riva compact he mk2 - biasi compact... · riva compact he mk2 are condensing high efficiency sealed...

Wall hung, fan flue, room sealed, high efficiency gas boiler

User manual andInstallation instructions

RIVA COMPACT HE MK2Models

M96A.24SR/C System boilerM96A.28SR/C System boiler

Congratulations on your choice.RIVA COMPACT HE MK2 are condensing high efficiency sealed chamber fan flue gasboilers.They are fully electronically controlled and have electronic ignition.Thematerials they aremadeof and thecontrol systemsthey areequippedwithgive yousafety,a high level of comfort and energy savings to allow you to get the greatest benefit out ofindependent heating.RIVACOMPACTHEMK2allowahigher efficiency by reducing the fluegas temperature suchthat the water vapour formed during the combustion is condensed out.This allows a gain of useful heat that otherwise would be lost.

Remember that...n The manual--- must be read thoroughly, so that you willbe 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.n First lighting up must be carried out bycompetent and responsible engineer.

n The manufacturer--- disclaim all liability for any translations ofthe present manual from which incorrect in-terpretation may occur--- cannot be held responsible for non---ob-servance of instructions contained in thismanual or for the consequences of any pro-cedure not specifically described.

Using the boiler...n Before lighting the boiler you are ad-vised to have a professionally qualified per-son check that the installation of the gassupply--- is gas--- tight;--- is of the correct gauge for the flow to theboiler;--- is fitted with all the safety and control de-vices required by the current Regulations.n Ensure that--- the installer has connected the pressurerelief valve outlet to a drain pipe. The manu-facturers are not responsible for damage

caused by opening of the pressure reliefvalve and consequent escape of water, if notconnected correctly to the drain.--- the installer has connected the conden-sate outlet to a suitable drain pipe.n On detecting the smell of gas--- don’t operate any electrical switches, thetelephone or any device that may producesparks;--- open the windows and doors at once tocreate a draught of air which will purge thearea;--- shut off the gas cocks;--- get the assistance of a qualified person.n Donot touch the appliancewith parts ofthe body that are wet or damp and/or barefeet.

n Do not block or modify the condensateoutlet and pipework

n In case of structural work or mainten-ance near the exhaust duct and/or fume ex-haust devices or their attachments, turn offthe appliance. On completion of the work,have a professionally qualified person checktheir efficiency.

n Repairs (under guarantee) must be car-ried out only by an approved engineer, usinggenuine spare parts. Thus do no more thanswitching off the boiler yourself (see the in-structions).

n Your boiler allows heating up of water toa 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 forwhich it has been specially designed;--- must not be touched by children or bythose unfamiliar with its operation;--- must not be exposed to weather condi-tions.

n During the operation it is quite normalthat the boiler produces a white plume ofcondensation vapour from the flue terminal.This is due to the high efficiency of the ap-pliance and may be particularly evident withlow outdoor temperatures.

Safe handling ofappliance

When handling or lifting always use safe tech-niques--- keep your backstraight, bend your knees, don’ttwist--- move your feet, avoid bending forwards andsideways and keep the load as close to your bodyas possible.Where possible transport the boiler using a sacktruck or other suitable trolley.Always grip the boiler firmly, and before lifting feelwhere the weight is concentrated to establish thecentre of gravity, repositioning yourself asnecess-ary.

Safe handling ofsubstances

These products are manufactured in accordancewith ISO 9000 and do not, and will not, contain any

hazardous materials or substances such as as-bestos, mercury or C.F.C.’s.The appliance packaging does not contain anysubstances,whichmaybe considered a hazard tohealth.

Combustion chamber panelsMaterial: mineral fibresKnown hazards --- Some people can suffer red-dening and itching of the skin. Fibre entry into theeye will cause foreign body irritation, which cancause severe irritation to people wearing contactlenses. Irritation to respiratory tract.Precautions --- Dust goggles will protect eyes.People with a history of skin complaints may beparticularly susceptible to irritation. High dust le-vels are only likely to arise following harsh ab-rasion. In general, normal handling and use willnot present high risk, follow good hygiene prac-tices,washhandsbefore, 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 theskin.

Thermostat / Temperature gaugeDescription --- Sealed phial and capillary contain-ing liquid.Known hazards --- irritating to skin, eyes andthroat. Vapour is harmful. Inflammable --- do notextinguish with water.Precautions --- Do not incinerate. Avoid contactwith broken/leaking phials. Do not purposelypuncture.First aid medical attention must be sought follow-ing eyes/skin contact, wash with clean water.

Appliance category II2H3+ Gas G20 20 mbar, G30 29 mbar, G31 37 mbarCountry of destination: United Kingdom (GB) Ireland (IE)

This appliance conforms with the following EEC directive:D Gas appliance Directive 90/396/CEED Boiler Efficiency Directive 92/42/CEED Electromagnetic Compatibility Directive 89/336/CEED Low voltage Directive 73/23/CEE

Themanufacturer, in the continuous process to improve his products, reserves the right to modify thedata 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-wards third parties.

Boiler installation and commissioning tipsn The installation must be carried out bya qualified personwhowill be responsible forobserving the current Regulations.

Installing the boiler...n Do not forget to remove the transit capsand plugs from the boiler connections theseare fitted to every boiler.

n Keep the boiler clear of dust during in-stallation and in particular do not allow anydust or debris to enter the top of the boilerwhere the flue connection is made. It is rec-ommended that youput adust sheet over thetop of the boiler until you are ready to makethe flue connection.

n Because every boiler is fired and testedlive at the factory, a small amount of water re-mains within the boiler. It is possible for thiswater to initially cause the pump to seize. It istherefore recommended that the pump rotorbe manually turned to free its rotation beforeturning the boiler on.

n Remember to release the auto air purgebefore filling theboiler. See the instructions toidentify the location of this device.

n Do not remove the cap of the pressuretest points of the air switch (top left side of theboiler).

n You are strongly advised to flush out thesystem both cold and hot in order to removesystem and installation debris.

n It is also sensible to initially fire and com-mission the boiler before connecting any ex-ternal controls suchas a room thermostat. Bythis method if you have a subsequent prob-lem following the addition of an external con-trol you can eliminate the boiler from yourfault analysis.

n Do not forget to range rate the boiler tosuit the system requirements. This pro-cedure is covered in the commissioning sec-tion of the installation manual.

n If the boiler is fitted with a digital pro-grammer, when setting the times for auto-matic operation, remember that for every“ON” time theremustbean “OFF” time to fol-low and that on every occasion you enter atime you must also indicate which days thatyou want the boiler to follow the timed set-tings.

n Some products incorporate an anti cycl-ing time delay. It is normal when first switch-ing the boiler on for the boiler to operate onheating for a few seconds then switch off.After 3--- 4minutes has elapsed the boiler willthen re ignite and operate perfectly normally.The ignition delay cycle does not preventnormal operation of the boiler to provided.h.w.

n If you are in any doubts as to the installa-tion or operation of the boiler please read theinstruction manuals thoroughly and then ifnecessary contact Biasi UK for advice andassistance.

Please remember that if you are in any doubt about the installation of this product you can contact ourTechnical Helpline on tel. 0121 506 1350

TABLE OF CONTENTS

1

1 Appliance description 2. . . . . . . . . .1.1 Overview 2. . . . . . . . . . . . . . . . . . . . . .1.2 Control panel 2. . . . . . . . . . . . . . . . . .1.3 Isolation valves 2. . . . . . . . . . . . . . . . .1.4 Technical data 2. . . . . . . . . . . . . . . . .1.5 Operation lights 3. . . . . . . . . . . . . . . .

2 Instructions for use 4. . . . . . . . . . . .2.1 Warnings 4. . . . . . . . . . . . . . . . . . . . . .2.2 Refilling procedure 4. . . . . . . . . . . . . .2.3 Ignition 5. . . . . . . . . . . . . . . . . . . . . . . .2.4 C.h. circuit temperature 5. . . . . . . . . .2.5 Extinguishing 5. . . . . . . . . . . . . . . . . .

3 Useful advice 7. . . . . . . . . . . . . . . . .3.1 Central heating 7. . . . . . . . . . . . . . . . .3.2 Frost protection 7. . . . . . . . . . . . . . . .3.3 Condensate drain 7. . . . . . . . . . . . . .3.4 Periodic maintenance 7. . . . . . . . . . .3.5 External cleaning 7. . . . . . . . . . . . . . .3.6 Operational faults 7. . . . . . . . . . . . . . .

4 Technical information 9. . . . . . . . . .4.1 Overview 9. . . . . . . . . . . . . . . . . . . . . .4.2 Main diagram 10. . . . . . . . . . . . . . . . . .4.3 Hydraulic specifications 11. . . . . . . . .4.4 Expansion vessel 11. . . . . . . . . . . . . . .4.5 Technical data mod. M96A.24SR/... 124.6 Technical data mod. M96A.28SR/... 14

5 General requirements 16. . . . . . . . . .5.1 Related documents 16. . . . . . . . . . . . .5.2 Location of appliance 16. . . . . . . . . . .5.3 Flue system 16. . . . . . . . . . . . . . . . . . . .5.4 Gas supply 17. . . . . . . . . . . . . . . . . . . .5.5 Air supply 17. . . . . . . . . . . . . . . . . . . . .5.6 Ventilation 17. . . . . . . . . . . . . . . . . . . . .5.7 Condensate drain 17. . . . . . . . . . . . . .5.8 Water circulation (c.h.) 18. . . . . . . . . . .5.9 Water treatment 19. . . . . . . . . . . . . . . .5.10 Electrical supply 19. . . . . . . . . . . . . . . .

6 Installation 20. . . . . . . . . . . . . . . . . . . .6.1 Warnings 20. . . . . . . . . . . . . . . . . . . . . .6.2 Precautions for installation 20. . . . . . .6.3 Installing the bracket 20. . . . . . . . . . . .6.4 Overall dimensions 21. . . . . . . . . . . . .6.5 Joints 21. . . . . . . . . . . . . . . . . . . . . . . . .6.6 Mounting the boiler 21. . . . . . . . . . . . .6.7 Fitting the flue system 22. . . . . . . . . . .6.8 Choice of flue 22. . . . . . . . . . . . . . . . . .6.9 Electrical connections 25. . . . . . . . . . .6.10 External frost protection 26. . . . . . . . .6.11 Connecting a system boiler

to a cylinder 27. . . . . . . . . . . . . . . . . . .

7 Commissioning 30. . . . . . . . . . . . . . .7.1 Electrical installation 30. . . . . . . . . . . .7.2 Gas supply installation 30. . . . . . . . . .7.3 Initial filling of the system 30. . . . . . . .7.4 Condensate pipe and traps 31. . . . . .7.5 Lighting the boiler 31. . . . . . . . . . . . . .7.6 Checking the gas pressure

at the burner 31. . . . . . . . . . . . . . . . . . .7.7 Checking the burner ignition 32. . . . .7.8 Checking the ignition device 33. . . . .7.9 Checking the flue system 33. . . . . . . .7.10 Checking the condensate drain pipe 337.11 Instructing the user 33. . . . . . . . . . . . .

8 Gas conversion 34. . . . . . . . . . . . . . .8.1 Warnings 34. . . . . . . . . . . . . . . . . . . . . .8.2 Procedures 34. . . . . . . . . . . . . . . . . . . .

9 Maintenance 36. . . . . . . . . . . . . . . . . .9.1 Warnings 36. . . . . . . . . . . . . . . . . . . . . .9.2 Dismantling the external panels 36. . .9.3 Emptying the c.h. system 36. . . . . . . .9.4 Combustion analysis check 37. . . . . .

9.5 Cleaning the primary heat exchanger 379.6 Checking the pressurisation

in the expansion vessel 37. . . . . . . . . .9.7 Cleaning the burner 37. . . . . . . . . . . . .9.8 Checking the flue 37. . . . . . . . . . . . . . .9.9 Drain pipe inspection 37. . . . . . . . . . . .9.10 Visual inspection of appliance 37. . . .9.11 Gas pressures and tightness 37. . . . .

Abbreviations used in the manual:C.h. = Central heating

D.h.w. = Domestic hot waterD.c.w. = Domestic cold water

USE

INSTALLATION

MAINTENANCE

1 APPLIANCE DESCRIPTION

2

1.1 Overview

2

1

3Fig. 1.1

1 Case front panel2 Control panel3 Control panel cover

1.2 Control panel4 C.h. circuit temperature and pressure gauge5 Lock---out signal lamp6 Lockout reset button7 Function selector and c.h. temp. control knob8 Service knob9 Appliance operation lightsThe service knob 8 is useless for the normal oper-ation of the boiler.

It must be used only by a qualified person duringcommissioning and servicing.

1.3 Isolation valves

12

11

13

10

Fig. 1.2 (bottom view of the boiler)

10 Condensate drain pipe11 C.h. return valve12 Gas inlet valve13 C.h. flow valve

1.4 Technical dataFor detailed technical data see section 4.5 or 4.6of this manual.

78 6 5 49

Fig. 1.3

USE

Appliance description

3

1.5 Operation lightsThree lights (9 in Fig. 1.3) give detailed indicationregarding the operation of the boiler.The following table gives the relationship betweeneach of the possible light combinations and theirmeaning.

A short pulse every 4seconds:stand---by conditionFunction selector inposition.Anti--- freeze system active1 second pulse every 2seconds: normallyoperating boiler. Functionselector in position

C.h. operation

Frost protect operation

Faulty c.h. temperatureprobe NTCFaulty flue temperatureprobe NTCFaulty primary circuit(no water or low c.h.pressure)Faulty primary circuit(absence of flow)

Faulty air pressure sensor

Lack of burner ignition (noignition signal from the fullseqence ignition device)

Safety thermostat lock out

Flue temperature probeNTC lock out

Flame detection error

Other faults

Lack of power supply orfauly electr. control p.c.b.

Meaning of symbols

Lamp OFF

Lamp ON

Flashing lamp, alone or simultaneouslywith an other lamp.

Flashing lamp, alternate with anotherlamp.

If the lights combination observed is not includedin 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 insection 2.5 on page5 andcall a competent and re-sponsible Service Engineer.

USE

2 INSTRUCTIONS FOR USE

4

2.1 WarningsOur Company supports the Benchmark in-itiative. The Benchmark Log Book is lo-cated at the back of this manual and shouldbe completed by the Installing/Commiss-sioning Engineer and handed over to theUser for future reference by other visitingEngineers. Also included is the Service In-terval Record card that should be com-pleted by the Service Engineer followingthe annual service maintenance of theboiler and system.

All CORGI Registered Installers carry aCORGI ID card, and have a registrationnumber. Both should be recorded in yourBenchmark Log Book. You can check yourinstaller is registered by calling CORGI di-rect on 01256 372300.In order to guarantee safety and correct oper-ation, it is essential that all the tests are carriedout by a competent and responsible serviceengineer 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 filledwith water (even if the boiler is only used ford.h.w. supply) checking that the pressure indi-cated on the temperature and pressure gauge4 is not lower than that shown in Fig. 2.2.If the pressure reading on the pressure gaugeisbelow that shown in Fig. 2.2, then thesystemwill require toppingup.A filling loop isnormallyprovided 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 whenthe temperature is below 5 ˚CTherefore, when the boiler is not lit or used incold weather, with consequent risk of freezingdonot switch off the boiler at the fused spurisolation switch or close the gas inlet cock.When you do not expect to use the boiler for along period and the boiler is not to be used forfrost protection then follow the instructionsgiven in section 2.5 on page 5.

2.2 Refilling procedure1 Isolate the boiler from the electrical supply atthe fused spur. Reconnect the filling loop asdemonstrated in Fig. 2.1.

Temporaryconnection

Control valve

Control valve

Double check valve

Supply pipe(cold water inlet)

C.h. return pipe

Fig. 2.1

2 Open the valves of the filling loop and watchthe gauge until it reaches normal filling pres-sure as shown in Fig. 2.2.

4

Normal fillingpressure

Fig. 2.2

3 Close the valves and remove the filling loop.

If you experience any difficulty with the oper-ation of the boiler, switch off the boiler immedi-ately at the fused spur isolation switch andcontact your Installer or an approved ServiceEngineerAir introduced into the boiler during this filling pro-cess will vent through the automatic air purgerfitted to the boiler. You may also find it necessaryto vent air from your radiator circuit using yourradiator key, however be aware that excessiveventing will cause the pressure in the system todrop.Alwaysensure that thepressuregauge isset at therequired pressure.

USE

Instructions for use

5

2.3 Ignition1 Check that the valves located in the lower partof the boiler are open (Fig. 2.3).

Open positionFig. 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) willflash 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 every2 seconds (operating boiler).

79

Fig. 2.4

2.4 C.h. circuit temperatureThe output temperature of c.h. water is adjustablefrom a minimum of about 40°C to a maximum ofabout 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 factorycan, however, be reduced in level according toactual system requirements; this does not affectthe maximum output in d.h.w. operation.Such adjustments must be carried out by a quali-fied person; therefore we advise you to contactyour installer or Service Agent.

Adjustment of the boiler temperature alters thegas flow at the burner according to the thermalde-mand in the system. So it isusual to see theburnerlit at the minimum level for more or less longperiods.

Minimum

Maximum

Fig. 2.5

AdjustmentIn order to achieve optimal settings for economyand comfort, we recommend adjusting the oper-ating temperature of the c.h. water according tothe outside temperature, positioning the knob asfollows:

Lower than---5 ˚C

From 5 to 15 ˚CBetween---5 and +5 ˚C

Fig. 2.6

Your qualified installer will be able to recommendthe most suitable adjustment for your system.The temperature and pressure gauge (4, Fig. 1.3on page 2) will allow you to check that the set tem-perature is obtained.

2.5 ExtinguishingTo turn the boiler off set the function selector 7 tothe position shown in Fig. 2.7.

USE

Instructions for use

6

The appliance operation light 9 will flash every 4seconds.

79

Fig. 2.7

Whenyoudonot expect to use the boiler for a longperiod:1 Switch off the electricity supply to the boiler, bymeans of the fused spur isolation switch;

2 Shut off the gas supply cock 12 and the valvesfor the water circuits fitted under the boiler(Fig. 2.8).

3 Empty the water circuits, if necessary, asshown in sectionGeneral access andemptyinghydraulic circuits in the service manual.

Closed position12Fig. 2.8

USE

3 USEFUL ADVICE

7

3.1 Central heatingFor reasonably economical service install a roomthermostat.Never shut off the radiator in the area where theroom thermostat is installed.If a radiator (or a convector) does not heat up,check that no air is present in it and that its valveis open.If the ambient temperature is too high, do not alterthe radiator valves. Reduce the central heatingtemperature instead by means of the room ther-mostat and the function selector (7 in Fig. 3.1).

7

Fig. 3.1

3.2 Frost protectionThis appliance is provided with a built in anti---freeze system that operates the boiler when thetemperature is below 5 ˚CTherefore, when the boiler is not lit and used incold weather, with consequent risk of freezing donot switch off the boiler at the fused spur isola-tion switch or close the gas inlet cock.

3.3 Condensate drainThe condensate drain must not be modified orblocked.Blockage of the condensate drain, caused by de-bris or freezing, can cause automatic shutdown ofthe boiler.If freezing is suspected and the pipe run isaccess-ible an attempt may be made to free the obstruc-tion by pouring hot water over the exposed pipean cleaning any blockage from the end of thepipe. If this fails to remedy the problem the assist-ance of a CORGI registered installer or in IE acom-petent person should be sought.

3.4 Periodic maintenanceFor efficient and continuous operation of theboiler, 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 followingchecks 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 thecentral heating system;--- general check of the appliance’s operation.

3.5 External cleaningBefore carrying out any cleaning, disconnect theappliance from the electrical mains, using thefused spur isolation switch fitted adjacent to theappliance.To clean the external panels, use a cloth soaked insoapy water. Do not use solvents, abrasive powd-ers or sponges.Do not carry out cleaning of the appliance and/orits parts with readily flammable substances (forexample petrol, alcohols, naphtha, etc.).

3.6 Operational faults

If the lock---out signal lamp comes onthis indicates that the safety lock---out 5 (Fig. 3.2)has stopped the boilerTo re---start the boiler, it is necessary to press theboiler reset button 6 (Fig. 3.2).

6

5

Fig. 3.2

For the first lighting up and followingmaintenanceprocedures for the gas supply, it may be necess-ary to repeat the resetting operation several timesso as to remove the air present in the pipework.

USE

Useful advice

8

After five consecutive resetting attempts the resetbutton is inhibited. To restore its function it isnecessary to switch the boiler off and on from theelectrical mains, using the fused spur isolationswitch fitted adjacent to the appliance.Safety lock---out may occour even in case of anblockage of the condensate drainage (e.g.plugged drain pipe).It is advisable to check the condensate drainagepipe and traps for cleaness.In case of persistent lock---out call a competentand responsible service engineer.

If noises due to air bubbles are heard duringoperation...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...it is necessary to top up the appliance with wateragain, so as to raise the pressure to an adequatelevel as described in thesection 2.2of thismanual.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 valveCheck on the temperature and pressure gauge (4on 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 reliefvalve to open.So that this does not happen and to decrease thepressure to a normal value, it is advisable to ventsome of the water in the appliance through thebleed valves present in the radiators.

If water should occasionally leak from theboiler...shut off the valves positioned under the boiler(Fig. 2.8onpage6) and call an AuthorisedServiceCentre Engineer.

If the left appliance operation light 9 (Fig. 3.3)flashes very quickly the boiler is detecting afault.

9

Fig. 3.3

In this case or in case of problems other thanthose mentioned here, switch off the boiler, asdescribed in section 2.5 on page 5 and call acompetent and responsible service engineer.

USE

4 TECHNICAL INFORMATION

9

4.1 Overview

21

36

35

34

33

31

32

23

1814

25

1615

2427

17 19

20

2226Fig. 4.1

10 Condensate drain pipe11 C.h. return valve12 Gas inlet valve13 C.h. flow valve14 Fan15 Air pressure sensor test points16 Air pressure sensor17 Flue temperature probe NTC18 Condensing heat exchanger19 Safety thermostat20 C.h. temperature probe NTC21 Main circuit drain valve22 Condensate trap23 Automatic air purger valve24 Pump vent plug25 Pump26 C.h. pressure relief valve27 Modulation gas valve28 Modulation operator29 Gas valve outlet pressure test point30 Gas valve inlet pressure test point31 Primary circuit pressure switch32 Flame---detecting electrode33 Burner34 Ignition electrodes35 Combustion chamber36 Primary heat exchanger37 C.h. expansion tank38 By---pass valve39 Fan pressure connection40 Flue outlet pipe41 Air intake pipe

INSTALLATION

Technical information

10

4.2 Main diagram

3916

41

40

31

36

34

29

25

26

27

30

23

38

11 1312

37

14

32

2028

19

33

21

18

22

10

17

Fig. 4.2

INSTALLATION


11

4.3 Hydraulic specifications

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0 200 400 600 800 1000 1200 1400

0

10

20

30

40

kPa bar

l/h

60

50

Fig. 4.3

The hydraulic specifications in Fig. 4.3 representthe 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 beensubtracted.

Output with thermostat cocks shut offThe boiler is fitted with an automatic by---passvalve (38 on page 9), which protects the primaryheat exchanger.In case of excessive reduction or total blockage ofwater circulation in the central heating systemowing to closure of the thermostatic valves or sys-tem component cocks, the by---pass valve ensur-

es a minimum flow of water through the primaryheat exchanger.

4.4 Expansion vessel

Note: this boiler is designed for operation onlyin a sealed central heating systemThe height difference between the pressure reliefvalve and the highest point in the system may be10m at most.For greater differences, increase the pre--- loadpressure in the expansion vessel (37 on page 9)and the system, when cold, by 0.1 bar for eachadditional 1m.

Capacity l 6,0

Pre--- load pressure kPabar

1001,0

Maximum volume of waterin the system *

l 94

Tab. 4.1

* Where conditions are:--- Average maximum temperature of the systemis 85°C

--- Initial temperature when filling up the system is10°C

For systems with volumes greater than 94 l, anadditional expansion vessel must be provided.

INSTALLATION


12

4.5 Technical datamod. M96A.24SR/...

Heat input (A)

Nominal kWBTU/h

25,085 295

Minimum kWBTU/h

11,037 530

Useful output

Maximum kWBTU/h

24,382 908

Minimum kWBTU/h

10,535 825

Maximum condensing kWBTU/h

26,088 708

Minimum condensing kWBTU/h

11,238 213

Central heatingMaximum flow temp. ˚C 85

Minimum flow temp. ˚C 40

Minimum return temp. ˚C 40

Maximum pressure kPabar

2502,5

Minimum pressure kPabar

300,3

Available head(in 1000 l/h)

kPabar

250,25

Seasonal efficiencyG20 (B)

band%

B87,6

Seasonal efficiencyG30 G31 (B)

band%

B88,5

Gas supply pressures

Gas NaturalG20

ButaneG30

PropaneG31

Norm. Pambar

2 00020

2 90029

3 70037

Max Pambar

2 50025

3 50035

4 50045

Min. Pambar

1 70017

2 00020

2 50025

1 mbar approximately equals 10 mm H2O

Gas pressures at the burnerGas Natural

G20ButaneG30

PropaneG31

Max. Pambar

113011,3

281028,1

361036,1

Min. Pambar

2502,5

5805,8

7807,8

Ignition Pambar

8508,5

211021,1

270027,0


Gas rate

Gas NaturalG20m3/h

ButaneG30kg/h

PropaneG31kg/h

Max. 2,65 1,97 1,94

Min. 1,16 0,87 0,85

(A) referred to the net calorific value at 15 ˚C and 1013,25 mbarG 20 = 34,02 MJ/m3, 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 ratingof dwellings. The test data from which it has been calculated have been certified by a notified body.(C) Values subject to tolerance

INSTALLATION


13

Injectors mm/100ø

Natural G20 130

Butane G30 77

Propane G31 77

Electrical Data

Voltage V~ 230

Frequency Hz 50

Power consumption W 140

Protection degree IPX4D

External fuse rating A 3

Internal fuse rating A F1---F2 3,15 AF

Flue designType C12 C32 C42 C52 C82

Flue pipe diameter

Coaxial mm 60/100

Twin split pipes mm 80

Roof mm 80/125

Nominal heat flow rate(A)(D)

kW 25,0

Exhaust temperature (D) ˚C 71

Mass flow rate (D) g/s 16,0

Flue gas figures

Nominal heat input (A)(D) kW 25,0

CO2 content % 6,5

O2 content % 9,3

CO content ppm 75


NOx class 2

Weighted NOx ppm 99

Other specificationsHeight mm 803

Width mm 400

Depth mm 350

Weight (dry) kg 41,0

Water volume in the boiler(up to 1 bar)

l (kg) 4,0

(D) Values refer to tests with a 1 m chimney working at the nominal heat input

INSTALLATION


14

4.6 Technical data mod.M96A.28SR/...

Heat input (A)

Nominal kWBTU/h

29,098 942

Minimum kWBTU/h

13,044 353

Useful output

Maximum kWBTU/h

28,496 897

Minimum kWBTU/h

12,542 648

Maximum condensing kWBTU/h

30,4103 721

Minimum condensing kWBTU/h

13,345 378

Central heatingMaximum flow temp. ˚C 85

Minimum flow temp. ˚C 40

Minimum return temp. ˚C 40

Maximum pressure kPabar

2502,5

Minimum pressure kPabar

300,3

Available head(in 1000 l/h)

kPabar

250,25

Seasonal efficiencyG20 (B)

band%

B88,5

Seasonal efficiencyG30 G31 (B)

band%

B89,5

Gas supply pressures

Gas NaturalG20

ButaneG30

PropaneG31

Norm. Pambar

2 00020

2 90029

3 70037

Max Pambar

2 50025

3 50035

4 50045

Min. Pambar

1 70017

2 00020

2 50025


Gas pressures at the burnerGas Natural

G20ButaneG30

PropaneG31

Max. Pambar

113011,3

281028,1

360036,0

Min. Pambar

2402,4

5805,8

7807,8

Ignition Pambar

8508,5

211021,1

270027,0


Gas rate

Gas NaturalG20m3/h

ButaneG30kg/h

PropaneG31kg/h

Max. 3,07 2,29 2,25

Min. 1,38 1,03 1,01

(A) referred to the net calorific value at 15 ˚C and 1013,25 mbarG 20 = 34,02 MJ/m3, 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 ratingof dwellings. The test data from which it has been calculated have been certified by a notified body.(C) Values subject to tolerance

INSTALLATION


15

Injectors mm/100ø

Natural G20 130

Butane G30 77

Propane G31 77

Electrical Data

Voltage V~ 230

Frequency Hz 50

Power consumption W 150

Protection degree IPX4D

External fuse rating A 3

Internal fuse rating A F1---F2 3,15 AF

Flue designType C12 C32 C42 C52 C82

Flue pipe diameter

Coaxial mm 60/100

Twin split pipes mm 80

Roof mm 80/125

Nominal heat flow rate(A)(D)

kW 29,0


Mass flow rate (D) g/s 17,8

Flue gas figures

Nominal heat input (A)(D) kW 29,0

CO2 content % 6,8

O2 content % 8,8

CO content ppm 52


NOx class 2

Weighted NOx ppm 92

Other specificationsHeight mm 803

Width mm 400

Depth mm 350

Weight (dry) kg 42,5

Water volume in the boiler(up to 1 bar)

l (kg) 4,1

(D) Values refer to tests with a 1 m chimney working at the nominal heat input

INSTALLATION

5 GENERAL REQUIREMENTS

rev 17 09 9316

Our Company supports the Benchmark initiat-ive. The Benchmark Log Book is located at theback of this manual and should be completedby the Installing/Commisssioning Engineerand handed over to the User for future refer-ence by other visiting Engineers. Also in-cluded is the Service Interval Record card thatshould be completed by the Service Engineerfollowing the annual service maintenance ofthe boiler and system.

For Ireland (IE), it is necessary to complete a“Declaration of Conformity” to indicate com-pliance to I.S.813.2002.

This appliance must be installed by a compet-ent person in accordance with the Gas Safety(installation & Use) Regulations.

5.1 Related documentsThe installation of this appliance must be in ac-cordance with the relevant requirements of thecurrent Gas Safety (Installation & Use) Regula-tions, the Local Building Regulations, the currentI.E.E. Wiring Regulations, the Regulations andby--- laws of the local water undertaking, and inScotland, in accordance with the Building Stan-dards (Scotland) Regulation. Health and safetydocument n˚ 635 ”Electricity at work regs.”.It should also be in accordance with the BritishStandard Codes of Practice:In Ireland (IE). The installation must be carried outby a Competent Person and installed in accord-ance with the current edition of I.S.813.2002 “Do-mestic Gas Installations” the current BuildingRegulations and reference should be made to thecurrent ETCI rules for electrical installations.

5.2 Location of applianceThe appliance may be installed in any room or in-ternal space, although particular attention isdrawn to the requirementsof thecurrent I.E.E.Wir-ing Regulations, and in Scotland, the electricalprovisions of the Building Regulations applicablein Scotland, with respect to the installation of thecombined appliance in a room containing a bathor shower.

For Ireland (IE), reference should be made to thecurrent edition of I.S.813.2002 and the currentETCI rules for electrical installations.

Where a room---sealed appliance is installed ina roomcontainingabath or shower, anyelectri-cal switch or appliance control, utilisingmainselectricity should be so situated that it cannotbe touched by a person using the bath orshower.The location must permit the provision of an ad-equate flue and termination.For unusual locations special procedures may benecessary and BS 6798 gives detailed guidanceon this aspect.A compartment used to enclose the appliancemust be designed specifically for this purpose.This appliance is not suitable for external installa-tion.

5.3 Flue systemTheprovision for satisfactory flue terminationmustbe made as described in BS 5440 part 1.For Ireland (IE), refer to I.S.813.2002.Theappliancemustbe installed so that the 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 positionof the terminal allows a free passage of air acrossat all times.The terminal should be located with due regard forthe damage or discoloration that might occur tobuilding products in the vicinity.In cold and/or humid weather water vapour maycondense on leaving the flue terminal; the effectofsuch ”steaming” must be considered.Pluming may easily occur at the terminal. Wherepossible, terminal position which could cause anuisance should be avoided.

INSTALLATION

General requirements

rev 17 09 9317

The minimum acceptable spacing from the ter-minal to obstructions and ventilation openings arespecified in Fig. 5.1.

A

BC

E

F

G

I

JK L

MN

H

I

O

P

QD

Fig. 5.1Terminal position mm

A Directly below a 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. . . . . . . . . . . . . . . . . . . .I 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.

than or equal to 30˚ 350. . . . . . . . . . . . . . . . . . . . . .Above the roof pitch with roof slopemore 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 ex-tended beyond the perimeter of the balcony** Consideration should be given to adding protectionagainst condensate to the adjacent structure

5.4 Gas supplyTheGasmeter is connected to the service pipe bythe local gas region or a local gas region contrac-tor.If the gas supply for the boiler serves otherappliances ensure that an adequate supply isavailable both to the boiler and the otherappliance when they are in use at the same time.

Pipework must be of adequate size. Pipes of asmaller size than the boiler inlet connection shouldnot be used.Installation pipes should be fitted in accordancewith BS 6891 and the complete installation shouldbe tested for tightness.For Ireland (IE), refer to I.S.813.2002.

5.5 Air supplyThe room in which the boiler is installed does notrequire a purpose provided air vent.

5.6 VentilationIf installed in a cupboard or compartment, it is notnecessary to provide additional ventilation forcooling for this particular product. However con-sideration must be given to clearance require-ments for maintenance (see section 6.2) andunder nocircumstancesmust stored articles beal-lowed to come into contact with the boiler or fluepipe.

5.7 Condensate drainEnsure that the condensate discharge complieswith the national or local regulations in force.The condensate pipemust be fitted in accordancewith Building Regulations.Drainpipe material should be resistant to acid asthe condensate is slightly acid with a pH less than6.5.The boiler includes a trap (22 on page 9) that pre-vents the combustion products entering the drain.The boilers incorporate a condensate trap a75mm seal ti comply with BS6798.2000.Two schematic diagrams of possible connectionsare given in Fig. 5.2 and Fig. 5.3.The length of the condensate pipe should be keptat minimum.To avoid condensate being trapped:--- thedrainpipeshould be runwith a fall of at least2.5˚ (45 mm/m) away from the boiler;

--- the number of bends and joints should be keptat minimum;

--- the drainpipe should be adequately fixed topevent pipe sagging.

INSTALLATION


rev 17 09 9318

If a part of the drainpipe runs externally this partshould be kept as short as possible and protectedto reduce the risk of freezing.

Connection of condensate drainage pipe to in-ternal soil and vent stack.

A

B

D

C

Dimensions in mm

450

Condensatedrain

Fig. 5.2

A BoilerB Internal soil and vent stackC InvertD 450 mm up to three storeys

Connection of condensate drainage pipedownstream of a sink waste trap

A

E

F

Dimensions in mm

Condensatedrain

Fig. 5.3

A BoilerE SinkF Open end of condensate drainage pipe directinto gully below grating but above water level

5.8 Water circulation (c.h.)Detailed recommendations are given in BS 6798and BS 5449; the following notes are given forgeneral guidance.For Ireland (IE), refer to I.S.813.2002.

PipeworkThe return temperature must not be lower of40 ˚C.Copper tubing to BSEN 1057 is recommended forwater pipes. Jointing should be either with capil-lary soldered or with compression fittings.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand water flows naturally to drain taps.The appliance has a built--- in automatic air releasevalve, it should be ensured as far as possible thatthe appliance heat exchanger is not a natural col-lecting point for air.Except where providing useful heat, pipes shouldbe insulated to prevent heat loss and to avoidfreezing.Particular attention should be paid to pipes pas-sing through ventilated spaces in roofs and underfloors.

By---passThe appliance includes an automatic by---passvalve which protects the main heat exchanger incase of reduced or interrupted water circulationthrough the heating system due to the closing ofthermostatic valvesor cock--- typevalveswithin thesystem.The by---pass is calibrated to assure a minimumflow of 200---300 lts/hr through the main heat ex-changer.If you are installing a system that includes thermo-static radiator valves (TRV) and/or small bore(8---10 mm) it may be necessary to fit an externalby---pass to facilitate correct operation of theboiler.The fitting of an external bypass helps to preventand limit system noise.

Air release pointsThesemust be fitted at all high pointswhere airwillnatural collect and must be sited to facilitate com-plete filling of the system.

INSTALLATION


rev 17 09 9319

Expansion vesselThe appliance has an integral sealed expansionvessel 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 watercontent, calculate the total expansion and add anadditional sealed expansion vessel with adequatecapacity.

Mains water feed: central heatingThere must be no direct connection to the mainswater supply even through a non return valve,without the approval of the Local Water Authority.

FillingA method for initially filling the system and replac-ing water lost during servicing must be providedand itmust comply with local water authority regu-lations.The correct method is shown in Fig. 5.4.

The temporary connection must be removedimmediately after filling.

Temporaryconnection

Control valve

Control valve

Double check valve

Supply pipe(cold water inlet)

C.h. return pipe

Fig. 5.4

The installer should ensure that no leaks existeither inside the boiler or on the system as fre-quent filling of the system could cause prematurescaling of the heat exchanger.

5.9 Water treatment

Central heating circuitWhere a new boiler is fitted to a new system witheither plastic or copper pipes, it is important thesystem is fully flushed, on completion, to ensureflux 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 systemis fully removed in order to ensure the efficiency ofthe new appliance is maintained.Details on flushing procedure are given in the sec-tion 7.3 of this manual.

5.10 Electrical supply

Warning, this appliance must be earthed.External wiring to the appliance must be carriedout by a competent person and be in accordancewith the current I.E.E. Regulations and any localregulations which apply.Reference should be made to the current ETCIrules for electrical installations.For Ireland (IE), refer to I.S.813.2002.The boiler is supplied for connection to a 230 V~50 Hz supply. The supply must be fused at 3A.Themethod of connection to the electricity supplymust facilitate complete electrical isolation of theappliance by the use of a fused spur isolationswitch. Its installation permits a complete switch-ing off in the conditions of the overvoltage cat-egory III. Alternatively it can be used a 3A fusedthree pin plug and unswitched shuttered socketoutlet both complying with BS 1363.The point of connection to the electricity supplymust be readily accessible and adjacent to theappliance except were the appliance is installed ina bathroom this must then be sited outside thebathroom.

INSTALLATION

6 INSTALLATION

20

6.1 WarningsThe use of gas appliances is subject tostatutory control; it is essential to observethe current regulations and laws in force(see also chapter 5).The appliance must discharge combustionproducts directly outside or into a suitable ex-haust duct designed for this purpose.Combustion products must be dischargedusing original flue kits only, since they are inte-gral parts of the boiler.For LPG, the appliancemustalso conformwiththe requirements of the distributors and com-ply with current Regulations and laws in force.The safety relief valve and the condensatedrainmust be connected to a suitable drain, ordischarge in a safe manner.The electrical wiringmust conformwith currentRegulations, in particular:--- the boiler must be earthed using the cor-rect bonding clamp.

--- Adjacent to the boiler a fused spur isolationswitch must be installed which permits acomplete switching off in the conditions ofthe overvoltage category III. Refer to sec-tion 6.9 in thischapter for the electrical con-nections.

In no circumstances will the manufacturerbe held responsible if the warnings and in-structions contained in this manual havenot been complied with.

6.2 Precautions for installationFor the installation proceed as follows:--- The boiler must be fixed to a strong wall.--- The dimensions for the exhaust fume duct de-tailed in section6.7 and the correctproceduresfor installing the duct, depicted in the instruc-tion leaflet included with the flue kit, must becomplied with during installation.

--- To allow maintenance procedures it is necess-ary to leave the minimum gaps indicated inFig. 6.1.

25 50

250

200

Fig. 6.1 (all dimensions in mm)

--- When installing the boiler in a cupboard, coveror alcove allow at least 50mmpermanent clear-ance from the front face of the boiler. Also en-sure sufficient clearance to allow free accessfor 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 andadd some special anti--- freeze (neutralised) tothe c.h. system.

--- Before installing the boiler on an existing c.h.system, flush it out thoroughly before fitting theboiler, so as to remove muddy deposits.

--- It is advisable to equip the system with a sedi-ment filter, or use awater--- treatment product inthe circulating water.The latter option in particular, not only cleansout the system, but also has an anti---corrosiveeffect by promoting formation of a protectiveskin on metal surfaces and neutralising gasespresent in the water.We recommend the use of a suitable universalinhibitory to protect the c.h. system from cor-rosion.

6.3 Installing the bracketPrecautionsBefore mounting the bracket, check that the di-mensions for fitting the exhaust fume duct arecomplied with (refer to the leaflet included with theflue kit, packed separately).Utilise the paper template supplied with the boilerto determine the fixing position for the bracket andboiler. Securely mount the bracket to the wallusing appropriate fixings suitable for the type ofwall construction and capable of supporting thetotal (wet) load. Refer to the weight given in thetechnical data tables specific for each model.

INSTALLATION

Installation

21

6.4 Overall dimensions

ø80 ø80

ø100

400

20047245

196

803

700

35

115 142

16

31

6060

100 257

200129117

50

73

350

198A, B and C

Boilerfront

B

A

C

GasC.h.

C.h.

return

flow

Electricconnectionarea

A --- air intake/flue outlet pipe (co---axial)B --- flue outlet pipe ø 80 mm (twin kit)C --- air intake pipe ø 80 mm (twin kit)

Condensate drainconnectionarea

Fig. 6.2 (all dimensions in mm)

6.5 Joints

Functions Pipe sizes (o.d)Gas, c.h. return, c.h. flow ø 22Pressure relief valve ø 15Condensate drain ø 25 (plastic)

Tab. 6.1 (sizes in mm o.d.)

6.6 Mounting the boiler1 Take the protective caps off the boiler pipe-work.

2 Thoroughly clean the connections.3 Mount the boiler on its bracket.4 Fix the c.h. valves A and gas cock B (¾”) to theboiler using the ¾” gaskets (Fig. 6.3)

5 Fix the ø 22mmpipes C (c.h. circuit) to the c.h.valves A and the ø 22 mm pipe D (gas) to thecock B using the ¾” gaskets.

C

A

A

B

D

C

Fig. 6.3

6 Connect the pipeE (Fig. 6.4) from thepressurerelief valve to the safety discharge pipework.

7 Fit the condensate drain 10 (Fig. 6.4) in the airbrake connected to the drainage pipework.See also section 5.7 in this manual.

10EFig. 6.4

INSTALLATION

Installation

22

6.7 Fitting the flue systemRefer 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 thatthe horizontal sections of the flue pipe must havean horizontal sloping not less than 1.5 deg. (25mm per metre) towards the boiler.In the standard horizontal flue kit (Fig. 6.6A) theflue pipe is angled within the air duct therefore theair duct must be horizontally installed.If one or more extensions have to be used theymust be adequately supported so that there is nosag in the flue pipe and a minimum fall of 1,5 deg.(25 mm per metre) over the whole length towardsthe boiler is ensured.Before fitting the flue system, ensure that the fluegasket shown in Fig. 6.5 (given with the boiler) isfitted to the boiler.

Fig. 6.5

6.8 Choice of flueThe following flue kits are available for connectingto the boiler:

Standard horizontal flue kit (Fig. 6.6A)Co---axial 60/100mm --- nominal length 1mThiskit isnormally suppliedwith theboiler and canbe fitted to allow discharge to the rear or eitherside of the boiler via the flanged boiler adapterelbow. Minimum length required is 0.3 m. Maxi-mum equivalent length of 2,7 metres can beachieved utilising extensions. This flue systemcan

only be used to discharge horizontally, it is not de-signed to enable termination in the vertical plane.

Vertical kit with 90˚ elbow (Fig. 6.6B)Co---axial 60/100 mmSupplied with a straight flanged adapter a co---axial elbow and a co---axial pipe with terminal, thiskit 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 lengthmust not exceed 2,7 metres.

Elbows 45˚ & 90˚ (Fig. 6.6C)Co---axial 60/100mm.Elbow kits enable the standard flue kits to beoffsetto overcome obstructions or ensure the correctclearances for the flue terminal. Each elbow usedin addition to the standard flanged elbow reducesthe overall acceptable length of the flue systemasfollows:45˚ reduce length by 0,5 m.90˚ reduce length by 1 m.

ø 60/100

ø 60/100

90˚=---1 m

45˚=---0,5 m

A

B

C

Min = 0,3 mMax = 2,7 m

Type C12

Fig. 6.6

Twin pipe kits ø 80 mm (Fig. 6.7 --- Fig. 6.8 ---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 ina location remote to an outside wall.These kits allow for separation of the air supplypipe from the pipe that discharges the exhaustgasses. Consequently it is possible to extend theflue system to a greater distance than that pro-vided by the standard horizontal co---axial flue.

INSTALLATION

Installation

23

Type C12

Fig. 6.7

If either an additional 45˚ or 90˚ accessory elbowis used then the maximum permissible length ofeither pipe must be reduced by 0.90 m or 1,65 mrespectively.N.B: The air intake and the flue outlet must notterminate on opposite sides of the building.

Type C52

90˚=---1,65 m

45˚=---0,90 m

Type C42

Fig. 6.8

Type C82

Fig. 6.9

Two restrictors with different size are suppliedwith the twin pipe kit and have to be installedbetween 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 twinpipes refer to Tab. 6.2.

Equivalent length(air duct + flue duct)

Restrictor

Between 1 and 15 m ø 50 mm

More than 15 m up to 30 m ø 55 mm

Tab. 6.2

INSTALLATION

Installation

24

Vertical--- roof kit (Fig. 6.11)

90˚=---1 m

45˚=---0,5 m

max =8,5 m

ø 125

Type C32

Fig. 6.11

This kit allows vertical termination of the flue pipethrough 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 totaloverall maximum permissible length.Optional 45˚ and90˚ elbowscan beused tooffsetthe 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 ø60/100mm+verticalpart ø 60mm(flueoutlet)This kit allows the comburent air to be sucked upand expel the burnt gasses directly to the outsidethrough a telescopic co---axial flue (450---950mm).In the last section, the fumes are expelled througha vertical section.Extensions and elbows can be added to extendthe kit’s length.

90˚=---1 m

45˚=---0,5 m

90˚=---0,85 m

45˚=---0,65 m

ø 60 mm

ø 60/100 mm

Type C52

Fig. 6.12

The chart of Fig. 6.13 gives the allowable dimen-sions of the ducts “a” and “b” of Fig. 6.12

”a” vertical length (m)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8

”b” horizontal length (m)

Allowed values

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.

INSTALLATION

Installation

25

6.9 Electrical connections

Connection to the electricity supply1 Remove the front panel of the case (see thesection 9.2 in this manual).

2 Remove the screws F and G (Fig. 6.14).

FG

GH

Fig. 6.14

3 Loosen the screws H.4 Remove the side panels ormove the lower partof the side panels as indicated in Fig. 6.15 andpull the control panel.When completely pulled out, the panel can ro-tate 45˚ downwards to facilitate the operationson the internal parts.

Fig. 6.15

5 Loosen the screws I and remove the servicepanel (Fig. 6.16).

I

Fig. 6.16

For the electrical connection to the boiler use elec-tricwireswhich conform to the current regulations,with flexible cord, each core having a cross sec-tion area not less than 0,75 mm2.6 Connect the electrical supply flexible cordcoming from the fused spur isolation switch tothe power supply terminal block of the boiler(Fig. 6.17) keeping the same connections forthe live (brown wire) and the neutral (bluewire). External 3 A fuseor fusedplug with samecurrent rating is recommended.Do not connect live wires to terminals towhich the room thermostat must be con-nected.

7 Connect the earth wire (yellow/green).

Connection of a room thermostatThe room thermostat must be connected to theterminal block situated next to the control panel.

Any external controls and connection linesmust be rated at 230 V but under no circum-stances should external live voltage be con-nected to the room thermostat link on theboiler.

Do not connect live wires to terminals to whichthe room thermostat must be connected.

When connecting any type of external control,the link J in Fig. 6.17 must be removed.

INSTALLATION

Installation

26

12

L N

3

To fused spurisolation switch

Power supplyterminal block

External controlsterminal block

J

Fig. 6.17

8 Connect the room thermostat between ter-minals 1 and 3 as shown in Fig. 6.18 orFig. 6.19.



T Room thermostat

12

L N

3

(230V rating)

Fig. 6.18



T Room thermostat

12

L N

3

with delay resistor(230V rating)

Fig. 6.19

9 Route the electrical supply flexible cord andthe external control flexible cord as illustratedin Fig. 6.20.Lock the flexible cords in placewith the flexiblecord clamps

To the fused spurTo the externalcontrol device

isolation switch

Fig. 6.20

6.10 External frost protection10 Connect the frost thermostat between ter-minals 1 and 2 as shown in Fig. 6.21 orFig. 6.22Do not connect live wires to terminals towhich the room thermostat must be con-nected.



T Room thermostat

12

L N

3

(230V rating)TFrost Thermostat

(230V rating)

Fig. 6.21

INSTALLATION

Installation

27



T

Room

12

L N

3

thermostatT

Frostthermostat with anticipating(230V rating) resistor

(230V rating)

Fig. 6.22

6.11 Connecting a system boilerto a cylinder

Two schematic wiring diagrams are given in thissection showing two possible ways to connect an

external programmer to a mid---position divertervalve to provide independent timed and thermo-static control of heating and hot water.Fig. 6.23 and Fig. 6.24 are divided in two parts.The upper shows the single components used onthe diagrams with their connection to the 10 wayjunction box. The bold numbers represent the ter-minal of the junction box where the componentmust be connected to.The lower part shows how to realize a system thatprovides independent timed and thermostaticcontrol of heating and hot water.In Fig. 6.23 the boiler is permanently connected tothemain supply. The boiler operation is controlledby the external control terminal block.In Fig. 6.24 the boiler is not permanently con-nected to the supply line. The boiler operation iscontrolled by switching the mains supply.In this case, when the boiler is switched off someimportant features like the antifreeze system, themonitoring of the boiler by theoperation lights, thepost circulation of the pump, etc. are completelydeactivated.For these reasons it is advisable to use the first dia-gram (Fig. 6.23).

INSTALLATION

Installation

28

GYWH

OR

GRYE

321 4 5 6 7 1098

321 4 5 6 7 1098

BL

C12

Cylinderthermostat

Room thermostat

A B

MAINS230V a.c.Switched 3 Amp fused,spur

L

N

Programmer

HTG

HW OFFHW ON

L N

Power supplyL N

123

remove roomthermostat link

External controlterminal block

Room thermostatA B

5

4

Cylinderthermostat

C1

2

876

GYWH

OR

GRYEBU 2

3

8

57


L

N 2

3

1

Programmer

HTG

HW OFFHW ON

L N 2

1

4

67

Power supplyL N

231

123


8

10 wayjunction box

Valve colour key

WH --- WhiteGRYE --- Green/Yellow

GY --- GreyOR --- Orange

BU --- Blue

Mid---positiondiverter valve

HTG = HeatingHW ON = Hot Water ONHW OFF = Hot Water OFF

bnbkbu

bnbkbu

BK --- BlackBN --- BrownFig. 6.23 --- Permanent live Y---plan

INSTALLATION

Installation

29

GYWH

OR

GRYE

321 4 5 6 7 1098

321 4 5 6 7 1098

BU

C12

Cylinderthermostat

Room thermostat

A B


L

N

Programmer

HTG

HW OFFHW ON

L N

Power supplyL N

123

Do notremove roomthermostat link

Room thermostatA B

4

5

Cylinderthermostat

C1

2

876

GYWH

OR

GRYEBU 2

3

8

57


L

N 2

3

1

Programmer

HTG

HW OFFHW ON

L N 2

1

4

67

Power supplyL N

238


10 wayjunction box

Mid---positiondiverter valve

HTG = HeatingHW ON = Hot Water ONHW OFF = Hot Water OFF

bnbkbu

Valve colour key

WH --- WhiteGRYE --- Green/Yellow

GY --- GreyOR --- Orange

BU --- Blue

BK --- BlackBN --- BrownFig. 6.24 --- Not permanent live Y---plan

INSTALLATION

7 COMMISSIONING

30

WARNINGThe commissioning of this boiler and systemmust only be undertaken by a professionallyqualified person in accordance with the re-quirements of the Gas Safety Installation andUse Regulations and be approved byC.O.R.G.I.

Ensure that the Benchmark Log Book is satis-factorily completed during the commissioningprocess. The Log Book is located at the end ofthis manual. This manual should be handed tothe User following completion of the installa-tion and commissioning process. Failure tocomply 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 I.S.813.2002.

7.1 Electrical installationPreliminary electrical system checks to ensureelectrical 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-ing procedure should be followed as specified in theservice manual.

7.2 Gas supply installation1 Inspect the entire installation including the gasmeter, test for tightness and purge, all as de-scribed in BS 6891;For Ireland (IE), refer to I.S.813.2002.

2 Open the gas cock 12 (Fig. 7.1) on theappliance and check the gas connector on theappliance for leaks.

Open position12

Fig. 7.1

7.3 Initial filling of the system1 Open the c.h. flow and return valves.2 Remove the front panel of the case (see thesection 9.2 in this manual.

3 Lift the capon theautomatic air purger valve23(Fig. 7.2) one full turn and leave open perma-nently.

4 Gradually open stopcock at the filling pointconnection to the c.h. system until water isheard to flow; do not open fully.

23

24

Fig. 7.2

5 Open each radiator air vent starting at thelowest point of the system and close it onlywhen clear water, free of bubbles, flows out.

6 Purge theair from the pumpby unscrewing thepump plug 24 (Fig. 7.2); release the pumpshaft by turning in the direction indicated bythe arrow on the information plate.

7 Replace the pump plug.8 Continue filling the system. The actual readingshould ideally be 1,3 bar and not less than 0,3bar.

9 Close all air release valves on the c.h. system.10 Inspect the boiler and the system for watersoundness and remedy any leaks discovered.

11 Cold flush the system to remove any loose par-ticlesandany systemdebrisbefore starting theboiler for the first time

The flushing procedure must be in line withBS7593 Treatment of Water in d.h.w. c.h. Sys-tems.

INSTALLATION

Commissioning

31

When the installation and second filling arecompleted turn on the c.h. system and run ituntil the temperature has reached the boileroperating temperature. The system must thenbe immediately flushed through.

This procedure must be repeated twice more.

During this operation we highly recommendthe use of a c.h. flushing detergent in the quan-tities as specified by the appropriate manufac-turer, whose function it is to dissolve anyforeign matter which may be in the system.

The above operation could save the invalida-tion of your boilers guarantee andwill alsopre-vent problems which you may experience inthe future if an inhibitory is not used.

7.4 Condensate pipe and trapsThe full length of the condensate pipe should becheck for leaks.The boiler has a built--- in condensate trap pro-vided with a ball valve that prevents the escape ofcombustion products when the trap is empty.

It is however recommended that any other trapin the drain system is correctly filled withwaterbefore to run the boiler.

7.5 Lighting the boilerSome products incorporate an anti cycling timedelay. It isnormalwhen first switching the boiler onfor the boiler to operate on heating for a few sec-onds then switch off. After 3---4 minutes haselapsed the boiler will then re ignite and operateperfectly normally. The ignition delay cycle doesnot prevent normal operation of the boiler to pro-vide d.h.w..If external controls are fitted (e. g. Timeclock, roomthermostat) 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 every4 seconds.

2 Turn the function selector 7 as in Fig. 7.3. Theappliance operation light 9 will flash every 2seconds.

79 6 5

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 failsto light, the full sequence control p.c.b. will go tolockout and the lock---out signal lamp 5 will ap-pear.To reset the boiler press and release the boiler re-set button 6.

7.6 Checking the gas pressure atthe burner

This boiler has been tested to the highest qual-ity control standards.

Themaximumandminimumgas pressuresarealready set during this quality control processhowever the checking procedure must be fol-lowed to ensuremaximumoperatingefficiencyfrom the boiler.1 Remove the front panel of the case (see sec-tion 9.2 in this manual) and the sealedchamber lid.

2 Loosen the internal screw 29 (Fig. 7.4) on theOutlet Pressure Test Point of theGas Valve andconnect a pressure gauge using a suitablehose.

3 Set the c.h. temperature control knob to itsmaximum position. If external controls arefitted (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 gaugewith the value indi-cated in the sections 4.5 or 4.6 (gas pressuresat the burner), accordingly with the model ofboiler installed.

INSTALLATION

Commissioning

32

6 Check the maximum gas flow at the gasmeterand compare the value indicated in the sec-tions 4.5 or 4.6 (gas rate), accordingly with themodel of boiler installed.

7 Switch off the boiler.8 Disconnect the gas modulator coil by remov-ing the electrical connector A (Fig. 7.4).

29 A

Fig. 7.4

9 Switch on the boiler.10 Check the minimum gas pressure and com-pare the value on the gaugewith the value indi-cated in the sections 4.5 or 4.6 (gas pressuresat the burner), accordingly with the model ofboiler 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 “Ignitiongas pressuread-justment” of theServiceManual for thenecess-ary adjustment procedures.

14 Switch off the boiler and disconnect the pres-sure gauge.

15 Reassemble the sealed chamber lid and thefront panel of the case (see section 9.2 in thismanual).

If the maximum and minimum gas pressuresmeasuredabovearenot in accordancewith thetechnical data (sections 4.5 or 4.6) then adjust-mentwill be necessary.A full explanation of thegas pressure adjustment procedure is given inthe Gas Valve section of the service manual. If

maximum and/or minimum gas pressures areadjusted then the ignition gas pressure mustbe checked and adjusted if necessary.

Important: after the gas pressure checks andanyadjustmentoperations,all of the testpointsand adjustment devices must be sealed. Re-place the adjustment protection cap.

7.7 Checking the burner ignition1 Turn the boiler OFF2 Open the gas valve outlet pressure test point29 (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 inFig. 7.5 and ensure that the timer selectorswitch and room thermostat, if fitted, are set to“heat demand”.

79 6 5

Fig. 7.5

4 Watch the gauge and check to see if the igni-tion pressure registered corresponds to the va-lues as given in the Technical Data. Turn off theboiler and reignite it by turning the function se-lector 8 to the OFF position and then back tothat indicated in Fig. 7.5

5 Repeat this process two to three times leaving30 second intervals between each ignition.Check the ignition pressures and visuallycheck that the burner lights uniformly and in acontrolled manner.

6 If the burner ignition is not uniformly controlledthen checks should be made to:

--- the flue installation and termination.--- that the flue gasket as shown in Fig. 6.5 page22 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)

INSTALLATION

Commissioning

33

7 If the ignition pressure recorded is not as indi-cated in the TechnicalData 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 andanyadjustmentoperations,all of the testpointsmust be sealed and replace the adjustmentprotection cap.

7.8 Checking the ignition deviceWith the burner on high flame close the gas cock.After three ignition attempts (within about threeminutes), the lock---out signal lamp 5 (Fig. 1.3 onpage 2) must appear.To reset the boiler press and release the boilerreset button 6 (Fig. 1.3 on page 2).

7.9 Checking the flue systemThe flue system should be visually checked forsoundness. Check all clamps, gaskets and fixingare secure and tight.Ensure that the flue terminal is sited correctly in ac-cordance with the flue fitting instructions andFig. 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 or4.6 of this manual (Flue gas figures).

7.10 Checking the condensatedrain pipe

Check the soundness and integrity of the conden-sate drain pipe.

Verify the cleanness and correct filling of the con-densate traps.

7.11 Instructing the userHand over this combined User & Installation man-ual and the Servicemanual to the enduser andex-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 appliancequickly and indicate the position of the electricsupply isolator.Explain the proper use and adjustment of all sys-tem controls; this will ensure the greatest possiblefuel economy.Explain the function and use of the function selec-tor.Explain and demonstrate the function of time andtemperature controls (if fitted).Explain how to turn off the appliance for both shortand long periods and advise on the precautionsnecessary to prevent damage should theappliance be inoperative when freezing condi-tions may occur.Fill in the details required on the Boiler GuaranteeCertificate and hand to the User advising them toreturn the correct section for boiler Guarantee reg-istration.Finally, advise the User that, for continued safeand efficient operation, the appliancemust beser-viced by a competent person at least once a year.

INSTALLATION

8 GAS CONVERSION

34

8.1 WarningsThe commissioning of this boiler and sys-tem must only be undertaken by a pro-fessionally qualified person in accordancewith the requirements of the Gas Safety In-stallation and Use Regulations and be ap-proved by C.O.R.G.I.Components used to adapt it to the type of gasavailable must be genuine parts only.

8.2 Procedures1 Check that the gas cock (12 in Fig. 8.1) fittedunder the boiler is turned off and the applianceis switched off at the mains isolating spur.

Closed position12Fig. 8.1

2 Remove the front panel of the case (see thesectionGeneral accessand emptyinghydrauliccircuits in the service manual).

3 Take off the lid of the sealed chamber.4 Take the front panel of the combustionchamber off and remove the burner (33 onpage 9). See section Ignition and detectionelectrodes in the servicemanual for detailed in-structions.

5 Carry out the conversion for the type of gas, re-placing the burner injectors correctly.

6 Re---assemble the burner, the front panel of thecombustion chamber.

7 Switch on the appliance at the mains isolatingspur.

8 Turn the boiler OFFpositioning the function se-lector 7 as indicated in Fig. 8.2.

79 6 58

Fig. 8.2

9 Disconnect the electrical connectors of theC.h. temperature probe NTC 20 in Fig. 8.3

20

Fig. 8.3

10 Keep pressed the reset button 6 for about 10seconds until the lock---out signal lamp 5blinks.

11 Connect the the elctrical connectors of theC.h.temperature probe NTC 20 in Fig. 8.3

12 Press the reset button 6 repeatedly (4 times)until the lamps 9 give the indication as inFig. 8.4 (gas type mode).

Where: Lamp OFF

Lamp ON

Fig. 8.4

At this step it is possible to visualize the current set-ting by keeping the reset button 6 pressed formore than 5 seconds. The lamps 9 will flash a

MAINTENANCE

Gas conversion

35

number of times corresponding to the setting ofthe knob 8 in Fig. 8.5.

NATURAL

4L.P.G.

8

Gas typeSetting No.

1GAS

Fig. 8.5

Gassupply

Position ofknob 8

Approx. Max currentthrough the modulatordevice

Naturalgas

1 125 mA

L.P.G. 4 165 mA

Fig. 8.6

13 Tochange the setting turn theknob 8on aposi-tion corresponding to the gas used as shownin Fig. 8.5.By turning the knob 8, the lock---out signallamp 5 blinks quickly (2 per seconds) indicat-ing that the setting has changed and must bememorised.

14 To memorize the setting keep pressed thereset button 6 for about 5 seconds until thelamps 9 briefly blinks simultaneously.

15 Open the gas cock (12 in Fig. 8.7)

Open position12Fig. 8.7

16 To reset the boiler to the normal operation turnit ON by the function selector 7 on the desiredoperation and checking the ignition pressureand that the burner lights up uniformly. In anycase, the boiler automatically resets to its nor-mal operation after 10 minutes.

Factory setting = Natural gas (as illustrated)17 Calibrate the gas valve according to the in-structions given in the service manual, sectionModulating gas valve --- Adjustment.

18 Re---assemble the lid of the sealed chamber.19 Replace the self ---adhesive label indicating thetype of gas, and thegas pressures towhich theappliance has been set with the label includedwith the conversion kit. The label is placed onthe botton of the appliance.

20 Replace the adjustment protection cap.21 Replace the front panels of the case.

MAINTENANCE

9 MAINTENANCE

36

9.1 WarningsThe procedures detailed in this chapter mustbe carried out only by a professionallyqualified person. Thus you are advised tocontact an Authorised Service Agent.

For Ireland (IE), the servicing work must becarried out by a competent PersonFor efficient and continuous operation of theboiler you are advised to have, at least once ayear, maintenance and cleaning done by anApproved Service engineer.Isolate the appliance from the electricitysupply by turning off the fused spur isolationswitch adjacent to the appliance and turn offthe gas cock, before carrying out any pro-cedures, whatsoever, for cleaning, mainten-ance, opening or dismantling boiler panels.

9.2 Dismantling the externalpanels

Front panel

A

Sampling pointsAir---Flue exhaust

Fig. 9.1

1 Loosen the three screws A (Fig. 9.1).2 Lift and remove the panel.

Side panels3 Loosen the screws B. Bring the bottom of thepanels away from the boiler and lift them, free-ing them from the top hooks (Fig. 9.2).

B

Fig. 9.2

9.3 Emptying the c.h. system1 Close the c.h. isolating valves (11 and 13 inFig. 9.3).

1213

11

Closed position

Fig. 9.3

MAINTENANCE

Maintenance

37

2 Open the central heating drain cock (21 inFig. 9.4).

21

Fig. 9.4

9.4 Combustion analysis checkIf it is necessary tocarry out a combustion analysisremove the plugs indicated in Fig. 9.1.Reference figures are given in thesections 4.5, 4.6of this manual (Flue gas figures).

9.5 Cleaning the primary heatexchanger

1 Take off the front of the case.2 Take off the removable front of the sealedchamber and the front panelof thecombustionchamber.

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 onpage 9) entirely in a protective layer (sheets ofnewspaper or similar).

4 Brush out the primary heat exchanger (36 onpage 9) with a bristle paintbrush.

9.6 Checking the pressurisationin the expansion vessel

Empty the central heating system as described insection 9.3 of this chapter and check that thepres-sure in the expansion vessel is not less than 1 bar.See also section 4.4 page 11 of this manual.

If the pressure is lower, take steps to correct thepressure level.

9.7 Cleaning the burnerThe sloping and multi---gas type burner (33 onpage 9) does not need special maintenance, butit 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 sealedchamber and the front panelof thecombustionchamber.

3 Brush out the burner with a bristle paintbrush.

9.8 Checking the flueHave the integrity of the flue outlet pipe (40 onpage 10) air intake pipe (41 on page 10), checkedperiodically, the air pressure sensor* (16 on page9) and the efficiency of the flue safety circuitchecked at least once a year.* For details see the section Fan and air pressuresensor in the service manual.For all the above maintenance operations it is ad-visable to call an approved Service Engineer.

9.9 Drain pipe inspectionCheck the soundness and integrity of the conden-sate drain pipe.Verify the cleaness and correct filling of the con-densate traps.

9.10 Visual inspection ofappliance

Visually inspect all water joints, seals and connec-tions for any evidence of leakage and retighten,grease or replace them as necessary.

9.11 Gas pressures and tightnessCheck appliance for gas tightness. Recheckoper-ational pressures and adjust as necessary as de-scribed in section 7.6 page 31 of this manual.

MAINTENANCE

*1796215520*17962.1552.0 4908 44A5 UK

Biasi UK LtdNewman Park, Western WayWednesbury, WS10 7BJSales Tel No: 0121 506 1340Sales Fax No: 0121 506 1360Service Tel No: 0121 506 1350Service Fax No: 0121 506 1370www.biasi.co.uk

03/122008

N

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