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User manual and Installation instructions

1. When connecting any type of external control i Z the link M in Fig 6 16 must be removed o To fused spur N 119 E isolation switch Ll S q Power supply era a terminal block J CIL 5 5 D KD Fig 6 18 iU N TN SL EAT External frost protection IO Cn 10 Connect the frost thermostat between ter i minals 1 and 2 as shown in Fig 6 19 Fig 6 16 Do not connect live wires to terminals to 8 Connect the room thermostat between ter MR room thermostat must be con minals 1 and 3 as shown in Fig 6 17 Do not connect live wires to terminals to Frostthermostat Room thermosta which the room thermostat must be con nected Room thermosta Power supply AN terminal block T T Al le L N 7 9 ali fa 1 S Y 5 Power supply 7 terminal block 241 NE External controls O 2 Y 9 9 S NO 7 9 9 3 DOS terminal block External controls oo e terminal block KD Fig 6 19 o e DOKA i Fig 6 17 31 COMMISSIONING WARNING Filling the d h w system The com
2. 35 8 Gas conversion 36 9 5 Combustion analysis check 39 81 36 9 6 Cleaning the primary heat exchanger 39 MM 8 2 66 36 9 7 Checking the pressurisation in the expansion vessel 39 9 Maintenance 38 9 8 Cleaning the burner 39 E 9 1 38 99 Checking the flue 39 9 2 Dismantling the external panels 38 9 10 Drain pipe inspection 39 5 9 3 Emptying the d h w system 38 9 11 Visual inspection of appliance 39 E 9 4 Emptying the c h system 38 9 12 Gas pressures and tightness 39 g Abbreviations used in the manual C h Central heating D h w Domestic hot water D c w Domestic cold water EN APPLIANCE DESCRIPTION Overview 10 Appliance operation lights KEN Isolation valves 16 15 14 13 12 11 Fig 1 2 bottom view of the boiler Fig 1 1 11 Condensate drain pipe 1 Case front panel 12 C h return valve 2 Control panel 13 D c w inlet valve 3 Control panel cover 14 Gas inlet valve 15 D h w outlet pipe Control pane 16 C h flow valve C h circuit temperature and pressure gauge e Time switch c h control EN Technical data Lock out signal lamp For detailed technical data see section 4 5 or 4 6 Lockout reset button of this manual Function sele
3. l min Gas supply pressures Gas Natural Butane Propane G20 G30 G31 Norm Pa 2 000 2 900 3 700 mbar 20 29 37 Max Pa 2 500 3 500 4 500 mbar 25 35 45 Min Pa 1 700 2 000 2 500 mbar 17 20 25 1 mbar approximately equals 10 mm H2O Maximum kW 28 4 BTU h 96 897 Minimum kw 125 BTU h 42 648 Maximum condensing kW 30 4 BTU h 103 721 Minimum condensing kW 13 3 BTU h 45 378 Central heating Maximum flow temp Minimum return temp C 85 C 40 C 40 Maximum pressure kPa 250 bar 2 5 kPa 30 bar 0 3 kPa 25 Minimum flow temp Minimum pressure Available head in 1000 I h 0 25 Seasonal efficiency G20 B Seasonal efficiency G30 G31 B A referred to the net calorific value at 15 C and 1013 25 mbar G 20 34 02 MJ m G 30 45 6 MJ kg G 31 46 4 MJ kg B The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body O Values subject to tolerance 18 Technical information Gas pressures at the burner Flue design Gas Natural Butane Propane Type C12 C32 C42 C52 C82 G20 G30 G31 Flue pipe diameter Max Pa 1130 2810 3600 Coaxial mm 60 100 mbar 11 3 28 1 36 0 Min Pa 240 580 780 Twin split pipes mm 80 Ignition Pa 850 2110 2700 Nominal heat flow rate kW 29 0 mbar 8 5 21 1 27 0 1 mbar approximately equals 10 mm H20 Exhaust temperature D C 69 Mass flow rate
4. Wall hung fan flue room sealed high efficiency gas boiler User manual and Installation instructions GARDA HE MK2 Models M96A 24SM B Combi boiler M96A 28SM B Combi boiler A GARDA HE MK2 are condensing high efficiency sealed chamber fan flue gas boilers They are fully electronically controlled and have electronic ignition The materials they are made of and the control systems they are equipped with give you safety a high level of comfort and energy savings to allow you to get the greatest benefit out of Congratulations on your choice independent heating GARDA HE MK allow a higher efficiency by reducing the flue gas temperature such that the water vapour formed during the combustion is condensed out This allows a gain of useful heat that otherwise would be lost Remember that 1 The manual must be read thoroughly so that you will be able to use the boiler in a safe and sen sible way must be carefully kept It may be necess ary for reference in the future First lighting up must be carried out by competent and responsible engineer The manufacturer disclaim all liability for any translations of the present manual from which incorrect in terpretation may occur cannot be held responsible for non ob servance of instructions contained in this manual or for the consequences of any pro cedure not specifically described Using the boiler 1 Before lighting the boiler y
5. con nection nut and a Y gasket Kc B un d e es E SY F ES QU L C eZ A pl 9 e AC 6 9 _ 2 Fig 6 3 8 Connect the pipe H Fig 6 4 from the pres sure relief valve to the safety discharge pipe work 9 Fit the condensate drain 11 Fig 6 4 in the air brake connected to the drainage pipework See also section 5 7 in this manual Installation Fig 6 4 Fitting the flue system Refer to the assembly instructions contained with in the chosen flue kit packaging for the correct as sembly and installation In general it has to be taken in consideration that the horizontal sections of the flue pipe must have an horizontal sloping not less than 1 5 deg 25 mm per metre towards the boiler In the standard horizontal flue kit Fig 6 6A the flue pipe is angled within the air duct therefore the air duct must be horizontally installed If one or more extensions have to be used they must be adequately supported so that there is no sag in the flue pipe and a minimum fall of 1 5 deg 25 mm per metre over the whole length towards the boiler is ensured Before fitting the flue system ensure that the flue gasket shown in Fig 6 5 given with the boiler is fitted to the boiler Fig 6 5 CO Choice of flue The following flue kits are available for connecting to the boiler Standard horizontal flue kit Fig 6 6A Co axial 60 100mm nominal l
6. 9 2 Fig 9 2 9 3 Emptying the d h w system 1 Turn off the d c w inlet isolating valve 13 in Fig 9 3 andturn on the hot watertaps and any drain cocks mn Closed position 9 4 Emptying the c h system 1 2 3 Close the c h isolating valves 12 and 16 in Fig 9 3 Open the central heating drain cock 24 in Fig 9 4 A small quantity of water will remain in the d h w heat exchanger after draining If the boiler is being drained to prevent freezing the Maintenance d h w heat exchanger must be removed and inverted to drain fully or an antifreeze solution added wr Fig 9 4 EE Combustion analysis check If itis necessary to carry outa combustion analysis remove the plugs indicated in Fig 9 1 Reference figures are given in the sections 4 5 4 6 of this manual Flue gas figures 9 6 Cleaning the primary heat exchanger 1 Take off the front of the case 2 Take off the removable front of the sealed chamber and the front panel ofthe combustion chamber If you notice dirt on the fins of the primary heat ex changer 43 on page 13 3 cover the sloping surfaces of the burner 40 on page 13 entirely in a protective layer sheets of newspaper or similar 4 Brush out the primary heat exchanger 43 on page 13 with a bristle paintbrush Checking the pressurisation in the expansion vessel Empty the central heating system as described in s
7. MEASURE amp RECORD GAS RATE mehr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE N A mbar COLD WATER INLET TEMPERATURE 19 HOT WATER OUTLET TEMPERATURE 50 WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO RATIO READING NA YES CO CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER E MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER nz I COMMISSIONING ENG S NAME PRINT________________zCORG ID No SIGN DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufactu
8. Optional 45 and 90 elbows can be used to offset the flue route Each additional elbow reduces the overall accept able length of the flue system as follows 45 reduce length by 0 5 m 90 reduce length by 1 m Pluming kit Fig 6 11 Co axial 60 100mm vertical part o 60mm flue outlet Type C52 90 0 85 m AS 9 60 mm de Fig 6 11 This kit allows the comburent air to be sucked up and expel the burnt gasses directly to the outside through a telescopic co axial flue 450 950 mm In the last section the fumes are expelled through a vertical section Extensions and elbows can be added to extend the kit s length The chart of Fig 6 12 gives the allowable dimen sions of the ducts a and b of Fig 6 11 29 z g E 3 E E z a E 3 E E Installation a vertical length m 24 22 2 0 1 8 1 6 04 06 08 10 12 14 16 18 b horizontal length m Fig 6 12 Each additional elbow reduces the overall accept able length of the flue system as follows 45 60 100 mm reduce length by 0 5 m 90 60 100 mm reduce length by 1 m 45 60 mm reduce length by 0 65 m 90 60 mm reduce length by 0 85 m DA CON Electrical connections Connection to the electricity supply 1 Remove the front panel of the case see the section 9 2 in this manual 2 Remove the screws and J Fig 6 13 Fig 6 13 30
9. products directly outside or into a suitable ex haust duct designed for this purpose Combustion products must be discharged using original flue kits only since they are inte gral parts of the boiler For LPG the appliance must also conform with the requirements of the distributors and com ply with current Regulations and laws in force The safety relief valve and the condensate drain must be connected to a suitable drain or discharge in a safe manner The electrical wiring must conform with current Regulations in particular the boiler must be earthed using the cor rect bonding clamp Adjacentto the boiler a fused spur isolation Switch must be installed which permits a complete switching off in the conditions of the overvoltage category Ill Refer to sec tion 6 9in this chapter forthe electrical con nections In no circumstances will the manufacturer be held responsible if the warnings and in structions contained in this manual have not been complied with 6 2 Precautions for installation For the installation proceed as follows The boiler must be fixed to a strong wall The dimensions for the exhaust fume duct de tailed in section 6 7 and the correct procedures for installing the duct depicted in the instruc tion leaflet included with the flue kit must be complied with during installation allow maintenance procedures it is necess ary to leave the minimum gaps indicated in
10. 2 16 Note when the mode selector switch A is in the AUTO position and the boiler is switched off atthe fused spur isolation switch the display H indicates only the OFF state The other indications are blanked Reading the timed settings Setthe mode selector switch A to the C1 position The symbols shown in Fig 2 14 appears in the display Press the enter button C Each time the button is pressed the display showsthe details of the next setting Changing or deleting the timed settings Setthe mode selector switch A to the C1 position The symbols shown in Fig 2 14 appears in the display Press the enter button C until the display shows the setting to be modified or deleted The time setting can be modified now by pressing button D or E and the operation can be switched on or off by pressing the button F To delete a time set press the button D or E until the symbols shown in Fig 2 14 appears in the time display G The new settings are memorized by moving the Switch A to a different position Manual operation The operation of the time switch can be forced on or off constantly or for a timed period To force constantly on or off the timer operation setthe mode selector switch A to the TIMER posi tion The symbols shown in Fig 2 17 appears on the display gt J id AUTO TIMER Fig 2 17 The operation can be switched permanently on or off by pressing the button F and leaving the switch A i
11. 3 Loosen the screws K 4 Removethe side panels or move the lower part ofthe side panels as indicated in Fig 6 14 and pull the control panel When completely pulled out the panel can ro tate 45 downwards to facilitate the operations on the internal parts Fig 6 14 5 Loosen the screws L and remove the service panel Fig 6 15 Fig 6 15 For the electrical connection to the boiler use elec tric wires which conform to the current regulations with flexible cord each core having a cross sec tion area not less than 0 75 mm 6 Connect the electrical supply flexible cord coming from the fused spur isolation switch to the power supply terminal block of the boiler Fig 6 16 keeping the same connections for the live brown wire and the neutral blue Installation wire External 3 A fuse or fused plug withsame 9 Route the electrical supply flexible cord and current rating is recommended the external control flexible cord as illustrated Do not connect live wires to terminals to in Fig 6 18 which the room thermostat must be con Lock the flexible cords in place with the flexible nected cord clamps 7 Connectthe earth wire yellow green Jj Connection of a room thermostat p The room thermostat must be connected to the 6 EEN terminal block situated next to the control panel J0 tne exiemal Tho digg epr isolation switch
12. 4 Atthis step itis possibleto visualize the current set ting by keeping the reset button 7 pressed for O Lamp OFF 9 Lamp Gas conversion more than 5 seconds The lamps 10 will flash a 15 Open the gas cock 14 in Fig 8 7 number of times corresponding to the setting of the knob 9 in Fig 8 5 Pa Gas type 39 LPG ES Setting No 4 a N l S 2 6 y NATURAL 1 27 OOO DB DIE Open position Fig 8 5 Fig 8 7 16 To reset the boiler to the normal operation turn Gas Position of Approx Max current it ON by the function selector 8 on the desired supply knob 9 through the modulator operation and checking the ignition pressure device and that the burner lights up uniformly In any case the boiler automatically resets to its nor Natural 125 mA mal operation after 10 minutes gas Factory setting Natural gas as illustrated L PG 165 mA 17 Calibrate the gas valve according to the in o structions given in the service manual section eZ Fig 8 6 Modulating gas valve Adjustment g 13 To change the setting turn the knob 9on a posi 18 Re assemble the lid of the sealed chamber iim tion corresponding to the gas used as shown 19 Replace the self adhesive label indicating the 5 in Fig 8 5 f type of gas and the gas pressures to which the z By turning the knob 9 the lock out signal appliance has been set with the label included Mi lamp 6 blinks quickly 2 per sec
13. C h return pipe r Fig 2 1 2 Open the valves of the filling loop and watch the gauge until it reaches normal filling pres sure as shown in Fig 2 2 4 SY Normal filling Hi pressure Fig 2 2 3 Close the valves and remove the filling loop If you experience any difficulty with the oper ation of the boiler switch off the boiler immedi ately at the fused spur isolation switch and contact your Installer or an approved Service Engineer Air introduced into the boiler during this filling pro cess will vent through the automatic air purger fitted to the boiler You may also find it necessary to vent air from your radiator circuit using your radiator key however be aware that excessive venting will cause the pressure in the system to drop Always ensure thatthe pressure gauge is set atthe required pressure Instructions for use 2 3 Ignition 1 Checkthatthe valves located in the lower part of the boiler are open Fig 2 3 Pearl j cS 9 i P s Open position Fig 2 3 2 Turn on the electricity supply to the boiler switching on the fused spur isolation switch The appliance operation light 10 Fig 2 4 will flash every 4 seconds stand by condition 3 If the boiler is to be used for c h and d h w position the function selector 8 as in Fig 2 4 The appliance operation light 10 will flash every 2 seconds operating boiler 10 N 8 N 8 1 7 OO OO aw Fi
14. D g s 17 8 Natural Butane Propane Flue gas figures G20 G30 G31 Nominal heat input X k 29 0 m3 h kg h kg h INSTALLATION D W M 3 07 229 225 CO content 96 6 8 l l O content 88 Min CO content ppm 52 D Injectors mm 1009 temperature C E Natural G20 130 Butane G30 7 P 1 77 ROMER Electrical Data dd mm a t BE Power consumption W 150 eight dry 9 Water volume in the boiler I k 4 1 Protection degree IPX4D up to 1 bar 9 External fuse rating 3 Internal fuse rating A 1 2 3 15 AF D Values refer to tests with a 1 m chimney working at the nominal heat input z g E 3 E E EM GENERAL REQUIREMENTS Our Company supports the Benchmark initiat ive The Benchmark Log Book is located atthe back of this manual and should be completed by the Installing Commisssioning Engineer and handed over to the User for future refer ence by other visiting Engineers Also in cluded is the Service Interval Record card that should be completed by the Service Engineer following the annual service maintenance of the boiler and system For Ireland IE it is necessary to complete a Declaration of Conformity to indicate com pliance to 1 S 813 2002 This appliance must be installed by a compet ent person in accordance with the Gas Safety installation 8 Use Regulations EXI Related documents The installation of this appliance must be in ac cordan
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16. an adequate supply is available both to the boiler and the other appliance when they are in use at the same time Pipework must be of adequate size Pipes of a smaller size than the boiler inlet connection should not be used Installation pipes should be fitted in accordance with BS 6891 and the complete installation should be tested for tightness For Ireland IE refer to 1 5 813 2002 air supply The room in which the boiler is installed does not require a purpose provided air vent EN Ventilation If installed in a cupboard or compartment it is not necessary to provide additional ventilation for cooling for this particular product However con sideration must be given to clearance require ments for maintenance see section 6 2 and under no circumstances must stored articles be al lowed to come into contact with the boiler or flue pipe Condensate drain Ensure that the condensate discharge complies with the national or local regulations in force The condensate pipe must be fitted in accordance with Building Regulations Drainpipe material should be resistant to acid as the condensate is slightly acid with a pH less than 6 5 The boiler includes atrap 25 on page 13 that pre vents the combustion products entering the drain The boilers incorporate a condensate trap a 75mm seal ti comply with BS6798 2000 Two schematic diagrams of possible connections are given in Fig 5 2 and Fig 5 3 The leng
17. gas valve 32 Modulation operator 33 Gas valve outlet pressure test point 34 Gas valve inlet pressure test point 35 D h w temperature probe NTC 36 Three way diverter valve 37 D h w heat exchanger 38 Primary circuit pressure switch 39 Flame detecting electrode 40 Burner 41 Ignition electrodes 42 Combustion chamber 43 Primary heat exchanger 44 C h expansion tank 45 By pass valve Z o E 3 E z 36 35 31 30 29 28 27 26 25 24 46 Fan pressure connection Fig 4 1 47 Domestic water circuit filter 11 Condensate drain pipe 48 D h w flow limiter 12 C h return valve 49 Flue outlet pipe 13 Domestic cold water inlet valve 50 Air intake pipe 18 Technical information 4 2 Main diagram 50 20 E g 49 E Gas 2 17 19 g A E 43 yl z C 2 29 K 37 ao 0000000000008 10 26 l J JL 3 S 25 N 38 44 QU E T 48 y MEA m se 31 J 36 E E B RS 11 t 45 P 35 24U 3 t X X X X 14 12 16 13 15 Fig 4 2 Technical information EEN Hydraulic specifications kPa bar
18. off at the fused spur isolation switch the display H indicates only the OFF state The other indications are blanked Reading the timed settings Instructions for use Press repeatedly the button A until the display shows the symbol C1 Fig 2 21 The symbols shown in Fig 2 21 appears in the display Press the OK button C Each time the button is pressed the display shows the details of the next setting Changing or deleting the timed settings Press repeatedly the button A until the display shows the symbol C1 Fig 2 21 The symbols shown in Fig 2 21 appears in the display Press the OK button C until the display shows the setting to be modified or deleted The time setting can be modified now by pressing button D or E and the operation can be switched on or off by pressing the button F To delete a time set press the button D or E until the symbols shown in Fig 2 21 appears in the time display G The new settings are memorised by pressing the button A Manual operation The operation of the time switch can be forced on or off constantly or for a timed period To force constantly on or off the timer operation press repeatedly the button A until the display shows the symbol TIMER The symbols shown in Fig 2 24 appears on the display OFF yt M ca TA Fig 2 24 The operation can be switched permanently on or off by pressing the button F and leaving the dis play shows the symbol T
19. water treatment device or softener With such a device you should avoid periodic descal ing Consequently the d h w heat exchanger will keep its performance consistent for a longer period of time with resulting gas savings If the demand for d h w is so great as to prevent reaching a high enough temperature have the ap propriate output limiting valve installed by your in staller or an Authorised Service Engineer 2 6 Extinguishing To turn the boiler off set the function selector 8 to the position shown in Fig 2 10 The appliance operation light 10 will flash every 4 seconds 9 A 9 e Fig 2 10 When you do not expectto usethe boilerfor along period 1 Switch off the electricity supply to the boiler by means of the fused spur isolation switch 2 Shutoffthe gas supply cock 14 and the valves for the water circuits fitted under the boiler Fig 2 11 Instructions for use 3 Empty the water circuits if necessary as shown in section General access and emptying hydraulic circuits in the service manual 14 Closed position Fig 2 11 Built in time switch A The boilers are equipped with a built in electronic time switch 5 Fig 1 3 on page 2 which controls the c h operation F E D B Fig 2 12 Display and control panel Mode selector switch Reset button Enter button Increase setting button Decrease setting button On off button Time dis
20. 60 0 6 50 0 5 40 0 4 30 0 3 20 0 2 10 0 1 0 0 0 0 200 400 600 800 1000 1200 1400 l h Fig 4 3 The hydraulic specifications in Fig 4 3 represent the pressure available head for the central heat ing system as a function of the flow rate The load loss due to the boiler has already been subtracted Output with thermostat cocks shut off The boiler is fitted with an automatic by pass valve 45 on page 13 which protects the primary heat exchanger In case of excessive reduction or total blockage of water circulation in the central heating system owing to closure of the thermostatic valves or sys tem component cocks the by pass valve ensur es a minimum flow of water through the primary heat exchanger Expansion vessel Note this boiler is designed for operation only in a sealed central heating system The height difference between the pressure relief valve and the highest point in the system may be 10m at most For greater differences increase the pre load pressure in the expansion vessel 44 on page 13 and the system when cold by 0 1 bar for each additional 1m For 24 Kw and 28 Kw Capacity l kPa bar Maximum volume of water in the system Pre load pressure Tab 4 1 Where conditions are Average maximum temperature of the system is 85 C Initial temperature when filling up the system is 10 C For systems 24 Kw and 28 Kw with vol
21. Fig 6 1 250 200 Fig 6 1 all dimensions in mm Wheninstalling the boiler in a cupboard cover or alcove allow at least 50mm permanent clear ance from the front face of the boiler Also en sure sufficient clearance to allow free access for servicing and the lowering of the front con trol panel If the boiler is installed outside cover the ap pliance to protect it against the elements and add some special anti freeze neutralised to the c h system Before installing the boiler on an existing c h system flush it out thoroughly before fitting the boiler so as to remove muddy deposits Itis advisable to equip the system with a sedi ment filter or use a water treatment product in the circulating water The latter option in particular not only cleans out the system but also has an anti corrosive effect by promoting formation of a protective skin on metal surfaces and neutralising gases present in the water We recommend the use of a suitable universal inhibitory to protect the c h system from cor rosion 16 3 Installing the bracket Precautions Before mounting the bracket check that the di mensions for fitting the exhaust fume duct are complied with refer to the leaflet included with the flue kit packed separately Utilise the paper template supplied with the boiler to determine the fixing position for the bracket and boiler Securely mount the bracket to the wall using appropriate fi
22. IMER 10 To force a timed delay on or off operation press repeatedly the button A until the display shows the symbol TIMER Set the time delay by pressing the button D or E and the operation can be forced on or off by pres sing the button F The time delay can be set within the following ranges 1 to 23 hours with steps of 1 hour 1 to 27 days with steps of 1 day Press the button A until the display shows the sym bol AUTO The ON OFF display H flashes indicating that the current state of operation has been forced To delete the timed delay setting press repeatedly the button A until the display shows the symbol TIMER press the button D or E until the symbols shown in Fig 2 25 appears in the display and then press the button A until the display shows the sym bol AUTO Setting example shown in Fig 2 25 forced ON state for 4 hours Lt 1 y M e Fig 2 25 Note If during manual operation power supply turns off timer must be set again following previ ous steps Resetting To completely reset the timer press the reset but ton with a pointed object pencil CAUTION pushing the reset button will complete ly erase the settings as well as all the data includ ing the current time EM USEFUL ADVICE EM Central heating For reasonably economical service install a room thermostat Never shut off the radiator in the area where the room thermostat is installed If a radiator or a con
23. aled expansion vessel to accommodate the increase of water vol ume when the system is heated Refer to Tab 4 1 on page 15 for its technical data If the heating circuit has an unusually high water content calculate the total expansion and add an additional sealed expansion vessel with adequate capacity Mains water feed central heating There must be no direct connection to the mains water supply even through a non return valve without the approval of the Local Water Authority Mains water feed hot water supply The domestic section of the boiler is designed to withstand an internal domestic water pressure of 10 bar Where it is likely that the mains domestic water pressure may exceed 5 bar it is possible due to internal water hammer effects that the pressure within the domestic system can increase to a level in excess of the 10 bar limit In these circumstances it is therefore recom mended that a 3 bar pressure reducing valve be fitted to the incoming mains water supply and a mini expansion vessel installed on the domestic circuit These devices will protect the boiler and the do mestic system from damage due to excessive do mestic water pressure Filling A method for initially filling the system and replac ing water lost during servicing must be provided and it must comply with local water authority regu lations The correct method is shown in Fig 5 4 The temporary connection must be removed immediatel
24. and run it until the temperature has reached the boiler operating temperature The system must then be immediately flushed through This procedure must be repeated twice more During this operation we highly recommend the use of a c h flushing detergent in the quan tities as specified by the appropriate manufac turer whose function it is to dissolve any foreign matter which may be in the system The above operation could save the invalida tion of your boilers guarantee and will also pre vent problems which you may experience in the future if an inhibitory is not used Condensate pipe and traps The full length of the condensate pipe should be check for leaks The boiler has a built in condensate trap pro vided with a ball valve that prevents the escape of combustion products when the trap is empty Itis however recommended that any other trap in the drain systemis correctly filled with water before to run the boiler Lighting the boiler Some products incorporate an anti cycling time delay Itis normal when first switching the boiler on for the boiler to operate on heating for a few sec onds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The ignition delay cycle does not prevent normal operation of the boiler to pro vide d h w If external controls are fitted e g Timeclock room thermostat ensure they call for heat 1 Turn on the electricity s
25. been certified by a notified body 0 Values subject to tolerance 16 Technical information Gas pressures at the burner Flue design Gas Natural Butane Propane Type C12 C32 C42 C52 C82 G20 G30 Gat Flue pipe diameter Max Pa 1130 2810 3610 Coaxial mm 60 100 mbar 11 3 28 1 36 1 Min Pa 250 580 780 Twin split pipes mm 80 Ignition Pa 850 2110 2700 Nominal heat flow rate kW 25 0 mbar 8 5 21 1 27 0 1 mbar approximately equals 10 mm H20 Exhaust temperature D C 71 Mass flow rate D g s 16 0 Natural Butane Propane Flue gas figures G20 G30 G31 Nominal heat input 25 0 m3 h kg h kg h INSTALLATION D W M 2 65 197 194 CO content 96 6 5 O content 7 93 Min 1 16 085 CO content ppm 75 D 71 Injectors mm 1009 temperature C E Natural G20 130 Bie a0 7 P 1 77 ROMER Electrical Data dd mm a t BE Power consumption W 140 eight dry 9 Water volume in the boiler k 4 0 Protection degree IPX4D up to 1 bar kg External fuse rating 3 Internal fuse rating A 1 2 3 15 AF D Values refer to tests with a 1 m chimney working at the nominal heat input INSTALLATION Technical information Technical data mod C 35 Heat input lA Minimum temperature Nominal kW 29 0 BTU h 98 942 Minimum kW 13 0 BTU h 44 353 Maximum pressure kPa 1 000 bar 10 Minimum pressure kPa 30 bar 0 3 Flow rate minimum l min 30 rise O l min 35 rise O l min 40 rise
26. before filling the boiler See the instructions to identify the location of this device Do not remove the cap of the pressure test points ofthe air switch top left side ofthe boiler You are strongly advised to flush out the system both cold and hot in order to remove System and installation debris Itis also sensible to initially fire and com mission the boiler before connecting any ex ternal controls such as a room thermostat By this method if you have a subsequent prob lem following the addition of an external con trol you can eliminate the boiler from your fault analysis V Do not forget to range rate the boiler to suit the system requirements This pro cedure is covered in the commissioning sec tion of the installation manual If the boiler is fitted with a digital pro grammer when setting the times for auto matic operation remember that for every ON time there must be an OFF time to fol low and that on every occasion you enter a time you must also indicate which days that you want the boiler to follow the timed set tings V Some products incorporate an anti cycl ing time delay It is normal when first switch ing the boiler on for the boiler to operate on heating for a few seconds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The ignition delay cycle does not prevent normal operation of the boiler to provide d h w V f yo
27. ble to assist in the ter mination of the flue where the boiler is installed in a location remote to an outside wall These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses Consequently it is possible to extend the flue system to a greater distance than that pro vided by the standard horizontal axial flue If either an additional 45 or 90 accessory elbow is used then the maximum permissible length of either pipe must be reduced by 0 90 m or 1 65 m respectively N B The air intake and the flue outlet must not terminate on opposite sides of the building Type C42 Fig 6 8 Two restrictors with different size are supplied with the twin pipe kit and have to be installed between the boiler and the air intake adapter Fig 6 9 Installation Air intake adapter Restrictor doe Fig 6 9 For the correct use of the restrictors with twin pipes refer to Tab 6 2 For M96A 24SM M96A 28SM Equivalent length air duct flue duct Tab 6 2 Vertical roof kit Fig 6 10 E Type C32 67 90 1m max 8 5 m sa o 9125 Y 45 0 5 m E Fig 6 10 This kit allows vertical termination of the flue pipe through the roof The kit is 1 2 m in length Exten sion pieces axial are also available which al lows the flue system to be extended to a total overall maximum permissible length
28. by C O R G I Components used to adaptitto thetype of gas available must be genuine parts only LEN Procedures 1 Check that the gas cock 14 in Fig 8 1 fitted under the boiler is turned off and the appliance is switched off at the mains isolating spur 14 Fig 8 1 2 Remove the front panel of the case see the section General access and emptying hydraulic circuits in the service manual 3 Take off the lid of the sealed chamber 4 Take the front panel of the combustion chamber off and remove the burner 40 on page 13 See section gnition and detection electrodes in the service manualfor detailed in structions 5 Carry outthe conversion for the type of gas re placing the burner injectors correctly 6 Re assemble the burner the front panel ofthe combustion chamber 7 Switch on the appliance at the mains isolating spur Closed position 36 8 Turn the boiler OFF positioning the function se lector 8 as indicated in Fig 8 2 Fig 8 2 9 Disconnect the electrical connectors of the C h temperature probe NTC 23 in Fig 8 3 x Fig 8 3 10 Keep pressed the reset button 7 for about 10 seconds until the lock out signal lamp 6 blinks 11 Connectthe the elctrical connectors of the C h temperature probe NTC 23 in Fig 8 3 12 Press the reset button 7 repeatedly 4 times until the lamps 10 give the indication as in Fig 8 4 gas type mode 00 90 Where OLD Fig 8
29. ce with the relevant requirements of the current Gas Safety Installation amp Use Regula tions the Local Building Regulations the current E E Wiring Regulations the Regulations and by laws of the local water undertaking and in Scotland in accordance with the Building Stan dards Scotland Regulation Health and safety document n 635 Electricity at work regs It should also be in accordance with the British Standard Codes of Practice In Ireland IE The installation must be carried out by a Competent Person and installed in accord ance with the current edition of 1 5 813 2002 Do mestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installations EE B Location of appliance The appliance may be installed in any room or in ternal space although particular attention is drawn to the requirements of the current I E E Wir ing Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the combined appliance in a room containing a bath or shower 20 For Ireland IE reference should be made to the current edition of 1 5 813 2002 and the current ETCI rules for electrical installations Where a room sealed appliance is installed in aroom containing a bath or shower any electri cal switch or appliance control utilising mains electricity should be so situat
30. ctor and c h temp control knob 4 5 6 7 8 9 D h w temperature control knob 1 oi Fig 1 3 000 e Appliance description 14 5 Operation lights Three lights 10 in Fig 1 3 give detailed indication regarding the operation of the boiler The following table gives the relationship between each of the possible light combinations and their meaning 0 u uj A short pulse every 4 seconds SN stand by condition O O O Function selector in position Anti freeze system active 1 second pulse every 2 seconds normally operating boiler Function selector in or 8 position IX C h operation D h w operation Frost protect operation a D h w operation O O IOX Excessive temperature on primary circuit If the lights combination observed is not included in the above table a fault may be indicated Reference should be made to the following table In this case switch off the boiler as described in section 2 6 on page 6 and call a competent and re sponsible Service Engineer E Faulty c h temperature S e oo MC MC probe NTC P9 Faulty d h w temperature MAS probe NTC A Faulty flue temperature probe NTC Faulty primary circuit no water or low c h pressure Faulty primary circuit absence of flow A ryN A ryN Faulty air pressure sensor 5
31. e 0 A Lack of burner ignition no ignition signal from the full segence ignition device A Safety thermostat lock out Flue temperature probe NTC lock out A Flame detection error Dres A A O O Other faults Dres O Lack of power supply or fauly electr control p c b O O O Meaning of symbols Q Lamp OFF Lamp ON Flashing lamp alone or simultaneously with an other lamp X Flashing lamp alternate with another lamp EN INSTRUCTIONS FOR USE EXB Warnings Our Company supports the Benchmark in itiative The Benchmark Log Book is lo cated atthe back of this manual and should be completed by the Installing Commiss sioning Engineer and handed over to the User for future reference by other visiting Engineers Also included is the Service In terval Record card that should be com pleted by the Service Engineer following the annual service maintenance of the boiler and system All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your Benchmark Log Book You can check your installer is registered by calling CORGI di rect on 01256 372300 In order to guarantee safety and correct oper ation it is essential that all the tests are carried out by a competent and responsible service engineer be
32. e user Hand over this combined User amp Installation man ual and the Service manual to the end user and ex plain how to use the unit in both c h and d h w modes Take the User step by step through the lighting in structions Show the User how to switch off the appliance quickly and indicate the position of the electric supply isolator Explain the proper use and adjustment of all sys tem controls this will ensure the greatest possible fuel economy Explain the function and use of the function selec tor Explain and demonstrate the function of time and temperature controls if fitted Explain how to turn off the appliance for both short and long periods and advise on the precautions necessary to prevent damage should the appliance be inoperative when freezing condi tions may occur Fill in the details required on the Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee reg istration Finally advise the User that for continued safe and efficient operation the appliance must be ser viced by a competent person at least once a year 35 z g E 3 E E 4 EJ GAS CONVERSION EAN Warnings The commissioning of this boiler and sys tem must only be undertaken by a pro fessionally qualified person in accordance with the requirements of the Gas Safety In stallation and Use Regulations and be ap proved
33. ection 9 4 ofthis chapter and check thatthe pres sure in the expansion vessel is not less than 1 bar See also section 4 4 page 15 of this manual If the pressure is lower take steps to correct the pressure level 9 8 Cleaning the burner The sloping and multi gas type burner 40 on page 13 does not need special maintenance but it is sufficient to dust it with a bristle paintbrush To reach the burner 1 Take off the front of the case 2 Take off the removable front of the sealed chamber and the front panel of the combustion chamber 3 Brush out the burner with a bristle paintbrush 99 Checking the flue Have the integrity of the flue outlet pipe 49 on page 14 air intake pipe 50 on page 14 checked periodically the air pressure sensor 19 on page 13 and the efficiency of the flue safety circuit checked at least once a year For details see the section Fan and air pressure sensor in the service manual For all the above maintenance operations it is ad visable to call an approved Service Engineer Em Drain pipe inspection Check the soundness and integrity of the conden sate drain pipe Verify the cleaness and correct filling of the con densate traps ERI visual inspection of appliance Visually inspect all water joints seals and connec tions for any evidence of leakage and retighten grease or replace them as necessary EXP Gas pressures and tightness Check appliance for gas tightness Rechec
34. ectors are clean that the boiler is set for the correct gas used see Section Gas Conversion of this manual Commissioning 7 If the ignition pressure recorded is not as indi cated in the Technical Data then refer to section Ignition gas pressure adjustment of the Ser vice Manual for the necessary adjustment pro cedures Important after the gas pressure checks and any adjustment operations all of the test points must be sealed and replace the adjustment protection cap Checking the ignition device With the burner on high flame close the gas cock After three ignition attempts within about three minutes the lock out signal lamp 6 Fig 1 3 on page 2 must appear To reset the boiler press and release the boiler reset button 7 Fig 1 3 on page 2 Checking the flue system The flue system should be visually checked for soundness Check all clamps gaskets and fixing are secure and tight Ensure that the flue terminal is sited correctly in ac cordance with the flue fitting instructions and Fig 5 1 on page 21 of this manual To carry out a combustion check refer to the in structions given in the section 9 5 of this manual Reference figures are given in the sections 4 5 or 4 6 of this manual Flue gas figures Checking the condensate drain pipe Check the soundness and integrity of the conden sate drain pipe Verify the cleanness and correct filling of the con densate traps Instructing th
35. ed that it cannot be touched by a person using the bath or shower The location must permit the provision of an ad equate flue and termination For unusual locations special procedures may be necessary and BS 6798 gives detailed guidance on this aspect A compartment used to enclose the appliance must be designed specifically for this purpose This appliance is not suitable for external installa tion Flue system The provision for satisfactory flue termination must be made as described in BS 5440 part 1 For Ireland IE refer to 1 5 813 2002 Theappliance mustbe installed so thatthe flue ter minal is exposed to external air It must not be installed so that the terminal dis charges into an other room or space as an out house or lean to It is important that the position of the terminal allows a free passage of air across at all times Theterminal should be located with due regard for the damage or discoloration that might occur to building products in the vicinity In cold and or humid weather water vapour may condense on leaving the flue terminal the effect of such steaming must be considered Pluming may easily occur at the terminal Where possible terminal position which could cause a nuisance should be avoided General requirements The minimum acceptable spacing from the ter minal to obstructions and ventilation openings are specified in Fig 5 1 Fig 5 1 Terminal position mm A D
36. ength 1m This kitis normally supplied with the boiler and can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter el bow Minimum length required is 0 3 m Maximum equivalent length of 2 7 metres for M96A 24SM and M96A 28SM can be achieved utilising ex tensions This flue system can only be used to dis charge horizontally it is not designed to enable termination in the vertical plane Vertical kit with 90 elbow Fig 6 6B Co axial 60 100 mm Supplied with a straight flanged adapter a co axial elbow and a co axial pipe with terminal this kit allows for a vertical rise of 0 5 m from the boiler In all circumstances the flue terminal must dis charge horizontally and the equivalent flue length must not exceed 2 7 metres for M96A 24SM and M96A 28SM 27 z g E 3 E E 4 z o E 3 E E Installation Elbows 45 amp 90 Fig 6 6C Co axial 60 100mm Elbow kits enablethe standard flue kits to be offset to overcome obstructions or ensure the correct clearances for the flue terminal Each elbow used in addition to the standard flanged elbow reduces the overall acceptable length of the flue system as follows 45 reduce length by 0 5 m 90 reduce length by 1 m Type C12 9 60 100 Fig 6 6 Twin pipe kits o 80 mm Fig 6 7 Fig 6 8 Various twin split pipes kits and optional acces sories elbows are availa
37. fore lighting up the boiler The tests are described in the installation in structions in section 7 commissioning Ensure that the c h circuit is regularly filled with water even if the boiler is only used for d h w supply checking thatthe pressure indi cated on the temperature and pressure gauge 4 is not lower than that shown in Fig 2 2 If the pressure reading on the pressure gauge is below that shown in Fig 2 2 then the system will require topping up A filling loop is normally provided by the installer for this purpose If you are in any doubt regarding this pro cedure you are advised to contact your In staller or an Approved Engineer This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 C Therefore when the boiler is not lit or used in cold weather with consequent risk of freezing do not switch off the boiler atthe fused spur isolation switch or close the gas inlet cock When you do not expect to use the boiler for a long period and the boiler is notto be used for frost protection then follow the instructions given in section 2 6 on page 6 EX Refilling procedure 1 Isolate the boiler from the electrical supply at the fused spur Reconnect the filling loop as demonstrated in Fig 2 1 Control valve Double check valve Temporary connection rte Control valve Supply pipe cold water inlet
38. g 2 4 4 If d h w supply only is required position the function selector 8 as in Fig 2 5 The appliance operation light 10 will flash every 2 seconds operating boiler 3 Y Ss GB 1 7 TZ is 1 Y 0 Fig 2 5 EXI c n circuit temperature The output temperature of c h water is adjustable from a minimum of about 40 C to a maximum of about 85 C Fig 2 6 by turning the function se lector 8 Adjustment of c h output on the boiler is auto matic The greatest output pre set in the factory can however be reduced in level according to actual system requirements this does not affect the maximum output in d h w operation Such adjustments must be carried out by a quali fied person therefore we advise you to contact your installer or Service Agent Adjustment of the boiler temperature alters the gas flow atthe burner according tothe thermal de mand in the system So itis usual to see the burner lit at the minimum level for more or less long periods Minimum mit 5 Maximum E Fig 2 6 Adjustment In order to achieve optimal settings for economy and comfort we recommend adjusting the oper ating temperature of the c h water according to the outside temperature positioning the knob as follows From 5 to 15 C Between 5and 5 C Lower than 5 C Fig 2 7 Instructions for use Your qualified installer will be able to recommend
39. h compression fittings Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps The appliance has a built in automatic air release valve it should be ensured as far as possible that the appliance heat exchanger is not a natural col lecting point for air Except where providing useful heat pipes should be insulated to prevent heat loss and to avoid freezing Particular attention should be paid to pipes pas sing through ventilated spaces in roofs and under floors By pass The appliance includes an automatic by pass valve which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system due to the closing of thermostatic valves or cock type valves within the system The by pass is calibrated to assure a minimum flow of 200 300 Its hr through the main heat ex changer If you are installing a system that includes thermo static radiator valves TRV and or small bore 8 10 mm it may be necessary to fit an external by pass to facilitate correct operation of the boiler The fitting of an external bypass helps to prevent and limit system noise Air release points These must be fitted at all high points where air will natural collect and must be sited to facilitate com plete filling of the system General requirements Expansion vessel The appliance has an integral se
40. in the Gas Valve section of the service manual If maximum and or minimum gas pressures are adjusted then the ignition gas pressure must be checked and adjusted if necessary Important after the gas pressure checks and any adjustment operations all of the test points and adjustment devices must be sealed Re place the adjustment protection cap Checking the burner ignition 1 Turn the boiler OFF 2 Open the gas valve outlet pressure test point 33 Fig 7 4 and connect the gauge 3 Turn the boiler ON positioning the control se lectors 8 in the positions as shown in as in Fig 7 5 and ensure that the timer selector switch and room thermostat if fitted are set to heat demand 4 f s 2 3 1 i 000 OO cow Fig 7 5 4 Watch the gauge and check to see if the igni tion pressure registered correspondsto the va lues as given in the Technical Data Turn offthe boiler and reignite it by turning the function se lector 8 to the OFF position and then back to that indicated in Fig 7 5 5 Repeatthis process two to three times leaving 30 second intervals between each ignition Check the ignition pressures and visually check that the burner lights uniformly and in a controlled manner 6 Ifthe burner ignition is not uniformly controlled then checks should be made to the flue installation and termination that the flue gasket as shown in Fig 6 5 page 27 is in place that the burner and inj
41. irectly below a window or other opening 300 B Below gutters soil pipes or drain pipes 75 C 6 200 D Below 600 E Below car portroof F From vertical drain pipes and soil pipes 150 G From internal corners 450 H From external corners 300 l Above ground or balcony level 300 J From a surface facing a terminal 600 K From a terminal facing a terminal 1 200 L From an opening in the car port e g door window into dwelling NO M Vertically from a terminal in the same wall 1 500 N Horizontally from a terminal in the same wall 300 O Above the roof pitch with roof slope less 8 0 350 Above the roof pitch with roof slope 8 980 600 P Fromwallface 600 Q From above or to side of an opening 300 Wherever practicable to do so the flue should be ex tended beyond the perimeter of the balcony Consideration should be given to adding protection against condensate to the adjacent structure Gas supply The Gas meter is connected to the service pipe by the local gas region or a local gas region contrac tor If the gas supply for the boiler serves other appliances ensure that
42. k oper ational pressures and adjust as necessary as de scribed in section 7 7 page 33 of this manual 39 BENCHMARKNo ET PT Benchmar GAS BOILER COMMISSIONING CHECKLIST SELLESIIVE YAAK BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER _ CYLINDER T STAT 8 PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m hr ft hr BURNER OPERATING PRESSURE IF APPLICABLE L NA mbar CENTRAL HEATING FLOW TEMPERATURE C 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
43. leaned This service can be part of a maintenance con tract In particular you are advised to have the following checks carried out primary heat exchanger domestic hot water heat exchanger burner exhaust fume duct and flue pressurisation of the expansion tank filling up of the central heating circuit bleeding of air from the central heating system general check of the appliance s operation 13 5 External cleaning Before carrying out any cleaning disconnect the appliance from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance To clean the external panels use a cloth soaked in soapy water Do not use solvents abrasive powd ers or sponges Do not carry out cleaning of the appliance and or its parts with readily flammable substances for example petrol alcohols naphtha etc EN Operational faults If the lock out signal lamp comes on this indicates that the safety lock out 6 Fig 3 2 has stopped the boiler To re start the boiler it is necessary to press the boiler reset button 7 Fig 3 2 he Forthe first lighting up and following maintenance procedures for the gas supply it may be necess ary to repeatthe resetting operation several times 80 as to remove the air present in the pipework After five consecutive resetting attempts the reset button is inhibited To restore its function it is necessary to switch the boiler
44. liance packaging does not contain any substances which may be considered a hazard to health Combustion chamber panels Material mineral fibres Known hazards Some people can suffer red dening and itching of the skin Fibre entry into the eye will cause foreign body irritation which can cause severe irritation to people wearing contact lenses Irritation to respiratory tract Precautions Dust goggles will protect eyes People with a history of skin complaints may be particularly susceptible to irritation High dust le vels are only likely to arise following harsh ab rasion In general normal handling and use will not present high risk follow good hygiene prac tices wash hands before touching eyes consum ing food drinking or using the toilet First aid Medical attention must be sought fol lowing eye contact or prolonged reddening of the skin Thermostat Temperature gauge Description Sealed phial and capillary contain ing liquid Known hazards irritating to skin eyes and throat Vapour is harmful Inflammable do not extinguish with water Precautions Do not incinerate Avoid contact with broken leaking phials Do not purposely puncture First aid medical attention must be sought follow ing eyes skin contact wash with clean water Gas appliance Directive 90 396 CEE Boiler Efficiency Directive 92 42 CEE Low voltage Directive 73 23 CEE wards third parties Appliance categ
45. missioning of this boiler and system must only be undertaken by a professionally 1 Close all hot water draw off taps qualified person in accordance with the re 2 Open the cold water inlet valve 13 Fig 7 1 quirements of the Gas Safety Installation and 4 Slowly open each draw off tap and close it Use Regulations and be approved by only when clear water free of bubbles flows C O R G l p Ensure that the Benchmark Log Book is satis factorily completed during the commissioning Initial filling of the system process The Log Book is located at the end of this manual This manual should be handedto Open the c h flow and return valves the User following completion of the installa 2 Remove the front panel of the case see the tion and commissioning process Failure to section 9 2 in this manual comply with these requirements may invali 3 Unscrew the cap on the automatic air purger date the manufacturers guarantee valve 26 Fig 7 2 one full turn and leave open For Ireland IE it is necessary to complete a permanently Declaration of Conformity to indicate com 4 Gradually open stopcock at the filling point pliance to 1 S 813 2002 connection to the c h system until water is heard to flow do not open fully z 2 E 3 E E de XA i Electrical installation Preliminary electrical system checks to ensure electrical safety shall be carried out by a compet ent person i e polarity earth continuit
46. n switching off the boiler yourself see the in structions Your boiler allows heating up of water to a temperature less than boiling point must be connected to a central heating system and or a hot water supply system compatible with its performance and output can be used only for those purposes for which it has been specially designed must not be touched by children or by those unfamiliar with its operation must not be exposed to weather condi tions 1 During the operation it is quite normal that the boiler produces a white plume of condensation vapour from the flue terminal This is due to the high efficiency of the ap pliance and may be particularly evident with low outdoor temperatures Safe handling of appliance When handling or lifting always use safe tech niques keep your back straight bend your knees don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack truck or other suitable trolley Always grip the boiler firmly and before lifting feel where the weight is concentrated to establish the centre of gravity repositioning yourself as necess ary Safe handling of substances These products are manufactured in accordance with ISO 9000 and do not and will not contain any hazardous materials or substances such as as bestos mercury or C F C s The app
47. n the TIMER position To force a timed delay on or off operation setthe mode selector switch A in the TIMER position Set the time delay by pressing the button D or E and the operation can be forced on or off by pres sing the button F The time delay can be set within the following ranges 1 to 23 hours with steps of 1 hour 1 to 27 days with steps of 1 day The time delay setting is activated by moving the Switch A to the AUTO position The ON OFF display H flashes indicating that the current state of operation has been forced To delete the timed delay setting setthe mode se lector switch A in the TIMER position press the button D or E until the symbols shown in Fig 2 17 appears in the display and then set the mode se lector switch A to the AUTO position Setting example shown in Fig 2 18 forced ON state for 4 hours O C1 AUTO TIMER Resetting To completely reset the timer press the reset but ton with a pointed object pencil CAUTION pushing the reset button will complete ly erase the settings as well as all the data includ ing the current time Fig 2 18 Instructions for use PES Built in time switch B The combi boilers are equipped with a built in elec tronic time switch which controls the c h oper ation Fig 2 19 Display and control panel Mode selector switch Reset button OK button Increase setting button Decrease setting button On off b
48. nical information 13 6 6 Mounting the boiler 26 2 41 13 6 7 Fitting the flue system 27 ES nd 6 8 Choice of flue 27 ei 6 9 Electrical connections 30 4 3 Hydraulic specifications 15 6 10 Ext oi orot ction 31 4 4 Expansion vessel 15 Xema MOSE DIOTOCHOTY npin 4 5 Technical data mod M96A 24SM 16 7 Commissioning 32 4 6 Technical data mod M96A 28SM 18 7 1 Electrical installation 32 7 2 Gas supply installation 32 5 Generalrequirements 20 73 Filling the d h w system 32 a doo Vesa sprays 20 74 Initial filling of the system 32 5 2 Location of appliance 20 75 Condensate pipe and traps 33 5 3 20 76 Lighting the boiler 33 5 4 Gas supply sssssseeee 21 77 Checking the gas pressure 5 5 Air supply eee eee eee 21 33 5 6 Ventilation 21 7 8 Checking the burner ignition 34 5 7 Condensate drain 21 7 9 Checking the ignition device 35 5 8 Water circulation 22 7 10 Checking the flue system 35 5 9 Domestic water 23 7 11 Checking the condensate drain pipe 35 5 10 Water treatment 23 7 12 Instructing the user
49. off and on from the 11 Useful advice electrical mains using the fused spur isolation switch fitted adjacent to the appliance Safety lock out may occour even in case of an blockage of the condensate drainage e g plugged drain pipe It is advisable to check the condensate drainage pipe and traps for cleaness In case of persistent lock out call a competent and responsible service engineer If noises due to air bubbles are heard during operation you should check that the pressure on the tem perature and pressure gauge Fig 2 2 on page 4 is not below the correct setting If required top up the system correctly as de scribed in the section 2 2 of this manual Bleed any air present in the radiators if necessary If the pressure on the temperature and pres sure gauge 4 on page 2 has gone down itis necessary to top up the appliance with water again so as to raise the pressure to an adequate levelas described in the section 2 2 of this manual If topping up with water has to be done very fre quently have the system checked for leaks If water comes out of the pressure relief valve Check on the temperature and pressure gauge 4 on page 2 that the pressure in the central heating circuit is not close to 3 bars In this case tempera ture rise in the circuit can cause the pressure relief valve to open So that this does not happen and to decrease the pressure to a normal value it is advi
50. oiler cold supply within the requirements of the local water company EXT Electrical supply Warning this appliance must be earthed External wiring to the appliance must be carried out by a competent person and be in accordance with the current I E E Regulations and any local regulations which apply Reference should be made to the current ETCI rules for electrical installations For Ireland IE refer to 1 5 813 2002 The boiler is supplied for connection to a 230 V 50 Hz supply The supply must be fused at 3A The method of connection to the electricity supply must facilitate complete electrical isolation of the 23 z g E 3 E E z 2 E 3 E E z General requirements appliance by the use of a fused spur isolation Switch Its installation permits a complete switch ing off in the conditions of the overvoltage cat egory Ill Alternatively it can be used a 3A fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363 The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except were the appliance is installed in 24 a bathroom this must then be sited outside the bathroom EH INSTALLATION CM Warnings The use of gas appliances is subject to statutory control it is essential to observe the current regulations and laws in force see also chapter 5 The appliance must discharge combustion
51. onds indicat with the conversion kit The label is placed on ing that the setting has changed and must be the botton of the appliance memorised 20 Replace the adjustment protection cap 14 To memorize the setting keep pressed the 21 Replace the front panels of the case reset button 7 for about 5 seconds until the lamps 10 briefly blinks simultaneously 37 EB MAINTENANCE EX Warnings The procedures detailed in this chapter must be carried out only by a professionally qualified person Thus you are advised to contact an Authorised Service Agent For Ireland IE the servicing work must be carried out by a competent Person For efficient and continuous operation of the boiler you are advised to have at least once a year maintenance and cleaning done by an Approved Service engineer Isolate the appliance from the electricity supply by turning off the fused spur isolation switch adjacent to the appliance and turn off the gas cock before carrying out any pro cedures whatsoever for cleaning mainten ance opening or dismantling boiler panels 9 2 Dismantling the external panels Front panel 1 Loosen the three screws A Fig 9 1 2 Liftand remove the panel Air Flue exhaust d Sampling points Ld Fig 9 1 Side panels 38 3 Loosen the screws B Bring the bottom of the panels away from the boiler and lift them free ing them from the top hooks Fig
52. ory ll2 3 Gas G20 20 mbar G30 29 mbar G31 37 mbar Country of destination United Kingdom GB Ireland IE This appliance conforms with the following EEC directive Electromagnetic Compatibility Directive 89 336 CEE The manufacturer in the continuous process to improve his products reserves the rightto 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 to Boiler installation and commissioning tips The installation must be carried out by a qualified person who will be responsible for observing the current Regulations Installing the boiler V Do not forget to remove the transit caps and plugs from the boiler connections these are fitted to every boiler V Keep the boiler clear of dust during in stallation and in particular do not allow any dust or debris to enter the top of the boiler where the flue connection is made It is rec ommended that you puta dust sheet over the top of the boiler until you are ready to make the flue connection 1 Because every boiler is fired and tested live at the factory a small amount of water re mains within the boiler It is possible for this water to initially cause the pump to seize It is therefore recommended that the pump rotor be manually turned to free its rotation before turning the boiler on Remember to release the auto air purge
53. ou are ad vised to have a professionally qualified per son check that the installation of the gas supply is gas tight is of the correct gauge for the flow to the boiler is fitted with all the safety and control de vices required by the current Regulations Ensure that the installer has connected the pressure relief valve outlet to a drain pipe The manu facturers are not responsible for damage caused by opening of the pressure relief valve and consequent escape of water if not connected correctly to the drain the installer has connected the conden sate outlet to a suitable drain pipe On detecting the smell of gas don t operate any electrical switches the telephone or any device that may produce sparks Open the windows and doors at once to create a draught of air which will purge the area shut off the gas cocks getthe assistance of a qualified person 1 Donottouch the appliance with parts of the body that are wet or damp and or bare feet 1 Do not block or modify the condensate outlet and pipework Y In case of structural work or mainten ance near the exhaust duct and or fume ex haust devices or their attachments turn off the appliance On completion of the work have a professionally qualified person check their efficiency 1 Repairs under guarantee must be car ried out only by an approved engineer using genuine spare parts Thus do no more tha
54. play ON OFF display SYS Setting the current time Note with a new unit or when the reset button B has been pressed and the selector switch A is to the position the time display G is flashing Set the mode selector switch A to the position and press the buttons D or E until the current time appears in the display G The clock starts by moving the switch A to the AUTO position Setting example shown in Fig 2 13 Current time 16 30 Q i A AUTO TIMER Setting the switching time 20 memory locations are available corresponding to 10 on off sequences Set the mode selector switch A to the C1 position The symbols shown in Fig 2 14 appears in the display Fig 2 13 Fig 2 14 Press the buttons D or E to set the desired ON time Press the enter button C to confirm the setting and to continue programming the OFF time Set the OFF time as explained above for the ON setting and confirm by pressing the enter button C Proceed in the same way for other settings Setting example shown in Fig 2 15 A ON time 7 45 B OFF time 10 30 Instructions for use A Fig 2 15 Activating the timed settings Set the mode selector switch A to the AUTO posi tion shown in Fig 2 16 The current time appears in the display The ON OFF display H indicates the current state of oper ation according to the settings O A ll auto TIMER Fig
55. rer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SERVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE E MI 17962 1578 0 4908 48A5 UK Biasi UK Ltd Newman Park Western Way Wednesbury WS10 7BJ Sales Tel No 0121 506 1340 Sales Fax No 0121 506 1360 Service Tel No 0121 506 1350 Service Fax
56. sable to vent 12 some of the water in the appliance through the bleed valves present in the radiators If in time a reduction in domestic hot water supply is observed The likely causes may be impurities caught in the domestic hot water flow switch filter or limescale deposited in the domestic hot water heat ex changer It is advisable to have the appliance cleaned out by an Authorised Service Centre En gineer If water should occasionally leak from the boiler shut off the valves positioned under the boiler Fig 2 11 on page 7 and call an Authorised Ser vice Centre Engineer If the left appliance operation light 10 Fig 3 3 flashes very quickly the boiler is detecting a fault 10 t qa a 1 o OO G9 OO DT ow Fig 3 3 In this case or in case of problems other than those mentioned here switch off the boiler as described in section 2 6 on page 6 and call a competent and responsible service engineer LN TECHNICAL INFORMATION EXE Overview 14 Gas inlet valve 17 i 19 20 22 15 D h w outlet pipe 16 C h flow valve 17 Fan 18 Air pressure sensor test points 19 Air pressure sensor 20 Flue temperature probe NTC 21 Condensing heat exchanger 22 Safety thermostat 23 C h temperature probe NTC 24 Main circuit drain valve 25 Condensate trap 26 Automatic air purger valve 27 Pump vent plug 28 Pump 29 C h pressure relief valve 30 D h w flow switch 31 Modulation
57. sioning 5 Check the maximum gas pressure and com pare the value on the gauge with the value indi cated in the sections 4 5 or 4 6 gas pressures at the burner accordingly with the model of boiler installed 6 Checkthe maximum gas flow at the gas meter and compare the value indicated in the sec tions 4 5 or 4 6 gas rate accordingly with the model of boiler installed Switch off the boiler Disconnect the gas modulator coil by remov ing the electrical connector A Fig 7 4 9 Switch on the boiler 10 Check the minimum gas pressure and com pare the value on the gauge with the value indi cated in the sections 4 5 or 4 6 gas pressures at the burner accordingly with the model of boiler installed 11 Switch off the boiler and re connect the elec trical connector A to the modulator coil 12 Switch on the boiler 13 Check that the boiler lights up uniformly If not referto section Ignition gas pressure ad justment ofthe Service Manualfor the necess ary adjustment procedures 14 Switch off the boiler turn off the hot water tap s and disconnect the pressure gauge 15 Reassemble the sealed chamber lid and the front panel of the case see section 9 2 in this manual If the maximum and minimum gas pressures measuredabove are notin accordance with the 34 technical data sections 4 5 or 4 6 then adjust ment will be necessary A full explanation of the gas pressure adjustment procedure is given
58. th of the condensate pipe should be kept at minimum To avoid condensate being trapped thedrainpipe should berun with a fall of atleast 2 5 45 mm m away from the boiler the number of bends and joints should be kept at minimum the drainpipe should be adequately fixed to pevent pipe sagging 21 z g E 3 E E Z z a E 3 E E z General requirements If a part of the drainpipe runs externally this part should be kept as short as possible and protected to reduce the risk of freezing Connection of condensate drainage pipe to in ternal soil and vent stack Condensate drain be i D o lt Y C gt Dimensions in mm Fig 5 2 A Boiler B Internal soil and vent stack C Invert D 450 mm up to three storeys Connection of condensate drainage pipe downstream of a sink waste trap La Condensate drain E Dimensions in mm Fig 5 3 A Boiler E Sink F Open end of condensate drainage pipe direct into gully below grating but above water level 22 EN Water circulation c h Detailed recommendations are given in BS 6798 and BS 5449 the following notes are given for general guidance For Ireland IE refer to 1 5 813 2002 Pipework The return temperature must not be lower of 40 C Copper tubing to BS EN 1057 is recommended for water pipes Jointing should be either with capil lary soldered or wit
59. the most suitable adjustment for your system The temperature and pressure gauge 4 Fig 1 3 on page 2 will allow you to check thatthe settem perature is obtained PES D h w temperature The temperature of the d h w leaving the boiler can be varied from a minimum of about 35 C to a maximum of about 55 C Fig 2 8 by turning the temperature control knob 9 Maximum Fig 2 8 Adjustment of the d h w temperature is complete ly separate from that of the c h circuit The adjustment system integrated within the boiler automatically controls the flow of gas to the burner in order to keep the temperature of d h w delivered constant between the limits of maxi mum and minimum output Where the demand is ata low level or with the tem perature set to the minimum it is normal to see a cycle of lighting and extinguishing of the burner when running Adjustment It is advisable to adjust the d h w temperature to a level commensurate with the demand minimis ing the need to mix with cold water In this way the automatic control facilities will be fully exploited Moreover where the amount of limescale present in the water may be particularly great not exceed ing the position in Fig 2 9 of the d h w tempera ture control knob 9 corresponding to about 50 C Fig 2 9 minimises annoying incidences of scale deposits and clogging OOO dl In these cases however itis advisable to install a small
60. u are in any doubts as to the installa tion or operation ofthe boiler please read the instruction manuals thoroughly and then if necessary contact Biasi UK for advice and assistance Please remember that if you are in any doubt aboutthe installation of this product you can contact our Technical Helpline on tel 0121 506 1350 TABLE OF CONTENTS 1 Appliance description 2 22 Refilling procedure 4 1 1 Overview AE 2 23 5 Le Control panels sentie ideian 2 2 4 circuit temperature 5 1 3 Isolation valves 2 1 4 Technicaldata 2 2 5 D h w temperature 6 1 5 Operation lights 3 2 6 Extinguishing 6 2 Instructions for use 4 2 7 BuiltintimeswitchA 7 2 4 Warnings so ack cP eke 4 2 8 Built in time switch B 9 3 Useful advice 11 5 11 Electrical supply 23 3 1 Central heating 11 i z 82 Frostprotecon ie Wane BIS 3 3 Condensate drain 11 6 2 Precautions for installation 25 bz 3 4 Periodic maintenance 11 63 Installing the bracket 25 g 3 5 External cleaning 11 64 Overall dimensions 26 a 3 6 Operational faults 11 6 5 26 E 4 Tech
61. umes greater than 94 an additional expansion vessel must be provided 15 z g j E E z INSTALLATION Technical information EEH Technical data mod M96A 24SW Maximum temperature C 55 Heat input 4 Nominal kW 25 0 BTU h 85 295 Minimum kW 11 0 BTU h 37 530 Minimum temperature C 35 Maximum pressure kPa 1 000 bar 10 Minimum pressure kPa 30 bar 0 3 Flow rate minimum l min 30 rise O l min 35 rise 0 l min 40 rise 0 l min Maximum kW 24 3 BTU h 82 908 Minimum kw 10 5 BTU h 35 825 Maximum condensing kW 26 0 BTU h 88 708 Minimum condensing kW 11 2 BTU h 38 213 Central heating Maximum flow temp Gas supply pressures Gas Natural Butane Propane G20 G30 G31 Norm Pa 2 000 2 900 3 700 mbar 20 29 37 Max Pa 2 500 3 500 4 500 mbar 25 35 45 Min Pa 1700 2 000 2 500 mbar 17 20 25 1 mbar approximately equals 10 mm H2O Minimum return temp C 85 C 40 C 40 Maximum pressure kPa 250 bar 2 5 kPa 30 bar 0 3 kPa 25 Minimum flow temp Minimum pressure Available head in 1000 I h bar 0 25 Seasonal efficiency band G20 8 96 Seasonal efficiency G30 G31 B referred to the net calorific value at 15 C and 1013 25 mbar G 20 34 02 MJ m G 30 45 6 MJ kg G 31 46 4 MJ kg B The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have
62. upply to the boiler switching on the fused spur isolation switch The appliance operation light 10 will flash every 4 seconds 2 Turn the function selector 8 as in Fig 7 3 The appliance operation light 10 will flash every 2 seconds 10 Fig 7 3 The boiler will now go through an ignition se quence and the burner will light If during the ignition attempt period the boiler fails to light the full sequence control p c b will go to lockout and the lock out signal lamp 6 will ap pear To reset the boiler press and release the boiler re set button 7 Checking the gas pressure at the burner This boiler has been tested to the highest qual ity control standards The maximum and minimum gas pressures are already set during this quality control process however the checking procedure must be fol lowed to ensure maximum operating efficiency from the boiler 1 Remove the front panel of the case see sec tion 9 2 in this manual and the sealed chamber lid 2 Loosen the internal screw 33 Fig 7 4 on the Outlet Pressure Test Point of the Gas Valve and connect a pressure gauge using a suitable hose 3 Set the d h w and c h temperature control knobs to their maximum position If external controls are fitted e g Timeclock room ther mostat ensure they call for heat 4 Switch on the boiler and open at least one hot water tap fully 33 z g E 3 E E 4 INSTALLATION Commis
63. utton Time display ON OFF display SE Setting the current time Press repeatedly the button A until the display shows the symbol O Press the buttons D or E until the current time ap pears in the display G The clock starts by pressing the button A to show the symbol AUTO Setting example shown in Fig 2 20 Current time 16 30 day Thursday IC O ON Fig 2 20 Setting the switching time 28 memory locations are available corresponding to 14 on off sequences Press repeatedly the button A until the display shows the symbol C1 Fig 2 21 The symbols shown in Fig 2 21 appears in the display LA e M i 0 O Fig 2 21 Press the buttons D or E to set the desired ON time Pressthe OK button C to confirm the setting and to continue programming the OFF time Set the OFF time as explained above for the ON setting and confirm by pressing the enter button C Proceed in the same way for other settings Setting example shown in Fig 2 22 A ON time 7 45 B OFF time 10 30 oC amp om m an tae Fig 2 22 UJ Activating the timed settings The currenttime appears in the display The ON OFF display H indicates the current state of oper ation according to the settings ON Fig 2 23 Note when the display shows the symbol AUTO and the boiler is switched
64. vector does not heat up check that no air is present in it and that its valve is open Ifthe ambient temperature is too high do not alter the radiator valves Reduce the central heating temperature instead by means of the room ther mostat and the function selector 8 in Fig 3 1 Fig 3 1 Era Frost protection This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 C Therefore when the boiler is not lit and used in cold weather with consequent risk of freezing do not switch off the boiler at the fused spur isola tion switch or close the gas inlet cock EE Condensate drain The condensate drain must not be modified or blocked Blockage of the condensate drain caused by de bris or freezing can cause automatic shutdown of the boiler Iffreezing is suspected and the pipe run is access ible an attempt may be made to free the obstruc tion by pouring hot water over the exposed pipe an cleaning any blockage from the end of the pipe If this fails to remedy the problem the assist ance ofa CORGI registered installer or in IE a com petent person should be sought EY Periodic maintenance For efficient and continuous operation of the boiler it is advisable to arrange maintenance and cleaning by an Authorised Service Centre En gineer at least once a year During the service the most important compo nents of the boiler will be inspected and c
65. xings suitable for the type of wall construction and capable of supporting the total wet load Refer to the weight given in the technical data tables specific for each model 25 z g j E E z Installation Iu Overall dimensions B C e 980 A A z 2 E 3 E E Electric connection area 257 Cold water C h Gas inlet return A Band C E 2 3 o a Condensate drain connection area A air intake flue outlet pipe co axial B flue outlet pipe 80 mm twin kit C air intake pipe 80 mm twin kit Fig 6 2 all dimensions in mm 26 DEB Joints Pipe sues od Gas c h return c h flow Drw outei Pressure relief valve Condensate drain 9 25 plastic Tab 6 1 sizes in mm o d CO Mounting the boiler 1 Take the protective caps off the boiler pipe work 2 Thoroughly clean the connections 3 Mount the boiler on its bracket 4 Fixthec h valves A and gas cock B 943 to the boiler using the Y gaskets Fig 6 3 5 Fixthe 22 mm pipes C c h circuit to the c h valves A and the 22 mm pipe D gas to the cock B using the Y gaskets 6 Repeatthe above procedure for the d c w inlet utilising the 1 2 cold water inlet valve E the 15 mm copper tail F with its connection nut and two Y gaskets 7 Fixthe o 15 mm copper tail G with the 1 2
66. y resis tance to earth and short circuit If a fault has occurred on the appliance the fault find ing procedure should be followed as specified in the service manual Gas supply installation 1 Inspectthe entire installation including the gas meter test for tightness and purge all as de x y scribed in BS 6891 For Ireland IE refer to 9 813 2002 Fig 7 2 2 Open the gas cock 14 Fig 7 1 on the 5 Open each radiator air vent starting at the appliance and check the gas connector on the lowest point of the system and close it only appliance for leaks when clear water free of bubbles flows out 6 Purge the air from the pump by unscrewing the x F shaft by turning in the direction indicated by the arrow on the information plate 7 Replace the pump plug 8 Continue filing the system The actual reading should ideally be 1 3 bar and not less than 0 3 bar 9 Close all air release valves on the c h system gt 10 Inspect the boiler and the system for water a 14 13 Open position soundness and remedy any leaks discovered 2 pump plug 27 Fig 7 2 release the pump Commissioning 11 Cold flush the system to remove any loose par ticles and any system debris before starting the boiler for the first time The flushing procedure must be in line with BS7593 Treatment of Water in d h w c h Sys tems When the installation and second filling are completed turn on the c h system
67. y after filling Control valve Double check valve Temporary connection Supply pipe cold water inlet adip Control valve C h return pipe r Fig 5 4 The installer should ensure that no leaks exist either inside the boiler or on the system as fre quent filling of the system could cause premature scaling of the heat exchanger 5 9 Domestic water The domestic water installation must be in accord ance with the relevant recommendations of BS 5546 Copper tubing to BS EN 1057 is recom mended for water carrying pipework and must be use for pipework carrying potable water For Ireland IE refer to 1 5 813 2002 Water treatment Central heating circuit Where a new boiler is fitted to a new system with either plastic or copper pipes it is important the System is fully flushed on completion to ensure flux residues swarfs oils and other installation de bris is removed Where a new boiler is fitted to an existing system it is important the debris from the existing system is fully removed in order to ensure the efficiency of the new appliance is maintained Details on flushing procedure are given in the sec tion 7 4 of this manual Domestic hot water circuit scale protection In areas where the water is hard i e more than 200 ppm total hardness as defined by BS 7593 1993 Table 2 itis recommended that a proprietary Scale reducing device is fitted into the b

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