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1. F1 2A WHITE F2 2A Figure 9 3 10 Boiler Installation 10 1 Prior to installing the boiler check the contents of the carton Appliance Valves Fixing Jig Optional Wall Hanging Bracket Mounting Template Service Installation and User Manual Guarantee Card and Benchmark Log Book The boiler dimensions are given in Figure 70 7 10 2 Ensure that the boiler is suitable for the gas supply by checking the data plate which is situated on the inside of the control panel door and that the system and chosen boiler position is in accordance to Sections 5 6 and 7 of these instructions 10 3 Position the supplied template on the wall ensuring it is level both vertically and horizontally Figure 10 2 the boiler fixing jig if required wall bracket fixing positions and flue outlet position rear flue only For flue side exit from the boiler Mark the horizontal flue centre line on the rear wall Extend the horizontal line to the side wall allowing a 3 decline back towards the boiler to enable condensate to drain back through the boiler Mark the flue centre vertical line Figure 10 3 Figure 10 2 aS CONDENSATE CONNECTION lil CENTRAL HEATING Figure 10 1 Dimension Capriz 25S Cap
2. IM 1 Im m 18 amp III Flashing 1 Flashing it Flashing Flashing Fault on CH Fault on Fault on Air Flames or Gas sensor Outdoor sensor Pressure Switch Failure Pa Flashing bar Flashing 18 Flashing Fault on w Low System Overheat Pressure Themostat DHW sensor Figure 13 2 18 Important Note In order to maintain the appliance s warranty and so as to comply with the Domestic Heating Compliance Guide when the boiler is to be installed to an existing central heating system the system must be properly cleansed using a proprietary cleanser before the boiler is connected to the system On all installations after connecting the boiler to the system and initially filling with water a proprietary inhibitor must be added to the system water to prevent corrosion 14 Commissioning 14 1 The CAPRIZ 25S amp CAPRIZ 285 boilers have been tested pre set at the factory and is dispatched with its on board controls set to provide maximum central heating output Consequently once all the connections have been made and the boiler has been filled with water to the designed system operating pressure the boiler may be fired prior to adjusting it s on board controls set to a mid heating output position 14 2 Prior to firing check that the electrical supply to the boiler is On The green boiler Stand by indi
3. 25S 285 Installation Servicing amp User Instructions Natural Gas LPG QIMQ Genchmark WRAS lt CAPRIZ 255 Condensing System Boiler G C No 41 157 10 CAPRIZ 28S Condensing System Boiler G C No 41 157 11 HEATLINE CAPRIZ 25S CAPRIZ 285 Condensing System Boilers British Gas Service Listing The Heatline range of heating boilers is manufactured from hight quality materials enabling reliability and optimum performance Heatline is committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings Benchmark Log Book As part of the industry wide initiative the CAPRIZ 25S CAPRIZ 28S boilers come complete with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current regulations complete all sections relevant to the appliance and installation The details within the Log Book will be required in the event of any warranty work On completion the Log Book must be left with the end user and the relevant sections completed on each subsequent Service visit Type test for purpose of EEC Regulations certified by Notified Body IMQ 51BP2727 CE Directive 90 396 EEC 51BP2728DR CE Directive 92 42 EEC CE Directive 73 23 EEC CE Directive 89 396 EEC modified from 93 68 NOTE
4. UNDER CAR PORT etc Figure 7 1 lt 5 0 HR n 1 F J 7 Al ER _11_ Internal Corner External Corner Double Corners Location Description See diagram Clearance mm A Below an opening S ee Note 1 300 B Above an opening 300 C Horizontally to an opening 300 D Below gutters soil pipes or drain pipes 75 E Below eaves 200 F Below balcony or car port roof 200 G From a vertical drain pipe or soil pipe 150 H From an internal or external corner or to a boundary alongside the 300 terminal See Note 2 Above ground roof or balcony level 300 J From a surface or a boundary facing the terminal See Note 2 600 K From a terminal facing the terminal 1200 L From an opening in the car port into the building 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wall 300 P From a structure on the roof or another roof terminal 600 Q From a vertical flue terminal to an adjacent wall 300 R From a vertical flue terminal to an adjacent wall which includes an 1000 opening window See Note 3 Notes 1 Anopening here means an opening element such as an openable window or a fixed opening such as a air vent However in addition the outlet should not be nearer than 150mm to an opening into the building fabric formed for the purpose of accommodating a built in element such as a windo
5. Its min FOR CONDENSING BOILERS ONLY HAS THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS YES NO FOR ALL INSTALLATIONS DOES THE HEATING AND HOT WATER SYSTEM COMPLY WITH THE APPROPRIATE BUILDING REGULATIONS YES HAS APPLIANCE AND ASSOCIATED EQUIPMENT BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS YES HAVE YOU DEMONSTRATED THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS TO THE CUSTOMER YES HAVE YOU LEFT ALL THE MANUFACTURER S LITERATURE WITH THE CUSTOMER YES COMPETENT PERSON S CUSTOMER S SIGNATURE SIGNATURE To confirm demonstrations of equipment and receipt of appliance instructions 37 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate Service Interval Record below SERVICE PROVIDER Before completing the appropriate Service Interval Record below please ensure you have carriedout the service as described in the boiler manufacturer s instructions and in compliance with The Gas Safety Regulations Always use the appliance manufacturer s specified spare part when replacing gas controls SERVICE 1 pate SERVICE 2 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID SERIAL No CORGI ID SERIAL No CO
6. M20 1831NI WALSAS OL SSVdA8 SILVIWNOLNY S3ATVA HOLVIGVH OL LV1SONtI3HI S3ATVA ANOZ SNI1VdH YALVM LOH OL TOHLNOO 3univuadii3l AWIL ONILVAH OL TOHLNOD SYNLVYAdISAL AWIL LNAWAHINOHH S9XOq 8U JO 19470 10 QUO eui Ajdwos S TOH LNOO IN3N3OV d3H 10 IN31SAS MAN NOI1V20O1 ON lt 39NVITddV 33VIN 4371104 STIV13 1091 0 8 40NVITddV ON TVIH3S QI 19409 93H STIVLAG NOILVHISIO3H 19809 ON 131 55 31VG SNINOISSIIINOD 3INVN ON TVIHHS QI ID9H09 ON 93H S 1IV13a NOI1VHISIO93H 19805 ON TAL AWVN S H3T1V1SNI 55 3IWVN ANVdWOD waw rrr rn P STVL3Q H33NI9N3 9NINOISSIIWIAOS 8 H3TIVISNI 31VG NOILVTIVLSNI L69vL LSOOE NOILLVINYOANI TVHIN3O e 19409 ATLA 4 uoneynsuoo u u q sey 601 SIU jo U9 U09 991 Aq peuoddns s yaewyoueg 5 ino 129jJe you s op AqUELIEM 991 Aew suononulsu S 181NIDEJNUELW S9UEI ddE siu uoissiuiuioo pue O Buipiing sjeudo1dde ay eoueijduioo 52u piA se p 1d 55e UBD JEU Buriuois
7. Gas Appliance Directive 90 396 EEC Efficiency Directive 92 42 EEC Low Voltage Directive 73 23 EEC modified from 93 68 Electromagnetic Compatibility Directive 89 396 EEC modified from 93 68 Heatline declares that the materials used in the manufacturer of this appliance are non hazardous and that no substances harmful to health are contained within the appliance Manual Handling As this appliance is heavy it is recommended that you get assistance when lifting When manoeuvring the boiler always use safe techniques keep your back straight bend your knees don t twist move your feet Avoid bending forwards or sideways and keep the load as close to your body as possible Where possible transport the boiler using a suitable trolley sack truck or get some assistance Grip the boiler firmly and before lifting establish where the weight is concentrated to determine the centre of gravity repositioning yourself if necessary IMPORTANT Installation of the Condensate Waste Hose The condensate trap bottom part should be filled with 50 cc of water before operating the boiler 1 When the boiler is mounted push the plastic hose supplied all the way onto the condensate outlet to the bottom left hand corner of the boiler as shown in the diagram 2 Cut the plastic hose to desired length and fit a plastic coupling to connect to your plastic waste pipe NOTE Removal of the condensate trap for cleaning purposes 1 Pull
8. 3 4 An interface unit which includes boiler adjustment potentiometers and fault display provides easy service ability to the boiler 3 5 Heat transfer to the boiler s primary hydraulic circuit is obtained via a primary gas to water heat exchanger contained within a hermetically sealed combustion chamber A 230 volt duel speed fan expels the products of combustion from the combustion chamber to outside air via an associated flue system The fan is activated at the beginning of each ignition cycle and its operation monitored by means of negative and positive sensing points connected to an air pressure switch 3 6 An integral pump located in the boilers main hydraulic circuit circulates water through the primary heat exchanger to either the central heating circuit depending on the demand In the event of reduced interrupted water circulation in the central heating circuit a system by pass should be fitted as far away from the boiler as possible Note It is no longer permissible to utilise a non thermostatic controlled radiator as a by pass 3 7 Room temperature can be controlled by the use of an external room thermostat or temperature regulator Note connection of the room thermostat is dependant on the operating voltage of the thermostat See section 9 for details 3 8 The boiler boiler s control panel incorporates an LED display which indicates the state of operation and fault defect codes 4 Operation 4 1 Using
9. 9 3 9 9 Fuse Ratings Circuit Board F1 2 amp fast blow F2 2 amp fast blow Important Note Connection to the mains electrical supply must be maintained at all times in order to provide frost protection and pump over run facility Ensure that the boilers electrical supply is not interrupted by any external controls 14 HALL EFFECT SENSOR r GAS CONTROL NAN Y VALVE 2 b J EN 9 al lo PUMP D Ow LIMIT SAFETY IGNITION r THERMOSTAT WATER ELECTRODES y PRESSURE f 3 r SENSOR W FLAME IONISATION w w ELECTRODE e e g CENTRAL HEATING SENSOR gly 230V ROOM OVERHEAT cHASSIS THERMOSTAT THERMOSTAT EARTH CONNECTION w high voltage W gly FUSES 2 O go I bi br B 88 L JS H 00000000 i r r F1 F2 25 O 8 b br lg y gly Eo 222255 PRINTED 88 8 br m g y CIRCUIT L b gly EO BOARD FW w 2 8 m 00 ap 3 de m O O 3 ce o 188 am WIW KEY nr BROWN LEN Yw BLUE ca 230V 50Hz PERMANENT MAINS SUPPLY LCEevs GREEN FUSED AT 3A ini USER BLACK INTERFACE 24V TIME MAUVE FUSE RATINGS CLOCK RED low voltage AIR PRESSURE
10. air is removed as the system fills Do not use the pressure relief valve as a means of flushing the system please use the valve below the pump Discharging water from the pressure relief valve may allow water to seep after you have left the job causing the boiler to lose pressure and debris to collect on the seating The boiler is fitted with inlet filters both on the cold water inlet and the central heating return If you are unable to obtain hot water at an outlet It is likely that the cold water inlet valve filter has become blocked whilst blockage of the filter on central heating return valve the overheat thermostat will cause the heater to lock out at as the water flow is reduced f you are able to obtain hot water but not heating it is also advisable to check that the room thermostat and any external time clock that may be fitted are calling for heat When commissioning the boiler check the inlet pressure is at 20mbar and burner pressure against the Technical data section 2 f you experience any problems please refer to the installation and commissioning guidelines within the boiler instruction manual If necessary please contact Heatline Service Enquiries in the UK for further advice and assistance on 0870 777 8318 NOTE FOR INSTALLERS REMEMBER IT IS A REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION 5 2 The boiler is designed to operate on fully pum
11. electronically provides direct burner ignition and combustion supervision along with continuous modulation of the burner s gas supply By means of a manual switch the CAPRIZ 25S CAPRIZ 28S can be set to operate central heating CENTRAL HEATING MODE When heating demand is requested the boiler will fire automatically An integral pump is then energised and hot water from the boilers primary circuit is circulated around the heating systems pipe work and radiators The heat output from the boiler is automatically adjusted by the boiler s internal control unit to match the heating demand As the water temperature of the heating system increases the gas input to the burner decreases conserving energy and increasing efficiency When the demand for heating no longer exists either the room thermostat is satisfied or the heating period has ended the burner will shut down and the boiler will revert to stand by waiting to respond to the next heating demand The integral pump may continue to run after shut down for a short while to dissipate any excess heat within the boiler Figure 7 ACCESS TO THE BOILER CONTROLS The boiler controls are sited at the bottom of the boiler s front case Figure 7 Hi C i 5 1 Timer 4 System pressure gauge 2 Function switch 5 LED display 3 C Heating temperature control BOILER CONTROLS The function and operation of the main controls located on
12. ensuring that the cut is square and free from burrs 10 11 Measuring from the back of the terminal connection mark distance L 20 mm Figure 10 5 onto the inner flue duct and cut the duct to size ensuring that the cut is square and free from burrs 10 12 Pass the flue assembly through the wall and connect the assembly to the boiler ensuring that both the air and flue duct joints are fully pushed home into the connecting elbow s collar 10 13 With the flue and joints secured fit the flue trim to the external wall surface using suitable mastic Note Where internal access only is available the flue trim must be attached to the flue assembly prior to passing the assembly through the wall 10 14 For maximum flue lengths refer to the Technical Data section 2 in this manual 10 15 Condensing type boilers must be connected to the drainage system A plastic drain must be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away Note if a soak way is used the drain must terminate at least 500 mm from the external wall 10 16 Extract the bottom part of condensate trap by turning anti clockwise and fill it with approximately 50 cc water re connecting it to the boiler Figure 10 7 CONDENSATE OUTLET PIPE 10 17 Conn
13. if possible and obtain assistance if required To remove the appliance 1 Carefully slit or remove the scaling tape being careful not to scratch the appliance door E CO fully open the carton lid and remove instructions amp components Read the instructions carefully before installation of the appliance Rollthe carton onto its open face Lift the carton free of the inner packaging Remove the mounting bracket and valve package Stand the boiler on its base within the styrene block and remove the top packaging piece If you wish to remove the stryene base lie the appliance on its back to do so 04 1 Installation Regulations 1 1 1 2 1 3 1 4 1 5 1 6 Correctly may invalidate your guarantee and may lead a dangerous situation Your CORGI registered engineer should carry a CORGI ID card containing their registration number which should be recorded in your Log Book which is supplied with the Instructions You can check the validity of this ID number by contacting CORGI on 0800 915 0480 This appliance must be installed in accordance with the Gas Safety Installation and Use Regulations current Building Regulations Building Standards Scotland 1 5 813 Installation of Gas Appliances Ireland IEE Wiring Regulations BS 7671 Health and Safety Document No 635 Electricity at Work Regulations and Local Water Authority Bye Laws On ins
14. injector bar and tighten ensuring that the injector size marked on each injector is the same as stated in the relevant section of the Technical Data for the type of gas that will be used Fit the burner replace if necessary and reassemble the boiler Check for gas soundness Dip switch 7 must be ON position for LPG and OFF for NG Check the pressures minimum and maximum burner Check the gas circuit for soundness and the correct operation of the boiler Important Attach the labels supplied as follows Replace the adhesive User Instruction label Stick the LPG label in a prominent position within the boiler Stick the foil label over the existing gas type on the data plate of the boiler SHOULD YOU SMELL GAS Turn the gas valve off at the Gas Meter or Gas Cylinder ventilate the room by opening windows and doors EXTINGUISH ANY NAKED FLAMES DO NOT OPERATE ANY ELECTRICAL SWITCHES and call Transco on 0800 111 999 or if you use LPG call your gas supplier 31 APPENDICES SPARE PARTS LIST PART No DESCRIPTION ORDER CASE 1 HYDROBLOCK PUMP PART 3003200232 2 LOW PRESSURE SWITCH 3003200038 3 SAFETY VALVE 3003200019 4 PUMP 3003201336 5 EXPANSION VESSEL 3003200028 6 GAS VALVE 3003200419 7 BURNER WITH MANIFOLD 24 kW NG 3003202153 8 BURNER WITH MANIFOLD 28 kW NG 3003202154 9 CONTROL PANEL 3003200421 10 PCB COV
15. must be sited at least 1m away from flammable materials and heat sensitive walls must be protected by an appropriate insulating material 6 6 The wall on which boiler is mounted must be non combustable and sufficient strong to support the weight of the boiler 6 7 A condensate drain pipe must be fitted to allow discharge of condensate to a drain or soak way Where possible condensate should be discharged into the household internal drainage system If this is not practical discharge can be made into an external drain If neither of the above options are possible then condensate must be discharged into a purpose designed soak way It is recommended that any external condensate pipe is insulated and increased to 32 mm diameter in order to prevent the condensate from freezing 10 To avoid excessive condensation occurring within the boiler flue the boiler should wherever possible be sited to ensure the shortest possible flue run is utilised 6 8 For compartment installation the requirements of BS6798 and BS5440 Part 2 must be met gt The compartment must be of sufficient size to permit access for inspection and servicing or the removal of the boiler and any ancillary equipment gt Any space used for airing clothes or storage must be separated from the appliance by a non combustible partition Where the partition is formed from perforated material then the major dimension of the apertures shall not exceed 13mm gt No comb
16. operate No Is the air pressure switch activated Check fan tubes flue assembly and Go to Chart 4 Replace Fan case seals Is 240 Vac present at FAULT FINDING CHART 4 Does appliance perform a pre purge of fan amp pump Are any LE No D faults indicated Fan Check the air pressure switch operation Replace PCB Replace PCB No Yes Yes Does sparking Yes Does burner ignite c Go to Chart 5 commence No No Replace PCB Yes P Yes Check wiring and condition of HT leads No Go to Chart 2 Y Yes Does the burner ignite amp remain on No v Does the boiler I Yes Yes i Yes attempt to light 3 Does boiler Reset by turning to Does the boiler Goto times in 1 minute gotolockout standby for 15 secs light Chart 5 intervals No ls flame present Check burner No No P injectors gas before lock out pressures amp probe No Check gas valve gas supply and Check ignition and ionisation probes for correct position amp damage Go to Chart 5 gt Goto Chart 5 Check related sensors amp replace gt Replace PCB 22 FAULT FINDING CHART 5 Does burner flame modulate Normal operation Chwck wiring from PCB to modulation coil on gas valve Replace gas valv
17. the control panel fascia Figure 2 15 as follows 1 Function switch This is the boilers main operating switch In the position the boiler is in stand by mode and power supply is ON For the boiler to operate the switch must be in the position 2 Central Heating temperature control The position of this control dial will determine the temperature of the water delivered to the radiators The water temperature can be set from a minimum of 30 C anticlockwise stop position to a maximum of 85 C clockwise stop position 35 4 Boiler On The boiler Stand by indicator green lights when power is supplied to the PCB 5 Water Temperature The temperature of the water leaving the boiler is given by the red light indicators situated alongside the burner Stand by indicator light 6 Fault Indicator The control unit has an in built fault diagnostic function When a fault occurs the type of fault is indicated by the appropriately flashing red light indicator A listing of the display lights and meanings can be found in Section 13 of the Installation and Servicing Instructions 7 Boiler Lockout When the first red light indicator from right flame or gas fault or the second from right overheat fault lights the boiler will need to re set To re set the boiler the function switch must be switched to the position and after 30 seconds back to position 8 Pressure gauge The pointer on the gauge indicates
18. up to a maximum length of 3m The terminal is suitable for a flat or pitched roof This length can be increased to 7 m using the 80 125mm flue kit 8 5 If horizontal and vertical flue lengths are less than 1m the restrictor air diaphragm Figure 8 2 must fitted on the combination boiler Please find the information sheet for the installation of restrictor given with documentation group The diameter of air diaphragm changes according to the installation types Figure 8 2 C12 C32 C42 C52 60 100 80 125 80 80 24 kW 80 80 080 28 kW 082 082 082 8 6 The air restrictor should not be fitted if the length of the flue pipe installation is below C12 C32 C42 C52 60 100 80 125 80 80 24 kW gt 1 m gt 2 m 28 kW gt 1 m gt 2 8 7 The connection of vertical flue system is similar to the Horizontal flue connection The flue is connected to the boiler via connection screws whilst the sections are held together with the clamps provided 8 8 To avoid condensate dripping from the terminal the flue should be installed with an upward gradient from the boiler of 3 Note that some new flue may have the 3 built in 8 9 The installation types for room sealed versions are C12 C32 C42 C52 8 10 The boiler can be used with separate ducts such as 80 80 to fit required type of installations Note For each additional 90 elbow used the maximum flue length m
19. when exchanging components 19 Component Replacement 19 1 Ensure that both the electrical and gas supplies to the boiler are isolated before replacing any component part 19 2 To prevent the need to drain the entire heating system when replacing the boiler s integral pump expansion vessel safety relief valve and pressure sensor the boiler s hydraulic circuit may be isolated from the central heating circuit by closing the boilers isolation valves Opening the discharge valve will then drain the boiler s hydraulic circuit Note clean the valve seat to ensure it seals before re filling the boiler 19 3 For replacement of the following components it will be necessary to remove the boiler casing panels as described in Section 18 19 4 Central heating sensor The c heating sensor is located on left side of the combustion chamber on the outlet of the primary heat exchanger Figure 19 1 Unclip the sensor from the pipe Disconnect the leads from the sensor PRIMARY HEAT EXCHANGER OUTLET PIPE CENTRAL HEATING SENSOR ELECTRICAL CONNECTIONS Figure 19 7 Fit replacement sensor Fit the leads and replacement the sensor 19 5 Fan Unit 19 7 Burner Disconnect the electrical leads from the fan Note The replacement burner is supplied as component To remove the fan disconnect the 90 bend from parts and requires assembly on site the top of the boiler Remove the burner assembly from the combustion c
20. ER 3003200084 11 ELECTRONIC CONTROL BOARD 3003202166 12 INTERFACE CARD 3003200183 13 CH SENSOR 3003200152 14 WATER PRESSURE GAUGE 3004090673 15 OVERHEAT SAFETY THERMOSTAT 3003200379 16 IGNITION ELECTRODE RIGHT 3003202200 17 IGNITION ELECTRODE LEFT 3003202201 18 FLAME SENSE ELECTRODE 3003202102 19 FAN 3003202165 20 AIR PRESSURE SWITCH 3003200032 21 FRONT PANEL CAPRIZ 25S 3003200176 22 FRONT PANEL CAPRIZ 28S 3003200177 23 CONDENSATE TRAP 3003201775 24 TURBO EXCHANGER 3003200486 25 WIRING HARNESS 3003202321 26 SYSTEM BY PASS PIPE 3003200937 Copriz 25S amp Copriz 28S Condensing Wall Mounted System Boiler User Instructions 33 Natural Gas LPG HEATLINETM CAPRIZ 25S CAPRIZ 28S Condensing System Boilers British Gas Service Listing CAPRIZ 25S Condensing System Boiler G C No 41 157 10 CAPRIZ 28S Condensing System Boiler G C No 41 157 11 The Heatline range of heating boilers is manufactured from hight quality materials enabling reliability and optimum performance Heatline is committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings Type test for purpose of EEC Regulations certified by Notified Body IMQ 51BP2727 CE Directive 90 396 EEC 51BP2728DR CE Directive 92 42 EEC CE Directive 73 23 EEC CE Directive 89 396 EEC modified from 93 68 The manufacturer in the continu
21. ICAL AND EARTH ELECTRICAL CONNECTIONS PLUG Figure 19 13 Release the main gas connection between the gas valve supply tube and gas inlet valve retaining the washer for use on reassembly Remove the gas valve s two securing screws and washers from the underside of the boiler Figure 19 14 Rotate the gas pipe and withdraw gas valve assembly Refit in reverse order to removal the polarity of the wires to the modulating coil is not important replace any damaged washers as required Check gas soundness and correct boiler operation SECURING GAS SCREWS i ISOLATION VALVE SUPPLY PIPE 77 CONNECTION a Figure 19 14 Following replacement the maximum and minimum settings for natural gas must be checked to Technical data section 2 Check the gas valve settings and re calibrated by the following method if required 19 13 Maximum and Minimum setting Connect a suitable pressure gauge to the pressure outlet on the gas valve Figure 19 15 Figure 19 15 Figure 19 16 Remove plastic cover from gas valve adjuster Create domestic hot water demand by operating a hot water faucet Adjust 10 mm brass nut to gain correct maximum burner pressure ensuring the inner screw is held in place with the use of a cross head screw driver clockwise to increase anti clockwise to decrease Refer to Technical Data for pressure settings Remove one lead from the modu
22. MMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 4 ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID SERIAL No CORGI ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 pate SERVICE 6 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID SERIAL No CORGI ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 pate SERVICE 8 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID SERIAL No CORGI ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 pate SERVICE 10 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID SERIAL CORGI ID SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE When all of the above services have been completed Please contact your Heatline Nottingham Road Belper Derbyshire DE5 1JT Tel 01773 596 099 Fox 01773 828 123 Email sales heatline co uk
23. NECTION TUBE 18 8 Remove the burner from the combustion chamber as follows assembly Pull off the ignition and flame electrode leads from the PCB and remove the wires with grommet from the combustion chamber base Figure 18 6 amp 18 7 SPARK GAP 4mm SENSING TUBE L GROMMET JJ SSS Figure 18 6 FLAME AND IGNITION ELECTRODE LEADS Figure 18 7 Figure 18 8 LEFT HAND SIDE OF BURNER RIGHT HAND SIDE OF BURNER Remove the burner retaining screws at the sides and remove the burner 18 9 Visually check for debris damage and clean replace as necessary the following items Heat exchanger Burner Fan compartment gt Electrodes Insulation gaskets Note All washers gaskets must be retained for use on re assembly replace if damaged 18 10 To clean the condensate trap which is located at the back left hand corner of the appliance remove the plastic hose from the outlet and insert a suitable allen key into the outlet and remove the sump by turning anti clockwise Clean the sump using a dilute solution of bleach Apply a little silicone grease to the O ring and replace the sump so that the O ring is just engaged Do not over tighten Important Clean the heat exchanger using a soft brush or vacuum cleaner Do not use any tool likely to damage painted finish of heat exchanger Clean the burn
24. You are also obliged to register the installation of this boiler with C O R G I Should you wish to check the SEDBUK website for the rating of this boiler search under DD HEATING or the boiler name and designation e g CAPRIZ 25S The manufacturer in the continuous process to improve his products reserves the right to modify the data expressed in the present documentation at any time and without prior notice The present documentation is an informative support and it cannot be considered as a contract towards third parties Section Page Preface 2 The Signs on Box 3 The Signs on Boiler 3 1 Installation Regulations 4 2 Technical Data 5 3 Boiler Characteristics 7 4 Operation 7 5 General Installation 8 6 Appliance Siting 9 7 Flue Terminal Location 10 8 General Flue Info 12 9 Electrical Connections 13 10 Boiler Installation 15 11 Gas Supply 16 12 Filling the System 17 13 Control Panel Functions 17 14 Commissioning 18 15 Onboard Adjustments 18 16 Safety Devices 19 17 Fault Finding Chart 20 18 Routine Servicing 22 19 Component Replacement 24 20 Gas Type Conversion 30 Appendices Spare Parts List 31 User Instructions 32 Benchmark Log Book 36 37 02 The Heatline gas fired condensing system boiler meets the requirements of all appropriate regulations and is deemed to meet the requirements of
25. ake this service work may invalidate your warranty All CORGI Registered Installers carry CORGI ID card and have a registration number which should be recorded and entered on your Benchmark log book You can check your Installer registration by contacting CORGI on 0800 915 0480 The boilers Log Book must be completed at each Service visit GAS SAFETY INSTALLATION AND USE REGULATIONS It is a legal requirement that all gas appliances must be installed and serviced by a competent person in accordance with the regulations Failure to install or service gas appliances correctly could lead to prosecution It is in your interest and that of safety to ensure compliance with the law For electrical safety the boiler must be earthed and protected by a 3 amp fuse Note In the event of a fault the appliance should not be used until fault has been rectified by a competent person VENTILATION On installation the boiler must be installed with minimum clearances of 50mm each side 200mm above 300mm below with 600mm access to the front If an opening door is to be fitted across the front of the boiler allow 5mm clearance to the front panel Should the boiler be installed in a closed compartment it is recommended that there are minimum air vents of 30 square cm at both high and low levels 34 GENERAL DESCRIPTION 0F BOILER The CAPRIZ 25S amp CAPRIZ 28S are system boilers for central heating appliances The internal control unit
26. amaged washers as necessary Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring all joints are sound SECURING LP JI Hi 5 a x 8 Je je poma NJ Js Ce 9 Y VIEWING COMBUSTION WINDOW CHAMBER 19 11 Primary Heat Exchanger Drain the boiler s hydraulic circuit as detailed in 19 2 Remove the pipe clips on the pipes of heat exchanger Release the union connections on the connection pipes retaining the washers for re assembly Remove the CH temperature sensor on the return pipe Remove the pump heat exchanger and heat exchanger three way valve connection pipes Remove the combustion chamber cover Remove the heat exchanger by pulling forward Fit the new heat exchanger and reassemble the boiler in reverse order ensuring all the washers are fitted or replaced as required Open the isolating valves on flow and return connections refill vent and re pressurise system ensuring the all joints are sound 19 12 Gas valve Ensure that gas supply to boiler is turned off Disconnect the electrical connections to gas valve modulating coil 28 Release the connection from gas valve and manifold inlet retaining the washers for use on reassembly Figure 19 13 tx O GAS VALVE AND MANIFOLD INLET CONNECTIONS SENSING TUBE MODULATING COIL ELECTR
27. cator will light and the gas service cock is in the open position Set the boiler s central heating water temperature control to maximum by turning fully clockwise Set the external room thermostat to maximum and open the thermostatic radiator valves to maximum 14 3 Switch the boilers function switch to the heating position The boiler s control unit will now automatically carry out pre ignition safety checks before igniting the burner 14 4 During the 10 second burner ignition attempt visually check that all of the burner blades ignite correctly If necessary adjustments tothe ignition rate may be made using potentiometer P4 Turning P4 clockwise increases the ignition rate and anti clockwise decreases the rate After successful ignition check the integrity of the boiler s flue for soundness and correct operation 14 5 In order to maintain the appliance warranty after initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants 14 6 Restart the boiler and again allow the central heating system to reach maximum operating temperature Check that all the water connections throughout the system are sound and bleed each of the heating systems radiators and purpose made air release points in turn Isolate the boiler before carrying out this operation 14 7 Check the system pressure and top up if necessary 14 8 Reset the central heating water temperature
28. control and room thermostat to the desired temperature settings Important Notice Failure to thoroughly power flush the heating system with the boiler disconnected or to add an anti corrosion inhibitor to the system water will invalidate the boiler s warranty The condensate trap must be filled with water and plastic discharge pipe connected to drain before operating the boiler 15 Onboard Adjustments 15 1 The boiler incorporates 4 potentiometers and a bank of dip switches to allow adjustment to its pre set parameters These are situated on the rear of the control panel Figure 15 1 The potentiometers can easily be accessed by removing the cover on the rear of control panel Figure 15 1 However to reach the dip switches the control panel must be opened Factory settings for potentiometers shown below P7 P5 P2 P4 CAPRIZ25S 6 line 6 line 4 line 4 line CAPRIZ 28S amp line 6 line 4 4 line 15 2 Setting the maximum c heating flow temperature The boiler is dispatched with a maximum flow temperature factory set to 85 C Where a lower maximum temperature is required such as in the case of under floor heating the factory setting can be altered between a maximum of 50 C and a minimum of 30 C by fitting dip switch 6 into ON position 15 3 255 seconds delay setting The boiler is capable of up to 255 seconds ignition delay anti cycling time before re ignition foll
29. device that fires the boiler s burner when the temperature of primary hydraulic water falls below 6 C The device works irrespective of any room thermostat setting and will protect the complete heating system On reaching a water temperature of 15 C the boiler reverts back to normal operation Dipswitch 7 must be ON position for LPG Propane 20 gt 1 17 Fault Finding Chart FAULT FINDING CHART 1 Create demand Mains LED ON Is 240 Vac present at pin X15 on PCB Check fuses F1 amp F2 on PCB replace as required N speed Yes No Yes Check pump wiring connections amp voltage LED ON FAULT FINDING CHART 2 Is Central Heating LED flashing Is overheat LED flashing No Is the pump running No 2 Check wiring con nections mains voltage pin X12 pin X16 amp X17 Check low water pressure switch cables amp connections clean or replace as required Yes Yes D G Bar LED Flashing Pa PA Repressurise system show ar No No Go to Chart 3 If boiler temperature gt 6 C frost Go to Chart 2 rotection activated Yes No Replace PCB No Replace user interface PCB Check or replace Central Heating NTC 10 12 kohms 20 C Check overheat thermostats Go to Chart 3 Replace pump Replace PCB 21 0 gt u JJ gt u FAULT FINDING CHART 3 Does Fan
30. e Replace PCB 18 Routine Servicing SERVICE PROCEDURE 1 Remove the outer case as outlined in section Replacing Components 2 Visually check all joints for gas water tightness 3 Visually inspect the flue system 4 Check the condition of the seals around the combustion chamber 5 Check condition of electrodes and their location 6 Conduct a flue gas analysis of CO CO ratio to confirm the combustion gas ratio is less that 0 004 If not check the combustion chamber and flue system for signs of leakage damage or blockage Remove any obstruction and clean as necessary If clear check burner pressures injectors or gas valve settings Adjust and clean as necessary 18 1 To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced regularly The servicing must be carried out by a competent person in accordance with the Gas Safety Installation and Use Regulations The frequency of servicing will depend upon the particular installation conditions and usage but in all cases the boiler must be serviced at least once a year 18 2 Following servicing of the boiler the relevant sections of the Benchmark Installation Commissioning and Servicing Log Book must be completed 18 3 Prior to servicing a check of the flue operation and terminal guard if fitted along with a preliminary check of the boilers operation must be undertaken 18 4 Ensure the boiler is cold and that bot
31. e that this pressure is maintained between 1 and 2 bar If there is a significant loss in pressure the boiler will lock out The system may be re charged by opening the filling loop to charge the system back up to 1 5 bar as indicated on the LED panel DO NOT OVERCHARGE THE BOILER PRESSURE BEYOND 2 BAR AS THE BOILER WILL NOT OPERATE The filling Loop a flexible hose with two valves should be located below the boiler connecting the second pipe on the right to either one of the outer pipes see Figure 70 DO NOT CLOSE ANY OF THE FOUR VALVES DIRECTLY CONNECTING TO THE BOILER If the boiler frequently loses pressure then your installer should be consulted CLEANING The boiler casing may be cleaned with a damp cloth followed by a dry cloth to polish Do not use abrasive or solvent cleaners FURTHER ADVICE For further information or advice UK contact Heatline Service please call 0870 609 2091 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 Or by E mail on our Web Site at www heatline co uk JHL HLIM 311 TWANVIN NOILVTIVLSNI SHL NI SNOILONHLSNI 9NINOISSIWINOO NOILVTIVLSNI MOTIO3 3SV31d 10N GALLIH qalla 10N GALLIH 437109 HJWILHJWWVHDOHd 9 18W09 1V1S H4GNIIAD 1V1SIWOOH H3WIL H3WIWVHSOtid 9 STAVWWVHDOHd 191 WOOH saunsval
32. ect the condensate drainage pipe to the drainage system Figure 70 7 Note due to the acidic nature of the condensate the drainage system must be made of non corrosive material such as plastic tubing More detailed information on condensate discharge is provided in BS 6798 Specification for installation of gas fired hot water boilers of rated input not exceeding 70kW 10 18 Connect the domestic hot water cold water inlet heating system flow amp return and pressure relief valve pipework to the boiler fittings ensuring that the pipework has been correctly flushed before final connection The electrical connections to the boiler must be in accordance to Section 9 of these instructions NOTE Place the filling loop in a visible accessible position and instruct the user how to pressurise the system if there is a fall in pressure 11 Gas Supply 11 1 The gas supply pipe must be capable of supplying the quantity of gas required by the boiler see Technical Data section 2 in addition to the demand of any other gas appliances being serviced from that supply 11 2 The internal diameter of the gas supply from the meter to the boiler s gas inlet connection must not be less than 22mm 11 3 The meter governor must be capable of delivering a nominal pressure of 20mbar for natural gas 11 4 On final connection of the gas supply to the boiler the complete gas installation including the gas meter must be tested for tightness and purg
33. ed 17 12 Filling the System 12 1 The boiler must not be operated without water 12 2 On completion of the boiler installation and ensuring that all water connections are correctly made the boiler may be filled with water via the filling loop not supplied with the boiler Ensure that manual feed valves and boiler isolation valves are open 12 3 Release the cover of the boiler s automatic air vent situated on top of the pump Figure 12 1 12 4 The manual feed valves must be closed and the filling loop disconnected once the pressure gauge sited on the boiler s control panel indicates a system pressure between 1 0 and 1 5 bar 12 5 Check that all the water connections throughout the system are sound and bleed each of the heating system s radiators in turn As air is vented the system pressure may need topping back up to 1 0 bar 12 6 Air must be vented from the boiler s pump by unscrewing the pump s integral vent plug and allowing water to bleed for a few seconds Take care not to allow water to splash onto any electrical components Release the cover cap behind the pump when the filling complete Figure 12 1 12 7 When the system is bled of any air it must be re filled until the pressure shown on the display gauge indicates a system pressure of 1 5 bar 12 8 If the pressure shown on the gauge exceeds 1 5 bar discharge the excess pressure from the system via a radiator valve or pipe connection Do not use t
34. er by washing in soapy water Allow to dry thoroughly before re fitting Do not use wire or a sharp instrument to clean the burner injectors Ensure the ignition electrode gap is set to 4 mm 18 11 The boiler is fitted with a cold water inlet filter which must be inspected on each service To access the filter Close the isolating valve on the boiler s cold water domestic inlet by turning the valve head fully clockwise Disconnect the cold water inlet connection to the boiler Clean and inspect the filter replace if necessary Re fit the filter and reinstate the cold water inlet connection to the boiler fit new gasket as required Fully open the isolating valve on boiler s cold water inlet and check for leaks 18 12 On completing the service reassemble the boiler components in reverse order of removal ensuring that all component joints and gaskets are sound Any damaged seal or gasket must be replaced 18 13 Reinstate the boiler s electrical and gas supplies and check for gas soundness and correct boiler operation CAUTION While there are no substances harmful to health contained within this appliance some component parts of the boiler insulation pads gaskets and rope seals are manufactured from man made fibres When damaged or broken these fibres may cause a temporary irritation High dust levels may irritate eyes and upper respiratory system It is important therefore that sensible precautions are applied
35. gure 2 1 C Cold Water Inlet 15mm D Heating Return 22mm Key 1 Condensate Trap 11 Air Pressure Switch 2 Limit Safety Thermostat 12 Condensing Unit Turbo heat exchanger 3 Expansion Vessel At rear of the boiler 13 Overheat Safety Thermostat 4 Burner 14 Ignition Electrode 5 Flame Sensor lonisation Electrode 15 Heating Circuit Pressure Safety Valve 6 C H Sensor Heating Sensor 16 Automatic Air Vent 7 Combustion Chamber 17 Water Pressure Switch Sensor 8 Primary Heat Exchanger 18 Pump 9 Fan Hood 19 Gas Valve 10 Fan 20 Filter Valve Below the pump 07 3 Boiler Characteristics 3 1 The CAPRIZ 25S amp CAPRIZ 28S are fan flued wall mounted condensing type system boilers that supply domestic central heating Being room sealed the boiler may be installed in any room or internal compartment without the need for purpose made ventilation However if the boiler is installed in a compartment it is recommended that the compartment is ventilated for cooling purposes A functional diagram of the boiler s components is given as VENTILATION section in user manual 3 2 Range rated from 25kW and 28kW the Capriz 25 Capriz 28 heat output can be focused to match the designed heating systems adjustments 3 3 An electronic control unit consisting of a PCB which includes ignition module provides direct burner ignition and flame supervision along with continuous modulation of the burner s gas supply
36. h the electrical and gas supplies to the boiler are isolated before commencing service of the boiler 18 5 Remove the boiler casing as follows Open the front panel by removing two screws at the bottom of the boiler Figure 18 f Figure 18 1 Release the hermetic chamber cover by removing two screws on both sides and by lifting them to release from their retaining hooks Figure 18 2 Figure 18 2 Release the side RETAINING 47968 INNER CASING PANEL VIEWING WINDOW N panels by removing the screws on SCREWS the upper and lower sides Figure 18 3 Remove the panels by swingin Figure 18 2 SECURING gthem out and lifting them up e SCREWS 4 OFF 18 6 Remove the combustion chamber cover by removing four screws on sides Figure 18 4 Figure 18 4 SECURING SCREWS 6 OFF LAT e Js lt VIEWING COMBUSTION WINDOW CHAMBER COVER 23 18 7 Disconnect the electrical leads and air pressure switch connection tube from the fan remove the fan screws and withdraw fan from fan hood with its 56 bend Figure 18 5 ELECTRICAL PRESSURE SWITCH EFFECT CONNECTIONS CONNECTION TUBE SENSO KA A B COR ES SN J ONE ZN gt S A 27 n oll w 2 Z lt 22 LEAD ES Nj lt N SECURING SCREW or p FAN HOOD CON
37. hamber as detailed in Section 18 8 retaining all washers gaskets for use on re assembly Disconnect the electrical leads and air pressure switch connection tube from the fan remove the fan screws and withdraw fan from fan hood with s its 56 bend Section 18 7 Remove the manifold as shown in Figure 78 8 Fit the replacement fan unit in reverse order and reconnect the electrical leads and sensing tube RIE the Hew DUMMEN injections ing tighten ensuring that the injector size marked on each injector is the same as stated in the Technical WARNING Data section for the type of gas being used Ensure that the earth lead is re connected INJECTOR 19 6 Air pressure switch d The air pressure switch is located on the top of the expansion vessel Figure 19 2 BURNER INJECTOR BAR Remove the sensing tube and electrical connections from the air pressure switch noting which tube is connected to which port Figure 19 3 Remove the air pressure switch by pulling forward off its bracket Fit the replacement switch in reverse order of removal Replace the burner bar and re fit the burner blades replace any damaged seals as necessary and BRACKET SECURING reassemble the boiler in reverse order SCREWS 2 OFF Check gas soundness and boiler operation ELECTRICAL 19 8 Printed circuit board CONNECTIONS Turn off and isolate t
38. he safety discharge valve as the valve seat may become contaminated with debris and fail to re seal 13 Control Panel Functions U Figure 13 1 1 Timer 2 Function switch 3 C Heating temperature control 4 System pressure gauge 5 LED display 13 1 C heating temperature controls The boiler s integral control unit monitors and adjusts the boiler s hydraulic circuit water outlet temperature by means of a sensor located on the C heating flow outlet The sensor s electrical resistance is dependant on temperature and determines the current passing through the control potentiometer located on the control panel The potentiometer control dial allows manual setting of the maximum required temperature reference value being between 30 and 85 C When the boiler operates the current received is compared to the manually set reference value The difference of the two values operates the modulation of the gas valve adjusting the useful heat output generated and stabilising the temperature to within 1 C 13 2 Re set function Should the boiler lock out at any time please check the gas supply and ionisation probe position the boiler may be re started by switching to standby O position Switch 2 Figure 13 1 waiting 15 30 seconds and switching back to its previous position once the fault has been eliminated Water Temperature Boiler Stand by Indicator
39. he electrical supply Remove the interface cover by lifting the two 7 latches Figure 19 4 19 5 Remove the electrical connections to the PCB by pulling carefully noting the locations of all the terminals Release the screws securing the PCB to the control SENSING TUBES paneland lift out the PCB Fit the replacement PCB in reverse order to removal ensuring that the PCB electrical connections are fully pushed home AIR PRESSURE SWITCH Figure 19 2 Check and re set as necessary the potentiometers and dip switches to the same value as the old PCB RETAINING CLIPS Figure 19 4 CONTROLS FASCIA RETAINING CLIPS CONTROLS CIRCUIT BOARD COVER PRINTED 8 C RC 26 LEJ LEJ LEJ CE O S m Q 19 9 Pump OFF Follow 19 9a or 9b depending on type of failure 19 9 a Replacing motor Drain the boiler s hydraulic circuit as detailed in 19 2 Remove the screws shown in Figure 19 7 COVER Figure 19 7 SECURING SCREWS 4 OFF Pull off the motor remove the cover and disconnect the electrical leads from cable box Figure 19 8 Figure 19 8 Fit the replacement motor in reverse order ensuring correct polarity of the electrical connections Re open the isolating valves on the flow and return connecti
40. lating gas valve coil Figure 19 16 Adjust inner screw to give correct min burner pressure whilst holding 10 mm nut on maximum adjuster Clockwise to increase Anti clockwise to decrease Figure 19 17 Figure 19 17 29 Re connect the lead of gas valve coil After adjustment refit plastic cap on gas valve adjuster and remove gauge and leak test pressure test point 19 14 Expansion vessel Drain the boiler s hydraulic circuit as detailed in 19 2 Disconnect the pipe coupling on expansion vessel Figure 19 18 SECURING NUT FLEXIBLE PIPE CONNECTION Figure 19 18 Release and remove the nut securing the expansion vessel to the boiler Remove the side panels as described in section 18 Lift the vessel out of boiler from the gap over the chasis Figure 19 12 and fit the replacement vessel to the boiler in reverse order to removal ensuring that sealing washer is fitted to pipe connection before tightening replace the washer if necessary Using a pressure gauge ensure that expansion vessel charge pressure is 1 bar 15 psi Figure 19 1 Open the isolating valves on the flow and return connections refill vent and pressurise the boiler ensuring all joints are sound 19 15 Safety Thermostats Remove the front panel combustion chamber cover and right side panel Locate the overheat safety thermostats at the front left handside of the boiler and on the right handside of the pri
41. mary heat exchanger Figures 19 20 amp 19 21 Disconnect the electrical connections from the thermostat LIMIT SAFETY THERMOSTAT Figure 19 20 ELECTRICAL BSA CONNECTIONS M Figure 19 21 PRIMARY HEAT EXCHANGER OVERHEAT SAFETY THERMOSTAT Unclip the thermostat from the pipe Fit the replacement thermostat in reverse order of removal 30 19 16 Pressure relief valve Figure 19 22 Drain the boiler s hydraulic circuit as detailed in 19 2 Disconnect the discharge pipe on the outlet of the safety valve Remove the safety valve from the hydraulic block and retain the o ring for use on reassembly replace as necessary Fit the replacement safety valve in reverse order to removal and refill vent and pressurise boiler ensuring all joints are sound PRESSURE SAFETY RELIEF UNSCREW VALVE TO REMOVE DISCHARGE PIPE R H HYDRAULIC BLOCK Figure 19 22 Factory Settings NG Factory Settings LPG OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ojojoj Di ojojo 20 Gas Conversion Warning Gas conversion must be carried out by a competent person as defined in the Gas Safety and Use Regulations If gas type conversion is required from NG to LPG etc follow the steps below The burner must be removed as section 18 8 shown Figure 18 8 Fit the
42. n the point of connection must be readily accessible at a distance no further than 1 5m adjacent to the appliance and provide complete electrical isolation for the boiler and control system Warning On no account must any external voltage be applied to any of the terminals on the heating control connection plug Figure 9 1 9 4 The low voltage room thermostat terminal block is located to behind of left side of the plastic cover Figure 9 1 On connection of a voltage free room thermostat to the boiler the factory fitted bridge across the room thermostat terminal connectors must be removed If a mains voltage thermostat is to be used please refer to Figure 9 2 9 5 Mains powered thermostats must be connected directly to the mains circuit board as indicated in Figure 2 2 Cut the existing link and connect the wires into the thermostat circuit 9 6 Ensure that the polarity of the mains connection is correct as reversed polarity may cause the appliance to malfunction 9 7 While the boiler s main pcb pump three way valve and gas valve are supplied at 230V AC all other components and associated circuits are supplied at low voltage 9 8 On connecting the mains electrical supply to the boiler it is essential to ensure that electrical safety checks for earth continuity earth resistance polarity and short circuit are carried out prior to making the final connection diagram of the boiler s electrical circuit is given as Figure
43. not be adjusted POTENTIOMETERS DIP SWITCHES BEBE Ep 12345678 Figure 15 3 5 DIP SWITCH r ON POSITION finn 1 2 34 5 6 7 8 ON DIP SWITCH OFF POSITION 23456 DII 1 5 LE 8 DIP SWITCHES IN THE OFF POSITION QH Chart 0 0 0 5 1 0 1 5 2 0 2 5 3 0 16 Safety Devices 16 1 An hydraulically operated primary pressure sensor monitors water pressure or water shortage in the primary hydraulic circuit and will switch the boiler off if the pressure is below 0 3bar and will switch the boiler off if the pressure falls below 0 8bar However it is recommended the pressure is set at 1 5 bar 3 5 Q Figure 15 4 16 2 The temperature of the water flowing from the primary heat exchanger is monitored by an overheat thermostat located on the outlet pipe If the water temperature gets too hot the switch opens cutting off the electrical supply to the gas valve and causing the boiler to Lock out Once activated the boiler has to be manually re set by switching the control knob off for 15 seconds and on again Refer to section 13 2 16 3 An air pressure switch situated in the boiler s fan compartment monitors the boiler s flue operation If a partial obstruction within the flue occurs the fan will continue operating but the boiler s burner will shut down until the blockage is cleared 16 4 The boiler s control unit has in built frost protection
44. off the plastic hose from the condensate trap 2 Unscrew the bottom of the trap in an anti clockwise direction by hand Note if Heatline accepts no responsibility for the unsatisfactory performance of the appliance or flue arising from the failure to comply with the installation and user instructions Incorrect installation could invalidate your guarantee and may lead to prosecution If the boiler is sold to another customer all documents must be transferred from existing customer to the new one and the appliance must be re registered with Heatline in order to mantain the guarantee The boiler must be installed in accordance with these instructions and all the regulations currently in force Read these instructions carefully before installing or using the appliance SHOULD YOU SMELL GAS Turn the gas valve off at the Gas Meter or Gas Cylinder ventilate the room by opening windows and doors EXTINGUISH ANY NAKED FLAMES DO NOT OPERATE ANY ELECTRICAL SWITCHES and call Transco on 0800 111 999 or if you use LPG call your gas supplier IMPORTANT NOTE Speed 2 is the factory default setting for the Pump This setting should be suitable for most of your applications The accessory for the condensate trap includes the hose the trap has be come stuck there is a hexagonal socket in the bottom of the trap to enable an allen key to be used NOTE Cables on the cap 1 lonisation cable 2 Earth cable 3 Condensate h
45. ons refill vent and re pressurise the system and check for leakage 19 9b Replacing the pump body Remove the motor as described above Remove the pressure gauge connection as detailed in 19 10 Remove the expansion vessel pipe by removing the clip on the pump body Disconnect the electrical leads of low pressure sensor Remove the return hydroblock Disconnect the pumps outlet fitting Figure 19 9 PRESSURE GAUGE BODY CONNECTION Figure 19 9 SCREW Remove the fixing screws from the pump and hydraulic block at the bottom of the boiler Figure 19 10 SECURING U UJ LJ SCREWS SECURING SCREW 2 Figure 19 10 Remove the pump assembly Remove the pump body from the hydraulic assembly by releasing the clip Fit the replacement body in reverse order ensuring that the pump washers are sound and fitted correctly and the polarity of the electrical connections are correct Open the isolating valves on the low and return connections refill vent and re pressurise the 97 system ensuring all joints are sound 19 10 Low water pressure sensor Drain the boiler s hydraulic circuit as detailed in 19 2 LOW WATER PRESSURE SENSOR Figure 19 11 W ELECTRICAL CONNECTIONS Remove the pressure sensor by turning it in an anticlockwise direction Fit the replacement sensor in reverse order of removal ensuring all washers are fitted Replace d
46. ose o 0 file c ZJ The Signs on Box The sign of approval the Capriz 25S amp Capriz 28S boilers have been certified by IMQ Italy This is a fragile piece of equipment Do not drop Avoid getting the box damp or wet The packed appliances may be stacked five high Do not crush the packaging as this may damage the appliance Store the appliance upright as indicated on the box The Signs on Boiler LOW VOLTAGE ROOM THERMOSTAT This picture shows the terminal block which is located at the left corner on the rear of the drop down control box Note these terminals are not intended to drive the thermostat but simply connect across the switch that opens and closes as the thermostat operates NOTE This is a voltage free connection and no power or DC should be applied to these terminals For mains powered thermostats see section 9 5 Warning High Voltage This sign is located on the back of the control box housing warning of high voltages within the control box Turn off and isolate the appliance before removing this cover NOTE Take care as there may be residual voltage within some components Potentiometer Cover Removal of the cover which is found on the back of the control box gives access to the adjustment potentiometers NOTE Do not make any adjustments without reading the instructions carefully I N SS YS Handling This appliance is heavy truck
47. ous process 10 improve his products reserves the right to modify the data expressed in the present documentation at any time and without prior notice The present documentation is an informative support and it cannot be considered as a contract towards third parties Benchmark Log Book As part of the industry wide initiative the CAPRIZ 25S CAPRIZ 28S boilers come complete with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current regulations complete all sections relevant to the appliance and installation The details within the Log Book will be required in the event of any warranty work On completion the Log Book must be left with the end user and the relevant sections completed on each subsequent Service visit NOTE You are also obliged to register the installation of this boiler with C O R G I Should you wish to check the SEDBUK website for the rating of this boiler search under DD HEATING or the boiler name and designation e g CAPRIZ 25S QIMQ ii enchmark WRAS XR PROS IMPORTANT INFORMATION The CAPRIZ 255 CAPRIZ 285 is a high efficiency gas fired system boiler and represents the highest level of technology found in today s gas boiler market In order to maintain peak efficiency and performance your boiler must be serviced annually This should be undertaken by a competent CORGI registered engineer Failure to undert
48. ow debris to enter the top of the boiler where the flue connection is made This may cause the fan outlet to get blocked or combustion chamber to fill with debris and will of course cause the boiler to fail to ignite on first ignition It is recommended that you check the fan outlet before you light the boiler Before you fit the boiler ensure that the pipe work that you are installing is connected to the appropriate connections on the boiler i e cold water pipe to cold water inlet hot water outlet to the hot water tap etc Because the boiler is actually operated at the end of each production stage a small amount of water is retained within the boiler when packed Please ensure that you spin the pump rotor manually before firing the boiler It is important that the boiler must be used in conjunction with a Heatline approved flue and all flue connections are correctly sealed Remember to flush out the system both cold and hot in order to remove the debris from the system This should be done particularly where boilers are being fitted to existing radiator circuits Refer to BS 7593 1992 for the details to clean Central heating systems This boilers central heating output has been set to a mid range position However you may choose to adjust this using potentiometer P2 to meet the requirement of the system Remember to release the small cap on top of the auto air purge device on the pump 1 turn before filling This will ensure that
49. owing burner shut down on the primary hydraulic water reaching its set temperature This delay can be increased up to a maximum of 255 seconds by turning potentiometer P5 Figure 15 2 clockwise m 5 P5 Ep e p POTENTIOMETERS H POTENTIOMETER lt 4 ADJUSTMENT P2 HS d COVER 7 ooo P4 H z a ina Figure 15 1 Figure 15 2 15 4 Setting the Heating output The CAPRIZ 25S amp CAPRIZ 28S boilers are factory set to give maximum c heating output The heat output for heating is pre set on potentiometer P2 Figure 15 3 This can be adjusted to suit the system as required 15 5 Gas valve ignition capacity The graduated opening of the gas valve for ignition rate is governed by the 1st potentiometer P4 control which is factory set to 4 o clock To assist in setting the boiler s modulating gas rate parameters the ignition rate of the valve can be forced from minimum to maximum rate by setting the potentiometer clockwise 15 6 The boilers integral pump is factory set to speed 2 setting to give a 1000 l hr flow on a nominal over 4 m head The pump may be adjusted to a lower speed to match the designed central heating system requirements Figure 15 4 15 7 Dip switch 8 is factory set to OFF for 25 kW and set to ON for 28 kW Important Gas Type Jumper Dip Switch 1 Dip Switch 4 and Dip Switch 5 are factory set and must
50. ped pressurised sealed systems operating at a maximum of 3 bar pressure and maximum design flow temperature of 85 5 3 The boiler s integral expansion vessel is pre charged to a pressure of 1 bar and will accommodate a system volume of 125 litres at an average water temperature of 75 and maximum system pressure of 3 bar If the system volume is more than 125 litres an additional expansion vessel must be fitted to suit the size of the system A typical installation of an additional pressure vessel is shown in Figure 5 1 5 4 The heating circuit should be designed and balanced to give a 20 temperature rise across the boiler flow and return 5 5 When fitting a new boiler to an existing system the system must be thoroughly flushed in accordance with the recommendations of BS7593 prior to installation 5 6 It is recommended that the system should be protected by an anticorrosion inhibitor Failure to comply with this requirement may invalidate your guarantee Cold water Boiler supply Additional expansion vessel if required Heating outlet Heating return Figure 5 1 09 5 7 installation it is important to ensure that the heat exchanger is not a natural collecting point for air and where possible the system pipe work should have a gradient to ensure any excess air is carried naturally to other purpose made air release points 9 8 In high water volume systems or under floor heating system
51. riz 28S A 405 430 B 169 169 C 60 100 60 100 Distance to centre line 169 mm Figure 10 3 10 4 When cutting the flue hole it is recommended that a 105mm diameter core drill is used where both internal and external access for the flue installation is available Where only internal access is available a 125mm diameter core drill should be used Note Please take adequate precautions to prevent debris entering the boiler via the flue outlet 10 5 Using a 8 5mm drill bit drill the holes for fixing jig optional and hanging bracket Locate and secure the supplied wall mounting bracket in position Figure 70 4 Bracket Fixing Slots Boiler Mounting Tabs 10 6 Mount the boiler onto the fixing bracket via the boiler mounting slots Figure 70 4 10 7 Connect isolation valves assembled to the boiler ensuring the washers are fitted correctly 10 8 On installing the flue determine the required length of the outer air duct by measuring the distance L Figure 10 6 from the face of the external wall to the back of boiler s elbow connecting collar The measurement for the inner flue duct will be L 20mm 16 10 9 Measuring from the back of the terminal connection mark distance L onto the outer air duct Figure 10 5 L 20 mm l Figure 10 5 External Waste lt wall face Figure 10 6 n 10 10 Cut the outer air duct only to the required length
52. rmance from your boiler it is suggested that supplies to outlets are run in 15mm copper as short as possible and where practical be insulated to reduce heat loss 5 15 The boiler incorporates a frost protection thermostat Therefore if the boiler will not be used for long periods of time during cold weather in order to avoid freezing the electric supply must be left ON and all the central heating isolation valves must be left open The internal frost thermostat will then operate the boiler if the temperature falls too low However if the electrical supply is to be turned off the boiler the heating system and domestic hot water circuit must be drained 6 Appliance Siting 6 1 If the boiler is to be installed in any room or compartment it requires no purpose made ventilation for combustion air If sited in a room containing a bath or shower then particular reference is drawn to the requirements of British Standard 7267 confirm I E E Wiring Regulations and Building Regulations 6 2 f the boiler is installed in a compartment there must be purpose made ventilation for cooling purposes 6 3 The boiler is not suitable for external installation unless protected by a purpose made building such as a boiler house 6 4 The following clearances are recommended for installation purposes 200mm above 300mm below and 50 mm at each side 600 mm is required at the front but this may be provided by opening a cupboard door 6 5 The boiler
53. s where prolonged operation of the boiler is expected at temperatures below 60 a by pass must be installed on the boiler outlet in order to prevent condensation forming inside the combustion chamber Failure to comply with this requirement will invalidate the manufacturer s guarantee 9 9 The pressure relief discharge must be directed away from any electrical equipment or where it could cause a hazardous situation 5 10 To enable adequate drainage of the system drain cocks compliant with BS2879 must be fitted at the lowest points in the system pipe work 9 11 To obtain the best hot water performance from your boiler it is suggested that the cold water supply to the boiler is the first draw off from the incoming mains supply Note that the boiler will not operate unless there is a minimum pressure of 0 25bar with a flow rate of 2 5l min Where inlet pressures exceed 8bar a pressure regulator must be fitted to the cold water supply 5 12 Where cold water mains are fitted with a water meter check valve s or loose jumper stopcock a domestic hot water mini expansion vessel may need to be fitted 5 13 Although the boiler is designed to inhibit the formation of scale in hard water areas above 200mg l a proprietary scale reduced should be fitted in the cold water supply to the boiler Failure to comply may invalidate your guarantee The local water undertaking will advise on water hardness 5 14 To obtain the best hot water perfo
54. siuiuloo e si yoog ay si 510 ueuA U6WO SNo eu pepueu Uday pue pojeroosse pue y peuoissiuiuio2 oym 1uejeduioo ay Aq u pejejduioo oj s 4oog 5141 Z enin eaejd ayes e ui yoog ay dea aseajd L TAL ssaquaav SVN 1003 601 p1038H 921 19 pue Huluoissiwwo4 U0I EJ EJSU Buijeau enuas seb jo Gursinios 9 Guluoissimuos UOl EJ EJSUI ay 10 921 22 0 Jo 8po3 ayy 6 UouryJuaq TNII 1V4iH 36 COMMISSIONING PROCEDURE INFORMATION FOR ALL BOILERS HAS THE SYSTEM BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS gt YES NO WHAT WAS THE CLEANSER USED HAS AN INHIBITOR BEEN USED YES NO WHICH INHIBITOR WAS USED FOR THE CENTRAL HEATING MODE MEASURE AND RECORD HEAT INPUT kW BURNER OPERTING PRESSURE mbar CENTRAL HEATING FLOW TEMPERATURE CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE AND RECORD MAXIMUM OPERATING WATER PRESSURE bar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE WATER FLOW RATE MAXIMUM SETTING
55. tallation the following British Standards must also be considered v BS 6798 Specification for installation of gas fired hot water boilers of rated input not exceeding 70kW v BS 5449 Central heating for Domestic Premises v BS 5546 Installation of gas hot water supplies for domestic purposes v BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding 70kW Part 1 Flues v BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding 70kW Part 2 Air Supply v BS 6891 Installation of low pressure gas pipe work installations up to 28mm R14 Reference should also be made to British Gas Guidance Notes for Installation of Domestic Gas Fired Boilers Due to the manufacturers continuous improvement policy the manufacturer reserves the right to change any specification of the appliance or make modifications to these instructions which meet current regulations at the time of print However the instructions must not be taken as overriding statutory requirements To ensure reliability and continued performance ensure that other components in the system are also approved to relevant standards and that the appliance and system is adequately protected and maintained on an annual basis For further information or advice UK contact Heatline Service please call 0870 609 2091 Spares please call 0870 777 8402 Technical assistance please call 0870 777 8318 Or by E mail on our Web Site at
56. the operating switch the boiler can be switched on 4 2 CENTRAL HEATING DEMAND When heating demand is requested and power is on with the timer thermo stat calling for heat the boiler will fire automatically An integral pump is then energised and hot water from the boilers primary circuit is circulated around the central heating systems pipe work and radiators When the demand for central heating is no longer present either the thermostat reaches temperature or the time clock reaches temperature or the time clock reaches the end of its set period the burner will shut down and the boiler will revert to stand by waiting to respond to the next heating demand The pump will continue to operate for a short period of time to dissipate any excess heat from within the boiler s heat exchanger CENTRAL HEATING HYDRAULIC CIRCUIT Figure 4 1 08 5 General Installation 5 1 Installer Testing amp Commissioning Tips The installer shall instruct the user in the operation of the boiler safety devices contained within the boiler and instruction on how to re pressurise the system if the water pressure falls The installer should then hand over the instructions with the Benchmark Logbook that has been completed The user should be instructed to keep the instructions in a safe place for servicing and future reference It is important to keep the boiler clear of dust during the installation In particular do not all
57. the pressure within the boiler and central heating system and should when the water is cold read between 1 and 2 bar If the pressure gauge falls below 1bar the system and boiler must be re pressurised via the filling loop The filling loop should be located below the boiler Note A Service Engineer must be contacted if a boiler fault continues to occur FROST PROTECTION The boiler has a built in frost protection device that protects the boiler from freezing If the boiler is to be left and there is a risk of frost ensure that the gas and electrical supplies are left connected The frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the temperature reaches 15 the boiler will shut down Note This device works irrespective of any room thermostat setting and will protect the boiler but not necessarily the full system Ensure that vulnerable sections of the circuit are adequately lagged SYSTEM PRESSURE and system to its effective working pressure The boiler s pressure gauge should be regularly checked to ensure that this pressure is maintained between 1 and 2 bar If there is a significant or frequent drop in pressure then your installer should be consulted OPERATING THE BOILER On installation your installer will have filled the boiler and system to its effective working pressure The boiler s pressure sensor should be regularly checked on the LED to ensur
58. ust be reduced by 1 5 whilst the use of 2 x 45 bends warrants a reduction of 2m WARNING ONLY A HEATLINE APPROVED FLUE IS TO BE USED WITH HIS PRODUCT FAILURE TO COMPLY WITH THIS REQUIREMENT WILL INVALIDATE YOUR GUARANTEE AND COULD LEAD TO A DANGEROUS SITUATION FOR CONDENSING BOILERS IT IS RECOMMENDED THAT AN ANTI PLUME KIT IS FITTED IF THE TERMINAL IS LESS THAN 2 5 m FROM A BOUNDARY IN ADDITION THERE IS 45 ELBOW AVAILABLE TO DEFLECT THE PLUME AWAY FROM WINDOWS ETC 9 Electrical Connections 9 1 The boiler is supplied factory wired complete with 1 5 m of mains fly lead All electrical connections to the mains supply must be made in full accordance with the current I E E regulations 9 2 The boiler must be connected to an effective earth system Using the cable supplied the boiler may be connected via a 3 amp fused three pin plug to an unswitched shuttered socket outlet However if the boiler is installed in a room containing a bath or shower regulations dictate that disconnection must be incorporated in the fixed wiring with a switch provided for disconnection from the mains supply having a contact separation of at least 3 mm on all poles and fused at 3 amp 24V LOW VOLTAGE ROOM THERMOSTAT TERMINAL BLOCK N Figure 9 1 FITTED BRIDGE BRIDGE PLUG PRINTED CIRCUIT BOARD Figure 9 2 9 3 Other than for a bathroom installatio
59. ustible surface must be within 50mm of the boiler casing without protection gt There must be 50mm clearance between the compartment door and boiler case gt Where the boiler s flue pipe passes through the airing space it must be protected by a combustible sleeve or fire stop which has a minimum clearance of 25 mm from the flue pipe In addition if the flue pipe passes through the partition then the clearance gap of the flue pipe or its guard with the partition must not exceed 13 mm 6 9 When the boiler is intended for use with LPG it must not be installed in a room or internal space below ground level 7 Flue Terminal Location 7 1 The flue terminal must be sited with minimum clearances as specified in Figure 77 Note if pluming becomes problematic or causes a nuisance a plume management kit is available from your stockist 7 2 Current regulations and standards require a terminal guard to be fitted where the terminal is accessible to touch or at risk of being damaged All wall mounted terminals sited within 2m of the level which people have normal access should be adequately protected with a suitably sited guard 7 3 Where the flue terminates within 1m of a plastic or painted gutter or within 500mm of painted eaves then protection should be provided in the form of an aluminium shield at least 1m in length fitted to the underside of the gutter or painted surface
60. w frame 2 Boundary as defined in the Building Regulations England amp Wales or the Building Standards Scotland Regulations 3 Where the wall adjacent to a vertical flue terminal includes an opening window the clearance between the terminal and any part of the opening window must not be less than 1000 mm 12 7 4 The flue should not be sited where the condensate plume may give rise to a nuisance factor under certain weather conditions NOTE If you have difficulty siting the flue in an appropriate location your supplier will be happy to supply an anti plume management kit which discharges the flue products at a higher level 8 General Flue Info 8 1 The boiler utilises a concentric flue arrangement which consists of a 60mm diameter inner flue and 100mm diameter outer air inlet duct 8 2 The standard 700 5 mm flue kit Figure 8 1 can be routed to the rear left or right of the appliance by means of a 90 degree bend This can be purchased with the boiler but there are other various types of flue available if required The bend is connected to the boiler using the screws provided and sealed with the gasket 658 60 698 100 Figure 8 1 8 3 The 60 100 mm flue pipes may be extended up to a maximum of 2 5 m using additional spare components available from your supplier This length can be increased to 7 m using the 80 125 mm flue kit 8 4 A vertical 60 100 mm flue kitis also available from your supplier
61. www heatline co uk 05 2 Technical Data Capriz 25S Capriz 28S Capriz 255 Capriz 285 25 kW 28 kW 25 kW 28 kW Maximum heating Heat Input kW 25 7 28 5 temperature C 85 85 PMS 3 3 Heat Output max kW Pur E Operating pressure Nominal 1 5 1 5 Min 0 8 0 8 Heat Input min kW 11 11 Expansion Vessel Capacity Litres 7 7 Heat Output kW 10 2 10 2 Expansion Vessel bar 1 1 Useful efficiency at 96 968 100 load Useful at 30 102 4 103 3 Air Intake Pipe Diameter mm 100 125 100 125 1 20 NG 1 15 NG Flue Pipe Diameter mm 60 80 60 80 Burner injector mm 0 75 LPG 0 75 LPG E Burner Pressure Max 12 5 14 60 100 60 100 Natural Gas 99 in 25 Min 2 3 Max Flue Length C12 C32 m 7 0 7 0 80 125 80 125 Burner Pressure w Max 28 5 36 5 Max 28 2 36 2 Min 6 7 8 Min 4 5 6 Max Flue Length 20 22 Propane C42 C52 m 0 80 80 80 Power Supply Input 220 240V 50Hz 220 240V 50Hz Equivalent Length 45 Bend m 1 0 1 0 Max power Watt 220 220 Equivalent Length 90 Bend m 1 5 1 5 consumption Level of Protection IPX 4 D IPX 4D Net weight kg 35 36 Case Dimensions mm 330d x 405w x 720h 330d x 430w x 720h Gross Weight kg 38 39 06 M Zn A Heating Flow 22mm B Gas Inlet 22mm Fi

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