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User manual and Installation instructions

1. Fig 9 1 36 1 Loosen the three screws A Fig 9 1 2 Lift and remove the panel Side panels 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 9 2 Fig 9 2 9 3 Emptying the c h system 1 Close the c h isolating valves 11 and 13 in Fig 9 3 Fu Closed position Maintenance 2 Open the central heating drain cock 21 in Fig 9 4 Fig 9 4 Combustion analysis check Ifitis 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 5 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 of the combustion chamber If you notice dirt on the fins of the primary heat ex changer 36 on page 9 3 cover the sloping surfaces of the burner 33 on page 9 entirely in a protective layer sheets of newspaper or similar 4 Brush out the primary heat exchanger 36 on page 9 with a bristle paintbrush 9 6 Checking the pressurisation in the expansion vessel Empty the central heating system as described in section 9 3 of this chapter and check that the pres sure in the expansion vessel is not less than 1 bar See also section 4 4 page 11 of this ma
2. 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 MEASURE amp RECORD GAS RATE mehr MAXIMUM BURNER O
3. Fig 6 9 Various twin split pipes kits and optional acces sories elbows are available 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 co axial flue Installation Fig 6 7 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 Type C82 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 10 Air intake adapter Restrictor Gasket Fig 6 10 For the correct use of the restrictors with twin pipes refer to Tab 6 2 Equivalent length Restrictor air duct flue duct Between 1 and 15m More than 15 m up to 30m Tab 6 2 23 z ke 3 E E z 2 E 3 E E 4 z Installation Vertical roof kit Fig 6 11 E Type C32 67 90 1m max 8 5 m 9125 e 45 0 5m Fig 6 11 This kit allows vertical termina
4. 4 Technical information 4 1 Overview cece oo NNNNNNN D EN z 2 ke 3 E E 4 2 Main diagram s sssusa 10 6 10 External frost protection 4 3 Hydraulic specifications 11 6 11 Connecting a system boiler 4 4 Expansion vessel 11 to a cylinder o 27 4 5 Technical data mod M96A 24SR 12 MEE 4 6 Technical data mod M96A 28Sh 14 7 Commissioning 30 7 1 Electrical installation 30 5 Generalrequirements 16 72 Gas supply installation 30 5 1 Related documents 16 73 Initial filing of the system 30 5 2 Location of appliance 16 74 Condensate pipe and traps 31 5 3 16 75 Lighting the boiler 31 5 4 855 1 17 7 6 Checking the gas pressure 5 5 6 17 31 5 6 Ventilation 17 7 7 Checking the burner ignition 32 5 7 Condensate drain 17 7 8 Checking the ignition device 33 5 8 Water circulation 18 7 9 Checking the flue system 33 5 9 Water treatment 19 7 10 Checking the condensate drain pipe 433 5 10 Electrical supply 19 7 11 Instructing the user 33 8 Gas conversion
5. 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 Directly 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 NO 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 From wall face
6. 12 Press the reset button 6 repeatedly 4 times until the lamps 9 give the indication as in Fig 8 4 gas type mode 0 90 whee LJ 00 000 Fig 8 4 Atthis step itis possible to visualize the current set ting by keeping the reset button 6 pressed for more than 5 seconds The lamps 9 will flash a Lamp OFF Lamp On Gas conversion number of times corresponding to the setting of 15 Open the gas cock 12 in Fig 8 7 the knob 8 in Fig 8 5 SOS P y ey n rua Gas type 39 L PG SN Setting No 399 4 i P NE 7 ee es o m EI NP P a Y p X NATURAL 4 di GAS E d 2 f oom 4 12 Open position Fig 8 7 16 To reset the boiler to the normal operation turn Fig 8 5 it ON by the function selector 7 on the desired operation and checking the ignition pressure and that the burner lights up uniformly In any Gas Position of Approx Max current A case the boiler automatically resets to its nor SUPPIY prd the modulator mal operation after 10 minutes Factory setting Natural gas as illustrated Natural Teg 17 Calibrate the gas valve according to the in o gas structions given in the service manual section eZ L PG 165 mA Modulating gas valve Adjustment 18 Re assemble the lid of the sealed chamber Fig 8 6 19 Replace the self adhesive label indicating the Biz 13 To change the setting turn the k
7. Wall hung fan flue room sealed high efficiency gas boiler User manual and Installation instructions RIVA COMPACT HE MK2 Models M96A 24SR C System boiler M96A 28SR C System boiler A RIVA COMPACT HE MK are condensing high efficiency sealed chamber fan flue gas Congratulations on your choice 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 COMPACT 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
8. 34 9 5 Cleaning the primary heat exchanger 97 8 1 Warnings ooooocoococoomm 34 9 6 Checking the pressurisation 8 2 65 34 in the expansion vessel 37 9 9 Maintenance 36 97 Cleaning the burner 37 E 9 1 Warnings SNO ASSERERE 36 9 8 Checking the flue GE SARUM DIE 37 9 2 Dismantling the external panels 36 99 Drain pipe inspection 37 9 3 Emptying the c h system 36 9 10 Visual inspection of appliance 37 9 4 Combustion analysis check 37 911 Gas pressures and tightness 37 g Abbreviations used in the manual D h w Domestic hot water C h Central heating D c w Domestic cold water EN APPLIANCE DESCRIPTION Overview Fig 1 1 1 Case front panel 2 Control panel 3 Control panel cover 11 2 Control panel C h circuit temperature and pressure gauge Lock out signal lamp Lockout reset button Function selector and c h temp control knob Service knob Appliance operation lights The service knob 8 is useless for the normal oper ation of the boiler OAN DO A 9 8 7 6 5 It must be used only by a qualified person during commissioning and servicing KEN Isolation valves 13 12 11 g Fig 1 2 bottom view of the boiler 10 Condensate drain pipe 11 C h return valve 12 Gas inlet valve 13 C h flow valve 1 4 Technical data For detaile
9. Before lighting the boiler you 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 toperate 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 I 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 Repairs under guarantee must be car ried out only by an approved engineer using genuine sp
10. X p V os MO RUN Pd c Fig 2 7 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 12 and the valves for the water circuits fitted under the boiler Fig 2 8 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 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 instead by means of the room ther mostat and the function selector 7 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 a
11. 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 gasflow atthe burner according to the thermal de mand in the system So itis usualto see the burner lit at the minimum level for more or less long periods Minimum Be gt Loo d 5 Maximum w i Fig 2 5 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 5 and 5 C HE Lower than 5 C Fig 2 6 Your qualified installer will be able to recommend the most suitable adjustment for your system The temperature and pressure gauge 4 Fig 1 3 on page 2 will allow you to check that the set tem perature is obtained 2 5 Extinguishing To turn the boiler off set the function selector 7 to the position shown in Fig 2 7 Instructions for use The appliance operation light 9 will flash every 4 3 Empty the water circuits if necessary as seconds shown in section General access and emptying hydraulic circuits in the service manual D m ue
12. into gully below grating but above water level 18 5 8 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 with 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 radiato
13. 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 38 on page 9 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 37 on page 9 and the system when cold by 0 1 bar for each additional 1m Capacity l Pre load pressure kPa INSTALLATION bar Maximum volume of water in the system 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 with volumes greater than 94 an additional expansion vessel must be provided 11 INSTALLATION Technical information EE Technical data mod M96A 24SR Heat input A Nominal kW BTU h Minimum kW B
14. 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 WE TA E E 35 A Y 17962 1552 0 4908 44A5 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 No 0121 506 1370 www biasi co uk
15. Electrical installation Preliminary electrical system checks to ensure electrical safety shall be carried out by a compet ent person i e polarity earth continuity resis tance to earth and short circuit If a fault has occurred on the appliance the fault find F ing procedure should be followed as specified inthe 5 Open each radiator air vent starting at the Fig 7 2 service manual lowest point of the system and close it only when clear water free of bubbles flows out 6 Purge the air from the pump by unscrewing the EZ cas supply installation plug 24 Fig felodse the Dump 1 Inspectthe entire installation including the gas shaft by turning in the direction indicated by meter test for tightness and purge all as de the arrow on the information plate scribed in BS 6891 7 Replace the pump plug Ferdreland IE tate t 1 9 813 2002 8 Continue filling the system The actual reading 2 Open the gas cock 12 Fig 7 1 on the should ideally be 1 3 bar and not less than 0 3 appliance and check the gas connector on the bar appliance for leaks poet 9 Close allair release valves on the c h system NS CES 10 Inspect the boiler and the system for water 2 2 soundness and remedy any leaks discovered AS d a ATA 11 Cold flush the system to remove any loose par P TR y PB ticles and any system debris before starting the K c boiler for the first time The flushing procedure mu
16. G30 G31 Minimum pressure kPa 30 m3 h kg h kg h bar 0 3 3 07 2 29 2 25 kPa 25 Available head 138 103 101 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 C Values subject to tolerance 14 Technical information Internal fuse rating A 1 2 3 15 AF Flue design Type C12 C32 C42 C52 C82 Flue pipe diameter 60 100 Twin split pipes mm 80 Roof mm 80 125 Nominal heat flow rate kW 29 0 A D Exhaust temperature D C 69 Mass flow rate 0 g s 17 8 Coaxial Flue gas figures Nominal heat input D kw 29 0 CO content 6 8 C 8 Water volume in the boiler kg 4 1 up to 1 bar D Values refer to tests with a 1 m chimney working at the nominal heat input INSTALLATION 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
17. Remove the front panel of the case see the section 9 2 in this manual 2 Remove the screws F and G Fig 6 14 Fig 6 16 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 17 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 z g E 3 E x 4 Fig 6 14 Do not connect live wires to terminals to 3 Loosen the screws H which the room thermostat must be con nected 4 Remove the side panels or move the lower part of the side panels as indicated in Fig 6 15 and 7 Connect the earth wire yellow green pull the control panel When completely pulled out the panel can ro Connection of a room thermostat tate 45 downwards to facilitate the operations The room thermostat must be connected to the on the internal parts terminal block situated next to the control panel Any external controls and connection lines must be rated at 230 V but under no circum stances should external live voltage be con nected to the room thermostat link on the boiler Do not connect live wires to terminals to which the
18. boiler operation is erminal block controlled by switching the mains supply O In this case when the boiler is switched off some Q important features like the antifreeze system the l E monitoring ofthe boiler by the operation lights the Fig 6 22 post circulation of the pump etc are completely deactivated Connecting a system boiler For these reasons it is advisable to use the first dia to a cylinder gram Fig 6 23 Two schematic wiring diagrams are given in this section showing two possible ways to connect an Wi E External controls__ e_ O terminal block 2 wm N z 2 E 3 E E 4 27 Installation Cylinder Room thermostat thermostat y BU 2 A 5 c 8 GRYE 3 7 WH 5 2 GY 7 4 6 OR 8 External control terminal block 1 L O 04 1 3 z 2 Q 3 lt 9 IO OQ NO 4 QO Ed MAINS L N Lr 230V a c Power supply dp Switched 3 Amp fused z Spur Mid position BL diverter valve GRYE O WH GY Room thermostat OR Cyli
19. comes on this indicates that the safety lock out 5 Fig 3 2 has stopped the boiler To re start the boiler it is necessary to press the boiler reset button 6 Fig 3 2 5 Fig 3 2 For the first lighting up and following maintenance procedures for the gas supply it may be necess ary to repeat the resetting operation several times so as to remove the air present in the pipework Useful advice After five consecutive resetting attempts the reset button is inhibited To restore its function 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 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 r
20. mercury or C F C s The appliance 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 thi
21. 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 a trap 22 on page 9 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 length 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 17 z g E 3 E E Z z a E 3 E E 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
22. 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 cordance 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 Reg
23. 6 7 8 9 10 l External control terminal block HTG Heating HW ON Hot Water ON HW OFF Hot Water OFF Valve colour key HTG KS S BU Blue oa GRYE Green Yellow HW ON 0 A O WH White HW OFF GY Grey LG N OR Orange Programmer Power supply BK Black BN Brown Fig 6 24 Not permanent live Y plan 29 COMMISSIONING WARNING Initial filling of the system The commissioning of this boiler and system must only be undertaken by a professionally 1 Open the c h flow and return valves qualified person in accordance with the re 2 Remove the front panel of the case see the quirements of the Gas Safety Installation and section 9 2 in this manual Use Regulations and be approved by 3 Liftthe cap on the automatic air purger valve 23 C O R G l Fig 7 2 one full turn and leave open perma Ensure that the Benchmark Log Book is satis nently factorily completed during the commissioning 4 Gradually open stopcock at the filling point process The Log Book is located at the end of connection to the c h system until water is this manual This manual should be handed to heard to flow do not open fully the User following completion of the installa tion and commissioning process Failure to comply with these requirements may invali date the manufacturers guarantee For Ireland IE it is necessary to complete a Declaration of Conformity to indicate com pliance to 1 S 813 2002 z 2 E 3 E E E
24. 600 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 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
25. PERATING PRESSURE IF APPLICABLE N A mbar COLD WATER INLET TEMPERATURE 19 HOT WATER OUTLET TEMPERATURE 50 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 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 CCORGIID 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 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME
26. TU h Maximum kW BTU h Minimum kW BTU h Maximum condensing kW BTU h Minimum condensing kW BTU h Central heating 25 0 85 295 11 0 37 530 24 3 82 908 10 5 35 825 26 0 88 708 11 2 38 213 Gas supply pressures Natural G20 Pa 2 000 mbar 20 Pa 2 500 mbar 25 Min Pa 1 700 mbar 17 Gas Norm Max Butane Propane G30 G31 2 900 3 700 29 37 3 500 4 500 35 45 2 000 2 500 20 25 1 mbar approximately equals 10 mm H2O Gas pressures at the burner Natural G20 Max Pa 1130 mbar 11 3 Min Pa 250 mbar 2 5 Ignition Pa 850 mbar 8 5 Gas Butane Propane G30 G31 2810 3610 28 1 36 1 580 780 5 8 7 8 2110 2700 21 1 27 0 Maximum flow temp i 1 mbar approximately equals 10 mm H20 Minimum flow temp Minimum return temp Minimum pressure Natural G20 m3 h 2 65 Butane Propane G30 G31 kg h kg h 1 97 1 94 C 85 C 40 C 40 Maximum pressure kPa 250 bar 2 5 kPa 30 bar 0 3 kPa 25 Available head in 1000 l h bar 0 25 Seasonal efficiency band G20 B 1 16 0 87 0 85 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 C Values subject to tolerance 12 Techni
27. aise 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 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 6 and call an Authorised Service Centre Engineer If the left appliance operation light 9 Fig 3 3 flashes very quickly the boiler is detecting a fault D m 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 5 on page 5 and call a competent and responsible service engineer LN TECHNICAL INFORMATION 4 1 Overview 10 Condensate drain pipe 14 15 16 17 19 11 C h return valve 12 Gas inlet valve 13 C h flow valve 14 Fan 15 Air pressure sensor test points 16 Air pressure sensor 17 Flue temperature probe NTC 18 Condensing heat exchanger 19 Safety thermosta
28. al control device Fig 6 20 an External frost protection 10 Connect the frost thermostat between ter minals 1 and 2 as shown in Fig 6 21 or Fig 6 22 Do not connect live wires to terminals to which the room thermostat must be con nected Room thermostat 230V rating Frost Thermostat 230V rating olr 9 2 1 Power supply erminal block OLOLLO External controls__e_ O _ O terminal block A O O Fig 6 21 Installation external programmer to a mid position diverter Room valve to provide independent timed and thermo Frost thermostat E thermostat with anticipating static control of heating and hot water a 230V rating Fig 6 23 and Fig 6 24 are divided in two parts The upper shows the single components used on the diagrams with their connection to the 10 way junction box The bold numbers represent the ter minal of the junction box where the component must be connected to The lower part shows how to realize a system that provides independent timed and thermostatic control of heating and hot water In Fig 6 23 the boiler is permanently connected to the main supply The boiler operation is controlled by the external control terminal block In Fig 6 24 the boiler is not permanently con Power supply nected to the supply line The
29. ance with the technical data sections 4 5 or 4 6 then adjust mentwill be necessary A full explanation of the gas pressure adjustment procedure is given in the Gas Valve section of the service manual If 32 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 29 Fig 7 4 and connect the gauge 3 Turn the boiler ON positioning the control se lectors 7 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 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
30. 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 12 3 Ignition 1 Check that the valves located in the lower part of the boiler are open Fig 2 3 LA P y P Q 3 DB s a 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 9 Fig 2 4 will flash every 4 seconds stand by condition 3 To operate the boiler position the function se lector 7 as in Fig 2 4 The appliance operation light 9 will flash every 2 seconds operating boiler 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 5 by turning the function se lector 7 Adjustment of c h output on the boiler is auto matic The greatest output pre set in the factory
31. are parts Thus do no more than switching off the boiler yourself see the in structions 1 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
32. at the 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 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 notto be used for frost protection then follow the instructions given in section 2 5 on page 5 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 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
33. cal information Internal fuse rating A 1 2 3 15 AF Flue design Type C12 C32 C42 C52 C82 Flue pipe diameter 60 100 Twin split pipes mm 80 Roof mm 80 125 Nominal heat flow rate kW 25 0 A D Exhaust temperature D C 71 Mass flow rate D g s 16 0 Coaxial Flue gas figures Nominal heat input D kW 25 0 CO content 96 6 96 9 C 5 Water volume in the boiler kg 4 0 up to 1 bar D Values refer to tests with a 1 m chimney working at the nominal heat input INSTALLATION Technical information 4 6 Technical data mod Gas supply pressures M96A 28SR Gas Natural Butane Propane G20 G30 G31 i A Heat input Norm Pa 2000 2900 3700 Nominal kW 29 0 mbar 20 29 37 BTU h 98 942 Max Pa 2500 3500 4500 Minimum kW 13 0 mbar 25 35 45 BTU h 44 353 Min Pa 1700 2000 2500 mbar 17 20 25 1 mbar approximately equals 10 mm H2O Maximum kW 28 4 BTU h 90 89 Gas pressures at the burner Minimum kw 12 5 Gas Natural Butane Propane BTU h 42 648 G20 G30 G31 i i kW 4 Maximum condensing 30 Max Pa 1130 2810 3600 BTU h 103 721 f mbar 11 3 28 1 36 0 Minimum condensing kW 13 3 Min Pa 240 580 780 BTU h 45 378 mbar 2 4 5 8 7 8 Ignition Pa 850 2110 2700 Central heating mbar 8 5 21 1 27 0 Maximum flow temp 1 mbar approximately equals 10 mm H20 Minimum flow temp INSTALLATION C 85 C 40 Minimum return temp C 40 Maximum pressure kPa 250 Natural Butane Propane bar 2 5 G20
34. d technical data see section 4 5 or 4 6 of this manual Appliance description 14 5 Operation lights Three lights 9 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 LJ 00 mW A short pulse every 4 seconds i stand by condition XE Qux Function selector in C position Anti freeze system active 1 second pulse every 2 seconds normally operating boiler Function selector in position 5 O 5 C h operation 5 5 O Frost protect operation Faulty c h temperature O Ce dE probe NTC Faulty flue temperature e le probe NTC Faulty primary circuit no water or low c h pressure Faulty primary circuit absence of flow Dn vty raS 00 oo vty vty Faulty air pressure sensor Lack of burner ignition no ignition signal from the full segence ignition device vty ry vty ry vty ES vty Safety thermostat lock out Flue temperature probe NTC lock out vty ETS Flame detection error vty Other faults olo X olo Lack of power supply or fauly electr control p c b O Meaning of symbols Q Lamp OFF Lamp On yx Flashing lamp alone or simultaneo
35. ective 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 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 Installation Iu Overall dimensions B C pem 980 E A 4 A B and C Boiler front Electric connection area AE 257 C h return 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 Joints Pipe sues od Gas c h return c h flow 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 b
36. er to provide d h w V f you 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 2 Instructions for use 11 2 23 Warmings er nS 1 2 Control panel 2 22 Refilling procedure 1 3 Isolation valves 2 219 Ignition eei er eres 1 4 Technical data 2 2 4 C h circuit temperature 1 5 Operation lights 3 2 5 Extinguishing 6 Installation 6 1 6 2 Precautions for installation 6 3 Installing the bracket 4 Overall dimensions 65 JOINS DE ieS 6 6 Mounting the boiler 6 7 Fitting the flue system 6 8 Choice of flue 6 9 Electrical connections 3 Useful advice 3 1 Central heating 3 2 Frost protection 3 3 Condensate drain 3 4 Periodic maintenance 3 5 External cleaning 3 6 Operational faults
37. flue installation and termination that the flue gasket as shown in Fig 6 5 page 22 is in place that the burner and injectors 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 5 Fig 1 3 on page 2 must appear To reset the boiler press and release the boiler reset button 6 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 terminalis sited correctly in ac cordance with the flue fitting instructions and Fig 5 1 on page 17 of this manual To carry out a combustion check refer to the in structions given in the section 9 4 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 a
38. gnition 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 supply to the boiler switching on the fused spur isolation switch The appliance operation light 9 will flash every 4 seconds 2 Turn the function selector 7 as in Fig 7 3 The appliance operation light 9 will flash every 2 seconds UA A a he 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 5 will ap pear To reset the boiler press and release the boiler re set button 6 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 29 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 c h temperature control knob to its maximum position If external contr
39. itted to the boiler Fig 6 5 XJ 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 length 1m This kit is 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 elbow Minimum length required is 0 3 m Maxi mum equivalent length of 2 7 metres can be achieved utilising extensions This flue system can 22 only be used to discharge horizontally itis not de signed 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 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 Min 0 3 m Max 2 7m Fig 6 6 Twin pipe kits o 80 mm Fig 6 7 Fig 6 8
40. nd integrity of the conden sate drain pipe Verify the cleanness and correct filling of the con densate traps Instructing the 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 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 33 z S E 3 E E MAINTENANCE 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
41. nder thermostat remove room L thermostat link 10 way junction box N 2 1 MAINS a a 230V a c DIO Switched 3 Amp fused NA INA spur bu bk bn tot External control terminal block HTG Heating l l LI HW ON Hot Water ON HW OFF Hot Water OFF Valve colour key BU Blue MTO SS Green Yellow o WH White GY Grey An 2 e O OR Orange L N 2 Black Programmer Power supply Fig 6 23 Permanent live Y plan 28 Installation Cylinder Room thermostat thermostat y BU 2 BS 5 c 8 GRYE 3 7 WH 5 2 7 4 6 OR 8 8 Lo 0 gt 0 1 3 ps i 3 DESIO Z aa Ng 2 0 aj E MAINS LG N q 230V a c Power sup Switched 3 Amp fused ey a Spur E ALI i a aan M E Y Mid position za diverter valve Room thermostat Cylinder thermostat Do not remove room thermostat link 10 way junction box N 4 5 6 7 8 9 10 XL KS KL 9 9 9 19 MAINS a lal 1 lal alla o a c Switched 3 Amp fused o 0 0 0 ae spur 4 5
42. nob 8 on aposi type of gas and the gas pressures to which the a tion corresponding to the gas used as shown appliance has been set with the label included lt in Fig 8 5 with the conversion kit The label is placed on By turning the knob 8 the lock out signal the botton of the appliance lamp 5 blinks quickly 2 per seconds indicat 20 Replace the adjustment protection cap ing that the setting has changed and must be memorised 14 To memorize the setting keep pressed the reset button 6 for about 5 seconds until the lamps 9 briefly blinks simultaneously 21 Replace the front panels of the case 35 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 Air Flue exhaust pling points d Sam MAINTENANCE
43. nual If the pressure is lower take steps to correct the pressure level Cleaning the burner The sloping and multi gas type burner 33 on page 9 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 9 8 Checking the flue Have the integrity of the flue outlet pipe 40 on page 10 air intake pipe 41 on page 10 checked periodically the air pressure sensor 16 on page 9 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 9 9 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 EXT 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 EXI Gas pressures and tightness Check appliance for gas tightness Recheck oper ational pressures and adjust as necessary as de scribed in section 7 6 page 31 of this manual 37 MAINTENANCE BENCHMARK No
44. oiler 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 y 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 d B gre o A SU i E o9 a A Fig 6 3 6 Connectthe pipe E Fig 6 4 from the pressure relief valve to the safety discharge pipework 7 Fit the condensate drain 10 Fig 6 4 in the air brake connected to the drainage pipework See also section 5 7 in this manual 21 z g E 3 E x z 2 E 3 E E z Installation 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 f
45. ols are fitted e g Timeclock room thermostat en sure they call for heat 4 Switch on the boiler 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 31 z g E 3 E E 4 2 z a E 3 E 4 z Commissioning 6 Check the 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 7 Switch off the boiler 8 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 refer to section Ignition gas pressure ad justment of the Service Manual for the necess ary adjustment procedures 14 Switch off the boiler and disconnect the pres sure 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 measured above are notin accord
46. r to release the auto air purge 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 boil
47. r 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 sealed expansion vessel to accommodate the increase of water vol ume when the system is heated Refer to Tab 4 1 on page 11 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 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 immediately after filling Control valve Double check valve Temporary connection Supply pipe cold water inlet aa Control valve C h return pipe j Fig 5 4 The installer should ensure that no leaks e
48. rd parties Appliance category 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 Remembe
49. rer 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 Fig 6 1 20 250 200 Fig 6 1 all dimensions in mm When installing 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 prot
50. room thermostat must be connected When connecting any type of external control Fig 6 15 the link J in Fig 6 17 must be removed 5 Loosen the screws and remove the service panel Fig 6 16 25 Installation To fused spur L N isolation switch Power supply terminal block SIL 5 5 its 2 1 1 ri Y Ext trol LALO sama os o aa Fig 6 17 Fig 6 19 z 2 E 3 E E O o ee Fig 6 18 Fig 6 19 26 8 Connect the room thermostat between ter minals 1 and 3 as shown in Fig 6 18 or Room thermostat 230V rating Q r Ort Q Qz Power supply terminal block gt External controls terminal block Room thermostat with delay resistor 230V rating L N Power supply 3l 2 4 OOO terminal block Y SOLO 2 External controls 2 0 E terminal block 9 Route the electrical supply flexible cord and the external control flexible cord as illustrated in Fig 6 20 Lock the flexible cords in place with the flexible cord clamps 6 mia EEN To the fused spur isolation switch To the extern
51. st be in line with LZ e BS7593 Treatment of Water in d h w c h Sys tems 12 Open position Fig 7 1 30 Commissioning When the installation and second filling are completed turn on the c h system 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 It is however recommended that any other trap in the drain system is correctly filled with water before to run the boiler Lighting the boiler Some products incorporate an anti cycling time delay It is normal when first switching the boiler on for the boiler to operate on heating for a few sec onds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The i
52. t 20 C h temperature probe NTC 21 Main circuit drain valve 22 Condensate trap 23 Automatic air purger valve 24 Pump vent plug 25 Pump 26 C h pressure relief valve 27 Modulation gas valve 28 Modulation operator 29 Gas valve outlet pressure test point 30 Gas valve inlet pressure test point 31 Primary circuit pressure switch 32 Flame detecting electrode 33 Burner 34 Ignition electrodes 35 Combustion chamber 36 Primary heat exchanger 37 C h expansion tank 38 By pass valve 39 Fan pressure connection 40 Flue outlet pipe 41 Air intake pipe Z o E 3 E 2 z 27 26 25 24 23 21 22 Fig 4 1 Technical information 4 2 Main diagram 17 NU 40 MAA T NM es um 2 14 16 g E 36 J Z 19 c SS s 23 25 j Vete 27 208 28 31 30 26 10 i E 21 3 A X 12 11 18 Fig 4 2 Technical information EEN Hydraulic specifications 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 The hydraulic specifications in Fig 4 3 represent
53. the requirements of the Gas Safety In stallation and Use Regulations and be ap proved by C O R G I Components used to adaptitto the type of gas available must be genuine parts only LEN Procedures 1 Check that the gas cock 12 in Fig 8 1 fitted under the boiler is turned off and the appliance is switched off at the mains isolating spur 5 FP A LA J Pa d ee Sg 12 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 33 on page 9 See section Ignition and detection electrodes in the service manual for 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 of the combustion chamber 7 Switch on the appliance at the mains isolating spur Closed position 34 8 Turn the boiler OFF positioning the function se lector 7 as indicated in Fig 8 2 Fig 8 2 9 Disconnect the electrical connectors of the C h temperature probe NTC 20 in Fig 8 3 10 Keep pressed the reset button 6 for about 10 seconds until the lock out signal lamp 5 blinks 11 Connectthe the elctrical connectors of the C h temperature probe NTC 20 in Fig 8 3
54. tion of the flue pipe through the roof The kit is 1 2 m in length Exten sion pieces Co axial are also available which al lows 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 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 12 Co axial 60 100mm vertical part 60mm flue outlet 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 24 Type C52 90 0 85 m AS 9 60 mm d Fig 6 12 The chart of Fig 6 13 gives the allowable dimen wm sions of the ducts a and b of Fig 6 12 Da a vertical length m 04 06 08 10 12 14 16 18 b horizontal length m Fig 6 13 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 annn Installation FEN Electrical connections Connection to the electricity supply 1
55. ttempt 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 cleaned 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 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 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
56. ug 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 a bathroom this must then be sited outside the bathroom 19 z g E 3 E E z o E 3 E E 4 all 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 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 manufactu
57. ulations applicable in Scotland with respect to the installation of the combined appliance in a room containing a bath or shower 16 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 situated 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
58. usly with an other lamp x Flashing lamp alternate with another 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 described in section 2 5 on page 5 and call a competent and re sponsible Service Engineer EN INSTRUCTIONS FOR USE EXB Warnings Our Company supports the Benchmark in itiative The Benchmark Log Book is lo cated at the 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 itis essential that all the tests are carried out by a competent and responsible service engineer before lighting up the boiler The tests are described in the installation in structions in section 7 commissioning Ensure that the c h circuit is regularly filled with water even if the boiler is only used for d h w supply checking th
59. xist either inside the boiler or on the system as fre quent filling of the system could cause premature scaling of the heat exchanger EN 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 3 of this manual 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 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 pl

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