User manual and Installation instructions
Contents
1. 32 1 MAINS SLO 230V a c P Switched 3 Amp fused O spur bu bk bn 1 External control terminal block HTG Heating HW ON Hot Water ON HW OFF Hot Water OFF Valve colour key BU Blue GRYE Green Yellow WH White GY Grey OR Orange BK Brack Programmer Power supply Fig 6 22 38 INSTALLATION Cylinder Room thermostat thermostat 4 BU 2 A Bs 8 GRYE 3 7 WH 5 2 GY 4 OR 8 L gt lt 04 1 6 3 2 MAINS 230V a c Programmer Switched 3 Amp fused spur Mid position diverter valve Room thermostat Cylinder thermostat Do not remove room 10 way thermostat link junction box 2 o m l lt MAINS 230V a c Switched 3 Amp fused spur External control terminal block HTG Heating HW ON Hot Water ON HW OFF Hot Water OFF Valve colour key BU Blue GRYE Green Yellow WH White GY Grey OR Orange Programmer BK Black BN Brown Fig 6 23 39 z lt E N COMMISSIONING 7 COMMISSIONING 7 1 Warnings The commissioning of this boiler and system must only be undertaken by a professionally qualified person in ac cordance with the requirements2. 11 72 Electrical installation iere 40 2 5 Extinguishitligu sene 12 5 ime Puppy DE I E nitial filling of the 3 VSEFUL ADVICE E E R a 13 7 5 Condensate pipe and traps 41 3 5 SErostarctocti ciues 1 7 6 42 33 Cord pro ws rd QD EET iA 13 7 7 Checking the gas pressure at the burner 42 34 en nee e et Hr Te ARDEN EE 13 7 8 Checking the burner ignition 43 E dea PATEE E ERE ESEE ia 7 9 Checking the ignition device 44 36 abs S UE PED 14 7 10 Checking the flue 44 MAUR Si 7 11 Checking the condensate drain pipe 44 4 TECHNICAL INFORMATION 16 7 12 Instructing the 44 OVet view iss RE PE 16 8 GAS CONVERSION 45 42 Main diagram 17 8 1 Warnings 45 4 3 Hydraulic specifications 19 82 Procedures Word UT WE 45 44 Expansion 19 IE MANDA I EE Ed 4 5 Technical data mod M296 24SR C 20 9 47 4 6 Technical data mod M296 28SR C 22 eer ae 1 ismantling the external panels 5 GENERAL R
3. C HOT WATER OUTLET TEMPERATURE WATER FLOW RATE Its 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 PARTS 4 amp 7 OF THE 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 N A YES CO CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT Gas Safe Register 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 manufacturer s specified spare part when replacing all controls SERVICE 1 pate SERVICE2 pate ENGINEER NAME ENGINEER NAME COMPANY NAME
4. COMPANY NAME TEL No TEL No Gas Safe Register ID CARD SERIAL No Gas Safe Register ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 pate SERVICE 4 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No Gas Safe Register ID CARD SERIAL No Gas Safe Register ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 pate SERVICE 6 pae ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No Gas Safe Register ID CARD SERIAL No Gas Safe Register ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 pate SERVICE 8 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No Gas Safe Register ID CARD SERIAL No Gas Safe Register ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 pae SERVICE 10 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No Gas Safe Register ID CARD SERIAL No Gas Safe Register ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE 0 UL UIT MI s 17962 1552 2 1111 52A5 Biasi UK Ltd Comm
5. A under the boiler is turned off and the appliance is switched off at the mains isolating spur A ra 7 J T Closed position Fig 8 1 Remove the front panel of the case see the section General access and emptying hydraulic circuits in the service manual Take off the lid of the sealed chamber Take the front panel of the combustion chamber off and remove the burner 310n page 18 See section gnition and detec tion electrodes in the service manual for detailed instructions Carry outthe conversion for the type of gas replacing the burner injectors correctly Re assemble the burner the front panel of the combustion chamber Switch on the appliance at the mains iso lating spur Turn the boiler OFF positioning the func tion selector 7 as indicated in Fig 8 2 Disconnect the electrical connectors of the C h temperature probe NTC 20 in Fig 8 3 1 P Keep pressed the reset button 6 for about 10 seconds until the lock out signal lamp 5 blinks Connect the the electrical connectors of the C h temperature probe NTC 20 in Fig 8 3 Press the reset button 6 repeatedly 4 times until the lamps 9 give the indication as in Fig 8 4 gas type mode Where O Lamp OFF e Lamp ON Fig 8 4 45 5 z lt Z lt x MAINTENANCE GAS CONVERSION At this step it is possible to
6. also available which allows the flue system to be extended to a total overall maximum permissible length Optional 45 and 90 elbows can be used to offset the flue route Each additional elbow reduces the overall acceptable length of the flue system as follows For the elbow of 45 loss 0 5 m For the elbow of 90 loss 1m E Type C32 E 90 1 m 8 5 Li GO m z o lt x m l E 2 lt x E a N INSTALLATION Pluming kit Fig 6 11 60 100 mm vertical part o 60 mm flue outlet This kit allows the comburent air to be sucked up and expel the burnt gases di rectly to the outside through a telescopic co axial flue 450 950 mm Type C52 90 0 85 m 60 100 mm Fig 6 11 In the last section the fumes are expelled through a vertical section Extensions and elbows can be added to ex tend the kit s length The chart of Fig 6 12 gives the allowable di mensions of the ducts and b of Fig 6 11 Each additional elbow reduces the overall ac ceptable 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 34 a vertical length m 24 22 2 0 1 8 1 6 1 4 1 2 1 0 0 8 0 6 0 4 0 2 0 0 0
7. 37 26 ic 39 5 22 E A X 12 11 13 Fig 4 2 10 Condensate drain pipe 17 Flue temperature probe NTC 11 C h return valve 18 Condensing heat exchanger 12 Gas inlet valve 19 Safety thermostat 13 C h flow valve 20 C h temperature probe NTC 14 Fan 21 Condensate trap 15 Air pressure sensor test points 22 Main circuit drain valve 16 Air pressure sensor 23 Automatic air purger valve 17 TECHNICAL INFORMATION 24 Pump vent plug 25 Pump 26 C h pressure relief valve 27 Modulation gas valve 28 Primary circuit pressure switch 29 Combustion chamber over heat 30 Flame detecting electrode 31 Burner 32 Ignition electrodes 33 Combustion chamber 34 Primary heat exchanger 35 Modulation operator 36 Gas valve outlet pressure test point 37 Gas valve inlet pressure test point 38 C h expansion tank 39 By pass valve 40 Fan pressure connection 41 Flue outlet pipe 42 Air intake pipe z lt l E 18 TECHNICAL INFORMATION 4 3 Hydraulic specifications The hydraulic specifications in Fig 4 3 rep resent the pressure available head for the central heating system as a function of the flow rate The load loss due to the boiler has already been subtracted kPa bar 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 Vh Fig 4 3 Output with thermostat cocks shut off The boiler is equipped
8. 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 4 Remember to release the auto air purge before filling the boiler See the instructions to identify the location of this device 4 This boiler allows to control the flow temperature of the central heating system at very low levels In case of underfloor heating system a temperature limiting device e g a safety thermostat is recommended to stop the boiler in case that the water temperature exceeds the design temperature You are strongly advised to flush out the system both cold and hot in order to remove system and installation debris Itis also sensible to initially fire and commission the boiler before connecting any external controls such as a room thermostat By this method if you have a subsequent problem following the addition of an external control you can eliminate the boiler from your fault analysis Ifthe boiler is fitted with a digital programmer when setting the times for automatic opera tion remember that for every ON time there must be an OFF time to follow and that on every occasion you enter a time you must also indicate which days that you want the boiler to follow the timed settings Some products incorporate an anti cycling time delay It is normal when first switching the boiler on for the boiler to opera
9. competent person in accordance with the Gas Safety installation amp Use Regula tions 5 1 Related documents The installation of this appliance must be in accordance with the relevant require ments of the current Gas Safety Installa tion amp Use Regulations the Local Building Regulations the current E E Wiring Regu lations the Regulations and by laws of the local water undertaking and in Scotland in accordance with the Building Standards Scotland Regulation Health and safety document n 635 Electricity at work regs It should also be in accordance with the Brit ish Standard Codes of Practice In Ireland IE The installation must be carried out by a Competent Person and in stalled in accordance with the current edi tion of 1 S 813 2002 Domestic Gas Installa tions the current Building Regulations and reference should be made to the current ETCI rules for electrical installations 5 2 Location of appliance The appliance may be installed in any room or internal space although particular atten tion is drawn to the requirementsof the current E E Wiring Regulations and in Scotland the electrical provisions of the Building Regu lations applicable in Scotland with respect to the installation of the combined appliance in a room containing a bath or shower For Ireland IE reference should be made to the current edition of 1 5 813 2002 the current ETCI rules for electrical instal lations
10. manual and the Service manual to the end user and explain how to use the unit Take the User step by step through the light ing instructions Show the User how to switch off the appli ance quickly and indicate the position of the electric supply isolator Explain the proper use and adjustment of all system controls this will ensure the great est possible fuel economy Explain the function and use of the function selector Explain and demonstrate the function of time and temperature controls if fitted 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 conditions may occur Fill in the details required on the Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee registration Finally advise the User that for continued safe and efficient operation the appliance must be serviced by a competent person at least once a year 44 GAS CONVERSION 8 GAS CONVERSION 8 1 Warnings The commissioning of this boiler and system must only be undertaken by a professionally qualified person in ac cordance with the requirements of the Gas Safe Installation and Use Regula tions and be approved by Gas Safe Components used to adapt it to the type of gas available must be genuine parts only 8 2 Procedures Check that the gas cock fitted
11. of the Gas Safe Installation and Use Regula tions and be approved by Gas Safe Ensure that the Benchmark Log Book is satisfactorily completed during the com missioning process The Log Book is located at the end of this manual This manual should be handed to the User following completion of the installation and commissioning process Failure to comply with these requirements may in validate the manufacturers guarantee For Ireland IE it is necessary to com plete a Declaration of Conformity to indicate compliance to 1 5 813 2002 7 2 Electrical installation Preliminary electrical system checks to en sure electrical safety shall be carried out by a competent person i e polarity earth con tinuity resistance to earth and short circuit If a fault has occurred on the appliance the fault finding procedure should be followed as specified in the service manual 7 3 Gas supply installation Inspect the entire installation including the gas meter test for tightness and purge all as described in BS 6891 For Ireland IE refer to 1 5 813 2002 Open the gas cock 12 Fig 7 1 on the ap pliance and check the gas connector on 40 the appliance for leaks xA TR 22 AS M 7 T 2 12 position gt K Fig 7 1 7 4 lnitial filling of the system Open the c h flow and return valves Remove the front panel of the case sec tion Disma
12. onds stand by condition Function selector in position Anti freeze system active 1 second pulse every 2 seconds normally oper ating boiler Function se lector in position IO 02 operation Frost protect operation CS bas Faulty c h temperature CASAS probe NTC o Faulty flue temperature PAS probe NTC v Faulty primary circuit 202 low c h AS pressure Faulty primary circuit CAEN DIEN absence of flow p Faulty air pressure sen TESTA LIN sor Lack of burner ignition no ZO X ignition signal from the full seqence ignition device E Safety thermostat lock V out e e Flue temperature probe v NTC lock out 2 M N N N xx OD Other faults Lack of power supply fauly electr control p c b Meaning of symbols Lamp OFF Lamp on Flashing lamp alone or simultane ously with an other lamp Flashing lamp alternate with another v lamp If the lights combination observed is not included in the above table a fault may be indicated Reference should be made to the following table In this case switch off the boiler as de Scribed in section Extinguishing to page 12 and call a competent and responsible Service Engineer INSTRUCTIONS FOR USE 2 INSTRUCTIONS FOR USE 2 4 Warnings Biasi UK Ltd
13. option in particular not only cleans out the system but also has an anti corrosive effect by promoting formation of a protective skin on metal surfaces and neu tralising gases present in the water We recommend the use of a suitable uni versal inhibitory to protect the c h system from corrosion 6 3 Installing the bracket Precautions Before mounting the bracket check that the dimensions for fitting the exhaust fume duct are complied with refer to the leaflet includ ed with the flue kit packed separately Utilise the paper template supplied with the boiler to determine the fixing position for the bracket and boiler Securely mount the bracket to the wall using appropriate fixings suitable for the type of wall construction and capable of supporting the total wet load Refer to the weight given in the technical data tables specific for each model 6 4 Overall dimensions The boiler respects the following dimensions Flue outlet air intake pipe co axial Flue outlet pipe 80mm twin kit Air intake pipe 80mm twin kit Electric connections area C h flow Gas mmocou G return H Condensate drain connection area Boiler front 6 5 Joints Pipe sizes o d 622 15 25 plastic Functions Gas c h return c h flow Pressure relief valve Condensate drain sizes in mm o d 6 6 Mounting the boiler Take the protective c
14. or damage to materials of the appliance or other objects ATTENTION The indications marked with this symbol is important informa tion that must be carefully read Remember that The manual must be read thoroughly so that you will be able to use the boiler a safe and sensible way must be carefully kept It may be necessary for reference in the fu ture o Z z a 4 The lighting up must be carried out by competent and responsible engineer The manufacturer disclaim all liability for any translations of the present manual from which incorrect inter pretation may occur cannot be held responsible for non observance of instructions contained in this manual or for the consequences of any procedure not specifically described Using the boiler 4 Before lighting the boiler you are advised to have a professionally qualified person 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 devices required by the current Regulations 4 Ensure that check with the Installer that he has connected and terminated the pressure relief valve in a manner which allows safe discharge The manufacturers are not responsible for damage caused by opening of the pressure relief valve and consequent escape of wa ter if this is not connected and terminated the installer has connected the condensate outlet to a sui
15. pressure must be checked and adjusted if necessary Important after the gas pressure checks and any adjustment operations all of the test points and adjustment devices must be sealed Replace the adjustment pro tection cap 7 8 Checking the burner ignition Turn the boiler OFF Open the gas valve outlet pressure test point 36 Fig 7 6 and connect the gauge Turn the boiler ON positioning the control selectors 7 in the positions as shown in as in Fig 7 7 and ensure that the timer se lector switch and room thermostat if fitted are set to heat demand Watch the gauge and check to see if the ignition pressure registered corresponds to the values as given in the Technical Data Turn off the boiler and reignite it by turning the function selector 7 to the OFF position and then back to that indicated in Fig 7 7 Repeat this process two to three times leaving 30 second intervals between each ignition Check the ignition pressures and visually check that the burner lights uni formly and in a controlled manner If the burner ignition is not uniformly con trolled then checks should be made to the flue installation and termination that the flue gasket as shown in Fig 6 5 on page 31 is in place that the burner and injectors are clean 43 z lt E l 2 2 2 lt COMMISSIONING that the boiler is set for the c
16. radia tor circuit using your radiator key however be aware that excessive venting will cause the pressure in the system to drop Always ensure that the pressure gauge is set at the required pressure 2 3 Ignition Check that the valves located in the lower part of the boiler are open Fig 2 3 FL PME SS RR n 9 Fa A Jl lt Rug 8 07 a Open position Fig 2 3 Turn on the electricity supply to the boil er switching on the fused spur isolation Switch The appliance operation light 9 Fig 2 4 will flash every 4 seconds stand by condition To operate the boiler position the function selector 7 as in Fig 2 4 The appliance op eration light 9 will flash every 2 seconds operating boiler Fig 2 4 2 4 circuit temperature The output temperature of c h water is ad justable from a minimum of about 40 C to a maximum of about 85 Fig 2 5 by turn ing the function selector 7 Adjustment of c h output on the boiler is automatic Minimum R h Maximum w h Fig 2 5 The greatest output pre set in the factory can however be reduced in level accord ing to actual system requirements this does not affect the maximum output in d h w op eration Such adjustments must be carried out by a qualified person therefore we advise you to f INSTRUCTIONS FOR USE contact your installer or
17. reasonably economical service install a room thermostat Never shut off the radia tor in the area where the room thermostat is installed If a radiator or a convector does not heat up check that no air is present in it and that its valve is open If the ambient temperature is too high do not alter the radiator valves Reduce the central heating temperature in stead by means of the room thermostat and the function selector 7 in Fig 3 1 Fig 3 1 3 2 Frost protection This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 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 isolation switch or close the gas inlet cock 3 3 Condensate drain The condensate drain must not be modi fied or blocked Blockage of the condensate drain caused by debris or freezing can cause automatic shutdown of the boiler If freezing is suspected and the pipe run is accessible an attempt may be made to free the obstruction by pouring hot water over the exposed pipe an cleaning any blockage from the end of the pipe If this fails to remedy the problem the assist ance of a Gas Safe registered installer or in IE a competent person should be sought 3 4 Periodic maintenance For efficient and continuous operation of the boiler it is advisable to arrange mainte nance and cl
18. support the Benchmark initiative The Benchmark Log Book is located at the back of this manual and should be completed by the Installing Commissioning Engineer and handed over to the User for future reference by other visiting Engineers Also included is the Service Interval Record card that should be completed by the Service Engineer following the annual service maintenance of the boiler and system All Gas Safe Registered Installers carry a Gas Safe ID card and have a registra tion number Both should be recorded in your Benchmark Log Book You can check your Installer is registered by call ing Gas Safe direct on 0800 408 5500 or go on line at www GasSafeRegister co uk In order to guarantee safety and correct op eration it is essential that all the tests are carried out by a competent and responsible service engineer before lighting up the boiler The tests are described in the installation instructions in section 7 commissioning Ensure that the c h circuit is regularly filled with water even if the boiler is only used for d h w supply checking that the pressure indicated on pressure gauge 4 is not lower than that shown in Fig 2 2 If the pressure reading on the pressure gauge is below that shown in Fig 2 2 then the system will require topping up A filling loop is normally provided by the Installer for this purpose If you are in any doubt regarding this procedure you are advised to contact your Installer or an A
19. system as frequent filling of the system could cause premature scaling of the heat exchanger 5 9 Water treatment C h circuit Where a new boiler is fitted to a new sys tem with either plastic or copper pipes it is important the system is fully flushed on completion to ensure flux residues swarfs oils and other installation debris is removed Where a new boiler is fitted to an existing System it is important the debris from the existing system is fully removed in order to ensure the efficiency of the new appliance is maintained Details on flushing procedure are given in the section Initial filling of the system to page 40 of this manual 5 10 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 E E Regula tions and any local regulations which apply Reference should be made to the current ETCI rules for electrical installations For Ireland IE refer to 1 5 813 2002 The boiler is supplied for connection to a 230 50 Hz supply The supply must be fused at 3A The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance by the use of a fused spur isolation switch Its installation permits a complete switching off in the con ditions of the overvoltage category III Alter natively it can be used a 3A fused three pin plug and unswitched shutte
20. with an automatic by pass valve 390n page 18 which protects the condensing primary exchanger In case of excessive reduction or total block age of water circulation in the central heating system owing to closure of the thermostatic valves or system component cocks the by pass valve ensures a minimum flow of wa ter through the primary heat exchanger 4 4 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 sys tem may be 10m at most For greater differences increase the pre load pressure in the expansion vessel and the system when cold by 0 1 bar for each additional 1 m Capacity Pre load pressure Maximum volume of water in the Where conditions are Average maximum temperature of the sys tem is 85 C Initial temperature when filling up the sys tem is 10 C For systems with volumes great Q er than 94 I an additional expan sion vessel must be provided 19 2 o lt x m TECHNICAL INFORMATION 4 5 Technical data mod M296 24SR C Heat input Gas supply pressures Nominal net 4 Nominal gross 8 Minimun net Minimun gross Maximun condensing Minimun condensing Central heating z o 4 m a E flow temp
21. 4 06 08 10 12 14 16 18 b horizontal length m Fig 6 12 6 9 Electrical connections Connection to the electricity supply Remove the front panel of the case see the section Dismantling the external pan els to page 47 Remove the screws and J Fig 6 13 Fig 6 13 Loosen the screws K Remove the side panels or move the low INSTALLATION er part of the side panels as indicated in Fig 6 14 and pull the control panel When completely pulled out the panel can rotate 45 downwards to facilitate the operations on the internal parts Loosen the screws L and remove the ser vice panel Fig 6 15 Fig 6 15 For the electrical connection to the boiler use electric wires which conform to the cur rent regulations with flexible cord each core having a cross section area not less than 0 75 mm Connect the electrical supply flexible cord coming from the fused spur isolation Switch to the power supply terminal block of the boiler Fig 6 16 keeping the same connections for the live brown wire and the neutral blue wire External 3 A fuse or fused plug with same current rating is recommended Do not connect live wires to terminals to which the room thermostat must be connected Connect the earth wire yellow green Connection of a room thermostat The room thermostat must be connected to the terminal block situated next to the con trol panel Any external controls and con
22. EQUIREMENTS 24 9 3 Emptying the c h 47 il ocatiomofdpplahices S o s oL 24 9 4 Combustion analysis check 48 53 FI 1 PRIOR 24 9 5 Cleaning the primary heat exchanger 48 gi ti gius 9 6 Checking the pressurisation in the expansion 5 4 supply 6 25 VeSSel cisas ase pce one ee 48 s supply RT MM A E E AE 28 9 7 Cleaning the burner 48 Condo nis dn 5 9 8 48 58 Water circulation T h iD OE 27 9 9 Drain pipe inspection 48 5 9 Water treatment a oa RI trug 28 9 10 Visual inspection of appliance 48 5 10 Electrical supply 28 9 11 Gas pressures and tightness 48 6 1 5 29 GAS BOILER COMMISSIONING CHEC 6 1 WamingS 22 25 iR e x beatae er 29 agai iia aote 50 6 2 Precautions for 29 SERVICE INTERVAL RECORD 51 6 3 Installing the 30 Abbreviations used in the manual C h Central heating D h w Domestic hot water D c w Domestic cold wate Appliance category 12 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 Ga
23. OMMISSIONING CHECKLIST CONTROLS ro 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 amp 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 INHIBITOR USED THE SYSTEM CLEANER USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m3 hr ft hr BURNER OPERATING PRESSURE IF APPLICABLE N A 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 MEASURE amp RECORD GAS RATE m3 hr ft hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE N A mbar COLD WATER INLET TEMPERATURE
24. Service Agent Adjustment of the boiler temperature alters the gas flowat the burner according to the thermal demand in the system So it is usual tosee theburner lit at the minimum level for more or less long periods Adjustment In order to achieve optimal settings for economy and comfort we recommend ad justing the operating temperature of the c h water according to the outside temperature positioning the knob as follows From 5 to 15 Between 5 and 5 Lower a than 5 C Fig 2 6 Your qualified installer will be able to rec ommend the most suitable adjustment for your system The temperature and pressure gauge 4 Fig 1 3 on page 8 will allow you to check that the set temperature is obtained 2 Extinguishing To turn the boiler off set the function selec tor 7 to the position shown in Fig 2 7 The appliance operation light 9 will flash every 4 seconds When you do not expect to use the boiler for a long period Switch off the electricity supply to the boil er by means of the fused spur isolation Switch Shut off the gas supply cock 12 and the valves for the water circuits fitted under the boiler Fig 2 8 Empty the water circuits if necessary as shown in section General access and emptying hydraulic circuits in the service manual i gt 12 Closed position 242 USEFUL ADVICE 3 USEFUL ADVICE 3 4 Central Heating For
25. Wall hung fanflue roomsealed high efficiency gas boiler User manual and Installation instructions Riva Plus HE Models G C Appl No M296 24SR C SYSTEM BOILER M296 28SR C SYSTEM BOILER recommended ABIASI WARNING Congratulations on your choice Riva Plus HE are condensing high efficiency sealed chamber fan flue gas boilers They are fully electronically controlled and have electronic ignition The materials they are made of and the control systems they are equipped with give you safety a high level of comfort and energy savings to allow you to get the greatest benefit out of independent heating Riva Plus HE allow a higher efficiency by reducing the flue gas temperature such that the water vapour formed during the combustion is condensed out This allows a gain of useful heat that otherwise would be lost o OP PE DANGER The indications marked with this symbol must be observed to pre vent accidents of mechanical or generic origin e g injuries or bruises DANGER The indications marked with this symbol must be observed to pre vent accidents of electric origin electrocution DANGER The indications marked with this symbol must be observed to pre vent the risk of fire or explosion DANGER The indications marked with this symbol must be observed to pre vent accidents of heat origin burns ATTENTION The indications marked with this symbol must be observed to prevent malfunctioning and
26. Where a room sealed appliance is in stalled in a room containing a bath or shower any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower The location must permit the provision of an adequate flue and termination For unusual locations special procedures may be necessary and BS 6798 gives de tailed guidance on this aspect A compartment used to enclose the appli ance must be designed specifically for this purpose This appliance is not suitable for external installation 5 3 Flue system The provision for satisfactory flue termina tion must be made as described in BS 5440 part 1 For Ireland IE referto 1 S 813 2002 The appliance must be installed so that the flue terminal is exposed to external air It must not be installed so that the terminal discharges into an other room or space as an outhouse or lean to It is important that the position of the terminal allows a free 24 GENERAL REQUIREMENTS passage of air across at all times The terminal should be located with due regard for the damage or discoloration that might occur to building products in the vi cinity 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 b
27. ace area 5 4 Gas supply The Gas meter is connected to the service pipe by the local gas region or a local gas region contractor If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other ap pliance when they are in use at the same time Pipework must be of adequate size Pipes of a smaller size than the boiler inlet con 2b 2 lt x m z E z lt E GENERAL REQUIREMENTS nection should not be used Installation pipes should be fitted in accord ance with BS 6891 and the complete instal lation should be tested for tightness For Ireland IE refer to 1 5 813 2002 5 5 Air supply The room in which the boiler is installed does not require a purpose provided air vent 5 6 Ventilation If installed in a cupboard or compartment it is not necessary to provide additional venti lation for cooling for this particular product However consideration must be given to clearance requirements for maintenance section Precautions for installation to page 29 and under no circumstances must stored articles be allowed to come into con tact with the boiler or flue pipe 5 7 Condensate drain Ensure that the condensate discharge com plies with the national or local regulations in force The condensate pipe must be fitted in accordance with Building Regulations Drain pipe material should be resistant t
28. aps off the boiler pipework Thoroughly clean the connections Mount the boiler on its bracket 30 INSTALLATION Fix the c h valves A and gas cock 2 to the boiler using the gaskets Fig 6 3 Fix the 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 77 gaskets gre A gt Fig 6 3 Connect the pipe E Fig 6 4 from the pressure relief valve to the safety dis charge pipework Fit the condensate drain 10 Fig 6 4 in the air brake connected to the drainage pipework See also section Condensate drain to page 26 6 7 Fitting the flue system Refer to the assembly instructions con tained within the chosen flue kit packaging for the correct assembly and installation In general it has to be taken in considera tion that the horizontal sections of the flue pipe must have an horizontal sloping not less than 1 5 deg 25 mm per metre to wards the boiler In the standard horizontal flue kit Fig 6 6 A 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 amini mum fall of 1 5 deg 25 mm per metre over the whole length towards the boiler is en sured Before fitting the flue system ensure that the flue gasket shown in Fig 6 5 given wit
29. case temperature rise in the circuit can cause the pressure relief valve to open So that this does not happen and to de crease the pressure to a normal value it is advisable to vent some of the water in the appliance through the bleed valves present in the radiators If water should occasionally leak from the boiler shut off the valves positioned under the boiler Fig 2 8 on page 12 and call an Au thorised Service Centre Engineer If the left appliance operation light 9 Fig 3 3 flashes very quickly the boiler is de tecting a fault 14 USEFUL ADVICE In this case or in case of prob lems other than those men tioned here switch off the boil er as described in section Extinguishing to page 12 and call a competent and responsi ble Service Engineer 5 15 TECHNICAL INFORMATION 4 TECHNICAL INFORMATION 4 1 Overview z lt l E Fig 4 1 16 TECHNICAL INFORMATION 4 2 Main diagram 42 jy AM 17 fcr CK 40 Ar 21 14 16 34 7 19 20 G N 30 ie ans 23 yr 25 32 SPI i a KOC 21 36 2 lt x m l E 29 F 28 M I 10
30. e air present in the pipe work After five consecutive resetting attempts the reset button is inhibited To restore its func tion it is necessary to switch the boiler off and on from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance Safety lock out may occur even in case of a blockage of the condensate drainage e g plugged drain pipe It is advisable to check the condensate drainage pipe and traps for cleanness In this case and in case of persist ent lock out call a competent and responsible Service Engineer Fig 3 2 If noises due to air bubbles are heard during operation you should check that the pressure on the temperature and pressure gauge Fig 2 2 on page 10 is not below the correct setting If required top up the system correctly as described in the section Refilling proce dure to page 10 Bleed any air present in the radiators if nec essary If the pressure on the temperature and pressure gauge has gone down It is necessary to top up the appliance with water again so as to raise the pressure to an adequate level as described in the sec tion Refilling procedure to page 10 If top ping up with water has to be done very fre quently have the system checked for leaks If water comes out of the pressure relief valve Check on the temperature and pressure gauge that the pressure in the central heat ing circuit is not close to 3 bars In this
31. e avoided The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig 5 1 s Fig 5 1 Terminal position mm A Directly below the window or other opening 300 B Below gutters soil pipes or drain pipes 75 C Below eaves 200 D Below balconies 600 E Below car port roof NO F From vertical drain pipes and Soil pipes 150 G From internal corners 450 H From external corners 300 Above ground or balcony lev el 300 J From a next door boundary 2500 K From a terminal facing a termi nal 2500 L From an opening in the car port e g door window into dwell ing NO M Vertically from a terminal in the same wall 1500 N Horizontally from a terminal in the same wall 300 O Above the roof pitch with roof slope less than or equal to 30 350 O Above the roof pitch with roof slope more than 30 600 P From wall face 600 Q From above or to side of an opening 300 Wherever practicable to do so the flue should be extended beyond the perim eter of the balcony Consideration should be given to adding protection against condensate to the ad jacent structure Wall terminals with horizontal discharge less than 2 5 m from a car parking space and less than 2 1 m above the ground Wall terminals less than 2 1 m above the ground with horizontal discharge of the flue products across a public footway or a frequently used private access route or a patio hard surf
32. eaning by an Authorised Serv ice Centre Engineer at least once a year During the service the most important com ponents of the boiler will be inspected and cleaned This service can be part of a main tenance contract In particular you are advised to have the following checks carried out primary heat exchanger burner exhaust fume duct and flue pressurisation of the expansion tank filling up of the central heating circuit bleeding of air fromthe central heating system general check of the appliance s operation 3 5 External cleaning Before carrying out any clean Q ing disconnect the appliance from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance To clean the external panels use a cloth soaked in soapy water Do not use solvents abrasive powders or sponges Do not carry out cleaning of the appliance and or its parts with readily flammable sub stances for example petrol alcohols naph tha etc 13 USEFUL ADVICE 3 6 Operational faults If the lock out signal lamp comes on this indicates that the safety lock out 5 Fig 3 2 has stopped the boiler To re start the boiler itis necessary to press the boiler reset button 6 Fig 3 2 5 2 4 For the first lighting up and following main tenance procedures for the gas supply it may be necessary to repeat the resetting operation several times so as to remove th
33. ed by a notified body Exhaust temperature 60 Mass flow rate 0 0128 0 Values subject to tolerance Values refer tests with a 1 m flue working at the nominal heat input 221 z o 4 m a E TECHNICAL INFORMATION 4 6 Technical data mod M296 28SR C Heat input Gas supply pressures Nominal net 4 Nominal gross 8 109837 8 7 Minimun net Minimun gross Maximun condensing 104411 9 1 Minimun condensing Central heating Min Max flow temperature settings Minimum return temperature Maximum pressure Minimum pressure Available head in 1000 l h Seasonal effiency G20 Seasonal effiency G30 G31 to the minimum useful output 1 mbar approximately equals 10 mm H O 222 5 TECHNICAL INFORMATION rate maximum Flue gas figures Nominal heat input CO2 content with gas G20 O2 content with gas G20 content with gas G20 Exhaust temperature Nominal heat input 2 content with gas G20 CO2 content with gas 30 G31 Minimum heat input 2 content with gas G20 CO2 content with gas G30 G31 Other specifications Power consumption Protection degree External fuse rating INSTALLATION Internal fu
34. erature settings Minimum return temperature Maximum pressure Minimum pressure Available head in 1000 l h Seasonal effiency G20 Seasonal effiency G30 G31 to the minimum useful output 1 mbar approximately equals 10 mm H O 20 TECHNICAL INFORMATION rate maximum Flue gas figures Nominal heat input CO2 content with gas G20 O2 content with gas G20 content with gas G20 Exhaust temperature Nominal heat input 2 content with gas G20 CO2 content with gas 30 G31 Minimum heat input 2 content with gas G20 CO2 content with gas G30 G31 Other specifications Power consumption Protection degree External fuse rating INSTALLATION Internal fuse rating Water volume in the boiler up to 1 bar referred to the net calorific value at 15 C and 1013 25 mbar G20 34 02 MJ m G31 46 34 MJ 12 C32 C42 C52 C82 kg p Coaxial 60 100 8 referred to the gross calorific value at 15 and Twin split pipes 80 80 1013 25 mbar G20 37 78 MJ m G31 50 37 MJ k Roof 80 125 i The value is used in the UK Government s Standard Nominal heat flow rate 25 0 Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calcula ted have been certifi
35. ercial Road Leamore Enterprise Park WALSALL WS2 7NQ Tel 01922 714 600 www biasi co uk
36. fitted e g Timeclock room thermostat ensure they call for heat Switch on the boiler Check the maximum gas pressure and compare the value on the gauge with the value indicated in the sections Technical Data on pag 20 or pag 22 gas pres sures at the burner accordingly with the model of boiler installed Check the maximum gas flow at the gas meter and compare the value indicated in the sections Technical Data on pag 20 or pag 22 gas rate accordingly with the model of boiler installed Switch off the boiler Disconnect the gas modulator coil by re moving the electrical connector A Fig 7 6 42 COMMISSIONING ise Fig 7 6 e Switch on the boiler e Check that the boiler lights up uniformly If not refer to section Ignition gas pressure adjustment of the Service Manual for the necessary adjustment procedures Switch off the boiler and disconnect the pressure gauge Reassemble the sealed chamber lid and the front panel of the case see Disman tling the external panels to page 47 If the maximum and minimum gas pres sures measured above are not in accord ance with the technical data sections Technical Data section pag 20 or pag 22 then adjustment will be necessary A full explanation of the gas pressure ad justment procedure is given in the Gas Valve section of the service manual If maximum and or minimum gas pres sures are adjusted then the ignition gas
37. h the boiler is fitted to the boiler Fig 6 5 6 8 Choice of flue The following flue kits are available for con necting to the boiler Standard horizontal flue kit Fig 6 6 A Co axial 60 100mm nominal length 1m This kit is normally suppliedwith the boil er and can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow Minimum length required is 0 3 m Maximum equiva lent length of 2 7 metres can be achieved utilising extensions This flue system can only be used to discharge horizontally it is 31 2 lt x m l E 2 lt x N INSTALLATION not designed to enable termination in the vertical plane Fig 6 6 Vertical kit with 90 elbow Fi Co axial 60 100 mm Supplied with a straight flanged adapter a co axial elbow and a co axial pipe with ter minal this kit allows for a vertical rise of 0 5 m from the boiler In all circumstances the flue terminal must discharge horizontally and the equivalent flue length must not ex ceed 2 7 metres 6 6B Elbows 45 amp 90 Fig 6 6 C Coaxial 60 100 mm Elbowkits enable the standard flue kits to be offset to overcome obstructions or ensure the correct clearances for the flue terminal Each elbow used in addition to the standard flanged elbow reduces the overall accept able length of the flue systemas follows For the elbow of 45 loss 0 5 m For the e
38. h the flexible cord clamps To the external control device To the fused Fig 6 19 eto k em IO S J spur isolation QE 6 10 External frost protection Connect the frost thermostat between ter minals 1 and 2 as shown in Fig 6 20 or Fig 6 21 Do not connect live wires to terminals to which the room thermostat must be connected Frost Thermostat 230V rating External controls terminal block Fig 6 20 3 2 1 2 Room thermostat 230V rating Power supply terminal block 36 INSTALLATION Room thermostat with anticipating resistor 230V rating Frost thermostat T 230V rating Power supply terminal block Ext trol oee xternal controls terminal block o Fig 6 21 6 11 Connecting a system boiler to a cylinder Two schematic wiring diagrams are given in this section showing two possible ways to connect an external programmer to a mid position diverter valve to provide independ ent timed and thermostatic control of heat ing and hot water Fig 6 22 and Fig 6 23 are divided in two parts The upper shows the single components used on the diagrams with their connection to the 10 way j
39. ition delay cycle does not prevent normal operation of the boiler to provide d h w If external controls are fitted e g Time clock room thermostat ensure they call for heat Turn on the electricity supply to the boil er switching on the fused spur isolation Switch The appliance operation light 9 will flash every 4 seconds Turn the function selector 7 as in Fig 7 5 The appliance operation light 9 will flash every 2 seconds The boiler will now go through an ignition sequence and the burner will light If during the ignition attempt period the boiler fails to light the full sequence control p c b will go to lockout and the lock out sig nal lamp 5 will appear To reset the boiler press and release the boiler reset button 6 7 7 Checking the gas pressure at the burner This boiler has been factory tested to the highest quality control standards The maximum and minimum gas pressures are already set during this quality control process however the checking procedure must be followed to ensure maximum op erating efficiency from the boiler Remove the front panel of the case see section Dismantling the external panels to page 47 and the sealed chamber lid Loosen the internal screw 36 Fig 7 6 on the Outlet Pressure Test Point of the Gas Valve and connect a pressure gauge using a suitable hose Setthe c h temperature control knob to its maximum position If external controls are
40. lbow of 90 loss 1m 32 kits 80 mm Fig 6 7 Fig 6 8 Twin Fig 6 7 Various twin split pipes kits and optional accessories elbows are available to as sist in the termination 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 pos sible to extend the flue system to a greater distance than that provided by the standard horizontal co axial flue If either an additional 45 or 90 accessory elbow is used then the maximum permissi ble length of either pipe must be reduced by 0 90 m or 1 65 m respectively N B The air intake and the flue outlet must not terminate on opposite sides of the building INSTALLATION 90 1 65 m 45 0 90 m Type C82 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 For the correct use of the restrictors with twin pipes refer to the table Equivalent length Restrictor air duct flue duct Between 1 and 15 m 50 mm More than 15 m up to 30 m 55 mm Restrictor Gasket Fig 6 9 Vertical roof kit Fig 6 10 This kit allows vertical termination of the flue pipe through the roof The kit is 1 2 m in length Extension pieces Co axial are
41. m the flue terminal This is due to the high efficiency of the appliance and may be particularly evident with low outdoor temperatures Safe handling of substances Biasi products are manufactured in accordance with ISO 9001 and do not and will not contain any hazardous materials or substances such as asbestos mercury or C F C s The appliance packaging does not contain any substances which may be considered a hazard to health When handling or lifting always use safe techniques keep your back straight bend your knees don t twist move your feet avoid bending forwards and side way sand keep the load as close to your body as possible Where possible transport the boiler using a sack truck or other suitable trolly Always grip the boiler firmly and before lifting feel where the weight is concentrated to estab lish the centre of gravity repositioning yourself as necessary Combustion chamber panels Material mineral fibres Known hazards Some people can suffer reddening and itching of the skin Fibre entry into the eye will cause foreign body irritation which can cause severe irritation to people wearing contact lenses Irritation to respiratory tract Precautions Dust goggles will protect eyes People with a history of skin complaints may be particularly susceptible to irritation High dust levels are only likely to arise following harsh abrasion In general normal handling and use will not present high risk follow g
42. nection lines must be rated at 230 V but under no circumstances should external live voltage be connected to the room ther mostat link on the boiler Do not connect live wires to terminals to which the room thermostat must be con nected Do not connect live wires to ter minals to which the room ther mostat must be connected When connecting any type of external control the link M in Fig 6 16 must be removed To the fused spur isolation L switch 4 Power supply Isl terminal block 2 Bag le im 9 External controls terminal block b z o lt x E l INSTALLATION Connect the room thermostat between ter minals 1 and 3 as shown in Fig 6 17 or Fig 6 18 Room thermostat 230V rating 3 2 1 iis TON Power supply oj e Fig 6 17 Room thermostat with delay resistor 230V rating N Power supply 9 terminal block ome Tee 202 External controls terminal block z o lt a E N 2 N D e Route the electrical supply flexible cord and the external control flexible cord as illustrated in Fig 6 19 Lock the flexible cords in placewit
43. ng valves 13 and 11 in Fig 9 3 fr oii i Closed position r Open the central heating drain cock 22 in Fig 9 4 62 LZ LL Fig 9 4 5 z lt zZ lt MAINTENANCE MAINTENANCE 94 Combustion analysis check If it is necessary to carry out a combus tion analysis remove the plugs indicated in Fig 9 1 Reference figures are given in the sections Technical Data on pag 20 or pag 22 Flue gas figures 9 5 Cleaning the primary heat exchanger Take off the front of the case Take off the removable front of the sealed chamber and the front panel of the com bustion chamber If you notice dirt on the fins of the primary heat exchanger 340n page 18 Cover the sloping surfaces of the burner 310n page 18 entirely in a protective lay er sheets of newspaper or similar Brush out the primary heat exchanger 34 page 18 with a bristle paintbrush 9 6 Checking the pressurisation in the expansion vessel Empty the central heating systemas de scribed in section Emptying the c h sys tem to page 47 and check that the expan sion vessel pressure is not less than 1 bar See also section Expansion vessel to page 19 If the pressure is lower take steps to correct the pressure level 9 7 Cleaning the burner The sloping and multi gas type burner 310n page 18 does not need special main tenance b
44. nsible if the warnings and instructions contained in this manu al have not been complied with 6 2 The boiler must be fixed to a strong wall The dimensions for the exhaust fume duct detailed in section Choice of flue to page 31 and the correct procedures for installing the duct depicted in the instruc tion leaflet included with the flue kit must be complied with during installation To allow maintenance procedures it is necessary to leave the minimum gaps in dicated in Fig 6 1 Precautions for installation The following prescriptions must be respected for installation 250 25 50 200 measures are in mm Fig 6 1 When installing the boiler in a cupboard cover or alcove allow at least 50 mm per manent clearance from the front face of the boiler Also ensure sufficient clearance to allow free access for servicing and the lowering of the front control panel If the boiler is installed outside cover the appliance to protect it against the ele ments and add some special anti freeze neutralised to the c h system 29 z o lt x m z E z lt l N INSTALLATION Before installing the boiler on an existing c h system flush it out thoroughly be fore fitting the boiler so as to remove muddy deposits It is advisable to equip the system with a sediment filter or use a water treatment product in the circulating water The latter
45. ntling the external panels to page 47 Lift the cap on the automatic air purger valve 23 in Fig 7 2 one full turn and leave open permanently Fig 7 2 Gradually open stopcock at the filling point connection to the c h system until water is heard to flow do not open fully Open each radiator air vent starting at the lowest point of the system and close it only when clear water free of bubbles COMMISSIONING flows out Purge the air from the pump by unscrew ing the pump plug 24 Fig 7 2 release the pump shaft by turning in the direction indicated by the arrow on the information plate Replace the pump plug Continue filling the system The actual reading should ideally be 1 3 bar and not less than 0 3 bar Close all air release valves on the c h system Inspect the boiler and the system for wa ter soundness and remedy any leaks dis covered Cold flush the system to remove any loose particles and any system debris be fore starting the boiler for the first time The flushing procedure must be in line with BS7593 Treatment of Water in d h w c h Systems When the installation and second fill ing are completed turn on the c h sys tem and run it until the temperature has reached the boiler operating tempera ture The system must then be immedi ately flushed through This procedure must be repeated twice more During this operation
46. o acid as the condensate is slightly acid with a pH less than 6 5 The boiler includes a trap 210n page 17 that prevents the combus tion products entering the drain The boilers incorporate a condensate trap with a 75 mm seal to comply with 56798 2000 The schematic diagrams of possible nections are given in Fig 5 2 and Fig 5 3 The length of the condensate pipe should be kept to a minimum any external pipe should not be more than 3 m in 32 mm pipe and insulated to prevent freezing To avoid condensate being trapped the drain pipe should be run with a fall of at least 2 5 45 mm m away from the boiler the number of bends and joints should be kept at minimum the drain pipe should be adequately fixed to prevent pipe sagging If a part of the drain pipe 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 internal soil and vent stack A Condensate drain Dimensions in mm Fig 5 2 Boiler B Internal soil and vent stack C Invert D 450 mm up to three storeys 226 GENERAL REQUIREMENTS Connection of condensate drainage pipe downstream of a sink waste trap Condensate drain 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 5 8 Wate
47. ood hygiene practices wash hands before touching eyes consuming food drinking or using the toilet First aid Medical attention must be sought following eye contact or prolonged reddening of the skin Thermostat Temperature gauge Description Sealed phial and capillary containing liquid Known hazards irritating to skin eyes and throat Vapour is harmful Inflammable do not extinguish with water Precautions Do not incinerate Avoid contact with broken leaking phials Do not purposely puncture First aid medical attention must be sought following eyes skin contact wash with clean water Sharp Edges Caution should be taken when handling the boiler to avoid sharp edges on the boiler Boiler installation and commissioning tips 4 The installation must be carried out by a qualified person who will be responsible for observing the current Regulations Installing the boiler 4 Do not forget to remove the transit caps and plugs from the boiler connections these are fitted to every boiler Keep the boiler clear of dust during installation and in particular do not allow any dust or debris to enter the top of the boiler where the flue connection is made It is recommended 5 o 2 a WARNING that you put a dust sheet over the top of the boiler until you are ready to make the flue connection 4 Because every boiler is fired and tested live at the factory a small amount of water re mains within the
48. orrect gas used see GAS CONVERSION to page 45 If the ignition pressure recorded is not as indicated in the Technical Data then refer to section Ignition gas pressure adjust ment of the Service Manual for the neces sary adjustment procedures Important after the gas pressure checks and any adjustment operations all of the test points must be sealed and replace the adjustment protection cap 7 9 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 5on page 8 must appear To reset the boiler press and release the boiler reset button page 8 7 10 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 cor rectly in accordance with the flue fitting in structions and Fig 5 1 on page 25 of this manual To carry out a combustion check refer to the instructions given in the section Combus tion analysis check to page 48 Reference figures are given in the Techni cal Data section page 20 of this manual Flue gas figures 7 11 Checking the condensate drain pipe Check the soundness and integrity of the condensate drain pipe Verify the cleanness and correct filling of the condensate traps 7 12 Instructing the user Hand over this combined User amp Installation
49. pproved Engineer This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 Therefore when the boiler is not lit or used in cold weather with consequent risk of freezing do not switch off the boiler at the fused spur isolation switch or close the gas inlet cock When you do not expect to use the boiler for a long period and the boiler is not to be used for frost protection then follow the in structions given in section Extinguishing to page 12 2 2 Refilling procedure solate the boiler from the electrical sup ply at the fused spur Reconnect the filling loop as demonstrated in Fig 2 1 Control valve Double check valve Temporary connection Supply pipe cold water inlet IA C h return Fig 2 1 Control valve Open the valves of the filling loop and watch the gauge until it reaches normal filling pressure as shown in Fig 2 2 pressure Fig 2 2 10 INSTRUCTIONS FOR USE Close the valves and remove the filling loop If you experience any difficulty with the operation of the boiler switch off the boiler immediately at the fused spur iso lation switch and contact your Installer or an approved Service Engineer Air introduced into the boiler during this fill ing process will vent through the automatic air purger fitted to the boiler You may also find it necessary to vent air from your
50. r 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 S 813 2002 Pipework The return temperature must not be lower of 40 Copper tubing to BSEN 1057 is recommended for water pipes Jointing should be either with capillary soldered or with compression fittings Where possible pipes should have a gradi ent to ensure air is carried naturally to air release points and water flows naturally to drain taps The appliance has a built in automatic air release valve it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air Except where providing useful heat pipes should be insulated to prevent heat loss and to avoid freezing Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors By 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 mini mum flow of 200 300 Its hr through the main heat exchanger If you are installing a system that includes thermostatic radiator valves TRV and or small bore 8 10 mm it may be necessary to fit an external by pass to facilitate correct ope
51. ration 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 complete filling of the system Expansion vessel The appliance has an integral sealed ex pansion vessel to accommodate the in crease of water volume when the system is heated Refer to Fig 4 4 on page 19 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 re 27 2 o lt x m l E 2 o m GENERAL REQUIREMENTS turn valve without the approval of the Local Water Authority Filling A method for initially filling the system and replacing water lost during servicing must be provided and it must comply with local water authority regulations The correct method is shown in Fig 5 4 The temporary connection must be re moved immediately after filling Control valve Double check valve Temporary i connection 4 Control valve Supply pipe cold water inlet C h return pipe Fig 5 4 The installer should ensure that no leaks ex ist either inside the boiler or on the
52. red socket outlet both complying with BS 1363 The point of connection to the electricity supply must be readily accessible and adja cent to the appliance except where the ap pliance is installed in a bathroom this must then be sited outside the bathroom 28 INSTALLATION 6 INSTALLATION 6 1 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 products directly outside or into a suitable ex haust duct designed for this purpose Combustion products must be discharged using origi nal flue kits only since they are integral parts of the boiler For LPG the appliance must also conform with the requirements of the distributors and comply with current Regulations and laws in force The safety relief valve and the condensate drain must be connected to a suitable drain or discharge in a safe manner The electrical wiring must conform with cur rent Regulations in particular the boiler must be earthed using the cor rect bonding clamp adjacent to the boiler a fused spur isola tion switch must be installed which permits a complete switching off in the conditions of the overvoltage category III Refer to section Electrical connections to page 34 in this chapter for the electrical connections In no circumstances will the manufac turer be held respo
53. s Directive 2009 142 CE Boiler Efficiency Directive 92 42 CE Electromagnetic Compatibility Directive 2004 108 CE Low Voltage Directive 2006 95 CE 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 can not be considered as a contract to wards third parties nm APPLIANCE DESCRIPTION 1 APPLIANCE DESCRIPTION 1 1 Overview Fig 1 1 1 Case front panel 2 Control panel 3 Control panel cover 1 2 Control panel 4 C h circuit temperature and pressure gauge 5 Lock out signal lamp Lockout reset button 7 Function selector and c h temp control knob 8 Service knob o 9 Appliance operation lights The service knob 8 is useless for the normal operation of the boiler 1 3 Isolation valves Fig 1 2 10 Condensate drain pipe 11 C h return valve 12 Gas inlet valve 13 C h flow valve 1 4 Technical data For detailed technical data see sections Technical Data on pag 20 or pag 22 APPLIANCE DESCRIPTION 1 5 Operation lights Three lights 9 in Fig 1 3 give detailed indi cation regarding the operation of the boiler The following table gives the relationship between each of the possible light combina tions and their meaning 11 A short pulse every 4 sec
54. se rating Water volume in the boiler up to 1 bar referred to the net calorific value at 15 C and 1013 25 mbar G20 34 02 MJ m G31 46 34 MJ 12 C32 C42 C52 C82 kg p Coaxial 60 100 8 referred to the gross calorific value at 15 and Twin split pipes 80 80 1013 25 mbar G20 37 78 MJ m G31 50 37 MJ k Roof 80 125 i The value is used in the UK Government s Standard Nominal heat flow rate 29 0 Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calcula ted have been certified by a notified body Exhaust temperature 60 Mass flow rate 9 0 0147 0 Values subject to tolerance Values refer tests with a 1 m flue working at the nominal heat input 23 z lt N GENERAL REQUIREMENTS 5 GENERAL REQUIREMENTS Our Company supports the Benchmark initiative The Benchmark Log Book is located at the back of this manual and should be completed by the Installing Commissioning Engineer and handed over to the User for future reference by other visiting Engineers Also included is the Service Interval Record card that should be completed by the Service Engi neer following the annual service mainte nance of the boiler and system For Ireland IE it is necessary to com plete a Declaration of Conformity to in dicate compliance to 1 5 813 2002 This appliance must be installed by a
55. semble the lid of the sealed chamber Replace the self adhesive label indicating the type of gas and the gas pressures to which the appliance has been set with the label included with the conversion kit The label is placed on the botton of the appliance Replace the adjustment protection cap Replace the front panels of the case 46 MAINTENANCE 9 MAINTENANCE 9 1 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 mainte nance opening or dismantling boiler panels 9 2 Dismantling the external panels Front panel Loosen the three screws A Fig 9 1 Lift and remove the panel Elue exhaust Sampling point Fig 9 1 Side panels Loosen the screws B Bring the bottom of the panels away from the boiler and lift them freeing them from the top hooks Fig 9 2 9 3 Emptying the c h system Close the c h isolati
56. table drain pipe 4 On detecting the smell of gas don t operate any electrical switches the telephone or any device that may produce sparks open the windows and doors at once to create a draught of air which will purge the area shut off the gas cocks get the assistance of a qualified person Emergency telephone number Tel 0800 111999 WARNING 4 Do not touch the appliance with parts of the body that are wet or damp and or bare feet 4 Do not block or modify the condensate outlet and pipework 4 In case of structural work or maintenance near the exhaust duct and or fume exhaust devices or their attachments turn off the appliance On completion of the work have a professionally qualified person check their efficiency 4 Repairs under guarantee must be carried out only by an approved engineer using genuine spare parts Thus do no more than 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 com patible with its performance and output can be used only for those purposes for which it has been specially designed must not be touched by children or by those unfamiliar with its operation must not be exposed to weather conditions 4 During the operation it is quite normal that the boiler produces a white plume of conden sation vapour fro
57. te on heating for a few seconds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The igni tion delay cycle does not prevent normal operation of the boiler to provide d h w If you are in any doubts as to the installation or operation of the boiler please read the instruction manuals thoroughly and then if necessary contact Biasi UK for advice and as sistance Please remember that if you are in any doubt about the installation of this product you can contact our Technical Help line on tel 0121 506 1350 6 TABLE OF CONTENTS 1 APPLIANCE DESCRIPTION 8 6 4 Overall 30 1 1 OVEIVIEWS oi cele eoim fare deb PRA 8 6 5 amp pobre EG 30 12 Control panel cesso cese eee meh 8 6 6 Mounting the 30 1 3 Isolation sess 8 6 7 Fitting the flue system 31 1 4 Technical d ta 2 200 ses e 8 6 8 Choice 31 1 5 Operationlights 9 e9 Electrical connections p TETE EE Ee 6 10 External frost 6 2 e FORUSE 10 6 11 Connecting a system boiler to a 37 22 Refilling procedure 10 7 COMMISSIONING teh rr rk rrt tnn 40 2 3 lgnition cest epee casa Y ERE ED 11 Warnings 40 2 4 circuit temperature
58. unction box The bold num bers represent the terminal of the junction box where the component must be con nected to The lower part shows how to realize a sys tem that provides independent timed and thermostatic control of heating and hot water In Fig 6 22 the boiler is permanently con nected to themain supply The boiler opera tion is controlled by the external control ter minal block In Fig 6 23 the boiler is not permanently connected to the supply line The boiler op eration is controlled by switching the mains supply In this case when the boiler is switched off some important features like the antifreeze system the monitoring of the boiler by the operation lights the post circulation of the pump etc are completely deactivated For these reasons it is advisable to use the first diagram Fig 6 22 safe z o lt x m INSTALLATION Cylinder 8 Room thermostat thermostat 4 BU 2 A B 3 5 3 S 5 7 4 8 bu bk bn dg External control terminal block NO MAINS 230V a c Switched 3 Amp fused spur Mid position BL diverter valve GRYE O WH GY Room thermostat OR Cylinder thermostat remove room thermostat link 10 way junction box z lt l E
59. ut it is sufficient to dust it with a bristle paintbrush To reach the burner 48 Take off the front of the case Take off the removable front of the sealed chamber and the front panel of the com bustion chamber Brush out the burner with a bristle paint brush 9 8 Checking the flue Have the integrity of the flue outlet pipe 410n page 18 air intake pipe 420 page 18 checked periodically the air pressure sensor 160n page 17 and the efficiency of the flue safety circuit checked at least once a year For details see the section Fan and air pressure sensor in the service manual For all the above maintenance operations it is advisable to call an approved Service Engineer 9 9 Drain pipe inspection Check the soundness and integrity of the condensate drain pipe Verify the cleaness and correct filling of the condensate traps 9 10 Visual inspection of appliance Visually inspect all water joints seals and connections for any evidence of leakage and retighten grease or replace them as necessary 9 11 Gas pressures and tightness Check appliance for gas tightness Recheck operational pressures and adjust as neces sary as described in section Checking the gas pressure at the burner to page 42 NOTES 49 benchma COLLECTIVE MARK BOILER SERIAL No BENCHMARK No NOTIFICATION No GAS BOILER C
60. visualize the cur rent setting by keeping the reset button 6 pressed for more than 5 seconds The lamps 9 will flash a number of times corresponding to the setting of the knob 8 in Fig 8 5 Gas type __ L PG Setting No 39 4 T NATURAL 4 GAS oom 4 Fig 8 5 Gas Position Approx Max supply of knob 8 current through the modulator device Natural 1 125 mA gas L P G 4 165 mA Fig 8 6 To change the setting turn the knob 8 on a position corresponding to the gas used as shown in Fig 8 5 By turning the knob 8 the lock out signal lamp 5 blinks quickly 2 per seconds indicating that the setting has changed and must be memorised To memorize the setting keep pressed the reset button 6 for about 5 seconds until the lamps 9 briefly blinks simultaneously Open the gas cock 12 in Fig 8 7 To reset the boiler to the normal operation turn it ON by the function selector 7 on the desired operation and checking the ignition pressure and that the burner lights up uni formly In any case the boiler automatically resets to its normal operation after 10 min utes Factory setting Natural gas as illustrated Ta x X prs J gt x p yt 1 Open position Fig 8 7 Calibrate the gas valve according to the instructions given in the service manual section Modulating gas valve Adjustment Re as
61. we highly recom mend the use of a c h flushing detergent in the quantities as specified by the ap propriatemanufacturer whose function it is to dissolve any foreign matter which may be in the system The above operation could save the in validation of your boilers guarantee and will also prevent problems which you may experience in the future if an inhibi tory is not used 7 5 Condensate pipe and traps The full length of the condensate pipe should be check for leaks The boiler has a built in condensate trap provided with a ball valve that prevents the escape of combustion products when the trap is empty It is however recommended that any oth er trap in the drain system is correctly filled with water before to run the boiler e Fill the built in condensate trap by removing the flue elbow and pouring a cupful of water into the flue outlet Fig 7 3 Fig 7 3 An alternative to avoid the removal of the flue elbow pour the water through the flue sampling point Fig 7 4 Sampling points Flue exhaust 44 2 o lt x m l E z o lt COMMISSIONING 7 6 Lighting the boiler Some products incorporate an anti cycling time delay It is normal when first switching the boiler on forthe boilerto operate on heat ing for a few seconds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The ign
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