heatline appliances are manufactured to the very highest standard so we are pleased to offer our customers
a Comprehensive Guarantee. For the manufacturer's warranty to be valid, the Benchmark Log Book must
be correctly completed by a suitably qualified person and be available for inspection prior to any repair.
Comprehensive Warranty, Terms and Conditions are available from: heatline@tfstore.co.uk or by calling
01773 596013. We recommend you complete and return as soon as possible your guarantee registration
card. If your guarantee registration card is missing you can obtain a copy or record your registration by
telephoning the Heatline Customer Service number 0844 736 9138.
Customer Service: 0844 736 9138
Technical Helpline (Chargeable): 0906 802 0253
For Complaints please contact:
Customer Care, Group Service, Nottingham Rd.,
Belper, Derbyshire
DE56 1JL
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, commissioned and serviced in accordance with the manufacturer’s
instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements 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 reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice
which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.central heating.co.uk for more information.
INTRODUCTION
1
Instructions guidance
1.1
Product documentation
The instructions are an integral part of the appliance and must
be handed to the user on completion of the installation in order
to comply with the current regulations.
• Carefully read and understand the manual, which will enable
you to complete your task of installing or servicing this
appliance safely. No liability can be accepted in the event of
damage for not complying with the guidance in this instruction
manual.
These instructions consist of, Installation, Servicing, Fault Finding,
Replacement of Parts and Spares. The instructions are an integral
part of the appliance and must, to comply with the current issue of
the Gas Safety (Installation and Use) Regulations, be handed to the
user on completion of the installation.
1.2
Associated documents
- 1 magnetic lighting instruction label
- 1 guarantee envelope pack
Explanation of symbols
a
DANGER: Risk of injury.
e
DANGER: Risk of electric shock.
ATTENTION: Risk of damage to the appliance or
to its surroundings.
IMPORTANT: Important information.
1.4
2
Appliance description
2.1
Safety devices
Overheating Safety Device
The appliance is designed to recognise the potential of an
overheat situation and will shutdown before a potentially
dangerous situation occurs.
Safety discharge valve
A safety discharge valve and discharge pipe are fitted to the
boiler. This valve must not be touched.
- The heating safety valve opens when the pressure in the
heating circuit exceeds 3bar.
• Should there be any discharge from the pipe, which should
terminate in a safe place outside the property, isolate the
boiler’s electrical supply and call your Installer, Service
Engineer or Heatline’s Service Department.
Frost protection
- 1 wall template
1.3
We recommend you complete and return as soon as possible
your guarantee registration card. If your guarantee registration
card is missing you can obtain a copy or record your registration
by telephoning the Heatline Customer Service number 0844 736
9138.
Guarantee registration
Thank you for installing a new Heatline appliance in your home.
Heatline appliances are manufactured to the very highest
standard so we are pleased to offer our customers a
Comprehensive 12 month Guarantee, with the option to extend it
to two years.
The appliance has a built in frost protection device that protects
the boiler from freezing. With the gas and electric supplies
ON and irrespective of any room thermostat setting, the frost
protection device will operate the pump when the temperature of
the boiler water falls below 8OC.
A timer is used so that the temperature can be checked
periodically. After 10 minutes the pump will be stopped if the
temperature is higher than 10OC or has already reached 35OC.
The burner will activate if the boiler temperature does not reach
10OC after 30 minutes or at any time if the temperature drops to
5OC.
The burner will switch off when the temperature reaches 35OC.
The frost-protection system is active when the appliance is
switched on.
The boiler controls cannot ensure that the installation is
fully protected against frost. Any exposed pipes should be
adequately protected and particular attention should be paid to
condensate drains. An additional frost thermostat may also be
required.
a
Your domestic water circuit (hot or cold) is not
protected by the boiler controls.
Condensate drain blockage
During freezing conditions this may be due to the forming of
ice in the condense drain external to the house. In this case, a
safety device shuts down the appliance.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
-3-
2.2
Data label
The data label certifies the country where the appliance is
intended to be installed. It is located on the rear of the drop
down control box
The data label contains the following data:
- The name of the manufacturer
- The country of intended destination
- The commercial name of the appliance and its serial number
- The types of flue installations authorised
- The appliance's gas category
- The gas type, group and pressure, set in the factory
Product/production certified by:
Notified body IMQ 52BP2727 CE Directives 2009/142/EEC.
52BP2728DR CE Directives 92/42/EEC.
The CE mark indicates that the appliances described in this
manual are in compliance with the following directives:
- European directive n°2009-142 relative to gas appliances
- European directive n°2004-108 from the European Parliament
and Council relative to electromagnetic compatibility
- European directive n°2006-95 from the European Parliament
and Council relative to low voltage
- European directive n°92-42 relative to the yield of boilers
2.5
Hydraulic schematic
- The DHW specific flow rate (D)
13
14
12
15
11
16
- The maximum pressure in the heating circuit (PMS)
- The maximum pressure in the domestic water circuit (PMW)
- The NOx class of the appliance
- The type and voltage of electricity supply
10
9
- The maximum power rating
17
- The electrical protection class
18
- The minimum and maximum heat input (Q)
- The minimum and maximum power output (P)
- The CE number and logo
a
19
8
7
23
6
The appliance shall only be connected to the gas
type(s) indicated on the data label.
20
21
22
5
24
2.3
Gas category
This boiler is for use only on G20, but can be converted for use
on G31.
• To adapt the appliance to another type of gas, see the
chapter "Gas conversion".
2.4
Regulation and statutory requirements
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on the
efficiency requirements for new hot water boilers fired with liquid
or gaseous fuels.
Type test for purposes of Regulation 5 certified by:
Notified body IMQ 52BP2727 CE Directives 2009/142/EEC.
52BP2728DR CE Directives 92/42/EEC.
-4-
3
25
2
1
Key
1
Gas service isolating valve (Yellow)
2
Heating flow isolating valve (Red)
3
Heating safety valve
4
N/A
5
DHW flow sensor
6
Domestic plate to plate heat exchanger
7
By-pass
8
Heating return thermistor (Blue)
9
Condensate trap
10 Ignition and control electrode
11 Burner
12 Main heat exchanger
13 Thermal fuse
14 Flue outlet
15 Silencer
16 Heating expansion vessel
17 Fan
18 Gas control valve
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
26
27
19
20
21
22
23
24
25
26
27
A
B
C
D
E
F
G
3
Ignition module
Heating flow thermistor (Red)
Air vent
Pump
Three way valve
Water pressure sensor
Heating return isolating valve and filter (Blue)
Domestic cold water isolating valve and filter (Blue)
Domestic hot water outlet valve
Heating flow
Domestic hot water outlet
Pipe for heating safety valve
Gas inlet
Cold water inlet
Heating return
Condensate drain
Safety instructions and regulations
• This appliance contains metal parts (components) and care
should be taken when handling and cleaning, with particular
regard to edges.
The basic safety instructions must be followed before attempting
to maintain or replace spare parts:
• Electrically isolate the appliance from the power supply.
• Turn off the appliance gas isolation valve.
• Hydraulically isolate the appliance using the isolation valves
below the boiler.
• Protect all the electrical components from water while working
on the appliance.
• Mop up any spillage of water within the boiler.
• Use only original spare parts.
3.1
Safety instructions
If the gas pressure at the input of the appliance is outside the
range specified, the appliance must not be put into operation.
e
Incorrect installation can cause electric shock or
appliance damage.
• Never disable safety devices and do not try to adjust them.
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended weight
for a one person lift.
The handling of the boiler may involve lifting, pushing and
pulling, the use of a sack truck may be required.
• Note this appliance is heavy and it is recommended that two
people are required to lift the boiler.
• Be sure to consider the following handling techniques and
precautions:
- Grip the appliance at its base
- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
• Ensure safe lifting techniques are used:
- Keep back straight.
- Avoid twisting at the waist.
- Avoid upper body/top heavy bending.
- Always grip using the palm of the hand.
- Keep load as close to body as possible.
- Always use assistance if required.
• Under no circumstances must the user interfere with or adjust
sealed parts.
• When assembling the connections, correctly position the
seals to avoid any leakage of gas or water.
• Use only new O-rings and gaskets.
• After having completed work on gas or water carrying
components, check for their tightness.
• When work on the appliance is completed, perform an
operational test and check for safety.
3.2
Statutory requirements
IMPORTANT
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
The installation of this boiler must be carried out by a competent
person approved at the time by the Health and Safety Executive
and in accordance with the rules in force in the Countries of
installation.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
Statutory Requirements
In GB, the installation of the boiler must comply with the
requirements of the current issue of BS6798 and be carried out
by a competent person approved at the time by the Health and
Safety Executive and as described in the following regulations:
- The manufacturer’s instructions supplied.
- The Gas Safety (Installation and Use) Regulations.
- The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland), The Building
Regulations (Northern Ireland).
- The Water Supply (water fittings) Regulations 1999 and water
byelaws 2000, Scotland.
- The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
- The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
-5-
In IE, the installation must be carried out by a competent person
approved at the time by the Health and Safety Executive and
installed in accordance with the current edition of I.S.813
“Domestic Gas Installations”, the current Building Regulations
and reference should be made to the current ETCI rules for
Electrical Installation.
GB: the following Codes of Practice apply: BS4814, BS6798,
BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891,
BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specification (CheSS) and
2) Controls for domestic central heating system and hot water.
BRECSU.
Gas Supply
The gas installation must be in accordance with the relevant
standards.
In GB, this is BS6891.
In IE, this is the current edition of I.S.813 “Domestic Gas
Installations”.
The supply from the governed meter to the boiler must be a
minimum of 22mm diameter and provide a steady inlet working
pressure of 20mbar (8in wg) at the boiler. On completion, test
the gas installation for tightness using the pressure drop method
and suitable leak detection fluid, purge in accordance with the
above standard.
Domestic Hot Water
All domestic hot water circuits, connections, fittings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24 of
the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland). To comply with the Water regulations your
attention is drawn to: The Water Regulations guide published
by the Water Regulations Advisory Service (WRAS) gives full
details of the requirements.
In IE, the requirements given in the current edition of I.S.813
“Domestic Gas Installations” and the current Building
Regulations must be followed.
Electrical Supply
The boiler MUST be earthed. All system components shall
be of an approved type and all wiring to current I.E.E. wiring
regulations. External wiring must be correctly earthed, polarised
and in accordance with the relevant standards.
The boiler MUST be connected to a permanent 230V ac, 50Hz
supply.
Connection of the whole electrical system of the boiler, including
any heating controls, to the electrical supply MUST be through
one common isolator and must be fused 3 Amp maximum.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to the
appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not less
than 0.75mm2 (24/0.20mm).
3.3
Other regulations
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL
gas appliances are installed by a competent person approved at
the time by the Health and Safety Executive in accordance with
the current issue of these regulations.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act 1974, we
are required to provide information on substances hazardous to
health. The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
Insulation Pads:
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to
irritation. High dust levels are usual only if the material is broken.
Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or
going to the lavatory.
• If you do suffer irritation to the eyes or severe irritation to the
skin seek medical attention.
4
Recycling
The recycling of the packaging must be carried
out by the qualified professional who installed the
appliance.
4.1
Packaging
We recommend that you recycle the packaging of the appliance
in a responsible fashion.
• Sort the waste in order to separate those elements which can
be recycled (cardboard, plastics ...) and those which cannot
be recycled.
• Dispose of waste in accordance with existing regulations.
In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.
-6-
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
4.2
Appliance
Description
Most of the appliance is manufactured from recyclable materials.
This symbol indicates that this appliance must not
be disposed of with household waste, that it should
be selectively collected for energy recovery, reuse or
recycling.
• Take the appliance to an appropriate collection point.
By complying with this directive, you will contribute
to the preservation of natural resources and the
protection of human health.
TECHNICAL DATA
Description
Unit
Gas Category
SEDBUK Rating
24
28
II2H3P
IIH3P
%
Heating
Maximum heating input power
Minimum heating output power at
800/600C (Pmin)
Maximum heating output power at
800/600C (Pmax)
Minimum heating output power at
500/300C (Pmin)
Maximum heating output power at
500/300C (Pmax)
Minimum heating temperature
Unit
24
28
230V
50Hz
3
130
2
IPX4D
230V
50Hz
3
130
2
IPX4D
22
(copper)
22
(copper)
15
(copper)
21.5
(plastic)
15
(copper)
32.5
36.7
22
(copper)
22
(copper)
15
(copper)
21.5
(plastic)
15
(copper)
33.8
38.2
m3/hr
2.482
2.974
3
1.936
2.482
Electrical
Electrical supply
V/Hz
Standby mode electrical power
Operating mode electrical power
Internal fuse rating on main PCB
Index of electrical protection (EN 60529)
Connections & weights
W
W
A
Gas connection Ø O.D.
mm
Heating flow and return connection Ø
O.D.
mm
Domestic Hot Water connection Ø O.D.
mm
Condensate connection Ø I.D.
mm
Safety valve discharge connection Ø
mm
O.D.
Lift weight
kg
Total weight (installed)
kg
Natural Gas G 20 (15 °C, 1013.25 mbar)
Maximum DHW gas flow rate
Maximum heating gas flow rate
m /hr
kW
18.0
24.0
Minimum gas flow rate
m /hr
0.882
0.989
kW
7.8
9.2
CO2 at Qmax DHW + "tolerance case
ON"
%
9.2 ±
0.3%
9.2 ±
0.3%
kW
17.6
23.4
%
kW
8.7
10.3
CO2 at Qmax DHW + "tolerance case
OFF"
9±
0.2%
9±
0.2%
%
kW
19.6
25.9
CO2 at Qmin +
"tolerance case ON"
8.9 ±
0.3%
8.9 ±
0.3%
CO2 at Qmin +
"tolerance case OFF"
%
8.7 ±
0.2%
8.7 ±
0.2%
Inlet pressure
mbar
Propane Gas G 31 (15 °C, 1013.25 mbar)
20
20
Maximum DHW gas flow rate
m3/hr
0.924
1.109
Maximum heating gas flow rate
m3/hr
0.704
0.950
0.376
3
0
C
10
10
Maximum heating temperature
0
C
75
75
Content of heating expansion vessel
l
bar
psi
8
0.75
10.9
8
0.75
10.9
Maximum heating system volume
(approx)
l
160
160
Minimum gas flow rate
m /hr
0.31
Heating safety valve preset pressure
(PMS)
bar
psi
2.5
36.3
2.5
36.3
CO2 at Qmax DHW + "tolerance case
ON"
%
10.3 ±
0.3%
10.3 ±
0.3%
kW
kW
0
C
l/min
bar
psi
bar
psi
24.0
8.0
60
9.4
0.8
11.6
10.0
145
28.0
9.5
60
11.4
0.8
11.6
10.0
145
CO2 at Qmax DHW + "tolerance case
OFF"
%
10.1 ±
0.2%
10.1 ±
0.2%
CO2 at Qmin +
"tolerance case ON"
%
9.8 ±
0.3%
9.8 ±
0.3%
CO2 at Qmin +
"tolerance case OFF"
%
9.6 ±
0.2%
9.6 ±
0.2%
Inlet pressure
mbar
37
37
5
5
Heating expansion vessel preset
pressure
Domestic hot water
Maximum DHW output power (P max)
Minimum DHW output power (P min)
Maximum DHW temperature
Specific flow rate (∆T of 35K) EN 13203
Minimum inlet water pressure
Maximum inlet water pressure
Combustion
Appliance NOX Class
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
3
-7-
5
CaprizPlus
6.2
• The clearances specified are the minimum required to allow
general service and maintenance of the appliance.
Boiler, type C13, C33
• To allow periodic maintenance, ensure the distances
indicated on the diagram.
INSTALLATION
All the dimensions are shown in mm.
6
Clearances
Additional clearances may be beneficial around the boiler for
installation and servicing.
For flue installations where external access is not practicable,
consideration should be given for the space required to insert
the flue from inside the property, which may necessitate
clearances larger than those specified in diagram below.
Appliance location
6.1
ØA
+1
ØA
Instructions
0m
in.
Before choosing a site for the appliance, carefully read the
safety warnings and installation manual.
• Ensure the wall to which the appliance will be mounted on is
structurally safe in order to support the weight of the appliance.
5
mi
n.
• Ensure that the space that the appliance is to be installed
within allows the appliance to be installed and the clearances
maintained. This will ensure that the connections to the water,
gas and flue can be accessed and inspected (see chapter
Clearances).
20
mi 0
n.
5
mi
n.
*
600n.
mi
• Explain these requirements to the appliance user.
30
mi 0
n.
• Do not install the appliance above another appliance that
could damage it (for example a cooker).
• Also ensure the flue terminates in a location where the air
required for combustion is not contaminated by excess debris
or corrosive emissions.
Key
*
A removable compartment door can be placed a minimum 5
mm in front of appliance. A clearance of 600 mm is required
from a fixed surface.
• The boiler must be fitted inside the property and exposed pipe
work may need to be protected from frost by fitting insulation
and/or a frost thermostat.
The boiler and flue are suitable for installation onto and through
combustible materials provided that:
Regulations
Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and 3.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813
“Domestic Gas Installations” and the current ETCI rules.
Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from local gas
undertaking or Heatline.
-8-
- Minimum 5mm clearance is maintained around the
circumference of the flue (air intake).
- The appliance may be installed on a combustible wall
provided that it is of adequate strength to support the boiler.
- The minimum clearances from the boiler case are maintained.
6.3
Ventilation
Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
Cupboard or Compartment Ventilation
Due to the high efficiency and low casing temperature of this
boiler, cupboard or compartment ventilation is not necessary.
• Existing ventilation should be investigated for its purpose
before removing.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
7
7.1
Appliance installation
The maximum working pressure of the domestic hot water circuit
is 10 bar. If the cold water supply pressure exceeds this, then a
pressure-reducing valve must be fitted in the supply to the boiler.
Scope of delivery
‘Hard’ water areas
The appliance is delivered in a single carton with a document
pack and fittings.
The temperatures within the heat exchanger are limited by the
boiler control system to minimise scale formation within the hot
water pipework. However, in areas where the water is ‘hard’ (i.e.
more than 200 mg/L of calcium carbonate), it is recommended
that the hot water setting is reduced and that a scale reducer is
fitted, refer to the manufacturer’s instructions or consult the local
water company for additional advice.
The flues package will be ordered according to the
configuration of the installation and is purchased
seperately.
• Please check the contents.
Domestic water flow rate
2.2
2.3
2.1
2.4
The domestic hot water flow has a restrictor, factory fitted, which
reduces the flow to a maximum of:
- CaprizPlus 24 ► 8l/min / CaprizPlus 28 ► 10l/min,
Central Heating water flow rate
3
2
4
If it is necessary to alter the flow rate, the system can be fitted
with a lockable balancing valve in the main flow or return pipes.
- Heating circuit design
4.1
12a
5
10
6
4.2
4.3
1
Key
1
Boiler (x1)
2
Accessories bag
2.1 Connection bag
2.2 Flexible pipe
2.3 Plugs and screws bag for boiler fixing
2.4 PRV pipe
3
Hanging Bracket
4
Documents bag
4.1 Wall template
4.2 User, Installation and servicing manual
4.3 Guarantee
NOTE: For flue accessories, see flue instructions.
7.2
Recommendations before installing
Domestic hot water circuit design
Water pressure
The minimum working pressure to obtain the maximum domestic
flow is 0.8 bar.
4
7
11
3
2
12
8
9
1
Key
1
System drain point
2
External bypass (if required)
3
Cold water in
4
Domestic hot water supply out
5
Boiler
6
Additional expansion vessel (if required)
7
Heating return circuit
8
Heating flow circuit
9
Drain point
10 Double check valve assembly
11 Domestic cold water supply in
12 Temporary filling loop
12a Back flow prevention device and tundish
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
-9-
General
This boiler is designed for use as part of a sealed water central
heating system with fully pumped circulation. The pump,
expansion vessel and associated safety devices are all fitted
within the boiler.
Safety valve
The safety valve is an integral part of the boiler and it cannot
be adjusted. The pipe from the safety discharge valve must
discharge safely in accordance with standards.
• Ensure all cleanser is removed from the whole system before
adding an inhibitor.
For long-term corrosion protection after flushing, an inhibitor
suitable for stainless steel heat exchangers can be used. Either
Sentinel X100 or Fernox F1 inhibitor can be used.
The boiler is suitable for use on systems using softened water.
7.3
Dimensions
Expansion vessel
130
The boiler has an integral expansion vessel with a capacity of 8
litres (1.76 gallons), with a charge pressure of 0.75bar.
The heating system volume should be calculated to
ensure that the expansion vessel is suitable, it may
be necessary to add an additional vessel.
740
- In GB, Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
- In IE, current edition of I.S.813 “Domestic Gas Installations”.
Bypass
425
The boiler is fitted with an automatic bypass.
• Ensure that under no circumstances does the flow rate drop
below the figure specified, refer to chapter "Technical data".
Filling the sealed system
Suitable external filling systems are shown diagrammatically,
see diagram - Heating circuit design.
7.4
10
3
W=
24k =340
W
28k
Mounting
• Make sure that the equipment used for implementing the
installation is compatible with that of the appliance.
• Determine the assembly location. See the "Appliance
location" chapter.
The system should be pressurised to 1.0bar, indicated on the
digital display with no heating demand.
Drain points
Drain taps must be provided at all low points of the system,
which will allow the entire system to be drained.
Drain taps shall be to the current issue of BS2879.
Water treatment
Existing system- It is essential that prior to installing the new
boiler the system is thoroughly flushed.
New system- For optimum performance after installation, the
boiler and its associated central heating system should also be
flushed.
Flushing shall be carried out in accordance with BS 7593, a
chemical cleanser can be used either Sentinel X300, X400 or
Fernox F3 are suitable.
It is recommended to flush existing systems first before fitting
the new boiler.
- 10 -
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The flue is designed with an internal fall of 44mm/
metre (2.5o), therefore the hole can be drilled
horizontally.
• Use a 105mm diameter core drill for external access flue
installation (60/100 flue).
• Use a 125mm diameter core drill for internal access only flue
installation (60/100 flue).
If flue extension pipes are to be used then a core
drill size of 125mm is required. This will allow the
extension pieces to slope at 44mm/metre (2.5o)
towards the boiler.
• If fitting a side flue, extend the flue centre line into the corner
then 130mm along the adjacent wall.
• If fitting an extended side flue, determine the flue hole centre
by extending the dashed inclined line on the template to the
side wall. This dashed line is drawn at 44mm/metre (2.5o)
rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of
the flue should then be marked at 130mm from the back wall.
To allow for the flue passing through the wall at this angle
a 125mm hole should be drilled irrespective of internal or
external installation.
Hanging bracket fixing
• Take the wall template and place in the desired position
on the wall, giving due consideration to the required boiler
clearances, see chapter "Appliance location ► Clearances",
and the flue you are fitting.
Fixing to the wall
3
Due to the varied site conditions the fixings supplied may not be
suitable, please make sure that those used are.
• Drill the holes for the fixing screws in accordance with the wall
template.
• Fix the hanging bracket on the wall.
130
2
1
90°
4
5
6
Key
1
Wall template
2
Standard flue length horizontal
3
2.5° 44mm/metre inclined extended flue length
4
Wall plug
5
Hanging bracket
6
Screw
Flue hole cutting
• Mark the position of the flue centre.
• Remove the wall template, then drilling the flue hole.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 11 -
Boiler hanging
a
Ensure that the appliance is disconnected before cleansing the
system.
With regards to the Manual Handling Operations,
1992 Regulations, the following lift operation
exceeds the recommended weight for a one
person lift, refer to chapter "Manual Handling".
2
• Do not use any solvent products, due to the risk of damaging
the circuit.
a
Do not perform any 'hot work' directly under
the appliance, this may cause damage to the
appliance base. Heat may also damage the
isolation valves. Always pre-assemble pipes
before fitting them to the boiler.
• Only use original seals supplied with the appliance.
• Check that there are no leaks. Repair if necessary.
Before turning on the cold mains supply to the boiler
turn off the cold water inlet to the boiler, lock the filling
loop in the closed position and close its filling taps.
1
8.2
Safety Discharge Valve
2
Key
1
Boiler
2
Hanging bracket
1
• Two persons recommended. Lifting the boiler into position,
lean the top of the boiler slightly to the wall and position just
above the hanging bracket.
• Lower the boiler slowly and engage onto the hanging bracket
8
3
B
A
Hydraulic connection
8.1
Gas and water connections
The whole of the gas installation, including the meter, should be
inspected, tested for tightness and purged in accordance with
the current issue of BS6891 and in IE the current edition of
I.S.813 “Domestic Gas Installations”.
The gas supply pipe should be a minimum of 22mm.
The appliance may contain a small amount of
water, place a water container beneath the boiler
connections.
• Take care to clean the pipes before assembly removing any
debris or burrs. Grease and oils may need to be removed they
are not possible to remove by cleansing and flushing. Foreign
bodies in the system may enter the appliance and interrupt its
operation.
- 12 -
Key
1
Discharge pipe 15mm o.d.
2
Pressure relief valve PRV
3
Draining outlet
A PRV outlet - Extend, using 15mm Cu pipe, to terminate in a
safe location outside the building
B Appliance drain
This must be extended, using not less than 15mm o.d. pipe,
to discharge, in a visible position, outside the building, facing
downwards, preferably over a drain. To ease future servicing
it is advisable to use a compression type fitting to extend the
safety discharge valve tube.
The pipe must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling,
or steam cannot create any danger to persons, damage to
property or external electrical components and wiring.
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- 13 -
8.3
a
Connection to the condensate trap
Condensate produced by the appliance is mildly
acidic (pH 3.5 - 5.0). Use protective gloves
Condensate must only be discharged in
accordance with these instructions.
• Should the condensate be drained externally then keep the
length of external pipe as short as possible. A minimum of
32mm diameter insulated pipe should be used, with a steep a
decent as possible to the termination point.
• The pipe insulation should be water, vermin and peck proof.
• Only use push-fit plastic pipe to connect the condensate
outlet – Do not use metal pipes. Joints should be free of burrs
and obstructions such as excess adhesive to avoid resistance
to condensate flow.
The volume of condensates evacuated can reach
about 15 litres per day for a detached house. This
volume is negligible compared to the volume of
waste water discharged by a house, because the
condensates are diluted in this water.
• Refer to BS5546 and BS6798 for advice on disposal of boiler
condensate.
2
1
Key
1
Condensate pipe
2
Condensate outlet pushfit
Make sure there is no protective plug fitted.
Connect the condensate pipe (1) to the condensate outlet (2).
The pipe should have a fall of a least 2.5° 44mm/
metre away from the boiler.
Condensate should, if possible be discharged into the household
internal drainage system.
• In order to avoid problems from freezing in adverse weather
conditions it is strongly advised that condensate is discharged
into the household internal drainage system. Note some
installations may require the use of a condensate pump in
order to achieve internal discharge.
• If internal discharge is not practicable, discharge can be
allowed into the external household drains or a purpose
built soak away, refer to diagram overleaf and BS5546 or
BS6798 for reference and advice. However, the possibility
of freezing of the condensate should be considered, and all
precautions taken to prevent this. This may include the use
of trace heating. The homeowner should be notified of the
possibility of freezing in severe weather conditions, and how
to overcome the problem should it occur.
- 14 -
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9
Evacuation of combustion products
9.1
Regulation
Only flue accessories supplied by Heatline must
be used. NOTE: In accordance with Building
Regulations Part J: 2010 and the Gas Safe
Register Technical Bulletin TB 008: For Boiler
flue systems installed within any concealed
enclosure (such as a ceiling space, floor void,
or a purpose built enclosure), the entire flue
system should be accessible. This is to allow
proper inspection of the flue to determine that it
is continuous and fully supported throughout its
length and all joints are correctly assembled.
Please refer to section 9.2, which describes the flue types
available.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from
the flue outlet. This should be taken into consideration when
selecting the position for the terminal.
Carports or similar extensions of a roof only, or a roof and one
wall, require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required
to protect the roof if made of plastic sheeting. If the carport
comprises of a roof and two or more walls, seek advice from the
local gas supply company before installing the boiler.
If the flue terminal is positioned near a light
source insects may enter the flue system.
Where safe and practical to do so advise the
homeowner to check the flue outlet and clear
visible insects from the terminal end.
• Consult your supplier for more information about the other
possibilities and associated accessories.
44 mm/m
1
2
4
3
• Standard flue terminal kits have an in-built fall back to the
boiler to drain the condensate. These can be fitted level
between the appliance and the termination position. All other
extended flues must have a fall of at least 44mm/m
The maximum length of the flue outlet is defined according to its
type (for example C13).
• Whatever the kind of flue system chosen, observe the
minimum distances indicated in the chart below to position
the flue terminals.
• To install the flue, refer to the flue instructions.
• Explain these requirements to the user of the appliance.
a
If necessary, you must install a flue terminal
guard.
Caution! The connection between the flue elbow
and the flue outlet must be sealed.
In GB the minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram overleaf.
In IE the minimum distances for flue terminal positioning must
be those detailed in I.S.813 “Domestic Gas Installations”.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 15 -
Position Position of the flue terminal
Horizontal flues
directly below an opening, air brick,
A
opening windows
B
above an opening, air brick, opening windows
horizontally to an opening, air brick, opening
C
windows
D
below gutter, drain/soil pipe
E
below eaves
F
below a balcony or car port
G
from vertical drain pipes and soil pipes
H
from internal/external corners
to a boundary alongside the terminal
H(2)
I
above adjacent ground or balcony level
mm
300
300
300
25
25(1)
25
25
25
300
300
Position Position of the flue terminal
mm
J(2)
600
from surface or a boundary facing the terminal
from opening (door/window) in car port
L
into dwelling
M
vertical from a terminal
N
horizontally from a terminal
Vertical flues
P
from another terminal
Q
above roof level
R
from adjacent opening window
S
from adjacent wall to flue
1200
1500
300
600
300
1000
300
(1) There should be no ventilation/opening in the eaves within
300mm distance of the terminal.
(2) These dimensions comply with the building regulations,
but they may need to be increased to avoid wall staining and
nuisance from pluming depending on site conditions.
- 16 -
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9.2
Flue configuration description
Horizontal concentric flue Ø 60/100 mm
(C13 type installation)
a
10 Remove/replace front panel and controls
fascia
1
If necessary, you must install a terminal
protection kit.
Ø 60/100 mm
L
2
1
63
Key
1
Controls fascia
2
Controls fascia retaining screw
• Release the controls fascia (1) by loosening the securing
screws (2). NOTE: Do not remove the screws as they are
held in place by a circlip.
Key
1 Gasket (fitted)
Type
Max length
Ø 60/100
6m
1
2
2
Each time an additional 90° bend is necessary (or 2 at 45°), the
length (L) must be reduced by 1 m.
3
Vertical concentric flue Ø 60/100 mm
(C33 type installation)
Key
1
Front panel
2
Front panel retaining screw
3
Pressure guage capillary grommet
L
• Undo the two screws (2) on the underside of the front panel
and remove the front panel (1).
When closing the controls fascia slowly feed the pressure gauge
capillary through the grommet (3) in order to prevent kinking.
10.1
Type
Max length (L)
Ø 60/100
6m
Each time an additional 90° bend is necessary (or 2 at 45°), the
length (L) must be reduced by 1 m.
e
Electrical connections
Incorrect installation can cause electric shock or
appliance damage. The electrical connection of
the appliance must be made only by a qualified
engineer.
The appliance must be connected directly to an accessible,
fixed, switched, electrical spur.
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- 17 -
The external wiring must be earthed, with correct polarity and in
accordance with current standards.
• Keep a distance of a maximum of 30 mm between connector
(1) and the start of the insulation (3).
The manufacturer declines any responsibility for damages to
persons or others caused by the incorrect installation of the
appliance earthing. This includes failure to comply with current
standards.
• If using single core wires are used(2) ensure that the are
wrapped together in an insulating sheath.
• Fix the cables in the cable-clamp on the eBox.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
10.4
• Do not use cable greater than 8 mm in diameter for the
electrical connections.
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
All system components must be of an approved type.
• Do not interrupt the mains supply with a time switch or
programmer.
The boiler is suitable for installation in bathroom zones 2 and 3.
10.2
Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on each
pole. The fused spur box should be readily accessible and
preferably adjacent to the boiler. It should be identified as to its
use.
A fused (3A) three pin plug and shuttered socket outlet may be
used instead of a fused spur box provided that it is not used in a
room containing a fixed bath or shower.
Access to main board
1
3
2
2
• Connect the appliance's power cable to the 230 V singlephase network + earth.
• Connect the appliance in accordance with the live and
neutral connections.
230V permanent supply
a
Key
1
Control box
2
Control box securing screw
3
Mains cable
• Route the mains cable (3) through the grommet and connect
to the electrical plug on the controls board.
1
All cables connected to the appliance should
be permanently fixed to the wall. Ensure the
incoming electrical cable is clamped in the clamp
provided.
2
• Remove the control box securing screws (2) and pull the
control box (1) forward into the service position.
10.3
Electrical wiring
1
Main board
2
3
3
Key
1
230V permanent supply
2
Main board terminal block:
neutral
L = Mains live
3
Fuse
4
Double pole connector
30mm
max
Key
1
Connector
2
Electrical wires
3
Insulation
4
= Mains earth, N = Mains
• Connect mains supply as described.
When you connect the electrical wires to a connector on the
electronic board:
- 18 -
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10.5
230V permanent supply + 230V system controls
a
e
All cables connected to the appliance should be
permanently fixed to the wall.
External accessories
Under no circumstances must any mains voltage
be applied to any of the terminals on the 24v
connection plug.
2
3
8
1
Key
1
230V permanent supply
2
230V room stat
3
Frost stat
4
Main board terminal block
RT = Switch live (230V)
= Mains earth
N = Mains neutral
L = Mains live
5
Junction box
6
Fuse
7
Double pole connector
8
Terminal block
• Connect the mains supply and system heating controls e.g.
room thermostat as described.
X17
24 V
BUS
RT 24V
BUS
T° ext
Key
1
24V room thermostat connector
2
24V Ebus room thermostat connector or Ebus radio receiver
3
24V Outdoor sensor connector
• Fit external controls in accordance with the rules in force.
10.6
Testing the electrical connections
Carry out preliminary electrical system checks as below:
• Resistance to earth (<1 Ohm)
• Short circuit test (L-N)
• Resistance to earth (L-E)
• Polarity check
When installing 24V or 230V controller, the link fitted to the 24V
terminals (X17 RT/24 V) shown below, must be removed.
This appliance will not operate without a link or
system controls fitted. The frost thermostat will only
operate the boiler when in Winter mode. (DHW+CH)
If 230V thermostats are connected into RT then they
must all be fed from the same live source as the
boiler.
If any external 24V or 230V thermostats are connected this link
should be removed.
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- 19 -
10.7
Wiring diagram
DESCRIPTION
B
: BLACK
BR : BROWN
R
: RED
Y/G : YELLOW/GREEN
BL : BLUE
G
: GREEN
GY : GREY
W
: WHITE
P
: PINK
O
: ORANGE
PP : PURPLE
Y
: YELLOW
- 20 -
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11
Commissioning
At the time of commissioning, complete all relevant
sections of the Benchmark Checklist located in the
centre pages of this document.
The commissioning should be carried out by a competent
person approved at the time by the Health and Safety Executive
and in accordance with the current issue of BS6798.
11.1
Key
1
Air vent
2
Pump
3
Screw for the pump shaft
• Open the plug on the air vent located on the pump and
automatic air vents on the installation.
If the (CH.) pressure falls below 0.4 bar, the display will flash
the current pressure and the boiler will not operate. To increase
the pressure, the CH circuit requires " Topping up".
Switching on
When turning the 230Vac supply on to the boiler
should the water pressure be less than 0.5 bar an
automatic air vent function will be activated for a
period of 5 minutes. During this time the pressure
should be increased and air vented from the system.
Note that the burner will not fire in either the CH or
DHW mode and the display will blink displaying the
current water pressure.
• Do not operate the boiler without water.
• Make sure that the system has been thoroughly flushed out with
cold water and that all cleanser if used has been removed.
• With the gas service isolation valve closed, with no demand
from any external controls and the power supply to the boiler
switched off.
• Test for gas soundness and purge air from the gas supply.
• Vent air from each radiator until the water flows normally,
then close the vents.
• Switch on the power supply to the appliance.
• Leave the pump's air vent open.
• Make sure that the domestic hot water and heating functions
on your appliance are not activated and the hot water taps
are turned off.
11.2
Filling the CH system (Central heating)
• Make sure that the installation's cold water inlet isolating valve
is open.
• Open the water isolating valves located on the connections:
they must be positioned in the direction of the flow.
With the gas isolation valve closed and with no demand from
any external controls.
a) Fill the heating system, using your preferred method
previously described.
The following two operations will unblock the
pump' s impeller after a prolonged storage period
and will purge the air from the pumps circuit.
• Remove the screw from the pump shaft and introduce a flat
screwdriver. A trickle of water, under no pressure should
normally come out of the pump.
• Rotate the pump's shaft through several turns, then replace
the screw.
11.3
Filling DHW Circuit
• Open the various hot water taps to fill the DHW circuit.
11.4
Filling the Condensate Trap
b) Vent all air from the system, repeat as necessary until the
system is full and all the air has beren removed.
c) To comply with the water regulations the filling loop connection
must be removed.
1
1
3
2
• Remove and fill the trap (1), 3/4 full, with water.
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- 21 -
• Activate the Heating and Domestic Hot Water functions.
Display
• Run the appliance for at least 15 minutes, with a heating
temperature set to greater than or equal to 50°C (not
applicable for an installation with underfloor heating).
• Light the appliance by following the procedure below.
• Select the "Heating + domestic hot water" function by
pressing the “Mode” button repeatedly to scroll through your
are shown.
options until
• Vent air from each radiator again until the water flows
normally, then close the vents.
• If you have difficulties in removing the air, launch the airremoval programs in the heating circuit (see the chapter
("Technical settings for the appliance and list of parameters").
• Make sure that the pressure indicator shows a value of 1.0
bar; if not, top up the water again.
11.5
Initial lighting
Control
• Check that the appliance has been installed in accordance
with the instructions.
• Check the integrity of the flue system and flue seals.
• Check the integrity of the appliance combustion circuit and
relevant
1
2seals. 3
4
5
• Check that all internal/external controls are calling for heat.
• To adapt the appliance to another 4type of3 gas, see "LPG
conversion".
Adjusting the temperature
1
2
3
4
5
12
11
10
9
8
or
buttons to adjust.
• Open a hot water tap, the display will indicate the domestic
hot water temperature.
• Check that hot water is available at all taps, then close.
11.6
Gas rates
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
17
18
19
24
23
22
21
20
3
• Activate the test mode "P.01" and set the value to 100 in
order to force the burner at P. max. See chapter "Specific
adjustment ► Appliance technical settings and parameter list
► Test modes".
2
4
reset
• Press
1
4
button and the factory
• Press the hot water temperature
setting temperature will be displayed.
3
bar
buttons to adjust.
4
16
5
15
mode
6
14
7
3
1
or
Due to the modulating operation of the boiler and the
need to check the gas inlet pressure and measure
the gas rate at maximum rate, it will be necessary to
force it to maximum.
6
13
2
• Press
• On completion, test the gas installation for tightness using
the pressure drop method and suitable leak detection fluid,
purge in accordance with the above standard.
• Check that the gas service isolation is open.
6
Key
1
2
3
4
5
6
If the burner fails to ignite “F28” will be displayed, initially, this
may be due to air in the gas supply line. Press the reset button.
Do not use the reset button to purge the installation - never
press reset more than 3 times.
central heating water temperature button and
• Press the
the factory setting temperature will be displayed.
The combustion for this appliance has been
checked, adjusted and preset at the factory for
operation on natural gas (G20) as defined on the
appliance data label.
No measurement of the combustion is necessary.
Should the appliance require to be converted to LPG
gas ensure you follow the gas conversion section
before lighting the boiler.
0
The appliance will enter a self checking routine, then the fan
will start and the ignition sequence commence. The boiler, if
necessary, will automatically repeat the ignition sequence a
further 4 times.
System pressure gauge
ON/OFF and Mode selection button
Display
Temperature adjustment
Anologue clock
Reset button
- 22 -
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Operational Gas Inlet Pressure
In communal or LPG installations where the gas rate cannot be
measured it is acceptable to measure the combustion rate as
described in section 18.2.3.
• On completion, press the "reset" button with a blunt
instrument to reset the boiler.
11.7
Testing heating system
• Ensure that the external controls and programmer are calling
for heat.
1
• Fully open all radiator valves, see chapter "Appliance
installation ► Recommendations before installing ► Heating
circuit design".
• Activate the C.H. function on the appliance's control panel.
• Balance the radiators as required to give the required system
differential.
• Turn off all radiators that can be shut off by the user and
check to see if less than the maximum differential allowed of
20°C can be achieved across flow and return.
Key
1
Set point
Should the appliance require adjustment refer to the
"Specific adjustment" section overleaf.
• With all other gas appliances operating, check the
operational supply pressure at the gas valve test point.
The nominal supply pressure for Natural Gas (G20) is 20mbar.
The nominal supply pressure for LPG (G31) is 37mbar.
• Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.
• Turn the taps and appliances off, then disconnect the
pressure gauge.
• Drain the entire system rapidly whilst hot, using the drain
taps at all the low points of the system. Fill and vent the
system as described previously in chapter "Commissioning
► Filling the CH system (Central heating)".
Additionally the safe nominal heat input of the appliance can be
achieved at an inlet pressure down to 15mbar.
• Adjust the boiler temperature controls and any system
controls to their required settings.
The burner pressure cannot be measured and is not
used to measure the gas rate.
11.8
Testing domestic hot water system
• Open a hot-water tap.
Gas Rate
• Make sure that all other gas burning appliances are off.
• Check that the temperature obtained is compliant with the
setting on the appliance.
• Check the gas rate using the gas meter test dial and stop
watch, at least 10 minutes after the burner has lit, see table
below for approximate rates. To set max rate refer to section
16.1.2.
11.9
Gas rates (G20)
Gas rates (G31)
(approx) after 10 mins from cold
Model
MIN
3
m /h
24
0.882
28
0.989
MAX
ft /h
3
m /h
31.2
1.936
34.9
2.482
3
MIN
MAX
ft /h
kg/h
kg/h
68.4
0.580
1.32
87.7
0.703
1.78
3
Completion
• Ensure that the magnetic operating instruction label is placed
on the surface of the boiler casing.
GB: It is a requirement that the “Benchmark” Installation,
Commissioning and Service Record is completed and left with
the user.
IE: it is necessary to complete a “Declaration of Conformity” to
indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.
1m3 Propane - 1.87kg
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- 23 -
12 Specified Adjustment
12.1
Heating circuit adjustment
By pass operation is automatic and not adjustable.
If necessary, fit an external by-pass.
CaprizPlus 24 : 25kW
Available pressure in mCE
6.0
KEY
HEATING // 35W V1 / bypass closed
5.0
HEATING //35W V2/ bypass closed
4.0
HEATING //35W V2 / bypass middle position
HEATING //35W V2 / bypass opened
3.0
2.0
1.0
0.0
0
0
10
0
20
0
30
0
40
0
50
0
60
0
70
0
80
0
90
Water Flow in L/hr
00
10
00
11
00
12
00
13
00
14
00
15
CaprizPlus 28 : 30KW
Available pressure in mCE
6.0
KEY
HEATING // 35W V1 / bypass closed
5.0
HEATING //35W V2/ bypass closed
HEATING //35W V2 / bypass middle position
4.0
HEATING //35W V2 / bypass opened
3.0
2.0
1.0
0.0
0
0
10
0
20
0
30
0
40
0
50
0
60
0
70
0
80
0
90
Water Flow in L/hr
- 24 -
00
10
00
11
00
12
00
13
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
00
14
00
15
13 Installation settings
• Press on
to validate. The screen displays a flashing
and alternating "d." and "00".
• To adjust the operational parameters:
• Press on button
to
• Press for more than 7 seconds on the button
access the configuration menu. The screen displays "0".
• Holding in the button
service parameters.
until 35 is displayed, accesses the
or
• Press on button
and select with the
to access the parameter to modify.
to modify the value of the parameter
or
keys.
• The parameter is changed after the screen flashes 3 times.
• To exit to display menu, press the
seconds.
The screen displays "96".
• Press 4 times on the button
This is the installer's password.
button for 3
Factory
setting
Modifiable
parameter
Code
Installation Parameters
Unit
Description
d.00
Maximum heating power
kW
Choose a value 24 > 8 to 18 and 28 > 9 to 24.
d.01
Pump over-run time - heating
min
Choose a value between 2 and 60
5
yes
min
To prevent the burner frequently switching on and
off. The reactivation of the burner is electronically
blocked for a period that is determined each
time the burner stops. The burner blocking
time can be adapted to the usage conditions
for the heating.Installation and depends
on the temperature that is set for heating:
-at 80°C, the period is fixed (2 minutes)
-at 10°C ,the period is adjustable: choose a value
between 2 and 60 minutes.
20
yes
Mode:
0 = With the burner
1 = Continuous with ambient temperature
2 = Continuous
1
yes
The recommended maximum temperature setting
for DHW is 60°C. Choose a value suitable for
your needs.
60
yes
100 = Domestic Hot Water.
0 = Central Heating.
-
no
d.02
Blocking time for burner in heating mode (anti-cycle
time)
enum
yes
-
d.18
Pump function
d.20
Maximum temperature setting for domestic hot water
d.34
Speed of fan
d.35
3 way valve position
%step
Fan speed is displayed between 0 and 99.
Multiply the display value by 100.
-
-
d.36
Domestic hot water flow
l/min.
Display domestic hot water flow.
-
no
d.40
Heating flow temperature
°C
Display the heating flow temperature.
-
no
d.41
Heating return temperature
°C
Display the heating return temperature.
-
no
d.67
Time remaining before the end of the anti-cycle in
heating mode.
Display the time remaining before the end of the
anti-cycle
-
no
d.71
Maximum temperature setting for heating outlet
°C
Select a value between 50°C and 80°C.
75
yes
d.85
Minimum power setting for heating mode
kW
Minimum power setting
kW
yes
d.94
Reset the fault codes
true/
false
true/false
yes
Code
Service Parameters
Unit
d.08
Current state of the 230V room thermostat
d.09
Flow temperature set point from external eBus control
°C
rpm
min.
°C
-
Factory
setting
Modifiable
parameter
230V room thermostat :
0 = open (no heating),
1 = closed (heating mode).
-
no
Description
External eBus set value.
-
no
0 = off
1 = on
-
no
d.10
Heating pump status
d.16
Current state of the 24V room thermostat
°C
0 = open (no heating),
1 = closed (heating mode)
-
no
d.17
Flow or Return temperature monitoring
°C
Temperature regulation on flow (radiator) or return
(under-floor heating) temperature sensor.
0
yes
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 25 -
Factory
setting
Modifiable
parameter
0 = off
1 = on
-
no
0 = CH not available (summer mode)
1 = CH available (winter mode)
-
no
Fan speed is displayed between 0 and 99.
Multiply the displayed value by 100.
-
no
V
Display the digitalized ionisation voltage. Multiply
the displayed value by 100.
-
no
Unsuccessfull ignitions at first attempt
-
Display the number of unsuccessfull ignitions at first
attempt.
-
no
d.69
Unsuccessfull ignitions at second attempt
-
Display the number of unsuccessfull ignitions at
second attempt.
-
no
d.80
Operating hours in heating mode
h
Display the number of operating hours in heating
mode. Multiply the displayed value by 100.
-
no
d.81
Operating hours in domestic hot water mode
h
Display the number of operating hours in domestic
hot water mode. Multiply the displayed value by 100.
-
no
d.82
Number of burner starts in heating mode
-
Display the number of burner starts in heating
mode. Multiply the displayed value by 100.
-
no
d.83
Number of burner starts in DHW mode
-
Display the number of burner starts in DHW mode.
Multiply the displayed value by 100.
-
no
d.93
Device Specific Number
-
Select the product code of the appliance:
24 = 1
28 = 2
15
22
yes
-
All parameters stored in EEPROM (main board +
appliance interface) are reset to factory settings if
this function is activated.
0 = deactivated
1 = activated
0
yes
Code
Service Parameters
d.22
DHW demand active (tapping)
-
d.23
Central heating mode
-
d.33
Speed setpoint of fan
rpm
d.44
Digitalized ionisation voltage
d.68
d.96
Unit
Factory reset
13.1.1
Status of the appliance
• Press button
for 7 seconds to learn the current state of
functioning of the appliance.
The screen displays "S" and the state of the appliance.
• To exit to display menu, press the
seconds.
Status
S.00
S.01
S.02
S.03
S.04
S.05
S.06
S.07
S.08
Status
S.10
S.11
S.13
S.14
S.15
S.16
S.17
Status
S.20
- 26 -
button for 3
Heating Mode
No request for heating
Pre-run fan
Pre-run pump
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
Time delay anti short-cycles after heating
Domestic hot water mode
Request for domestic hot water
Pre-run fan
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
Domestic hot water heating
Pre-run pump
Description
S.21
S.23
S.24
S.25
S.26
S.27
S.28
Status
S.30
S.31
S.32
S.34
Pre-run fan
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
The boiler blocks tank reheating after a reheating cycle.
Specific messages
No request for heating or domestic water.
"Hot water only" mode
Tolerance indication time of fan speed.
"Frost protection" mode
S.35
The speed of fan in functioning phase is outside tolerance
S.36
Heating Blockage
The speed of fan in functioning phase is outside tolerance
during operation
High pressure value
Waiting cycle: temperature differential between heating flow
and return is too high. If ∆T > 30, forcing to Pmin
Waiting cycle: lack of water in the installation/temperature
rise between heating flow and return is too high
S.37
S.41
S.53
S.54
S.58
A fixed modulation until the condition provides
S.90
End of final control test
S.92
Water flow sensor control, DHW and CH is in blockage
S.95
Voltage control, DHW and CH is in blockage
S.96
S.97
S.98
Return sensor control, DHW and CH is in blockage
Water pressure sensor control, DHW and CH is in blockage
Flow/Return sensor control, DHW and CH is in blockage
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
13.1.2
Test modes
By activating these various test modes, you can enable special
functions on the appliance.
• Press the on/off button to switch off the appliance.
- Should you wish to operate the appliance on full rate it is
first necessary to change parameter d.71 to 80 degrees as
described in Section 13 Installation Settings.
- To access Test Mode P1: Whilst pressing the mode button
also depress the reset button once, with a blunt instrument.
- Continue to depress the mode button for a further 5 seconds.
P1 appears on the screen.
- Pressing the mode button again fires the burner on Min rate
indicating Lo. Using the +/- buttons the rate can be adjusted
up to maximum at 99, when Hi is displayed.
- The boiler may be operated in DHW or CH mode at max rate.
- To exit wait 15min or simply press the reset button.
- Press on button
for 1 second to exit the submenu or
for more than 7 seconds to access the configuration menu.
• Test mode "P2" to "P7" :
If you wish to check the combustion then follow the instructions
in the Servicing section.
13.2
Re-check and restart
• Once the appliance is installed, check the operation of the
appliance.
• Start the appliance to ensure that any adjustments operate
correctly and check that the appliance operates safely.
• Check the gas-tightness and water-tightness of the appliance
and eliminate any leaks.
• Check that the flue joints are tested for tightness and fitted in
accordance with the instructions.
• Check the entire control and safety system, its settings and its
operation.
14 User information
At the end of the installation, the installer must:
- Press
to launch the test mode. The screen displays
"PX" and "On".
- explain the operation of the appliance and its safety devices
to the user, if necessary provide a demonstration and answer
any questions;
- The test mode will be automatically stop after 15 minutes.
- hand over to the user all the required documentation,
• When you have finished, press the reset button
test modes.
- fill in the documents where necessary;
to exit the
Code
Parameter
Description
P.01
Forcing the
adjustablepower burner
when heating
The appliance functions at a power
adjustable from "Lo" (Lo = Pmin.) to "Hi"
(Pmax.) by using buttons
or
under
the symbol
after successful ignition.
P.02
Forcing the
burner to
heating ignition
power
The appliance functions at ignition power
after successful ignition.
P.03
Forcing the
burner to
Heating Pmax.
The appliance functions at its maximum
power after successful ignition.
P.05
Filling the
appliance
The 3 way valve is in the central position,
the pump and the burner stop so that the
appliance can be filled.
P.06
Venting the
installation
The function is activated for a period of 5
minutes on the heating circuit.
Make sure that the air vent is open.
P.07
Venting the
appliance
The function is activated for a period of 5
minutes on the short circuit.
Make sure that the air vent is open.
13.1
CO2 measurement
The combustion for this appliance has been pre-set at the
factory for operation on Natural Gas G20 as defined on the
appliance data label.
No adjustment of the combustion is necessary.
- advise the user of the precautions necessary to prevent
damage to the system, appliance and the building;
- remind the user to service the appliance annually.
• Draw attention, if applicable, to the current issue of the
Gas Safety (Installation and Use) Regulations, Section 35,
which imposes a duty of care on all persons who let out any
property containing a gas appliance in the UK.
The user shall not interfere with or adjust sealed components.
It is the Law that any servicing is carried out by a competent
person approved at the time by the Health and Safety
Executive.
• Advise the user that, like all condensing boilers this appliance
will produce a plume of condensation from the flue terminal
in cool weather. This is due to the high efficiency and low flue
gas temperature of the boiler.
• Advise the user that the permanent mains electrical supply
should not be switched off, as the built in frost protection and
pump exercise program will not operate.
• Advise the User if the mains electricity and gas are to be
turned off for any long periods during severe weather, it is
recommended that the whole system, including the boiler,
should be drained to avoid the risk of freezing.
Sealed system: The system must be refilled and to
the correct pressure as indicated in these instructions
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 27 -
• Leave these instructions and the ‘Benchmark’ Installation,
Commissioning and Service Record with the user.
• Re-pressurise the system as instructed by your installer.
is displayed on the screen, display the
• If the symbol
fault code memory (see chapter " Trouble-shooting ►Fault
memory").
• Press the reset button
to restart the appliance.
• Check the functional flow diagram.
MAINTENANCE
15.1.1
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon
the particular installation and usage, but in general once a year
should be enough.
It is the Law that any servicing is carried out by a competent
person approved at the time by the Health and Safety
Executive.
Check the electrical installation
3
2
1
V
• Before commencing with a service or replacement of parts
isolate the boiler from the electrical supply and turn off the
gas supply at the gas isolation valve.
4
• When replacing a part on this appliance, use only spare
parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly
authorised by Heatline.
• If any electrical connections have been disconnected and
after their connection, checks to the earth continuity, polarity,
short circuit and resistance to earth must be repeated using a
suitable multimeter, as described in chapter "Trouble-shooting
► Fault diagnosis ► Check the electrical installation".
• After servicing, complete the relevant Service Interval Record
section of the Benchmark Checklist located in the back pages
of this document.
15 Trouble-shooting
15.1
Key
1
Main board
2
Neutral
3
Live
4
Multimeter
• Remove the front casing panel
Fault diagnosis
The following checks should be performed before proceeding
onto specific diagnostics:
• Make sure that the electricity supply has not been interrupted
and that the appliance is connected correctly (See chapter
"Trouble-shooting ► Fault diagnosis ► Check the electrical
installation")
• Check the appliance’s gas supply (See chapter "Troubleshooting ► Fault diagnosis ► Check the gas supply").
• Check the external electrical supply to the boiler is on and a
supply of 230V is present at the ‘L’ and ‘N’ terminals on the
main board.
• Check the electrical installation and appliance, carry out tests
for earth continuity, polarity, short circuit and resistance to
earth, using a suitable multimeter.
• Check the link FP –RT is secure or the connected control,
connected at these points, is functioning correctly.
• Bare metal points such as screws or rivets will act as suitable
earth check points on the appliance.
• Ensure that the isolating valves are open.
• Ensure that the pressure indicator displays a value of 1.0 bar
(if the pressure falls below 0.4 bar, the air vent function will
run automatically for a period of 5 minutes until you see 0.5
bar on the pressure indicator). If not, re-charge the system.
• Check that all external controls are connected correctly.
- 28 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
15.1.2
Check the gas supply
15.2
Fault memory
• This menu allows you to display the 10 most recent failure
codes registered by the appliance.
YELLOW
1
• In order to display the fault code memory, simultaneously
and
for more than 7 seconds.
press the buttons
• The screen will display the first fault "1." (record) and after
"XX" (fault code).
Key
1
Gas service isolation valve
• To display the other faults registered by the appliance, press
or
.
the button
• Check that there is a gas supply to the boiler and the gas
service isolation valve is turned on.
• Press button
menu.
• Check pressure at the gas service isolation valve.
for more than 3 seconds to exit this
Record
Fault code
1.
XX
Description
Consult the “Fault codes” chapter.
2.
XX
Consult the “Fault codes” chapter.
3.
XX
Consult the “Fault codes” chapter.
4.
XX
Consult the “Fault codes” chapter.
5.
XX
Consult the “Fault codes” chapter.
6.
XX
Consult the “Fault codes” chapter.
7.
XX
Consult the “Fault codes” chapter.
8.
XX
Consult the “Fault codes” chapter.
9.
XX
Consult the “Fault codes” chapter.
10
XX
Consult the “Fault codes” chapter.
• To erase the fault memory registered by the appliance,
consult the “Installation adjustments” chapter and use code
“d.94”.
15.3
Fault codes
The faults described in this chapter should be carried
out by a qualified engineer and if needed by the After
Sales Service.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 29 -
Fault
Description
codes
Cause
Solution
F00
Flow heating temperature sensor fault
Sensor open circuit
F01
Return heating temperature sensor fault
Return heating temperature sensor
disconnected
F10
Flow heating temperature sensor fault
Sensor short-circuit
F11
Return heating temperature sensor fault
Return heating temperature sensor
shorted.
Overheating fault
Overheating safety device activated
(97°C)
• Check the operation of the pump.
• Check the wiring harness.
• Check that the flow and return heating isolation
valves are open.
F22
Water pressure of the installation (<0.3 bar)
Return water valve closed
Pump disconnected
Leak in the installation
• Fill the installation.
• Purge the installation.
• Check the pump connections.
• Check the flow and return heating sensor
connections.
• Check that there are no leaks.
F23
Maximum temperature difference reached
between return and flow heating
Water circulation fault
• Check the flow and return heating sensor
connection.
• Check the pump speed.
F24
Water circulation fault
Malfunction of the pump (excessively
rapid temperature increase)
• Check that the flow and return heating isolation
valves are open.
F26
Fault in gas valve motor.
Disconnected or defective cables
• Check the gas valve connections.
• Check the operation of the gas valve.
• Check the operation of the condensate pump (option).
F27
Flame detection fault.
Abnormal flame detection
• Check the flame detection electrode.
• Check the main board.
• Check the igniter unit.
F28
Ignition fault
F29
Loss of flame during operation
No return gas / Insufficient gas flow
Gas valve incorrectly adjusted
Defective firing electrode and flame
control / Defective igniter unit
• Check the return gas circuit (gas valve open).
• Check the observe the flame picture and check
the CO2 setting.
• Check the igniter unit connections.
• Check the state of the electrode (corrosion).
F32
Incorrect air pressure
Incorrect fan speed.
• Check the entire flue system.
• Check the fan’s electrical connections.
F49
EBUS voltage fault
Fault in EBUS line
Short circuit in EBUS connector
• Check that the eBus controls are fitted and wired
correctly.
F20
F61
Gas valve command fault
F62
Gas valve closure fault
F63
Fault in the main board memory
F64
Fault in the main board
Rapid fluctuation of return or flow
heating sensor.
• Check the sensor’s connections.
• Check the wiring harness.
• Check the sensor.
• Check the main boards connections.
• Check the main board.
• Check the appliance DSN number is correct.
• Reset the appliance.
F65
Excessive main board temperature
F67
Flame signal fault in the main board
F68
No return gas / Insufficient gas flow
Gas valve incorrectly adjusted
Defective firing electrode and flame
control / Defective igniter unit
• Check the return gas circuit (gas valve open).
• Check the observe the flame picture and check
the CO2 setting.
• Check the igniter unit connections.
• Check the state of the electrode (corrosion).
Fluctuation of flame signal
F70
User interface incompatible with the main
board
Incorrect product code
• Check that the appliance DSN code on the screen
matches the product code of the nameplate (in the
event of a fault and the appliance DSN does not
appear, consult menu.d.93 reserved for the code).
• Check the boards reference.
F71
Flow heating temperature sensor fault
Flow heating temperature sensor
unclipped or defective (no
temperature variation)
• Check the sensor connections.
• Make sure that the sensor is clipped to the tube.
F72
Permanent temperature difference between
flow and return heating sensors
Mismatch between the flow and return
heating temperatures (permanent
difference)
• Check temperature sensors connections.
• Replace faulty sensors.
- 30 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
Fault
Description
codes
Cause
Solution
F73
Heating circuit pressure sensor fault
The sensor is shorted or disconnected.
F74
Heating circuit pressure sensor fault
Fault in pressure sensor
• Check the sensor’s connections.
• Check the sensor.
F76
Thermal fuse fault
Thermal fuse disconnected
Defective thermal fuse
• Check the fuses connections.
• Replace the heat exchanger.
F77
Fault in gas valve motor.
Defective gas valve.
Defective condensate pump (option)
• Check the gas valve connections.
• Check the operation of the gas valve.
• Check the operation of the condensate pump (option).
F83
No water in the installation : the temperature
does not increase when the burner is lit
Return water valve closed
Pump disconnected
Leak in the installation
• Fill the installation.
• Purge the installation.
• Check the pump connections.
• Check the flow and return heating sensor
connections.
• Check that there are no leaks.
F84
Permanent temperature difference between
flow and return heating sensors
Inverted or disconnected flow and
return heating temperature sensors
Defective temperature sensors
• Check temperature sensors connections.
• Replace faulty sensors.
F85
Flow and return heating sensors fault
Flow and return heating temperature
sensor connected to same tube
• Check temperature sensors connections.
F86
Underfloor heating contact fault
Floor heating contact open
Sensor disconnected or defective
• Check the sensor connections.
• Check that the sensor is connected to the main
board and the shunt is removed.
Err
User interface fault
Defective user interface
• Check connection from user interface PCB to main
PCB.
• Replace user interface.
15.4
15.4.1
Functional flow diagram
Central Heating
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 31 -
15.4.2
Domestic Hot Water
16 Gas conversion adjustments
Conversion of this appliance to run on LPG requires a
conversion kit . The kit and the conversion operation must be
done by the Heatline Service Team, please ring : 0844 736
9138 . Please note that if the appliance requires conversion,
the installer should be qualified by Gas Safe Register to install
LPG appliances in order to complete the installation and its
notification after conversion has been done.
- 32 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
17 Draining
• To obtain service, please call your installer or Heatline’s
own service organisation.
17.1
PLEASE NOTE: During routine servicing, and after any
maintenance, we recommend that the following must be
checked:
Heating circuit
- The integrity of the flue system and the flue seals,
- The integrity of the boiler combustion circuit and the
relevant seals,
- The operational (working) gas inlet pressure at maximum
rate,
2
B
A
- The combustion performance.
• See the "Safety instructions" chapter for a list of operations
to be performed prior to the maintenance of the application.
1
2
Key
1
Length of hose (not supplied)
2
Drain valve
• Drain down the heating circuit of the boiler only, by closing
the heating flow and return isolating valves. See chapter
"Hydraulic connection ► Gas and water connections"
• Attach a length of hose (1) to the drain point and open the
drain valve (2).
• After draining, close the drain valve (2) and remove the hose.
17.2
- The gas rate,
Domestic Hot water circuit
• Drain the Domestic Hot Water circuit by closing the coldwater isolation valve.
• Open one or more hot water taps to drain the hot water
circuit.
• Once the maintenance operations have been completed,
consult the ¨Start Up¨ chapter to restart the appliance.
18.1
18.1.1
Annual Maintenance
Verification of components
• Check that the flow sensor is working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.36”.
• Check that the fan is working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.34”.
• Check that the temperature sensors are working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.3, d.4, d.40, d.41”.
• Check the ionisation quality.
• Check that the thermal fuse protects the appliance against
dry fire. Disconnect the thermal fuse and check if "F76"
fault code is displayed on the screen.
18 Servicing
• To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals.
The frequency of servicing will depend upon the particular
installation conditions and usage.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
• Servicing/maintenance should be carried out by a
competent person approved at the time by the Health and
Safety Executive in accordance with the rules in force in the
countries of destination.
• Check that the pressure sensor is working properly. The
pressure must be displayed on the screen.
• Check the pressure of the expansion vessel.
18.1.2
Other checks
• Check the CO2 and fuel rate and compare them with the
values in the chapter “CO2 Measurement” If the flame
picture and combustion is OK then there is no need to
remove the combustion box door, continue with the checks
below. Should the combustion be out of range continue
with a full service noting that should the combustion
chamber be opened then the graphite seal (12) and
the locking nuts (7) as seen in diagram 18.9 should be
replaced.
• Check that there are no leaks in the joints and the safety
valves.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 33 -
• Check that there are no gas leaks.
• Ensure that the gas analyser is set to the correct fuel setting.
• Verify that the flue system is sound and complete.
• Select the “
+ ”, constant central heating with DHW
function by pressing the “
” button repeatedly, refer to
commissioning section. The boiler should fire automatically.
• Check the appliance’s electrical safety.
18.1.3
Cleaning the condensate system
Safe combustion can only be verified by measuring
CO/CO2 ratio. This must not exceed the value shown
in the table opposite.
- Pull off the hose from the trap bottom.
- Twist the base of the condensate trap anti-clockwise and
remove.
18.2.2
- Should the trap be stuck a large allen key can be inserted into
the bottom socket to ease its removal.
Prior to, during servicing and after any maintenance or changed
parts, the following must be checked.
- Clean as required filling half full before refitting.
• The integrity of the flue system and flue seals.
- Check the internal hose connections and pipes for any debris
& contact with any hot surfaces such as the flow & return
pipes.
• The integrity of the appliance combustion circuit and relevant
seals.
18.1.4
Corrosion and anti-sludge protection
In order to avoid corrosion, the addition of a corrosion inhibiter to
the heating circuit water is recommended. The inhibitor will stop
electrolytic reaction and bacterial growth between the different
metals used in the installation.
It will also avoid the formation of gas which could be produced
following the chemical reactions.
It is especially important to treat the water in underfloor heating
systems, as low temperatures favour bacterial growth. This can
lead to the formation of sludge, which in turn may block some or
all of the circuits.
In order to add the correct dosage of these products, you must
know the volume of water contained in the installation. It is
recommended that you note down the volume for future needs.
The inhibitors must be compatible with the materials employed
in the installation.
18.2
18.2.1
Preliminaries
• Electrical, gas and water connections.
• System pressure.
• The combustion performance, refer to the following
procedure.
• The operational gas inlet pressure and gas rates, refer to
the commissioning section paragraph 12.5. Correct any fault
before continuing.
Combustion check and setting the air/gas ratio
• Remove the front casing panel and pull the control box into
the service position as described previously. Taking care not
to touch any internal components, proceed as follows:
• Connect the CO2 combustion analyser to the relevant test
point.
2
3
Combustion check and setting the air/gas
ratio valve
Competency to carry out the check of
combustion performance
BS 6798: 2009 Specification for installation and
maintenance of gas-fired boilers of rated input not
exceeding 70kW net advises that:
1
24
- The person carrying out a combustion measurement must be
assessed as competent in the use of a flue gas analyser and
the interpretation of the results.
- The flue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated
in accordance with the analyser manufacturers’ requirements.
- Competence can be demonstrated by satisfactory completion
of the CPA1 ACS assessment, which covers the use of
electronic portable combustion gas analysers in accordance
with BS 7967, parts 1 to 4.
- 34 -
2B
2A
Key
1
Throttle
2
Combustion analyser sample point
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
18.2.5
2A Flue elbow
2B Vertical flue adaptor
3
Cap
18.2.3
If it is not possible to achieve the required results for either the
combustion or gas rates, it will be necessary to complete a full
service of the appliance and then repeat the combustion check
procedure.
Maximum rate check and adjustment
To verify the maximum gas rate CO2 setting the
appliance must be checked at the maximum rate.
• Activate the test mode "P.01" and set the value to 99? in
order to force the burner at P. max. See chapter "Specific
adjustment ► Appliance technical settings and parameter list
► Test modes".
• Wait approximately 5 minutes to read a stabilised CO2 value.
If after servicing and adjustment of the appliance the combustion
values are still unacceptable and after further remedial work has
been carried out, the appliance must be disconnected until the
CO/CO2 ratio is acceptable.
• Advice can be sought from the Heatline Technical Helpline.
18.3
28
Servicing
If the Flame Picture, Combustion & Gas Rate
checks did not identify a problem then it will not be
necessary to remove the combustion chamber door.
• Check that the value is within the range specified in table in
the “check” column.
24
Completion
G20
G31
G20
G31
Ratio
All routine servicing requirements can be achieved by the
removal of the front panel.
CO2 case ON
9.2 ± 0.3
10.3 ± 0.3
9.2 ± 0.3
10.3 ± 0.3
<0.004
• Position the control box into the service position.
CO2 case OFF
9.0 ± 0.2
10.1 ± 0.2
9.0 ± 0.3
10.1 ± 0.2
<0.004
• Before commencing with a service or replacement of parts,
isolate the boiler from the electrical and gas supplies.
Gas adjustment
• If the combustion reading is not within the acceptable values
and the integrity of the complete flue system and combustion
circuit seals have been verified and the inlet gas pressure
(and gas rate) have been verified, then, it will necessary to
adjust the combustion rate of the appliance.
Adjustment is made by turning the throttle an ⅛
of a turn, waiting 1 minute to allow the appliance
to stabilise before checking or making further
adjustments.
18.3.1
Service interval record
• Refer to benchmark Service Interval Record at the rear of this
manual.
18.4
Silencer
2
3
• Remove the sticker covering the “throttle” adjustment screw,
if fitted.
• Rotate the “throttle” (1) (anti-clockwise to increase), to the
required CO2, refer to previous diagram and the “Setting”
column in the table.
1
• When you have finished, press the On/Off button to exit the
test modes.
• Remove the analyser probe and replace the cap on the
sampling point, replace the controls fascia, and the front
casing panel.
Remember to replace the sample point cap on
completion of the test.
18.2.4
Gas rate check
• Check the gas rates as described in the commissioning
section.
Key
1
Silencer retaining screw
2
Fixed silencer
3
Removable silencer
• Remove the silencer retaining screws (1) and remove the
silencer (3).
• Clean the interior of the silencer with a dry cloth if necessary,
taking care not to damage the internal foam.
• Repeat the operation in reverse order to replace the silencer.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 35 -
18.5
Expansion vessel
There is a filter fitted that protects the plate heat exchanger from
blockage.
2
• After draining the boiler as previously described push and
turn the filter cap in an anti-clockwise direction to release it
from its housing.
• Pull the cap out with the filter attached.
• Clean and replace as necessary refilling and re-pressurising
the boiler as required.
1
18.7
Heating filter
1
2
Key
1
Expansion vessel
2
Expansion vessel pressure inlet
• Check the expansion vessel's supply pressure (see «
Technical Data » chapter) by means of the pressure inlet
located on the expansion vessel. Adjust the pressure if
necessary.
3
• Following the installation of a new expansion vessel, fill and
purge the appliance or installation, if necessary.
18.6
BL
UE
Plate heat exchanger filter
1
Key
1
Filter
2
Filter valve body
3
Cap
The filter valve located under the boiler at the right hand side
prevents debris from entering the boiler. Should this become
blocked
2
• shut off the Heating Flow and Return Filter Valve by turning
the levers clockwise.
• Drain the boiler from the drain cock behind the pump or by
removing the cap "3" from the filter valve.
3
• Remove and clean the filter and refit in reverse order, topping
up the water pressure via the filling loop as required.
Key
1
Filter housing
2
Filter
3
Filter cap
- 36 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
18.8
a
Condensate trap
• Disconnect the condensate drain (3) and the rain water
collector (4) from the heat exchanger.
Warning: condensate is mildly acidic. Use
protective gloves.
The condense trap will contain water, lift taking care not to spill
the water.
4
3
• Remove the screws (6) to disconnect the condensate trap (5).
• Clean the hose, the trap and the siphon, remove any
accumulated dirt.
5
• Reassemble the components, taking care to position the
gaskets correctly.
6
• Fill the reservoir (2) before assembly.
2
1
Key
1
Condensate outlet
2
Condensate reservoir
3
Condensate drain
4
Rain water collector
5
Condensate trap
6
Condensate retaining screw
• Place a container under the condensate trap (5).
• Disconnect the condensate pipe from the reservoir (1).
• Disconnect the condensation reservoir (2).
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 37 -
18.9
Combustion block
9
8
7
6
5
10
4
11
3
12
2
13
1
14
15
16
17
Legend
1
Gas valve connection
2
Grounding cable
3
Spark electrode inlet
4
Spark electrode retaining screw.
5
Spark electrode gasket
6
Spark electrode
7
Burner retaining nut
8
Burner retaining screw
9
Thermal fuse connection
10 Coil
- 38 -
11
12
13
14
15
16
17
Heat exchanger
Burner door seal
Burner
Gas valve
Fan
Fan connection
Gas pipe
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
18.9.1
Spark electrode
18.9.5
Re-assembling the burner group
• Disconnect the electrode inlet (3) and the grounding cable (2).
• Place the burner group on the heat exchanger (11).
• Remove the 2 spark electrode retaining screws (4).
• Progressively tighten 4 nuts (7) in an alternate order.
• Carefully remove the electrode from the combustion chamber.
• Reassemble the silencer.
• Check that the extremes of the electrode (6) are not
damaged.
• Check and replace the fibre washer as necessary.
• Clean away any accumulation of dirt and check that the
distance between the two electrodes is between 3.5 and 4.5
mm.
• Check that the gasket (5) is not damaged. Replace if
necessary.
18.9.2
Removing the combustion/door assembly
DO NOT REMOVE the burner door, unless
you have checked the flame picture and
the combustion with a flue gas analyser
and found a problem. Otherwise it will not
be necessary to remove the burner door.
Warning: The burner door seal (12) and nuts (7)
must be replaced each time the burner door is
removed and at least every 5 years. Note: the
nuts are supplied with the seal.
• Disconnect the spark electrode assembly (6) by removing the
screw (4).
• Remove the gas pipe (17).
• Remove the connectors from the gas valve (1) and the fan
(15).
• Remove the retaining screw of the silencer. Pull the silencer
down 90O.
• Loosen the 4 nuts (7).
• Remove the burner group from the heat exchanger (11).
• Connect the gas tube (17).
• Connect the connector (1) to the gas valve (14) and the fan
(15).
• Open the appliance gas input.
• Check the tightness of the gas connection.
18.10 Service completion
• Re-check the combustion, see chapter "Combustion check".
On completion of the service, the "Benchmark" Service Record
sould be completed.
19 Replacement of Parts
• Do not use reconditioned or copy parts, only use original
parts supplied by Heatline.
• If a part is required, contact the Heatline service organisation.
• Please quote the name and serial number of the appliance,
this information will be on the front of the appliance.
• If in doubt seek advice from the local gas company or
Heatline’s own service organisation.
a
Replacement of parts must be carried out by a
competent person approved at the time by the
Health and Safety Executive.
• The studs (8) fixed to the heat exchanger must not be
damaged. Should it be damaged, replace the heat exchanger.
PLEASE NOTE: After changing part of the combustion circuit
ALWAYS check the following:
• The combustion door assembly insulation should be
inspected and replaced if damaged.
- The integrity of the flue system and the flue seals,
18.9.3
Cleaning the heat exchanger
• Clean the coil (19) in the heat exchanger (11) with water.
18.9.4
Burner control
• The burner (13) does not require maintenance and should not
be cleaned.
- The integrity of the boiler combustion circuit and the relevant
seals,
- The operational (working) gas inlet pressure at maximum
rate,
- The gas rate,
- The combustion performance.
• Check that its surface is not damage. Replace the burner if
necessary.
• Following the verification or replacement of the burner,
assemble the burner group as described in the following
chapter.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 39 -
19.1
General
19.3.1
The replacement of parts described in sections
"Combustion block" will require the removal of
the burner module assembly and the replacement
of seal and self locking nuts.
Expansion vessel
3
4
2
Replacement parts that have associated components that need
replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be
supplied and should be fitted.
• Before replacing any parts of the boiler, isolate from the
mains electric supply and turn off the gas at the gas service
isolation valve on the boiler.
Unless stated otherwise parts are replaced in the reverse order
to removal.
• After replacing any parts, always test for gas soundness and
if necessary carry out functional test of the controls.
19.2
Boiler Access
For replacement of parts, the front casing panel of the boiler will
need to be removed.
• To remove, undo the two screws on the underside of the
front casing and open the control box door. Remove the two
front panel retaining screws, which are now accessible, and
remove the front panel.
19.3
2
Viewing window
5
C
B
1
Key
1
Connector (flexible hose)
2
Expansion vessel
3
Upper support bracket
4
Retaining screw
5
Gasket
2
1
Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
3
4
• Remove the two screws (4).
• Undo the connector (1) at the base of the vessel.
• Remove the expansion vessel (2).
5
Key
1
Fibre washer
2
Steel washer
3
Glass
4
Steel washer
5
Circlip
• Fit a new gasket between the expansion vessel and
connector.
• Refill, vent and pressurise the boiler.
• Remove the circlip (5).
• Remove the steel washer (4).
• Remove fibre washer (1).
• Remove the glass (3).
- 40 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
19.4
Hydraulic block
31
32
33
34
9
21mm
11
10
18mm
7
8
16
30
26
25
14
6
5
13
29
28
4
15
17
18
19
27
2
3
24
23
22
1
21
20
Key
1
Three-way valve motor
2
Three-way valve electrical plug
3
Three-way valve electrical plug retaining clip
4
Low water pressure sensor connector
5
Low water pressure sensor
6
Low water pressure sensor retaining clip
7
Heating flow pipe retaining clip
8
Heating flow pipe
9
Heating flow pipe filter assembly
10 Heating flow pipe retaining clip
11 Gas pipe
12 Flow sensor electrical plug
13 Flow sensor
14 Heating return pipe
15 Expansion vessel pipe
16 Plate-to-plate heat exchanger
17 Automatic air vent
18 Expansion vessel pipe clip
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Automatic air vent retaining clip
Pump head retaining screws
Pump housing
Pump head connector
Plate-to-plate heat exchanger retaining screws
Safety Discharge Valve
Bypass Valve
Bypass Valve retaining nut - rear
Bypass Valve retaining nut - front
Impeller housing
Safety discharge valve plastic housing
Hydroblock assembly clip
3 way valve housing
O-ring
3 way valve shaft group
3 way valve upper plastic block
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 41 -
19.4.1
Pump (head only)
19.4.5
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• Disconnect the electrical plug (22) from the main board.
• Remove the four cap head screws (20).
• Carefully remove the pump head (21) together with cable.
Do not strain cable.
Flow sensor and impeller
• Remove the the electrical connection (12).
• Unclip the flow sensor (13).
• Unscrew the impeller housing (28) and remove the impeller.
19.4.6
Bypass
• Reconnect wiring to new pump head and fit cover.
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• Fit the new pump head by repeating the operations in
reverse.
• Remove the bypass valve retaining nut (26) to remove the
bypass from its housing (25).
19.4.2
• After replacing the bypass, refill, vent and pressurise the
boiler.
Automatic air vent
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
19.4.7
• Remove the retaining clip (19).
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• Remove the automatic air vent (17).
3 way valve motor and diverter valve
• Disconnect the electrical plug (2).
• Fit the new automatic air vent and ‘O’ ring ensuring the vent
cap is left loose.
• Remove the retaining clip (3).
• Refill, vent and pressurise the boiler.
• Remove the three way valve motor (1).
19.4.3
Low water pressure sensor
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• Remove the diverter valve retaining nut.
• Remove the diverter valve.
• Fit new three way valve motor and diverter valve assembly.
• Disconnect the electrical lead (4).
• Refill, vent and pressurise the boiler.
• Remove the retaining clip (6), remove the low water pressure
sensor (5).
19.4.8
• Fit the new low water pressure sensor.
• Drain the boiler heating and domestic hot water circuits as
described in the appropriate chapter "Draining".
• Refill vent and pressurise the boiler.
19.4.4
Safety discharge valve
Plate-to-plate heat exchanger
• Remove the two securing screws (23).
• Remove the plate-to-plate heat exchanger (16).
• Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• When replacing the plate-to-plate heat exchanger, ensure that
the four rubber sealing washers are fitted into the hydroblock.
• Remove the low water pressure sensor as described in the
previous section.
NOTE: The plate-to-plate heat exchanger only fits one way.
• Undo the safety discharge valve union and remove the pipe.
• Refill, vent and pressurise the boiler.
• Disconnect the Central Heating isolation valve.
• Remove the securing clips and withdraw the safety discharge
valve plastic housing (29).
• Remove the safety discharge valve.
• Fit new ‘O’ ring. Refill, vent and pressurise the boiler.
- 42 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
19.5
Combustion block
19
20
21
18
17
16
15
14
13
12
22
11
23
10
24
9
25
8
26
27
29
28
30
7
31
6
38
32
5
4
37
33
3
36
2
1
34
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
35
Igniter unit retaining bracket
Igniter unit
Igniter unit retaining screw
Igniter unit electrical connector
Electrode / igniter unit connection cable
Earth cable
Spark electrode cap
Spark electrode retaining screw
Spark electrode gasket
Spark electrode
Combustion burner door assembly
Combustion burner door assembly - nut
Combustion burner door assembly - gasket
Burner gasket
Burner
Burner retaining screw
Heat exchanger retaining screw
Heat exchanger retaining bracket
Burner gate retaining screw
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Thermal fuse connection
Heat exchanger
Heat exchanger retaining bracket
Heat exchanger retaining screw
Heating return pipe
Heating return pipe retaining clip
Return heating temperature sensor (blue)
Heating flow pipe
Flow heating temperature sensor (red)
Heating flow pipe retaining clip
Gas valve retaining screw
Gas valve
Gas valve gasket
Fan
Fan electrical connection
Fan/burner gasket
Gas pipe
Gas valve electrical connection
Fan retaining screw
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 43 -
19.5.1
Spark electrode
19.5.5
• Disconnect the electrode cap (7) and the earthing cable (6).
Heat exchanger
There will be water in the heat exchanger.
Carefully ease heat exchanger out.
• Remove the 2 spark electrode retaining screws (8).
• Carefully remove the electrode (10) from the combustion
chamber.
• Drain the boiler heating and hot water circuits as described in
the appropriate chapter "Draining".
• Remove the gasket (9).
• Remove the flue connection.
• Check that the distance between the 2 electrodes is between
3.5 and 4.5 mm.
• Undo the two screws located on the top of each side panel.
• Install the electrode and a new gasket.
19.5.2
Igniter unit
• Remove the ignition connections.
• Remove electrical connections (4).
• Loosen the screws (3) located on the igniter unit (2).
• Remove the igniter unit (2).
19.5.3
Removing the combustion/door assembly
Warning: The gasket (13) must be replaced each
time the combustion/burner door assembly is
removed.
• Remove the thermal fuse connector (20).
• Remove the 2 heating pipe retaining clips (25) and (29).
• Release the heating pipes (24) and (27) from the heat
exchanger.
• Release the condensate trap pipe from the heat exchanger.
• Remove the combustion/burner door assembly (11) refering
to chapter "Removing the combustion/burner door assembly".
• Unscrew the 4 retaining screws (17) and (23) and remove the
2 retaining plates (18) and (22) from the heat exchanger.
• Pull the heat exchanger towards you to extract it from its 2
side rails.
19.5.6
Re-assembling the burner group
• Disconnect the spark electrode cap (7) from the igniter unit.
• Place the burner assembly on the heat exchanger (21).
• Disconnect the gas supply pipe (36) at the gas valve.
• Progressively tighten the 4 nuts (12) in an alternate order.
• Remove the electrical connectors from the gas valve (37) and
the fan (34).
• Reassemble the silencer.
• Remove the retaining screw of the silencer. Pull the silencer
down 90O.
• Loosen the 4 nuts (12).
• Remove the combustion/burner door assembly from the heat
exchanger (11).
• The studs (19) must not be damaged. If damaged you will
need to replace the heat exchanger.
• The combustion/burner door assembly insulation should be
inspected and replaced if damaged.
19.5.4
• Connect the gas pipe (36) with a new gasket to the burner
group.
• Connect the spark electrode connector (5) to the igniter unit.
• Connect the connector to the gas valve (37) and the fan (34).
• Open the appliance’s gas input.
• Check the tightness of the gas connection.
19.5.7
Heating Flow Thermistor
• Remove the electrical connections from the thermistor (28).
• Remove the thermistor and clip from the flow pipe (27).
Burner
• Remove the 3 burner retaining screws (16).
When reconnecting, the polarity of the wiring to
thermistors is not important.
• Remove the burner (15) and the gasket (14).
• Fit the new burner and the new gasket.
19.5.8
Heating Return Thermistor
• Remove the electrical connections from the thermistor (26).
• Remove the thermistor and clip from the return pipe (24).
- 44 -
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
When reconnecting, the polarity of the wiring to
thermistors is not important.
19.5.9
Gas valve
19.6
a
• Remove the burner door (11) refering to chapter "Dismantling
the burner door".
3
• Remove the two gas valve retaining screws (30).
5
Condensate trap
Warning: condensate is mildly acidic. Wear
protective gloves.
4
• Remove the gas valve (31) and the gasket (32).
• Fit the new gas valve and the new gasket by repeating the
operations in reverse.
6
• After assembly test for gas tightness and purge in accordance
with the current issue of BS6891or in IE, the current edition of
I.S.813 “Domestic Gas Installations”.
• Check the combustion CO2 and set value if required (see
sections 18.2.2 and 18.2.3).
19.5.10
2
Fan
• Remove the burner door (11) refering to chapter "Dismantling
the burner door".
• Remove the gas valve (31) (see previous paragraph).
1
• Loosen the 3 screws (38) located on the burner door (11).
• Remove the fan (33) and the gasket (35).
• Fit the new gasket (35).
• Screw the new fan to the burner door (11).
• After assembly test for gas tightness and purge in accordance
with the current issue of BS6891or in IE, the current edition of
I.S.813 “Domestic Gas Installations”.
Key
1
Condensate outlet
2
Condensate reservoir
3
Condensate trap
4
Condensate retaining screw
• Place a container under the condensate trap (3).
• Remove the condensate from the reservoir (2).
• Disconnect the condensate outlet (1).
• Disconnect condensate drain and rainwater collector from the
top of the condensate trap.
The condense trap will contain water, lift taking care not to spill
the water.
• Remove the condensate trap (2) using the retaining screws
(4).
• IMPORTANT: Partially fill the condensate trap with water
before replacing.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 45 -
19.7
PCB
19.7.3
User interface PCB
When replacing the board refer to instructions
supplied with the spare part.
19.7.1
3
Main PCB
4
1
3
2
Key
1
Retaining clips
2
User interface PCB
3
Electrical connection
Key
1
Main PCB
2
Retainings clips
3
Electrical connections
4
Control box
• Disconnect the electrical connections (3) from the Main PCB,
noting their positions.
• Ease back the two PCB retaining clips (2) and withdraw the
PCB (1) from the retaining lugs.
• When refitting, ensure leads are not trapped.
19.7.2
2A Fuse Rating
• For access, refer to chapter "Main PCB".
• The fuse is located at top right hand side of the PCB, see
chapter "Electrical connection ►Wiring diagram".
- 46 -
2
1
• Ease back the PCB retaining clips (1) and withdraw the user
interface PCB (2) from the retaining lugs.
• Remove the electrical connection (3) to the PCB.
• When refitting the user interface, ensure the leads are not
trapped.
19.7.4
e
Mains supply cable
The main supply cable must be replaced by a
qualified and competent electrician.
• If the main supply cable is damaged, replace it refering to the
chapter "Electrical connection".
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
20 Spare parts
In order to guarantee the safe and prolonged life of the product,
manufacturers genuine spare parts must be used.
This appliance displays a CE Mark of conformity.
Only use the manufacturer’s genuine, new spare
parts.
• Ensure that spare parts are correctly mounted in the right
position and direction. After fitting any spare part or servicing,
the appliance must be tested for its safe operation.
20.1
Short List of Parts
• When ordering spare parts, contact Heatline's own service
organisation.
• Please quote the name of the appliance and serial number, to
be found on the data label.
Key
No.
1
2
3
4
5
6
7
8
9
10
12
13
14
15
Part No.
Description
0020117666
0020111021
0020126681
0020116832
0020097278
0020038441
D003202903
D020116522
D020116523
D003200039
D003200022
D003200374
D003202741
D003202741
0020116836
D020103888
Fan
Spark igniter
Thermistor (flow and return)
Gas valve 24
Gas valve 28
Electrode assembly
User interface PCB
Plate to plate heat exchanger 24
Plate to plate heat exchanger 28
3 way valve motor
Pump cpl with head assembly 24/28
Water flow sensor
Main PCB
Low water pressure sensor
Burner Door Seal Kit
Diverter valve
GC Part No.
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
- 47 -
Manual Handling
IMPORTANT. With regards to the Manual Handling Operations, 1992
Regulations, the following lift operation exceeds the recommended
weight for a one man lift.
General recommendations when handling
Clear the route before attempting the lift.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. Do not twist –
reposition feet instead. If 2 persons performing lift, ensure co-ordinated
movements during lift. Avoid upper body/top heavy bending - do not
lean forward/sideways. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and ensure good grip.
Always use assistance if required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Always use
assistance if required.
Carriage of carton from point of delivery to point of installation –
ground floor.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Clear the route
before attempting the lift. If removing boiler from truck straddle the load
and tilt forwards to facilitate secure grip. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Do not twist – reposition feet instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use assistance if
required.
Carriage of carton from point of delivery to point of installation –
first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top
heavy bending - do not lean forward/sideways. Clear the route before
attempting the lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Do not twist – reposition
feet instead. Take care to avoid trip hazards, slippery or wet surfaces
and when climbing steps and stairs. Always use assistance if required.
Carriage of carton from point of delivery to point of installation –
roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during
lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route before attempting the lift. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend 1 person to be
in roofspace to receive the appliance and other person to be below to
pass up and support appliance. Ensure safe lifting techniques are used
– keep back straight – bend using legs. Keep load as close to body as
possible. Always use assistance if required. It is assumed safe access,
flooring and adequate lighting are provided in the roof space. It is
recommended a risk assessment of the roof space area be carried out
before moving the appliance into the area to take into account access,
stability of flooring, lighting and other factors, and appropriate measures
taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep
working area clear. Cut the carton straps, lift carton up and slide over
polystyrene end packs. Remove top polystyrene pack with fittings.
Positioning of Appliance for Final Installation – no obstructions.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm
grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure
safe lifting techniques are used – keep back straight – bend using
legs - when lifting load from floor level. Do not twist – reposition feet
instead. Keep boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure
equal spread of weight of load. Always use assistance if required.
Recommend wear suitable cut resistant gloves with good grip to protect
against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – above worktop,
foreseeable obstructions etc.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm grip
on front and sides of appliance, lift upwards, onto worktop if practicable.
Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure co-ordinated movements during 2 person
lifts to ensure equal spread of weight of load. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting
load from floor level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise strain on back.
Avoid upper body/top heavy bending - do not lean forward/sideways. Always use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip when handling appliance.
Positioning of Appliance for Final Installation – within compartment
etc. restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards, onto
worktop if practicable. Ensure stable balance achieved and lift upwards
to drop into place onto bracket. If 2 persons positioning onto bracket
obtain firm grip at front and sides/base of boiler. Ensure co-ordinated
movements during 2 person lifts to ensure equal spread of weight of
load. If 1 person positioning onto bracket recommend obtain firm grip
supporting base of boiler. Ensure safe lifting techniques are used – keep
back straight – bend using legs - when lifting load from floor level. Do
not twist – reposition feet instead. Keep boiler as close as possible to
body throughout lift to minimise strain on back. Always use assistance
if required. Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip when handling
appliance.
Positioning of Appliance for Final Installation – in roof space restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position.
Obtain firm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2
persons positioning onto bracket obtain firm grip at front and sides/base
of boiler. Ensure co-ordinated movements during 2 person lifts to ensure
equal spread of weight of load. If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler. Ensure safe lifting
techniques are used - keep back straight – bend using legs - when lifting
load from floor level. Do not twist – reposition feet instead. Keep boiler as
close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip when handling appliance. It is recommended a risk assessment of
the roof space area be carried out before moving the appliance into the
area to take into account access, stability of flooring, lighting and other
factors, and appropriate measures taken.
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
If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
Yes
Yes
Service Record
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
Before 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.
Service 1
Date:
Service 2
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 3
Date:
Service 4
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 5
Date:
Service 6
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 7
Date:
Service 8
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 9
Date:
Service 10
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
0020112883-03 06/11
Heatline, Nottingham Road, Belper DE56 1JT
www.heatline.co.uk
Service Call 0844 736 9138, Technical Help (Chargeable) Call 0906 802 0253
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