Certikin MBC100N Manual

GC No. 47 555 02 and 47 555 17
WRc No. 95 110 46 0087
Certikin
100 & 100W Condensing
Pool Heaters
Note to the Installer: Natural gas Only
Please leave these Instructions adjacent to the meter.
Installation,
Service & User
Instructions
Model: MBC100N MBC100NW
Serial No:

1
1. USER
INSTRUCTIONS
1.1 Important Safety Notes
1.2 Connections
1.3 Quick Start
1.4 Summary ofControls
1.5 Re-Pressurising
1.6 Running thePoolPump
1.7 Switching the Heater Off
–temporarily
1.8 Switching off for the
Winter
1.9 Maintenance
1.10 TroubleShooting –
Failure to Start
1.11 Service
1.12 WaterQuality
2. INSTALLATION
2.1 Introduction
2.2 Standards &Regulations
2.3 If Combined with a
HeatingSystem
2.3 Standards &Regulations
2.4 HeaterControls
2.5 Gas Supply
3. FLUEING
3.1 Air Supply
3.2 WaterSupply
3.3 CondensateDrain
3.4 Sealed Systems
3.5 Electricity Supply
4. INSTALLATION
WIRING
4.1 Wiring
4.2 Installation ofHeater
4.3 Fixing theHeater
4.4 Terminal
4.5 Twin Pipe Assembly
4.6 Plumbing
4.7 GasConnection
4.8 CondensateConnection
5. SPACE HEATING
5.1 System Design
5.2 Electrical Connections
6. COMMISSIONING
6.1 GeneralInformation
6.2 Procedure
6.3 Setting up the Controls
6.4 Pump PressureSwitch
6.5 Responsibility
7. FAULT FINDING
7.1 HeaterControl
7.11 ControlFault Diagnostics
7.2 Ignition Faults
8. SERVICING
8.1 HeaterServicing
8.2 ChangingComponents
8.2.1 ControlBoards
8.2.2 GasValve
8.2.3 SequenceController
8.2.4 CVIValve and
Full Pressure Set Up
8.2.5 PressureGauge
8.2.6 Pump
8.2.7 DiverterValve
8.2.8 Safety Valve
8.2.9 Water toWaterHeat
Exchanger
8.2.10 FlowRegulatorand
Strainer
8.2.11 DHWTemperatureSensor
8.2.12 Removingthe Case
8.2.13 Fan Assembly
8.2.14 Air Pressure Switch
8.2.15 FlueThermostat
8.2.16 PumpOverrun
Thermostat
8.2.17 ControlSensor
8.2.18 Overheat Cut-Off Device
8.2.19 ElectrodeandHT Lead
8.2.20 Pilot Assembly
8.2.21 Burner
8.2.22 Main Injector
8.2.23 CombustionChamber
Insulation
8.2.24 PrimaryHeat Exchanger
8.2.25 SecondaryHeat
Exchanger
9. PARTS
9.1 Spares
9.2 Electrical Components
1:4 ControlPanel
1:5 The FillingLoop
2:3 Typical Circuits
3:4 Alternative Methods of
Filling a Sealed System
4:1 InstallationWiring
DiagramforHeater
Controller
4:3 Fixing Positions
4:5 Twin Flue Positions
4:8 Installation Dimensions
Service Access
5:2a Model100 Schematic
Wiring
5:2b Model100W Schematic
Wiring
5:1 Hydraulic Schematic
6:2a Model 100 GasValve
6:2b 100WGasValve
6:3 Control Displayin Setup
Mode
6:4:a AdjustmentKnob
6:4:b HeaterInstallation Limits
7:1 ControlDisplay
7:2:a IndicatorLights, Model
100Only
7:2:b FaultFinding Operation
Sequence,100W
7:2:c FaultFindingHotWater
Operation,100W
7:2:d Fault FindingPool or
SpaceHeating,100W
8:2:2 GasValve Model
8:2:4 CVIValveModureg
Operator
9:2 Electrical Components
10:1 MajorComponents
10:2 ExampleCondensate
DisposalMethods
10:3 CondensateDrainTap
CONTENTS FIGURES
100 Gas Condensing Pool Heater 21/10/03

1: USER INSTRUCTIONS
1:1 Important Safety Notes
To obtain the best possibleperformanceand trouble
free operation from your Heater, it is important that
you read these instructions carefully. Your Pool
Heater has built-in safety features, which are
detailed in the relevant section of this manual.
If it is known or suspected that a fault exists on the
Heater, it MUST NOT be used until the fault has
beencorrected bya competentengineer (see
Section 1:10,TroubleShooting -FailuretoStart)
It is essential that these instructions are strictly
followed for safe and economic operation. Failure to
observe these instructions may invalidate your right
tofree breakdowncover duringthe guarantee
period.
We recommend that you keep these instructions in
aplace near yourHeater for easyreference.
1:2 Connections
YourHeater shouldbe connectedto an electrical
supplycomplying with theElectricalWiring Regula-
tions (BS7671): as well as a gas supply complying
withBS6891; and anappropriate fluesystem.
ALWAYSSWITCH OFFTHE ELECTRICAL
SUPPLY before removing any of the covers for
cleaning.
If any part of the Heater or its flue is modified then
theguarantee willbe invalidated.
1:3 Quick Start
Check the Electricity and Gas supplies to the
Heater are on.If the Pool Pump is not controlled by
theHeater, turn it on.Turnon the Heaterby turning
thePoolTemperature ControlKnob clockwiseto
showtherequired Pool temperature,the Heaterwill
fire.
If the Heater fails to light see Section 1:10, Trouble
Shooting - Failure to Start)
1:4 Summary of Controls (left to right)
HeaterPressure Gauge
Normal -The needleshould be in the area indicated
as * * NORMAL * * , if low, re-pressurise, see
Section 1:5
Flashing -The Pool Heating Demand is Met , the
pool is up to temperature.
Temperature is displayed after 3 seconds.
- Spa + - Setting for SpaTemperatures.Required
temperature is displayed when setting, actual Spa
Temperaturedisplayed after 3 seconds.
(NOTE: The Heater is delivered set to display in Fahren-
heit. For a Centigrade display, see 6:3
Commissioning Section of Installation Instructions)
PoolTemperature Mechanical Stop
Stop –This can be used to obtain a repeatable
setting and to limit maximum pool temperature.To
set, loosen the screw, adjust as required and then
re-tighten.
PoolTemperature Display
Display - Normally showstheactual PoolTempera-
ture, but also displays the SettingTemperature and
a Setting Dot lit whilst being adjusted.The display is
also used for commissioning and diagnostic pur-
poses.
Heating Demand LED - GREEN
(Only in use when heating system connected)
Off -There is no Heating Demand , heating is
switched off.
On -There is a Heating Demand , heating is on but
not yet up to temperature.
Flashing -The Heating Demand is met , heating is
upto temperature.
HeatingTemperature Control Knob
(Only used when heating system connected)
Off -There isno Heating Demand,heating is
switched off.
Normal - Normal setting for heating, it can be
adjustedlower ifrequired.
(NOTE: Supplied set for Pool Priority. It will satisfy the
Pool Temperature before supplying full Heating. To
change the priority, see 6:3 Commissioning Section of
the Installation Instructions)
Filter LED -YELLOW
On - Pool Filter Blocked - Insufficient pressure,
possibly due to a blocked pool filter.The heater will
notrun.
Flashing - Clean Pool Filter -The filter may require
back washing.The heater will run.Can be reset by
turning the PoolTemperatureknob offand backon
again.
PoolTemperature Control Knob
16°Cto 41°C(60°F to106°F)
Off -There is noPoolHeatingDemand , pool
heating is off.
Pump - Runs Pool Pump only, if connected via
heater.‘P’is indicated onPoolTemperature Display.
- Pool + - Setting for pool temperatures.Requested
temperature is displayed when setting, actual Pool
2100 Gas Condensing Pool Heater01/06/02

HeaterOverheat LED -ORANGE
On - Heater Overheat - This indicates that the
Heaterhas overheatedand shutdown. SeeOver-
heatReset instructions below.
OverheatReset 100 Only
In the unlikely event of an Overheat it will neces-
sary to obtain the assistance of a competent person
to reset the thermostat.
Turn the Mains supply off.Remove the single fixing
screw holding the Electrical Chassis and pull it out,
hanging it on the back support.Remove the Con-
trols Cover and locate the Reset Switch on the side
of the Control Chassis.Turn it off then back on
again.
Replaceall the panels in reverse order.
If the Heater repeated overheats a Service Engineer
should be called to inspect the Heater.
Overheat Reset - 100W Model Only
In the unlikely event of an Overheat it will neces-
sary to obtain the assistance of a competent person
to reset the thermostat.
Theprocedure isdetailed in Section 8:2:18
If the Heater repeated overheats a Service Engineer
should be called to inspect the Heater.
Automatic Frost Protection
The Heater will automatically run a Frost Protection
routineif the temperaturefallsbelow3°C (37°F).The
PoolTemperature Displaywill show0°C.This will
include the use of the Pool Pump if it is connected
tothe Heater.
1:5 Re-Pressurising
Connect a MainsWater supply then connect the
free end of the braided flexible hose (the Filling
Loop) (see Fig.1.5) tothe incoming mainsconnec-
tor.
Open theValve to the supply, then, slowly open the
Valve on the Base Panel until the Pressure Gauge
shows 1 Bar.
Close both valves then disconnect the Filling Loop.
ON
bar
0 4
2
1 3
us
erinstr
uction
sinside
userinstr
uctionsinside
100
seeinstructions
1:6 Running the Pool Pump
If this option has been installed the Heater can run
thePool Pump onits own.Turnthe PoolTempera-
ture Control Knob to‘Pump’, just next to Off.
1:7 Switching the Heater Off -
temporarily
The Heater may be stopped by turning the Pool
Temperature ControlKnoband/or theHeating
Temperature ControlKnobto OFFon ControlPanel.
1:8 Switching off for theWinter
TurnbothTemperatureControl Knobsto Off.
If the built in Frost Protection is required do not
isolate the Heater from its electrical supply.
If the Heater is to be shut off for the Winter, it is
advisable to have it thoroughly serviced when first
shutdown.Thorough cleaningwill minimisecorro-
sionduring the idle period.
1:9 Maintenance
For normal cleaning of the outside casing, simply
wipe with a dry cloth. To remove stubborn marks
and stains, wipe with a damp cloth and finish off
with a dry cloth. DO NOT use abrasive cleaning
materials.A spray ofWD40 or similar will also help
to protect it.
The Heater must be serviced every year by a
qualifiedserviceengineer.
1:10 Trouble Shooting - Failure to Start
If the Heater fails to start, adopt the following
procedure:-
1. Check that the Pool pump is operating and that
the Filter lamp is not illuminated.
2. Check that the Heater ControlThermostat is set
highenough to be“ON”and that thePoolDe-
mand lamp is on.
Fig 1:4
3
100 Gas Condensing Pool Heater 20/10/03

Fig 1:5
3. Checkwhether the HeaterOverheat lighton the
control fascia is glowing, if so it indicates an
overheatsituation. (See Section 1:4) If the
Heaterrepeatedly overheatsa ServiceEngineer
should be called to inspect the Heater.
1:11 Service
To ensure efficientandreliableoperationofthe Heater
it is essential that the Heater is serviced every year.
The Manufacturer recommends this is prior to start-
ingthe Heater eachseason.
1:12Water Quality
Chemicalimbalance can causesevere damage to
yourHeater andassociated equipment.
Maintainthe pool waterpH between7.4 and 7.6and
ensure that the free chlorine levels are within the
rangerecommended bythe chemicalsmanufacturer
for your size of pool.
Check the Filter regularly and keep the pool free of
debris such as leaves and grass cuttings.
4100 Gas Condensing Pool Heater20/10/03
FillingLoop
First Valve
SecondValve
100
FillingLoop
SecondValve
100W

2 INSTALLATION
2:1 Introduction
ThisManual coversOperation, Installation,Com-
missioning and Maintenanceof the 100and 100plus
CondensingPool Heater.
The Pool Heater is :-
•Designed for heating pools and Spas by utilising
an internal watertowaterheat exchanger.
•Incorporates its own sealed system
components; pressure vessel, filling loop, safety
valve,and pressuregauge.
•Can also be used for space heating.
•The 100 Plus also provides Instantaneous Hot
Water.
•Supplied with a manual reset limit thermostat.
•Suitable for new installations and for replacing
existing Heaters.
•Includes an internal automatic bypass to
accomodate all likely Space Heating designs.
These Instructions are for a Gas Fired, Condensing
Pool Heater which are room sealed and fan assisted
on the flue side.The flue system available is Twin
Pipe, horizontal total combined length of 22 metres
or vertical, up to a total length of 30 metres.The
ignition system is fully automatic.The 100 plus
incorporateselectronic gas modulation.
The Heater casing is of polyester powder coated
enamelled zinc coated steel.
Includesall the componentsrequired for a sealed
system including a pump and is designed for the
connectionof anoptional Heating orHotWater
system.
It includes a pump overrun device and an automatic
bypass valve.
There is no requirement for a scale reducer to be fit-
ted to the cold water mains supply to the 100 Plus.
TheHeater contains integral frost protection,the
Heater will fire if the temperature within it ap-
proaches 4 to 5 degrees Centigrade. It will do this
even when turned to Off, and can only be inhibited
by removing the Permanent Live supply to the
Heater.
Adequatearrangements for completelydraining the
system, by provision of drain cocks MUST be
provided.
2:2 Standards & Regulations
Gas Safety (Installation and Use)
Regulations, (as amended).
It is the law that all gas appliances are installed by
acompetent person (e.g.a CORGIregistered
operative)in accordance withthe aboveRegula-
tions.Failure to install appliances correctly could
leadto prosecution.
It is in your own interest, and that of safety, to
ensure that the law is complied with.The installation
of the Heater MUST also be in accordance with the
current I.E.E..Wiring Regulations, the Local Build-
ingRegulations, BuildingStandards (Scotland), the
Bye Laws of the Local Water Undertaking, any
relevant requirements of the Local Authority, and
Health and Safety document No 635, “Electricity at
WorkRegulations”.
Detailedrecommendations are containedin the
following British Standard Codes of Practice.
Codes of Practice.
BS.6798 Installation of gas fired hot water Heaters
of rated input not exceeding 70kW.
BS.5449:1 Forced circulation hot water systems
(smallbore andmicrobore domestic central heating
systems).
BS.5546 Installation of gas hot water supplies for
domesticpurpose(2nd Family Gases).
BS.5440:Part1.Flues (for gas appliances of rated
inputnot exceeding60kW).
BS 6891 Specification for installation of low pres-
suregas pipework.
BS 7074:1 Application, selection and installation of
expansionvessels and ancillary equipment for
sealed water systems.
BuildingRegulations PartL1.
IMPORTANT. It is important that no external control
devices are directly connected to this appliance -
unless covered by these‘Installation and Servicing
Instructions’or otherwiserecommended by the
manufacturer.If in doubt, please enquire.
Any direct connection of a control device not
recommendedby the manufacturercould infringe
the Gas Safety (Installation & Use) Regulations, the
aboveregulations and thenormal appliance war-
ranty.
Manufacturer’s notes must NOT be taken, in any
way, as overriding statutory obligations.
Locationof Heater
The Heater MUST be installed vertical and securely
fixed . The Heater is not suitable for an external
installation
5
100 Gas Condensing Pool Heater 05/02/03

Important Notice
If the Heater is to be fitted in a timber framed
building it should be fitted in accordance with the
British Gas publication‘Guide for Gas Installations
inTimber Frame Housing’, reference DM2.If in
doubt, advice must be sought from the Local Gas
Region of British Gas.
The Heater may be installed in any room or internal
space.Particular attention is drawn to the require-
ments of the current I.E.EWiring regulations and, in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland with respect to
the installation of the Heater in a room or internal
spacecontaining abath orshower.
Where a room sealed appliance is installed in a
roomcontaining abath orshower then the appliance
and any electrical switch or appliance control,
utilising mains electricity should be so situated that
it cannot be touched by a person using the bath or
shower.
Where installation will be in an unusual location then
specialprocedures may be necessary and BS.6798
gives detailed guidance on this aspect.
A compartment used to enclose the Heater MUST
be designed and constructed specially for this
purpose.An existingcupboard, orcompartment,
may be used provided it is modified for the purpose.
Details of essential features of cupboard compart-
mentdesign, includingairing cupboard installations
are given in BS.6798.
In siting the Heater, the following limitations MUST
beobserved:
1. The position selected for installation MUST allow
adequate space for servicing in front of the Heater
andforaircirculation around the Heater.
2. This position MUST also permit the provision of
a satisfactory balanced flue termination.
3. This position MUST also permit the provision of
a satisfactory connection to the condensate drain.
2:3 If CombinedWith A Heating System
TheControls providea watertemperature controlfor
usewithaheatingsystem,theHeatingDemand Knob.
Itrequires answitched live from the Heating controls
tobe connected toHeating Demand,as shown inthe
Wiring Diagram and a pipe circuit to be connected to
thetwo rear tappingsof the Heater in placeof the Air
Vent andDrain.
It is essential that the size of the expansion vessel
in the Heater is sufficient for the proposed system
Dependingupon thePriority set
(See commissioning Section 6:1) the Pool orThe
Heatingwill bebrought upto temperaturefirst.
Typical circuits are as Fig 2:3.
2:4 Heater Controls
This Heater uses a control specifically designed for
it and it has the following features:
A highly accurate PoolThermostat , 16°C to 41°C
(60°Fto106°F)
A HeaterThermostat.Fixed for Pool, 84°C, variable
forHeating 60- 82°C.
AFrostThermostatwhich runs theInternal andPool
Pump at 3°C or below but then fires the Heater
alone if the temperature has not risen sufficiently.
AReturnThermostatoperatingan internal bypass
forcondensation reduction.
Fig 2:3
Heater
Pump Pump
Zone Valve
Non return valve
Pump
Non return valve
Second water 2 water
heat exchanger
with Aquastat or similar
Pool Plus Heating and Hot Water
Pool Plus Heating Pool Plus Spa
3 Way Valve
Expansion vessel Expansion vessel
Heater Expansion
Vessel
4 litres
Heater
Heater Expansion
Vessel
4 litres
Heater
Heater Expansion
Vessel
4 litres
NB:Extra ExpansionVessel only required for very large systems.See Section 3:4
6100 Gas Condensing Pool Heater01/06/02

Terminal Position Minimum
Belowwindow or vent 300 mm
Belowgutter orpipes 75 mm
Beloweaves 200 mm
Belowbalcony orroof 200 mm
Froma window 200 mm
From vertical pipe 75 mm
Fromcorners 300 mm
Aboveground, roofor balcony 300 mm
From facing surface 600 mm
From facingterminal 1200mm
Fromopening undera car port 1200mm
Vertically from a terminal 1500 mm
Horizontallyfrom aterminal 300 mm
AnOverTemperatureThermostat(Overheat).
Internal Pump control with run on.
Pool Pump controlwith run onand out-of-season
exercise.(Requires external contactor)
PoolTemperature andSettingdisplay.Engineer
selectable °C or °F.
User Indicators for Pool, Heating, Overheat, and
Service.
Engineer indicators of all switched outputs for
simplediagnosis.
Priorityselection ofPoolor Heating,engineer
selectable.
Memoryof: Filteroccurrences.
Sensorfailure detectionand indication.
Control self checking with fault indication.
For more detail see the Commissioning (6:1) an
Fault Finding (7:1) sections .
2:5 Gas Supply
The Local Gas Region should be consulted, at the
installation planning stage, in order to establish the
availability of an adequate supply of gas.
An existing service pipe must NOT be used without
prior consultation with the Local Gas Region, or by
a local Gas region contractor.An existing meter
should be checked preferably by the Gas region, to
ensure that the meter is adequate to deal with the
rateof gas supply required.
Installation pipes should be fitted in accordance
withBS.6891
Do NOT use pipes of a smaller size than the Heater
inlet gas connection.
3 FLUEING
Detailedrecommendations forflueing are givenin
BS.5440:1.The following notes are intended for
generalguidance.
1. Be aware of the plume from the flue and the
wetting effect it has to adjacent property.
2. The flue can be taken upwards, left, right or to
therear of theappliance.
3. The Heater is supplied with aTwin Pipe flue
suitable for terminating on an outside wall 1
metre away.More complex and lengthy flues
are possible, please consult the Flue Application
Guidefor designsand the components.
4. The Heater MUST be installed so that the
terminal is exposed to external air.
5. It is important that the terminal allows the free
passage of air across it at all times.
Table 1.
IMPORTANT.
It is absolutely ESSENTIAL to ensure, in practice,
that products of combustion discharging from the
terminalcannot re-enterthe building, or any other
adjacentbuilding, through ventilators,windows,
doors, other sources of natural air infiltration or
forcedventilation/air conditioning.
If this should occur,the appliance MUST be
turned OFF IMMEDIATELY and the Local Gas
Region consulted.
6. The acceptable spacing from the terminal to
obstructionsand ventilationopenings are
specified inTable 1.
7. Because the flue gases and terminal are at very
low temperature it is not necessary to fit a
Terminal guard to protect against burns. If a
guardis requiredfor anyother reason the
followingisrecommended.
Forthe Twin FlueTerminal:
Model B (black plastic coated).
For the Single Flue Terminal:
Model H (black plastic coated).
All are available from:
Tower Flue Components Ltd.
Tower House.
Vale Rise.
Tonbridge
KENT
TN9 1TB
01732351555
7
100 Gas Condensing Pool Heater 01/06/02

3:4 Sealed Systems
The Pool Heater is supplied with an Expansion
Vessel (seeTechnical Data for details), a Pressure
Gauge, a SafetyValve and Filling Loop following the
guidelines given in the Code of Practice BS 7074 :1.
Please check that the supplied ExpansionVessel is
adequateforthe proposed system.Thefollowing
procedureis suggested.
1. Choose a vessel pressure by taking the static
head of the system, adding 0.3 bar, and taking
thenearest larger figure.
2. Select theVesselVolume from the table below
by finding the SystemVolume andVessel
Pressure.
3. Choose that size or larger from the manufactur-
ers’range.
Vessel SystemVolume Litres
Pressure 50 60 70 100 150
Bar VesselVolume
0.5 448812
1.0 8881218
1.5 8 12121824
Table 2.
A design as detailed below should be used for the
filling connection, it utilises a BS 1010 stop valve, a
double non-return valve and filling loop fitted at low
level and should be installed with the approval of
thelocalWaterUndertaking.
3:1 Air Supply
It is NOT necessary to have a purpose provided air
vent in the room or internal space in which the
Heater is installed.
Wherethe Heater is installed ina cupboard or
compartmentno airvents are required.Howeverthe
User may wish to ensure that is ventilated to
provideair circulation.
3:2 Water Supply
The central heating system should be in accord-
ancewith therelevant recommendationsgiven in
BS.6798, BS 7593:1992 and, in addition, for
smallboreand microboresystems -BS.5449:1.
The domestic hot water system, if applicable,
shouldbe inaccordance with the relevant recom-
mendationsof BS.5546.
Coppertubing toBS 2871:1is recommendedfor
watercarryingpipework.
The MainsWater supply should be clean and able to
producetherequiredflowrate,see theTechnical Data.
New pipework must be flushed through before con-
necting.
The 100W incorporates a strainer and flow regulator
set to 8.5 l/m on the ColdWater Mains Inlet, this can
be removed in countries with warm climates.The In-
letpressureshouldnotexceed10bar,areducershould
be fitted if it does.
Any hot water storage cylinder MUST be of the
indirecttype andshould preferably bemanufactured
ofcopper.
The hot water cylinder, & ancillary pipework, not
forming part of the useful heating surface should be
lagged, to prevent heat loss and any possible
freezing,particularlywhere pipes run throughroof
spacesand ventilatedunderfloor spaces.
Draining taps MUST be located in accessible
positions, which permit the draining of the whole
system,including Heaterand hotwater storage
vessel. Draining taps should be at least ½ in.
nominal size and be in accordance with BS.2879.
3:3 Condensate Drain
Refer to Fig. 1:5, 5:1, and 10:2
A condensate drain is provided on the Heater, this
drainmust beconnected to the household drainage
point, or soakaway on site. All pipework and fittings
in the condensate drainage system MUST be made
of plastic. Refer to British Gas publication “Guid-
ance notes for installation of domestic condensing
boilers”
The drain outlet on the Heater is :
Polypipe, 21.5mm pushfit overflow pipe.
ALTERNATIVE METHODS OF FILLING A SEALED
SYSTEM
Method A
Method B
Hose Unions
Air Inlet
Valve
Temporary Hose
Mains
Water
Supply
Mains
Water
Supply
Test Cock
Stop Valve
Drain &
Fill
Double
Check Valve
Assembly
Drain &
Fill
Cistern &
Overflow Pressure
Pump &
Reducing
Valve If
Required Stop Valve
3:5 Electricity Supply
Wiring external to the appliance MUST be in ac-
cordancewith thecurrent I.E.E.Wiring Regulations
and any Local Regulations that apply.
TheHeaterissupplied for230V~50Hz.Singlephase.
Fuse rating is 3A.
Fig. 3:4
8100 Gas Condensing Pool Heater
20/10/03

The method of connection to the mains electricity
supply MUST facilitate complete electrical isolation
ofthe Heater, preferably bytheuse ofa fused double
poleswitch having a3mm (1/8in.)contact separation
in both poles and servicing only the Heater and sys-
tem controls.
Thepoint ofconnection tothe mainsshould beread-
ilyaccessibleand adjacentto the Heater,exceptthat,
forshower roominstallations,the pointof connection
tothemains MUST besituatedoutside the bathroom.
Note.Where aroom sealedappliance isinstalled in
aroom containing abasin or shower, theappliance,
any electrical switch or appliance control utilising
mains electricity should be so situated that it
cannot be touched by a person using the bath or
shower.
4. INSTALLATION WIRING
4:1 Wiring
The designs below are in order of preference, the
QuickFitPoolControlPanel(CCP02)beingtheeasi-
est, quickest and most comprehensive solution.
Design 4 is the least preferred as it does not utilise
all the features of the Heater Control.
HeaterConnections are shownprefaced with‘HTR’
inthe diagramsbelow.
Fig. 4:1
9
100 Gas Condensing Pool Heater 01/06/02
LNE
Certikin Mk2 Oil Pool Heater
Pool Pump
Up to 16 A
Lights
Up to 6 A
Pool Pump
Rated to
suit pump
RELAY
T.S
> HTR, Permanent Live
> HTR, Pool Demand
< HTR, Pool Pump
Pool Pump
Up to 3 A
More than 3 A
Trip
L
N
N
T.S
> HTR, Permanent Live
> HTR, Pool Demand
Pool Pump
Trip
L
N
T.S
> HTR, Permanent Live
Pool Pump
Trip
L
N
> HTR, Pool Demand
DESIGN
# NOTES
Takes full advantage of all the features of the Certikin
Oil Pool Heater.
Pool Pump control providing overrun and Frost Protection action.
Provides the fastest installation
Optional connections for Lights and Space Heating all provided.
1
2
3
4
Takes full advantage of all the features of the Certikin
Oil Pool Heater. Considerable installation time.
Pool Pump control providing overrun and Frost Protection action.
Optional Space Heating only available with more wiring.
Limited application of Certikin Oil Pool Heater.
Moderate installation time.
No Pool Pump control, Overrun or Frost Protection action.
Non-preferred application of Certikin Oil Pool Heater.
Moderate installation time.
No Pool Pump control, overrun or Frost Protection action.
Optional Lighting only available with more wiring.
Optional Space Heating only available with more wiring.
Optional Lighting only available with more wiring.
Utilising the CCP02 "Quick Fit" Oil Pool Heater Control
Optional Space Heating only available with more wiring.
Optional Lighting only available with more wiring.
T.S = Time switch
T.S = Time switch
T.S = Time switch
HTR = Oil Heater
HTR = Oil Heater
HTR = Oil Heater
CCP02
IMPORTANT: Remove link, Live to Pool Demand, in Oil Heater
IMPORTANT: Remove link, Live to Pool Demand, in Oil Heater
OR, Certikin Condensing 100 Pool Heater
OR, Certikin Condensing 100 Plus, Pool Heater

4:2 Installation Of Heater
Suggestedprocedure:
1. Position to suit system and terminal limitations.
2. Mark & Drill Flue hole(s). (seeFig. 4:8).
3. Remove the ElectricalTray and the Lower Case
fromHeatermodule.
4. Plumb tails to pool, gas heating and hot water.
5. Test for leaks.
6.Replace the Lower Case and Electrical tray.
SpaceRequired forInstallation and Service.
Right or Left 30 mm 1 in.
Above 30mm 1 in.
Below 25mm 1 in.
InFront 450mm 18 in.
Table 3
4:3 Fixing the Heater
1. Position to suit system and terminal limitations.
2.Secure the frame, vertical, to the wall or floor
withthe bracets provided..
3. Mark the wall or ceiling for the flue exit points
and core drill the wall to give a 0 to 3 degree
slopedowntowardsthe Heater.Therecom-
mended core drill is 90mm for theTwin Pipe.
4:4Terminal
The terminal can be fixed vertical or horizontal.The
flue pipe must always be connected to the extended
outlet of the terminal.The spacing is 120mm and a
core drill of 90mm is recommended. See Fig. 4:8
4:5Twin Pipe Assembly
All theTwin Pipe components for this appliance are
lightweight plastic and utilise a push-fit system.
Very few fasteners are required and their use is
detailed on the instructions provided with the
components.
Important:
AllTwin Pipe Installations must comply with the
following.
1. The Flue pipe must slope back to the Heater by
threedegrees (1 in 20) on all horizontal runs.The
airpipe canbe aboveor belowhorizontal.
2. Flue Pipes must be supported every 1000mm,
minimum.
3. All connections should be made with the Socket
end furthest from the heater.
4. Usethe supplied CentraCerinor Silicone
Grease to ease the fitting of sections.
5. The combined Equivalent Length of Air and Flue
should not exceed 22m horizontal, or 30m
vertical and including any terminal parts.
6. The straight equivalent lengths of bends in a
horizontaldesign are as follows:
45degrees, 1.3m.
90degrees, 4m.
For more complex designs please see the details
provided with the components
It is recommended that:
1. That45 degreebends arealways usedwith
vertical flues and where possible used in prefer-
enceto 90degree bendsin horizontalinstalla-
tions.
2. Straight Flue pieces may be reduced in length
by cutting square. It will ease assembly if the
cutedge iscleaned, chamferedand greased
beforeinsertion.
4:6 Plumbing
Prepare the flow and return pipe work on the base of
theHeater.Ifthe requirement forSpace Heating
exceeds50,000 Btu/h(15kW), theFlow andReturn
pipework from the Heater must be 28mm until the
heatload allows smallerbore pipework.
Newpipework must beflushed throughbefore
connecting.
4:7 Gas Connection
The 15mm gas connection point is provided. A
minimum of 20mb.(8in.w.g.) must be available at
theHeater inlet, with the Heaterand othercon-
nectedappliances firing.Check forgas soundness
(B.S.6891: 1988)in pipework toHeater usinga
manometer.Open the gas cock.Gas soundness
within the Heater should be checked using sense of
smelland/or leak detection fluid. Check the burner
barpressure witha manometerconnected tothe
controland adjustif required with the pressure
regulator.
10 100 Gas Condensing Pool Heater
01/06/02

FIXING POSITIONS
TWIN FLUE POSITIONS
Fig.4:5
Flue Duct
Air Duct
100mm
Condensate Drain
Connection
(connects to drain point
on Flue Spigot Adapter)
Flue Spigot
Adapter
Drain Point
Twin Pipe Heater
Mounting Box
Assembly
Connects to condensate
drain point on Condensate
Drain Trap
11
100 Gas Condensing Pool Heater 01/06/02
PLAN VIEW
FRONT VIEW
Suggested fixings
3 into the floor OR
2 into the wall.
Fig.4:3

4:8 Condensate Connection
The position of the plastic condensate drain pipe is
shown in Fig 5:1
Wherepossible aninternal termination of the
Condensatedischargepipework should beused.
Installation pipework must be in plastic to a suitable
drain location with a gradient of 2.5° (45mm/ meter
run)minimum. If connectedto anotherdrainage
trap,an airbreak is required between theHeater
drainand that trap.(
See Fig.10:2 ).Internal runs
must be in a minimum of 19mm pipe. External runs
MUST be made in a minimum of 32mm pipe,
starting inside the building, and if possible insulated
todefer problemsfrom freezing.
Whichever method is used it should be checked
during commissioning to prove there is a leakfree
working connectionfrom theHeater tothe drain.The
simplest way to do this is to carefully pour some
water into the Heater flue and check it emerges at
thedrain.
The British Gas booklet “Guidance for the installa-
tionof DomesticCondensing Boilers”should alsobe
referredto.
5 SPACE HEATING
5:1 Typical Radiator System Design
General Principals
Nospecial requirementsare needfor theselection
ofradiators, normalsized radiatorsare acceptable.
TheManufacturerrecommends usingaprogramma-
bleroom thermostat,alternatively aseparate room
thermostat and timeswitch can be used.
The Heaters include a pump overrun device so it is
essential that there is an open circuit for water to
flowbetween theflow andreturn. AnAutomatic
Bypass is incorporated in the appliance which
should be sufficient for most system designs.
The Heater includes integral frost protection. If the
temperature approaches freezing it will first try and
use the heat in the pool by running the Pool Pump.
If this does not raise the temperature it will run the
Heater.It will do this even when turned to Off, and
can only be inhibited by removing the Permanent
Live supply to the Heater.
Thermostatic radiator valves can be used.
The Heater Pump is factory set at Speed 3 and
shouldnotbe alterered.
The Heater waterside is completely copper so all
goodcorrosion inhibitorsare suitable.Inhibitor isnot
requiredforPool only applications.
Thedesign temperaturedifference across the
Heater for optimum operating efficiency is 20°C. If
thermostatic valves or zone valves are used ensure
the minimum flow shown in the Technical Data on
page 1 is possible.
5:2 Electrical Connections
WARNING:The appliance MUST be
earthed.
All wiring for the Heater and system controls MUST
conform to I.E.E.Wiring Regulations, and work
should be tested using a suitable meter, for Earth
Continuity, Polarity, Short Circuit and Resistance to
Earth.
The supply must be through a common isolator, a
double pole 3A fused isolating switch with a contact
separation of 3mm minimum on both poles.The
cable used should be no less than 0.75mm2to
BS.6500 PVC, 3 core, and fixed ensuring the earth
connectionis longerthan theLive andNeutral.
Access to the Heater connections is made by
sliding out the bottom tray which is held by mag-
nets, removing the single screw retaining the
Electrical Tray then releasing the screws retaining
the Chassis Cover.
TheHeater internalwiring isshown in Fig.5:2a &
Fig.5:2b .
Connections are made by push fit connectors
Connectionsare asfollows :-
3 WayTerminal 4 WayTerminal
Earth Pool Pump
Neutral Neutral
PermanentLive HeatingDemand
PoolDemand
A link is factory fitted between the Permanent Live
and the Pool Demand and should be removed if a
separate switched supply is provided for Pool
Heating.
For systems using an external programmer, the
electricalwiring shouldfollow therelevant control
manufacturer’srecommendations,with theswitched
live from the controls returning to Pool Demand and/
or Heating Demand in the 4 way push-fit connector.
12
100 Gas Condensing Pool Heater 01/06/02

INSTALLATION DIMENSIONS FLUE POSITIONS AND SERVICE ACCESS
Fig 4:8
13 100 Gas Condensing Pool Heater08/09/03
HEATER HYDRAULIC SCHEMATICS
Fig.5:1
Safety Valve Drain
From Pool
Heating Flow
Heating Return
Fill & Drain
Condensate Drain
To Pool
Condensate Trap
Pump
Safety Valve
Diverter Valve
Auto Bypass
Valve
Expansion Vessel
Heat Exchanger
Pool Heat Exchanger
Auto
Air
Vent
Safety Valve Drain
From Pool
Heating Flow
Heating Return
Fill & Drain
Condensate Drain
To Pool
Condensate Trap
Pump
Safety Valve
Diverter Valve
Auto Bypass
Valve
CW Inlet
Three Way Valve
Water to Water
Heat Exchanger
Filling
Loop
Pool Heat Exchanger
Heat Exchanger
Expansion Vessel Auto
Air
Vent
HW Outlet
100W100
Front View
C
L
100
Rear Flue
Side View
Twin pipe
Maximum 22m horizontal
90mm
90° bend = 4.0m 45° bend = 1.3m
Suggested core drill
Service Access
Front 450mm Above 30mm
Sides 30mm
Equivelant lengths: Minimum 200mm
Maximum 30m vertical
Side Flue
Flue
Air
390
110 500
1750
1850
1850 120
100

SCHEMATIC WIRING
Fig.5:2a
14
100 Gas Condensing Pool Heater 14/03/03
100
SUPPLY
E
N
L
HT
N
Ls
L
Lp
COM
AIR
NOAIR
O/H O/H
SENSOR
SENSOR
12 Way connector
GV1
GV2
N
4 Core to Gas Valve
Fan
4 way Molex
10 way Molex
GV1 GV2
1 Amp 20mm
IGNITION BOARD
Or Or
Br
Br
R
W
Bk Gy Br R
Bk
Br
B
G/Y
G/Y
G/Y
B
G/Y
V
Gy
Br
R
Or
W
Bk
Gy
V
G/Y
B
Brown
Red
Orange
White
Black
Blue Grey
Violet
Green & Yellow
B
L
N
Pressure
Switch
O/H
PoolPump
Heating Demand
PoolDemand
PUMP
E
N
Lp
CONTROL BOARD
INTERNAL
G/Y
E
N
N
250mAASLRC
POOL DMD HTG DMD
HTR PUMP
POOL PUMP
BURNER
PressureSwitch
BurnerSensor
PoolSensor
Common
R R
B
Or
Y
Yellow
W
B
Br
B
Gy
V
Sensor
Pool
3 PORT VALVE
BROWN
RESET
SWITCH
Or
Br
Lockout Neon
14/03/03
Air Pressure Switch
NO
NC
Sensor
Flue Stat
O/H Stat
M4733
10k
B

SCHEMATIC WIRING
15 100 Gas Condensing Pool Heater
21/10/03
Fig.5:2b
100W
DRIVER PCB
X1
X2
X3 X4 X5
X6
X7
X8X10
CH SET MAX
MODUREG
DHW
SENSOR
NC
NC
24V
FLOW SWITCHES
PUMP
CVI VALVE ASSEMBLY
1
8
NC
R
Y W
R
V
Gy
Y
W
R
P
Br
B
HW SET MAX
R/B
Bk
Gy/Bk
NC
GyW
R
Or
B
B
Br
Br
B
Br
FAN PRESSURE
OH STAT
LOCKOUT
NEON
FLUE STAT
W
W
OVERRUN
PUMP
230 V
CH
Bk
BB
G/Y
G/Y
B
G/Y
Spark Electrode
230 V
Br
Or
Set Maximum CH Pressure
1
2
3
Fuse 315 mA
Fuse 2 A
P Pink
Set Minimum CH pressure
SWITCH
12 11 9 6
5
312
G/Y
8
Br
Cold
56
3
10k
10k
SUPPLY
E
N
L
R
Br
R
Or
W
Bk
Gy
V
G/Y
B
Brown
Red
Orange
White
Black
Blue Grey
Violet
Green & Yellow
L
N
Pressure
Switch
O/H
PoolPump
HeatingDemand
PoolDemand
CONTROL BOARD
G/Y
N
250mAASLRC
POOL DMD HTG DMD
HTR PUMP
POOL PUMP
BURNER
PressureSwitch
BurnerSensor
PoolSensor
Common
R R
B
Or
Y
Yellow
Y
W
B
Br
B
Gy
V
Sensors
Pool Burner
Or
Br
Bk
3 PORT
E
N
L
VALVE
B
r
B
G/Y
01/06/02

6. COMMISSIONING
6.1 General Information
For Systems with Space Heating
The elimination of air from systems is essential to
minimisethe occurrenceof heatexchanger and
generalsystem noise.
Metal swarf and flux chemicals make a very ag-
gressive mixture, the destructive nature of which
canbe drasticallyreduced byflushing. Conse-
quently this is a mandatory step in the commission-
ingprocedure.
Lowwater content, fabricatedHeaters arevulner-
able to damage by air, particularly when the system
water is‘hard’.(Contains a lot of dissolved calcium
salts).The result of this damage is evident in noisy
Heatersand reducedservice life.
Removal of air from a system mainly takes place
when the water is stopping, starting or not moving
at all. It is removed most easily when it is in large
bubbles, but the action of the pump is to chop it up
so that it becomes a foam, which is extremely
difficult to remove.
Two or three second bursts on the pump at the
initial stage will reduce the risk of foam formation.
Sloping the pipe runs towards the vent points will
greatly aid air removal. Sloping pipes are not just a
feature of gravity systems but can greatly aid the
pumped system because air can move towards a
vent when the pump stops.
Air is dissolved in water but is released when
heated. Always run a system at maximum tempera-
ture for at least 15 minutes to enable this potential
problemto beremoved during commissioning.
6.2 Procedure
MODEL 100 ONLY: If the Heater has just been filled
with very cold water, the built in FrostThermostat
could attempt to fire it, if it has a permanent live
and no switched live, this is completely normal. It is
recommended that the gas cock is turned off during
this early stage.
Pool Only Systems
There is an Automatic AirVent inside the Heater,
ensure that the cap is open before filling with mains
waterthrough the FillingLoop.
With the gas off, run the heater to circulate the
waterandremovethe air.Turning the supply on and
off will pulse the pump and help the air to rise to the
Automatic Air Vent.
Whencompletely clearof air,re-pressuriseand
removefilling loop.
Turn the gas back on.The Heater is ready for use.
The Heater is fitted with automatic ignition and will
start when the gas cock is open, Mains is con-
nected to the Heater and the controls are calling for
heat.
For the Model 100 only: It has a built in delay, and
the Heater can be held off for 120 seconds. How-
ever, for commissioning purposes, switching off
using the System Isolating Switch will avoid the
delay.
For Systems with Space Heating
It is strongly suggested that the following stages of
commissioningare followed,and notan immediate
connection of all services.This procedure prevents
substantialamounts ofair beingdispersed through
the system as small bubbles.
Carry out electrical tests as stated in Electrical
Connectionsif not alreadydone so.
With all radiator valves open, fill the system from
the Filling Loop, but do not start the pump.
With the temporary hose connected, fill from the
mains supply, then follow the procedure below.
Checkfor watersoundness andrectify where
necessary.
DO NOTTURN ON GAS
Drain the system by opening all draincocks.This
will flush the system of flux and swarf.
Pour ¾ of the inhibitor in and fill the system with
cleanwater andvent airfrom radiatorsand
pipework.
Pour in all the inhibitor, and fill to required pressure
plus 0.3 bar to allow for venting.
Switch on the electrical supply to the Heater and
switchthe programmer ON.
Switch OFF after about five seconds and vent all
pointsagain.
Repeat this for 5 minutes.
Re-pressuriseifrequired.
Turn on pump (do not turn on gas) and run for at
least 30 minutes.
Stop pump at five minute intervals and vent until no
more air can be removed and air noises are no
longer produced at the Heater.While the system is
venting check again for water soundness.
16 100 Gas Condensing Pool Heater22/07/03

Rating Table(1040 Btu/ft³) (38.8 MJ/m³ )
kW Btu/h sec/ft³m³/2 mins
22 75064 49.9 0.0680
24 81888 45.7 0.0742
26 88712 42.2 0.0804
TURN ONTHE GAS
Check for gas soundness (BS 6891) in pipework to
theHeater using amanometer.
Open the gas cock and after purging the system,
the Heater will light automatically.
Run the system at maximum thermostat setting.
Gassoundness withinthe Heatershould be
checked using sense of smell and/or leak detection
fluid.
Continuerunning for15 minutes,venting every5
minutes.
The MainValve gradually raises the pressure to the
set point. Allow at least 60 seconds for the Model
100 and 100 seconds for the Model 100W for the
final pressure to stabilise.NB The Pilot has no
adjustment.
IMPORTANT. It is essential when setting the burner
pressure that the inlet pressure is at least 20 mbar
with the Heater and any other connected appliances
running.
Check the burner pressure is correct by using a
manometerconnected tothe control. (See the
Datatable inside the cover,the chart below and
Fig.6:2a & 6:2b)
The pump speed is set by the Manufacturer at £
andshould notbe changed.
Re-pressurisetorequired pressure.
With the system hot, check again for water sound-
ness. Refit the case to the Heater.Add remainder
of corrosion inhibitor.If there is a Space Heating
system balance in the normal way to obtain even
heatingof allradiators.
If fitted, set the cylinder thermostat to 60oC, or
lowerifpreferred.
Completethe Logbook and pass tothe user when
explainingand demonstratethe operation ofthe
system.Their instructions are in the first pages of
this Installation Instructions.
Note:The Heater is fitted with a syphon trap that in-
cludes a blocked drain detection device. This is to
safeguardthe Heater andhelp defer theeffects from
the possible freezing of the condensate pipework in
extremeweather.
The user should be made aware of this feature and,
thatin theevent ofblocked condensate pipework,for
examplefrozen condensatepipework,the Heaterwill
automatically stop functioning. It will start again as
soon as the blockage has cleared.
COMMISSIONCHECK LIST (HYDRAULIC)
The key points which must be observed closely, are
shownbelow.
* With radiator valves and vents open fill the
system.
*Do not use pump. Do not light gas
* Check for and rectify leaks.
* Drain to flush system.
* Refill system, adding ¾ of the inhibitor.
*Do not light Heater.
* Vent all radiator and air release points.
* Runpump for 5-10 second bursts and revent.
*Do not light Heater.
* Run pump for at least 30 minutes.
* Stop at 5 minute intervals to vent.
* Continue venting until no more air noise can be
heard.
* Light Heater and run at max thermostat setting.
Continue for 15 minutes, venting every 5
minutes.
* Addremainder of inhibitor.
Table 6:2
17
100 Gas Condensing Pool Heater 20/10/03

GAS VALVE
Fig 6:2a
18 100 Gas Condensing Pool Heater
01/06/02
IN OUT
GAS INLET
GAS OUTLET
INLET PRESSURE POINT OUTLET PRESSURE POINT
GAS VALVE
Fig 6:2b
100W
100

6.3 SETTING UPTHE CONTROLS
It is recommended that you familiarise yourself with
the functions of the Control.These are detailed in
the User Instructions Section ,andthe Heater
Control Section .
There are two options that should be set to suit the
user and it also recommended that the Fault Logs
arecleared.
1. The display is factory set for
Fahrenheit Centigrade,it canbe alteredto
showCentigrade.
2. If the Heater is also providing Space Heat
ing/DHW, the factory setting of Pool priority
may want to be changed to Heating priority.
Priority means, whichever is chosen has to
be up to temperature before it heats the
other.
These settings can be altered, and other data
viewedin‘Setup Mode’
Setting Heating Knob On or Off Fascia Indicator
1 Heatertemperature* Actualtemperature Settemperature e.g 20 & 70
Factorysetting Alternative
2 Display Units °F =Fahrenheit °C=Centigrade °C or °F
3 Priority P = Pool H = Heating P or H
4 Filter Pressure log # Numberof Operations Resets to zero Yellow Filter LED On
5 Notused
6 Notused
7 VersionNumber __e.g.010
*In this position with the Pool Temperature Control off, the Heater can be run for test purposes, if there is a Space
Heating demand, by turning On the Heating Temperature Control Knob.
#Reset the log by turning the Heating Temperature Control Knob On or Off.
Table 6:3.Control Display in Setup Mode.
PROCEDURETO ENTER SETUP MODE
To enter SetupMode turn bothTemperatureControl
Knobs to OFF.
The following must be carried out within 5 seconds.
1.Turn on the Mains supply to the Heater.
2.Turn thePoolTemperatureControl KnobON.
3.Turn theHeatingTemperatureControlKnobON.
4.TurnthePoolTemperatureControl KnobOFF.
5.TurnThe HeatingTemperatureControlKnob OFF.
The Control is now in‘Setup Mode’and displaying
theHeater temperature.Additional data isdisplayed
as the PoolTemperature Knob is rotated. See Fig.
6:3 &Table 6:3
Settings that can be altered are changed by turning
theHeatingTemperature ControlKnob On orOff.
To leave‘Setup Mode’and retain the new settings,
turn off the Mains supply for a few seconds at any
time.
Note: At power-up the Display is also used to show
fault conditions. If an unexpected display is shown
please check the Fault Finding Section 10:2.
Fig 6:3
ON
bar
0 4
2
1 3
us
erinstr
uction
sinside
userinstr
uctionsinside
100
seeinstructions
2
3
45
6
7
1
Heater Temperature
Actual & Setting
Setting Knob Adjusting Knob
Display units
°C or °F
Priority
P = Pool
H = Heating
Filter Log
Not Used
Version
Number
Overheat LED
Filter LED
19
100 Gas Condensing Pool Heater 01/06/02