Glen dimplex Combi 24 User guide

Combi 24

Combi 30

Combi 38

Combination Condensing Boilers

Installation and

Servicing Instructions

These instructions should be left with the user

SALES AND SERVICE HELPLINE: 0844 371 1111

Glen Dimplex Boilers is continually improving its products and therefore

reserve the right to change product specifications without prior notice.

Errors & omissions excepted.

Glen Dimplex Boilers

Stoney Lane

Prescot

Merseyside. L35 2XW

For all telephone enquiries call:

0844 371 2222

website:

www.glendimplexboilers.com

Part of the Glen Dimplex Group

48pp MANUAL SPREADS 19/10/10 08:36 Page 1

GAS COUNCIL NUMBERS

Natural Gas

Dimplex Combi 38 - Gas Council Appliance No: 4

47 149 01

Dimplex Combi 30 - Gas Council Appliance No: 4

47 149 02

Dimplex Combi 24 - Gas Council Appliance No: 4

47 149 03

APPROVED PRODUCT

17.0 BENCHMARK

VENTED CYLINDER COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the

cylinder as a means of demonstrating compliance with the appropriate Building Regulations and should

remain attached to the cylinder for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the

warranty but does not affect statutory rights.

Commissioned by (print name)

Company Name

Company Address

Telephone Number Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate*:

Building Regulations Notiﬁcation Number (if applicable)

ALL CYLINDERS

The vent pipe has been installed to BS6700/BS5449 Yes

What is the static head? metres

Has an immersion heater been ﬁtted? Yes No

If yes, does it have a non-auto resetting energy cut out? Yes No

Is the cold feed cistern supported in accordance with BS4213? Yes

Is the cylinder solar (or other renewable) compatible? Yes No

All appropriate pipes including the vent pipe have been insulated

up to 1metre or the point where they become concealed Yes

*Where an installation is notiﬁable in England & Wales this will be made to Local Authority Building Control

(LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance

Certiﬁcate will then be issued to the customer.

©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

INDIRECT ONLY

A cylinder thermostat has been ﬁtted in the recommended position Yes

The hot water is controlled by a programmer or time switch Yes

Is the system fully pumped? Yes No

Type of control system Y Plan S Plan Other

18.0 WARRANTY TERMS & CONDITIONS

18.1 DIMPLEX 5YR WARRANTY

1. Registration must be completed within 30 days of installation. Failure to return within 30 days will invalidate your warranty. Registration if

effected by returning the enclosed registration card to the commercial center of Dimplex at 5 Spartan Close, Tachbrook Park, Leamington Spa,

CV34 6RR. Proof of postage should be obtained.

2. The Benchmark document must be completed by installer/householder at the time of installation and must be presented to our engineer at

subsequent visits.

3. The boiler must be serviced annually, at the householders expenses in accordance with manufacturer’s instructions, and this service must be

booked through Dimplex by calling 0844 371 1121

4. The service must be carried out by a Dimplex approved central heating engineer. Any work carried out by a non-Dimplex approved engineer

will invalidate this warranty.

5. Appropriate system cleaning (e.g. power flush) and the correct use of additives must be carried out at the time of installation. Failure to

cleanse the system will invalidate this warranty. Evidence of cleansing should be presented to our engineer upon request.

6. This warranty applies only to manufacturing problems with the boiler; damage caused through misuse, incorrect operation, foreign bodies in

the heating system, system faults and failures are not covered.

7. This warranty applies only if the boiler is installed and used in accordance with the manufacturer’s instructions, in normal domestic

applications.

8. Providing all the above Terms and Conditions are met, this warranty covers functional parts and labour.

9. Dimplex offer the opportunity for a system audit and commissioning check within 30 days of registration. This is chargeable at the same rate

as an annual service and if taken up then the first annual service will be provided free of charge. Failure to take up this offer may invalidate

the full warranty which will revert to a standard 2 year warranty which will require an annual service In year 2 in any event.

10. Failure to meet any of the above Terms and Conditions will invalidate this warranty.

48pp MANUAL SPREADS 19/10/10 08:36 Page 2

17.0 BENCHMARK

SERVICE RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s

instructions.

SERVICE 1 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 2 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 3 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 4 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 5 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 6 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 7 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 8 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 9 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 10 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

CONTENTS

SECTION DESCRIPTION PAGE

1.0 Introduction 4

2.0 Boiler Layout 7

3.0 Boiler Operation 8

4.0 Technical Data 9

5.0 Dimensions 10

6.0 System Details 11

7.0 Site Requirements 14

8.0 Flue options 18

9.0 Installation 22

10.0 Commissioning 26

11.0 Service Mode 28

12.0 Servicing & Maintenance 29

13.0 Changing Components 32

14.0 Electrical 40

15.0 Spare Parts 41

16.0 Error Codes 42

17.0 Benchmark 43

18.0 Warranty Terms & Conditions 47

48pp MANUAL SPREADS 19/10/10 08:36 Page 3

1.0 INTRODUCTION

1.1 BUILDING REGULATIONS AND BENCHMARK CHECKLIST

Building Regulations (England & Wales) require notification of

the installation of a heating appliance to the relevant Local

Authority Building Control Department.

From 1 April 2005 this can be achieved via a Competent

Persons Self Certification Scheme as an option to notifying the

Local Authority directly.

CORGI operates a Self Certification Scheme for gas heating

appliances.

With the introduction of Self Certification Schemes, the

Benchmark Logbook is being withdrawn. However, a similar

document in the form of a commissioning checklist and service

interval record is incorporated at the back of these

instructions.

This company is a member of the Benchmark initiative and

fully supports the aims of the programme. Its aim is to

improve the standards of installation and commissioning of

central heating systems in the UK and to encourage the regular

servicing of all central heating systems to ensure safety and

efficiency.

Building Regulations require that installations should comply

with manufacturer’s instructions. It is therefore important that

the commissioning checklist is completed by the installer. The

relevant section of Building Regulations only relates to

dwellings. Therefore the checklist only applies if the appliance

is being installed in a dwelling or some related structure.

1.2 INSTALLATION, COMMISSIONING, SERVICE & REPAIR

This appliance must be installed in accordance with the

manufacturer’s instructions and the regulations in force. Read

the instructions fully before installing or using the appliance.

In GB, this must be carried out by a competent person as

stated in the Gas Safety (Installation & Use) Regulations.

Definition of competence:

A person who works for a CORGI

registered company and holding current certificates in the

relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated

in I.S. 813 “Domestic Gas Installations”

No modifications or changes can be made to this appliance

without prior written permission from Dimplex Boilers.

The manufacturers instructions must not be taken as overriding

any statutory requirements. If in doubt contact Dimplex Boilers

on 0844 3711121.

Warning -

Check the information on the data plate is

compatible with local supply conditions.

All CORGI registered installers carry a CORGI identification card

and have a registration number. You can check your installer is

registered by telephoning 0870 4012300 or writing to:-

1 Elmwood

Chineham Business Park

Crockford Lane

Basingstoke

RG24 8WG

or check online at www.corgi-gas-safety.com

These appliances meet the requirements of;

Gas Appliance Directive 90/396/EEC

Efficiency of Hot Water Boilers Directive 92/42/EEC

Low Voltage Directive 92/42/EEC

Electromagnetic Compatibility Directive 92/31/EEC

Type test certified by:- Notified Body 0087 (Pin 87BT49).

Product/Production certified by:

Notified Body 0086.

For GB/IE only

17.0 BENCHMARK

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

*llA installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system? Sealed Open

What is the maximum primary ﬂow temperature? °C

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system? bar

Has a strainer been cleaned of installation debris (if ﬁtted)? Yes No

Is the installation in a hard water area (above 200ppm)? Yes No

If yes, has a water scale reducer been ﬁtted? Yes No

What type of scale reducer has been ﬁtted?

What is the hot water thermostat set temperature? °C

What is the maximum hot water ﬂow rate at set thermostat temperature (measured at high ﬂow outlet)?

l/min

Time and temperature controls have been ﬁtted in compliance with Part L of the Building Regulations? Yes

Type of control system (if applicable) Y Plan S Plan Other

Is the cylinder solar (or other renewable) compatible? Yes No

What is the hot water temperature at the nearest outlet? °C

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes

UNVENTED SYSTEMS ONLY

Where is the pressure reducing valve situated (if ﬁtted)?

What is the pressure reducing valve setting? bar

Has a combined temperature and pressure relief valve and expansion valve been ﬁtted and discharge tested? Yes No

The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes

Are all energy sources ﬁtted with a cut out device? Yes No

Has the expansion vessel or internal air space been checked? Yes No

THERMAL STORES ONLY

What store temperature is achievable? °C

What is the maximum hot water temperature? °C

ALL INSTALLATIONS

The hot water system complies with the appropriate Building Regulations Yes

The system has been installed and commissioned in accordance with the manufacturer’s instructions Yes

The system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of

demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name Telephone Number

Address

Cylinder Make and Model

Cylinder Serial Number

Commissioned by (print name) Registered Operative ID Number

Company Name Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate*:

Building Regulations Notiﬁcation Number (if applicable)

48pp MANUAL SPREADS 19/10/10 08:36 Page 4

17.0 BENCHMARK

It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s

instructions.

Always use the manufacturer’s speciﬁed spare part when replacing controls.

SERVICE 1 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 3 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 5 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 7 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 9 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 2 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 4 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 6 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 8 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 10 Date

Energy Efﬁciency Checklist completed? Yes No

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE RECORD

1.0 INTRODUCTION

1.3 LEGISLATION

The appliance is suitable only for installation in GB and IE and

should be installed in accordance with the rules in force, and

only used in a suitably ventilated location.

In GB, the installation must be carried out by a CORGI

Registered Installer. It must be carried out in accordance with

the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building

regulations, The Building Regulations (Scotland), Building

Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in

Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be

made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent

Person and installed in accordance with the current edition of

I.S. 813 ‘Domestic Gas Installations’, the current Building

Regulations and reference should be made to the current ETCI

rules for electrical installation.

All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

Codes of Practice - refer to the most recent version

In GB the following Codes of Practice apply:

Standard Scope

BS 7967 Carbon monoxide in dwellings and the

combustion performance of gas fired appliances

BS 7967-2 Guide for using electronic portable combustion

gas analysers in the measurement of carbon

monoxide and the determination of combustion

performance

BS 7967-3 Guide for responding to measurements obtained

from electronic portable combustion gas

analysers

BS 7967-4 Guide for using electronic portable combustion

gas analysers as part of the process of servicing

and maintenance of gas fired appliances

BS 6891 Gas installation

BS 5546 Installation of hot water supplies for domestic

purposes

BS 5449 Forced circulation hot water systems

BS 6798 Installation of gas fired hot water boilers

BS 5440 Part 1 Flues

BS 5440 Part 2 Ventilation

BS 7074 Expansion vessels and ancillary equipment

for sealed water systems

BS 7593 Treatment of water in domestic hot water

central heating systems

In IE the following Codes of Practice apply:

Standard Scope

I.S. 813 Domestic Gas Installation

The following standards give valuable additional information;

BS 5546 Installation of hot water supplies for domestic

purposes

BS 5449 Forced circulation hot water systems

BS 7074 Expansion vessels and ancillary equipment

for sealed water systems

BS 7593 Treatment of water in domestic hot water

central heating systems

GAS LEAKS

DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A

NAKED FLAME. TURN OFF THE GAS SUPPLY. VENTILATE THE

AREA BY OPENING DOORS AND WINDOWS. CALL OUT YOUR

LOCAL GAS SUPPLIER

TEL: 0800 111 999

Control of Substances Hazardous to Health

Under Section 6 of the Health and Safety at Work Act 1974, it

is required to provide information on substances hazardous to

health.

The adhesives and sealants used in this appliance are cured and

give no known hazard in this state.

Insulation Pads - These can cause irritation to skin, eye and

respiratory tract. If you have a history of skin complaint you

may be susceptible to irritation. High dust levels are usual only

if the material is broken. Normal handling should not cause

discomfort, but follow normal good hygiene and wash your

hands before eating, drinking or going to the lavatory. If you do

suffer irritation to the eyes or severe irritation to the skin seek

medical attention.

Gas and Electricity Consumer Council (Energywatch)

Energywatch is an independent organisation, which protects

the interests of gas users. If you need advice concerning

energy issues, they may be contacted on their consumer help

line number: 08459 060708, or via their website;

www.energywatch.org.uk.

This appliance is not intended for use by persons (including

children) with reduced physical, sensory or mental capabilities,

or lack of experience and knowledge, unless they have been

given supervision or instructions concerning use of the

appliance by a person responsible for their safety. Children

should be supervised to ensure that they do not play with the

appliance.

48pp MANUAL SPREADS 19/10/10 08:36 Page 5

1.0 INTRODUCTION

1. The appliances incorporate a microprocessor based, fully

modulating air/gas ratio control system with direct burner

ignition. This provides a modulated heat output to either

central heating (CH) or domestic hot water (DHW) demands,

with internal frost protection provided as standard. The heat

exchanger is constructed from stainless steel encased in high

temperature polymer.

A combined circulating pump, diverter valve and automatic air

vent assembly, pressure gauge, safety valve and system

expansion vessel are included.

Isolation valves are fitted to the service connections. The

appliances have a DHW flow detection device, which gives

priority to DHW demand and proportions the required heating

load to the DHW flow rate. An electro-mechanical 24 hour

time clock is also fitted as standard.

The boiler has a pump over run feature therefore the central

heating system must include either a proprietary automatic

bypass valve or a radiator must be fitted with lock shield

valves. A separate CH expansion vessel is not required if the

total CH system content is less than 84 litres. However one is

required for systems with volumes greater than 84 litres; refer

to section 6.5. A separate DHW expansion vessel is not

required. It is recommended that a drain cock is fitted at the

lowest point in the system.

1.5 DESCRIPTION

RF room thermostats etc, are available as optional extras.

The integral clock may be removed, however the hole in the

fascia must be covered using a fascia blanking panel

(part no. 300635).

2. The boiler is set to give a maximum output of:-

24kW Model - 24kW DHW

19.7kW CH (condensing)

30kW Model - 30kW DHW

25.4kW CH (condensing)

38kW Model - 38kW DHW

32kW CH (condensing)

3. It is designed for use on Natural Gas (G20). A natural gas to

propane conversion kit is available for each Dimplex Combi.

4. The boiler is suitable for use only on fully pumped sealed

heating systems. Priority is given to domestic hot water.

5. The boiler data badge gives details of the model, serial

number and Gas Council number and is situated on the inner

door panel. It is visible when the case front panel is lowered.

(Fig. 1)

6. The boiler model name and serial number are also shown on

the information label on the inside of the fascia. This is for

user reference.

7. The boiler is intended to be installed in residential /

commercial / light industrial E.M.C. environments on a

governed meter supply only.

8. The boiler must be installed with one of the purpose

designed flues such as the standard horizontal telescopic flue

kit, part no. 956120.

9. A

All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

1.6 OPTIONAL EXTRAS

• Boiler

• Wall fixing jig

• Templates & ‘Quick Fit’ Guide

• Literature Pack

• Filling Loop

• Plugs and screws

1.7 PACK CONTENTS

1.4 SAFE MANUAL HANDLING

1. The boiler should be handled and lifted by two people.

Wear appropriate Personal Protection Equipment e.g. protective

gloves, safety footwear etc.

Plan your route to minimise the number of turns needed to

handle/lift the boiler.

2. Where possible transport the boiler using a sack truck or

other suitable trolley. Try to avoid steps, wet or slippery

surfaces, unlit areas etc. and take special care on ladders/into

lofts.

3. When handling or lifting always use safe techniques - keep

your back straight, bend your knees. Don’t twist - move your

feet, avoid bending forwards and sideways and keep the load

as close to your body as possible.

4. Asses the risks associated with handling and lifting

according to the conditions on site. If in doubt seek advice

before proceeding. Health and Safety is the responsibility of

everyone.

17.0 BENCHMARK

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS Tick the appropriate boxes

Time and Temperature Control to Heating Room Thermostat and Programmable Load/Weather Optimum Start

Programmer/Timer Room Thermostat Compensation Control

Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer/Timer Combination Boiler

Heating Zone Valves Fitted Not Required

Hot Water Zone Valves Fitted Not Required

Thermostatic Radiator Valves Fitted Not Required

Automatic Bypass to System Fitted Not Required

Boiler Interlock Provided

ALL SYSTEMS

The system has been ﬂushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions Yes

What system cleaner was used?

What inhibitor was used? Quantity litres

CENTRAL HEATING MODE Measure and Record:

Gas Rate m3/hr OR

ft3/hr

Burner Operating Pressure (if applicable) mbar OR Gas Inlet Pressure mbar

Central Heating Flow Temperature °C

Central Heating Return Temperature °C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes No

If yes, has a water scale reducer been ﬁtted? Yes No

What type of scale reducer has been ﬁtted?

DOMESTIC HOT WATER MODE Measure and Record:

Gas Rate m3/hr OR

ft3/hr

Burner Operating Pressure (at maximum rate) mbar OR Gas Inlet Pressure (at maximum rate) mbar

Cold Water Inlet Temperature °C

Hot water has been checked at all outlets Yes Temperature °C

Water Flow Rate l/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS

If required by the manufacturer, record the following CO2% OR CO ppm OR CO/CO2Ratio

The heating and hot water system complies with the appropriate Building Regulations Yes

The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes

The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

*All installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating

compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name Telephone Number

Address

Boiler Make and Model

Boiler Serial Number

Commissioned by (print name) CORGI ID Number

Company Name Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate*:

Building Regulations Notiﬁcation Number (if applicable)

48pp MANUAL SPREADS 19/10/10 08:36 Page 6

16.0 ERROR CODES

The boiler is in an ERROR state when there is an error code flashing on the back lit display.

CH = Central Heating

DHW = Domestic Hot Water

BCC = Boiler Chip Card

Press and release the RESET button, the control tries to initiate a restart if possible

ERROR CODE DESCRIPTION REASON ACTION RESET POSSIBLE

1 Overheated CH Water temperature •Check no air is in heat exchanger/CH system

appliance greater than 105°C •Check plate heat exchanger for blockages Y

•Check CH thermistor

•Check system bypass is functional

4 No flame No flame signal on ignition •Check detection electrode/lead – electrode may require cleaning

•Check spark gap

•Check gas supply & pressure Y

•Check flue system is connected properly

•Check condensate trap not blocked

•Check gas valve and/or lead

5 Flame loss Loss of flame signal •Check detection electrode/lead Y

during operation •Check gas valve mains lead

6 Temporarily Water temperature •Check overheat thermostat

overheated appliance greater than 95°C •Check no air is in heat exchanger/CH system

•CH system and hot water plate heat exchanger blockage Auto Re-start after 1 minute

•Check CH thermistor

•Check system bypass is functional

7 Overheated appliance Flue over temperature •Check no air in heat exchanger

> 92°C •Check flue thermistor

•Check flue system Y

•Check pump

•Check PCB/X8 connector

11 Flame simulation Flame detected when •Check detection electrode/lead electrode may require cleaning Y

gas valve closed •Check gas valve operation.

12 No ignition CH Flow thermistor failure •Check CH flow thermistor – open circuit Auto Re-start when fixed

•Check PCB/X6 connector – open circuit

13 No flame Flue thermistor failure •Check PCB/X8 connector

•Check flue thermistor Auto Re-start when fixed

•Check thermal fuse – open circuit

16 No ignition CH Return thermistor failure •Check CH return thermistor – open circuit Auto Re-start when fixed

•Check PCB/X6 connector – open circuit

20 No flame Gas valve V1-V2 failure •Check/replace gas valve

•Check gas valve harness Y

•Check PCB/X2A

24 Faulty fan signal, Missing or defective •Check fan operation

no flame and fan signal from fan. •Check fan connection Y

runs continuously •Check PCB/X3 connector

•Check flue condition

32 No flame Power supply failure •Check mains supply voltage to boiler Auto Re-start when fixed

•Check all PCB connectors

34 CRC Error / No flame Incorrect BCC •Replace correct BCC Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

35 BCC Error / No flame Incorrect/missing BCC •Reseat or replace BCC Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

36 BCC Error / No flame Damaged BCC •Replace BCC Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

37 BCC Error / No flame Different BCC •BCC and PCB software incompatible, replace BCC Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

38 BCC Error / No flame Different BCC •Reset the appliance in accordance with BCC fitting instructions Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

39 BCC Error / No flame BCC installation failed •Refit BCC in accordance with BCC fitting instructions Auto Re-start when fixed

(BCC’s only fitted to replacement PCB’s)

41 Water flow failure/ Low water pressure •Check CH flow circulation

Flame for a short Reversed sensors •Check water pressure(> 0.5 bar)

period only •Check pump/lead Y

•Check expansion vessel

•Check flow and return sensors connected correct way around

42 Water flow failure/ Low water pressure •Check no air in heat exchanger

Flame for a short No flow •Check CH flow circulation

period only Dry run protection •Check water pressure(> 0.5 bar) Y

•Check pump/lead

•Check expansion vessel

50 BCC Error / No flame BCC Activation •Press reset to activate BCC (BCC’s only fitted to replacement PCB’s) Y

No light DHW cold Defective DHW flow switch •Check DHW flow turbine & lead Auto Re-start

display when or defective •Check DHW/CH thermistor when fixed

tap on DHW/CH thermistor •Check PCB/X4 connector

(No display) No light indication Defective power supply •Check power supply

•Check PCB/X1B connector Auto Re-start when fixed

•Check PCB fuse

2.0 BOILER LAYOUT

2.1 KEY

1. Expansion Vessel

2. Automatic Air Vent

3. DHW Plate Heat Exchanger

4. Circulation Pump

5. Drain Off Point

6. Pressure Relief Valve

7. Central Heating System Pressure Gauge

8. PCB

9. Control Box

10. 3-Way Valve Assembly

11. Flexible condensate pipe assembly

12. Flame Sensing Electrode

13. Spark Electrode

14. Primary Heat Exchanger

15. Fan Assembly

16. Gas Valve & Swirl Plate Assembly

17. Reset Button

18. Central Heating Temperature Control

19. Hot Water Temperature Control

20. Air / Gas Channel

21. Burner & Burner Door

22. Spark Generator

23. Data Badge

24. Flue Sample Point

25. Manual Air Vent

26. Burner On Light

27. Central Heating Mode Light

28. Domestic Hot Water Mode Light

29. Display

30. Integral Timer

31. Flue Thermistor

32. Thermal Fuse

33. Comfort + / Eco Mode Light

Comfort+

bar

Comfort +

bar

Fig. 1

17 29 33 1927

1830 2628

48pp MANUAL SPREADS 19/10/10 08:36 Page 7

3.0 BOILER OPERATION

3.1 CENTRAL HEATING MODE

1. With a demand for heating, the pump, circulates water

through the primary circuit.

2. Once the main burner ignites the fan speed controls the gas

rate to maintain the heating temperature measured by the

temperature sensors.

3. When the demand is satisfied the burner is extinguished and

a 5 minute delay occurs before the burner will re-light (anti-

cycling), the pump continues to run for a period of 2 minutes

(Pump Overrun).

3.2 DOMESTIC HOT WATER MODE

1. Priority is given to the domestic hot water supply. A demand at a

tap or shower will override any central heating requirement.

2. The flow of water will operate the Flow Turbine which requests the

3 way valve to change position. This will allow the pump to circulate

the primary water through the DHW plate heat exchanger.

3. The burner will light automatically and the temperature of the

domestic hot water is controlled by the temperature sensors.

4. When the domestic hot water demand ceases the burner will

extinguish and the diverter valve will remain in the domestic hot water

mode, unless there is demand for central heating.

3.3 FROST PROTECTION MODE

1. Providing there is mains power supply to the appliance, the frost

protection mode is integral.

If the system temperature falls below 5°C then the boiler will fire on

its minimum setting until a flow temperature of 20°C is reached.

Further protection can be incorporated by using a system frost

thermostat.

3.4 PUMP PROTECTION

1. The pump will automatically operate for 1 minute in every 24 hours

to prevent sticking.

Expansion

Vessel Primary

Heat Exchanger

Burner &

Burner Flange

Primary Flow Primary Return

CH flow

Thermistor

CH return

Thermistor

Plate Heat

Exchanger

Condensate

Trap

Pressure

Gauge Flow

Turbine

DHW Cold

Inlet

Return

3 BAR

Pressure Relief

Val ve

DHW Hot

Outlet

Pump &

Hydroblock

Automatic

Air

Vent

Flow

Flue Products

CH Mode Manual

Bleed Valve

Expansion

Vessel Primary

Heat Exchanger

Burner &

Burner Flange

Primary Flow Primary Return

CH flow

Thermistor

CH return

Thermistor

Plate Heat

Exchanger

Condensate

Trap

Pressure

Gauge Flow

Turbine

DHW Cold

Inlet

Return

3 BAR

Pressure Relief

Val ve

DHW Hot

Outlet

Pump &

Hydroblock

Automatic

Air

Vent

Flow

Flue Products

DHW Mode Manual

Bleed Valve

Flow Rate

Restrictor

Flow Rate

Restrictor

Fig. 2

Fig. 3

15.0 SPARE PARTS

15.1 SHORT PARTS LIST

Key GC Number Description QTY Pt. No.

1 H29-740 Electrode - Ignition c/w Gasket 1 988526

2 H38-213 Detection Electrode c/w Gasket 1 988540

3 H29-236 Spark Generator c/w Lead 1 500665

4a TBA Dimplex Combi 24 gas control valve assembly NG 1 988660

4b TBA Dimplex Combi 30 gas control valve assembly NG 1 988661

4c TBA Dimplex Combi 38 gas control valve assembly NG 1 988662

5 H38-215 Fan Assembly 1 601016

6a H29-171 Burner (Combi 24) 1 700600

6b H29-172 Burner (Combi 30) 1 700601

6c TBA Burner (Combi 30) 1 700602

7 TBA Burner Door Insulation 1 352671

8a H38-217 Heat Exchanger (Combi 24) 1 451101

8b H38-218 Heat Exchanger (Combi 30) 1 451100

8c TBA Heat Exchanger (Combi 38) 1 451151

9 H29-202 Pump Head 6m 1 500672

10 H29-203 Diverter valve Motorised Head 1 500750

11 H29-237 Expansion Vessel 1 451020

12 TBA 3 Bar Pressure Relief valve 1 500751

13 H29-213 Water Temperature sensor 2 500661

14 H38-219 Flue Thermistor 1 500662

15a TBA Dimplex Combi 24kW Plate Heat exchanger kit 1 988671

15b TBA Dimplex Combi 30kW Plate Heat exchanger kit 1 988672

15c TBA Dimplex Combi 38kW Plate Heat exchanger kit 1 988673

16 E23-541 Pressure Gauge 4bar 1 450961

17 TBA Auto Air Vent 1 500752

18a TBA Dimplex Combi 24 NG PCB Kit 1 988663

18b TBA Dimplex Combi 30 NG PCB Kit 1 988664

18c TBA Dimplex Combi 38 NG PCB Kit 1 988665

19 E23-671 Time Clock - Grasslin FM1STUH 1 600520

20 TBA DHW Flow Turbine 1 300766

21a TBA DHW Flow Regulator (Combi 24) 1 300717

21b TBA DHW Flow Regulator (Combi 30) 1 300715

21c TBA DHW Flow Regulator (Combi 35) 1 300719

22 H29-179 Valve - Manual Bleed 1 300730

23 H38-226 Heat Exchanger seal & Clip Kit 1 988546

24 H29-208 Hydroblock - O-Ring and Clip 1 988669

25 TBA Hydroblock Manual bleed cock 1 500708

13 14

24 25

48pp MANUAL SPREADS 19/10/10 08:36 Page 8

14.0 ELECTRICAL

14.1 ILLUSTRATED WIRING DIAGRAM

g/y

br b

g/y

L3 L2 L1N

X1A CH7 RT CLOCK

24Hr TIME CLOCK

LCD DISPLAY

RIBBON TO PCB

RIBBON TO

LCD DISPLAY

MAINS

POWER

GAS VALVES

230Vac

FAN

230Vac

RETURN TEMP

THERMISTER

(5K NTC)

BOILER

TO PC

COM PORT

FLOW TEMP

THERMISTER

(5K NTC)

BOILER PUMP

230Vac

FLOW TURBINE

230Vac

DETECTION

ELECTRODE

IGNITION

ELECTRODE

SPARK GENERATOR

230Vac

ROOMSTAT OR LINK

X1B MAINS

X1C BOILER PUMP

X2A GAS VALVES

X3 FAN

X5 COM PORT

X6 FLOW N.T.C.

BOILER CHIP CARD BCC

X6 RETURN N.T.C.

X2B IGNITER / FLAME SENSOR

bk bk

FLUE TEMP

THERMISTER

(5K NTC)

THERMAL FUSE

Key - Cable Colours

g Green

y Yellow

b Blue

r Red

bk Black

o Orange

g/y Green / Yellow

br Brown

gr Grey

w White

g/y

X8 FAN CONTROL

X8 FLUE

X8 DHW FLOW

(IF FITTED)

X4 HYDROBLOCK DIVERTER

o b g/y r br

Appliance Classification C13, C33, C53, B23

Appliance Combi 24 Combi 30 Combi 38

Mode Rate

Central Heating Output (non-condensing)(80-60°C) Max kW 18.0 23.3 30.0

Min kW 6.0 7.4 9.8

Central Heating Output (condensing)(50-30°C) Max kW 19.5 25.3 32.7

Central Heating Input Max Rate Net kW 18.4 23.9 30.6

Gross kW 20.4 26.5 34.0

Central Heating Input Min Rate Net kW 5.6 6.9 9.2

Gross kW 6.2 7.7 10.2

Domestic Hot Water Output Max kW 24.0 30.4 38.0

Min kW 6.0 7.4 9.8

Domestic Hot Water Input Max Rate Net kW 24.6 31.3 38.8

Gross kW 27.3 34.7 43.1

Domestic Hot Water Input Min Rate Net kW 5.6 6.9 9.2

Gross kW 6.2 7.7 10.2

Central Heating Gas Rate (after 10 min operation - hot) Max m3/h 1.95 2.49 3.24

Domestic Hot Water Gas Rate (after 10 min operation - hot) Max m3/h 2.6 3.31 4.1

Seasonal Efficiency % 90.3 90.3 90.5

Seasonal Efficiency (SEDBUK) Band “A” “A” “A”

Nox Classification Class “5” “5” “5”

Design Domestic Hot Water Performance raised 35°C Ltr/min 9.8 12.3 15.6

DHW Specific Rate (D) EN 625 Ltr/min 10.9 14.7 18.1

Min Mains Water Inlet Pressure for Max Heat Output Bar 1.0 1.0 1.0

Min Mains Water Inlet Pressure for Operation Bar 0.3 0.3 0.3

Max Mains Water Inlet Pressure Bar 10 10 10

Min Domestic Hot Water Flow Rate for Operation Ltr/min 2.0 2.0 2.5

Min Central Heating System Pressure Bar 0.5 0.5 0.5

Max Central Heating System Pressure Bar 2.5 2.5 2.5

Max Domestic Hot Water Temperature °C 60 60 60

Min Domestic Hot Water Temperature °C 40 40 40

Max Central Heating Flow Temperature °C 80 80 80

Min Central Heating Flow Temperature °C 30 30 30

General Specifications

Max lift weight kg 33.6 36.6 39.6

Total water capacity Ltr 1.8 2.1 3.1

Integral expansion vessel capacity Ltr 8 8 8

Maximum heating system water content using fitted expansion vessel, @ 0.75 bar Ltr 84 84 84

Electrical supply 230V 50Hz Fuse at 3A

Internal fuse T4H 4A 250V

Maximum power consumption W 125 140 146

IP Rating IPX4 IPX4 IPX4

Flue gas temperature Nat Gas 80/80 (Propane) °C 80 80 80

Flue gas temperature Nat Gas 50/30 °C 70 75 77

CO2value max rate (Nat Gas) (Case must be fitted when taking reading) % 8.8-9.2 9.1-9.5 8.9-9.3

CO2value min rate (Nat Gas) (Case must be fitted when taking reading) % 8.2-8.6 8.7-9.1 8.3-8.7

CO value max rate (Nat Gas) (Case must be fitted when taking reading) P.P.M 40-120 40-120 40-120

CO value min rate (Nat Gas) (Case must be fitted when taking reading) P.P.M 0-40 0-40 0-30

CO2 value max rate (Propane) (Case must be fitted when taking reading) % 10.5-10.9 10.7-11.1 10.5-10.9

CO2value min rate (Propane) (Case must be fitted when taking reading) % 10.2-10.6 10.2-10.6 10.4-10.8

CO value max rate (Propane) (Case must be fitted when taking reading) P.P.M 80-160 100-180 70-150

CO value min rate (Propane) (Case must be fitted when taking reading) P.P.M 0-40 0-40 0-40

Gas Pressure - Natural Gas mbar 18-20 18-20 18-20

Gas Pressure - Propane mbar 37 37 37

Connections

Gas 22 mm compression

CH flow 22 mm compression

CH return 22 mm compression

DHW inlet 15 mm compression

DHW outlet 15 mm compression

Pressure relief valve outlet 15 mm compression

Condensate Drain 21.5 - 22 mm plastic overflow pipe

P.P.M = Parts Per Million

4.0 TECHNICAL DATA

4.1 PERFORMANCE DATA

48pp MANUAL SPREADS 19/10/10 08:36 Page 9

5.0 DIMENSIONS

65mm 60mm 60mm 65mm

10mm

Condensate

Drain

CH Flow

(22mm)

Domestic Hot

Water Outlet

(15mm)

Gas Inlet

(22mm)

Mains Cold

Water Inlet

(15mm)

CH Return

(22mm)

Tap Rail

446mm

264mm 182mm

796mm

150mm

94mm

333mm

148mm185mm

1.5° - 3.0°

Tube Ø 100mm

Fig. 4

Fig. 5

13.0 CHANGING COMPONENTS

13.18 PCB

1. Ensure supply voltage is fully isolated.

2. Undo the screws holding the control box and gently ease

the box forward (Fig. 69).

3. Locate the retaining barbs on the top of the fascia and

unclip them from the control box.

4. Unclip the PCB from the plastic control box.

5. Note the positions of all the connections on the PCB

and disconnect them.

(DO NOT REMOVE THE YELLOW BCC (Fig. 69))

6. Carefully unclip and remove the ribbon cable

from the PCB and withdraw.

7. Fit all the connection plugs to the new PCB

including the ribbon cable, take care not to damage

the PCB.

8. Unless specifically instructed N

NOT

to do so by the Dimplex

Service Department, always fit the new BCC if supplied with

the replacement PCB.

NOTE:

Always double check the label on the BCC card to

ensure it is the correct BCC for the boiler model to which it

is being fitted. Never fit an incorrect BCC, as this is

extremely dangerous and could result in serious injury or

death.

9. Reassemble in reverse order, ensuring that the control knob

are reset to their previous positions

13.19 BCC

1. Ensure supply voltage is fully isolated.

2. Dismantle the control box as described above to gain access

to the PCB (Fig. 69).

3. Note the orientation of the existing BCC (if fitted) and

carefully remove by sliding it off the edge of the PCB.

4. Re-fit the new BCC by sliding it onto the edge of the PCB,

ensuring the orientation is correct.

NOTE:

Always double check the label on the BCC card to

ensure it is the correct BCC for the boiler model to which it

is being fitted.

NEVER FIT AN INCORRECT BCC.

5. Reassemble as above.

6. Power up boiler, and briefly press the reset button, wait for

at least 5 seconds and then briefly press the reset button

again.

7. The boiler should now be checked for operation in DHW and

CH modes.

PCB

Facia

Control Box

Retaining Barbs

Pressure

Gauge

Timer

User Interface

Control Knobs

Fig. 69

BCC

48pp MANUAL SPREADS 19/10/10 08:36 Page 10

13.0 CHANGING COMPONENTS

13.16 EXPANSION VESSEL

1. Drain the primary circuit and undo the nut on the vessel

connection pipe.

2. Remove the two screws holding the retaining bracket and

remove the bracket (Fig. 67).

3. Carefully slide out the vessel from the boiler.

4. Reassemble in reverse order.

Expansion Vessel

Vessel Connection Pipe

Retaining

Bracket

Fig. 67

Fig. 68

Flue Elbow

Flue Adaptor

Main Heat

Exchanger

Left Hand

Retaining Bracket

Right Hand

Retaining Bracket

Flow Pipe

Retaining Clip

Return Pipe Retaining Clip

Manual Air Vent

13.17 MAIN HEAT EXCHANGER

1. Drain the primary circuit.

2. Remove the electrode leads, noting their positions as

described in section 13.2.

3. Remove the valve and fan assembly as described in Section

13.3.

4. Examine the gasket and replace if necessary.

5. Undo the four nuts securing the burner door and remove the

cover plate from the heat exchanger.

6. Remove the two clips from the flow and return pipes on the

bottom of the heat exchanger and slide out the pipes (Fig. 68).

7. Remove the clip holding the manual air vent and remove the

pipe from the top of the heat exchanger.

8. Remove the four screws holding the left and right hand

retaining brackets and remove the brackets.

9. Remove the four screws securing the flue to the top of the

boiler. Lift the flue adaptor out of the flue outlet in the top of

the heat exchanger.

10. Carefully slide the heat exchanger out of the boiler.

11. Reassemble in reverse order.

6.0 SYSTEM DETAILS

6.1 INFORMATION

1. The Dimplex Combi is a ‘Water Byelaws Scheme - Approved

Product’. Reference to the Water Research Council publications,

‘Water fittings and materials directory’ and ‘Water supply

byelaws guide’ give full details of byelaws and the IRNs.

6.3 SYSTEM CONTROL

1. The boiler is fitted with an integral mechanical timer.

2. It is recommended that external controls e.g. room

thermostat are fitted to further improve the operating

efficiency of the boiler and system.

6.2 CENTRAL HEATING CIRCUIT

1. The appliance is suitable for fully pumped SEALED SYSTEMS

ONLY.

Treatment of Water Circulating Systems

Failure to flush and add inhibitor to the system will

invalidate the appliance warranty.

• Central heating water systems will be subject to corrosion

unless an appropriate water treatment is applied. This means

that the efficiency of the system will deteriorate as corrosion

sludge accumulates within the system, risking damage to pump

and valves, boiler noise and circulation problems.

• When fitting new systems flux will be evident within the

system, which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out.

Using, for example Betz-Dearborn Sentinel X300 or X400 or

Fernox Superfloc Universal Cleanser. They should be used

following the flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing

agents/descalers should comply to BS7593 requirements, e.g.

Betz-Dearborn Sentinel X300 and Femox-Copal which should

be used following the inhibitor manufacturer’s instructions.

• It is important to check the inhibitor concentration after

installation, system modification and at every service in

accordance with the manufacturer’s instructions. (Test kits are

available from inhibitor stockists.)

• For information or advice regarding any of the above contact

Technical Enquiries - Tel: 0844 3711121.

• If thermostatic radiator valves are fitted, a radiator must be

fitted with two lock shield valves or the system must include a

proprietary automatic bypass valve, to enable correct operation

of the pump over-run facility.

48pp MANUAL SPREADS 19/10/10 08:36 Page 11

6.0 SYSTEM DETAILS

6.4 SYSTEM FILLING AND PRESSURISING

1. A filling point connection on the central heating return

pipework must be provided for initial filling and pressurising

and subsequent topping up of the system.

A filling loop is provided loose with the boiler

2. The filling method adopted must comply with all relevant

water supply regulations and use approved equipment.

3. Further details are given in;

for GB: Guidance G24.2 and recommendation R24.2 of the

Water Regulations Guide.

for IE: the current edition of I.S. 813 “Domestic Gas

Installations”.

4. The sealed primary circuits may be filled or topped up using

a temporary connection between the circuit and a supply pipe,

provided a ‘Listed’ double check valve or some other no less

effective backflow prevention device is permanently connected

at the inlet to the circuit and the temporary connection is

removed after use.

6.5 EXPANSION VESSEL (CENTRAL HEATING ONLY)

1. The appliance expansion vessel is pre-charged to 1 bar.

Therefore the minimum cold fill pressure is 2 bar. The vessel is

suitable for correct operation for system capacities up to 84

litres. For greater system capacities an additional expansion

vessel must be fitted.

For GB refer to BS 7074 Pt 1.

For IE, the current edition of I.S. 813 “Domestic Gas

Installations”.

6.6 PRESSURE RELIEF VALVE

1. The pressure relief valve is set at 3 bar, therefore all

pipework, fittings, etc. should be suitable for pressures in

excess of 3 bar and temperature greater than 100°C.

2. The pressure relief discharge pipe should be not less than

15mm diameter, run continuously downward, and discharge

outside the building, preferably over a drain. It should be

routed in such a manner that no hazard occurs to occupants or

causes damage to wiring or electrical components. The end of

the pipe should terminate facing down and towards the wall.

NOTE: Boiling water/steam could discharge from the pipe,

therefore it should be terminated away from windows and

doors.

DHW

Mains

Inlet

Return

Pressure

Relief

Discharge

Pipe

Temporary

Loop

Stop

Val v e

Stop

Val v e

Double

Check

Val v e

GasDHW

Outlet

Flow

Condensate

Dimplex Combi Range Available Head

Flow L/Min

Available Head M

7.00

0 5 10 15 20

6.00

5.00

4.00

3.00

2.00

1.00

0.00

Dimplex Combi

Fig. 8

Fig. 7

Expansion Vessel

Pressure

Relief Valve

Vessel charge and initial

system pressure

Total water content of

system using 8 litres

capacity expansion

vessel supplied with

appliance

For systems having a

larger capacity multiply

the total system capacity

in litres by this factor to

obtain the total minimum

expansion vessel capacity

required in litres

bar

litres

0.5

0.75

0.093

1.0

1.5

Fig. 6

Fig. 9

NOTE: Do not use the pressure relief valve to drain the system, because dirt

and debris could prevent the valve seating correctly.

13.0 CHANGING COMPONENTS

13.12 AUTOMATIC AIR VENT

1. Drain the primary circuit and rotate the automatic air vent

1/4 turn and remove from the pump body.

2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to

the new automatic air vent.

3. Reassemble in reverse order.

13.13 PRESSURE GAUGE

1. Drain the primary circuit and undo the nut on the pressure

gauge capillary.

2. Examine the ‘O’ ring seal, replace if necessary.

3. Unclip the facia from the control box

4. Lever the barbs securing the gauge to remove the gauge

from the control box (Fig. 64).

5. Reassemble in reverse order.

13.14 PRESSURE RELIEF VALVE

1. Drain the primary circuit.

2. Disconnect the discharge pipe from the valve. Ease off the

retaining clip (Fig. 65).

3. Note the orientation of the valve, rotate it and withdraw it

from the manifold.

4. Fit the new valve and ‘O’ ring and set to the previously

noted orientation. Reassemble in reverse order.

Fig. 64

Fig. 65

Automatic Air Vent

‘O’ Ring

Pressure Gauge

Pressure

Relief Valve

Retaining Clip

‘O’ Ring

Discharge Pipe

Capillary

‘O’ Ring

13.15 PLATE HEAT EXCHANGER

1. Drain the primary circuit.

2. While supporting the heat exchanger undo the two screws

securing it to the plastic manifold.

3. Hold the heat exchanger at the right hand side and rotate it

upwards. Withdraw it from the boiler over the gas valve.

Seals

4. There are four seals between the manifolds and heat

exchanger which may need replacement (Fig. 65).

5. Ease the seals out of the manifold. Replace carefully,

ensuring that when the seal is inserted into the manifold it is

parallel and pushed fully in.

6. When re-assembling ensure that the ‘V’ pattern on the heat

exchanger points to the right hand side of the boiler.

7. Reassemble in reverse order.

Plate Heat

Exchanger

Seal

Fig. 66

48pp MANUAL SPREADS 19/10/10 08:36 Page 12

13.0 CHANGING COMPONENTS

13.10 PUMP - HEAD ONLY

1. Drain the primary circuit and disconnect the wiring

connector from the pump head.

2. Remove the four socket head screws securing the pump

head to the body and draw the head away (Fig. 62).

3. A replacement Grundfos 15-60 head can now be fitted

(Fig. 62)(Part No: 500672).

4. Reassemble in reverse order.

5. Replace the wiring connector into the socket on the pump

head.

13.11 HYDROBLOCK

1. Drain the primary circuit.

2. Remove the four stainless clips at the base of the hydro-

block and disconnect the four pipes (Fig. 63).

3. Un-lock the two locking clips on the flow and return ports.

4. Disconnect the discharge pipe from the pressure relief valve.

5. Remove the four securing screws from below the boiler.

6. Carefully remove the hydro-block and change the relevant

components.

7. Reassemble in reverse order taking care to replace all the

clips correctly. Ensure the locking clips are in the ‘Locked’

position as shown opposite.

Pump Head

Locking Clip

Front

Stainless Clips

Rear

Stainless Clips

Un-Locked

(viewed from pipe end)

Locked

(viewed from pipe end)

X 4

X 2

Fig. 62

Fig. 63

6.0 SYSTEM DETAILS

6.7 DOMESTIC HOT WATER CIRCUIT

1. All DHW circuits, connections, fittings, etc. should be fully in

accordance with relevant standards and water supply

regulations.

2. Further guidance is given in:

for GB: Guidance G17 to G24 and recommendation R17 to R24

of the Water Regulations Guide.

for IE: the current edition of I.S. 813 “Domestic Gas

Installations”.

3. When the domestic water system includes any device which

prevents water expanding back towards the supply (check

valve, loose jumpered stopcock, water meter, water treatment

device) then an expansion vessel must be fitted (e.g. Zilmet

160ml, R1/215bar).

A single check valve must be fitted as shown in Fig. 10 to

prevent backflow to the supply pipe and to ensure the efficient

operation of the expansion vessel which is required to

accommodate the thermal expansion of the water.

If the hot water expansion is not provided for, then high

pressures can develop which may result in damage to fittings

and devices on the system.

4. The boiler’s maximum working mains pressure is 10 bar,

therefore all pipework, connections, fittings, etc. should be

suitable for pressure in excess of 10 bar. A pressure reducing

valve must be fitted for pressures in excess of 10 bar.

5. The final 600mm of the cold mains supply and domestic hot

water outlet must be made in 15mm copper pipe.

6. A cold mains flow regulator is fitted on the inlet to the flow

turbine (see Figs. 2 & 3 - page 8) to control water flow rates.

This may be removed to obtain higher flow rates. Flow rates

higher than specified for the appliance will reduce the

domestic hot water temperature.

6.8 SHOWERS

1. If a shower control is supplied from the appliance it should

be of the thermostatic or pressure balanced type. Thermostatic

type shower valves provide comfort and guard against high

water temperatures. Existing controls may not be suitable -

refer to the shower valve manufacturer.

6.9 HARD WATER AREAS

1. If the area of the installation is recognised as a HARD WATER

AREA then a suitable device should be fitted to treat the mains

water supply to the boiler. Contact your Water Distribution

Company for advice on suitable devices.

Expansion

Vessel

Boiler

Check

Valve

Stop Tap

Pressure

Reducer

Valve

To Hot

Tap s

Other Tap

Outlets

Fig. 10

48pp MANUAL SPREADS 19/10/10 08:36 Page 13

7.0 SITE REQUIREMENTS

7.1 LOCATION

1. The boiler may be fitted to any suitable wall with the flue

passing through an outside wall or roof and discharging to

atmosphere in a position permitting satisfactory removal of

combustion products and providing an adequate air supply. The

boiler should be fitted within the building unless otherwise

protected by a suitable enclosure i.e. garage or outhouse. (The

boiler may be fitted inside an unvented cupboard - see section

7.3).

2. If the boiler is fitted in a room containing a bath or shower

reference must be made to the relevant requirements.

In GB this is the current I.E.E. Wiring Regulations and Building

Regulations.

In IE reference should be made to the current edition of I.S.

813 “Domestic Gas Installations” and current ETCI rules.

(Fig. 11 shows zone dimensions for a bathtub. For other

examples refer to Section 601 of the current I.E.E. Wiring

Regulations) reference must be made to the relevant

requirements.

The boiler is IPX4 rated and can be fitted in Zone 2 (Fig. 11).

In GB this is the current I.E.E. Wiring Regulations and Building

Regulations.

In IE reference should be made to the current edition of I.S.

813 “Domestic Gas Installations” and the current ETCI rules.

4. If the boiler is to be fitted into a building of timber frame

construction then reference must be made to the current

edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas

Installations in Timber Framed Housing).

7.2 CLEARANCES

1. A flat vertical area is required for the installation of the

boiler.

2. These dimensions include the necessary clearance around

the boiler for case removal, spanner access and air movement.

Additional clearances may be required for the passage of pipes

around local obstructions such as joists running parallel to the

front face of the boiler.

Zone 2

Zone 1

Zone 0 Zone 3

Zone 3

Window Recess

Zone 2

Window

Recess

Zone 2

0.6 m 2.4 m

Zone 2 Zone 3

Zone 2Zone 1

Zone 0

Zone 3

Outside Zones

Ceiling

Window

Recess

Zone 2

3.0 m

2.25 m

0.6 m 2.4 m

285mm Wall

450mm Min

For Servicing

Purposes 5mm Min

In Operation

2.5°

5mm Min

446mm

5mm Min

796mm

200mm

5mm Min

285mm Wall 285mm Wall

Fig. 11

Fig. 12

13.0 CHANGING COMPONENTS

13.6 FLUE/HEAT TEMPERATURE THERMOSTAT

1. Disconnect the electrical plug.

2. Turn the sensor 90° anticlockwise to remove - it is a

bayonet connection (Fig. 60).

3. Reassemble in reverse order.

13.7 THERMAL FUSE

1. The thermal fuse is non-changeable. If the fuse fails contact

Dimplex Technical Department.

13.8 CENTRAL HEATING FLOW TEMPERATURE THERMISTOR

1. Disconnect the electrical plug.

2. Ease the sensor clip away from the pipe and remove (Fig. 61).

3. Reassemble in reverse order.

13.9 CENTRAL HEATING RETURN TEMPERATURE THERMISTOR

1. Disconnect the electrical plug.

2. Ease the sensor clip away from the pipe and remove (Fig. 61).

3. Reassemble in reverse order.

Comfort+

bar

Fig. 60

Fig. 61

‘O’ Ring

Thermal Fuse

Central Heating Flow

Temperature Thermistor

Central Heating Return

Temperature Thermistor

Flue/Heat Temperature

Thermostat

48pp MANUAL SPREADS 19/10/10 08:36 Page 14

13.0 CHANGING COMPONENTS

13.4 BURNER

1. Remove the valve and fan assembly as described in Section

13.3.

2. Examine the gasket and replace if necessary.

3. Undo the four nuts securing the burner door and remove

from the heat exchanger.

4. Slowly withdraw the burner from the burner plate taking

care not to damage the insulation (Fig. 58).

5. Reassemble in reverse order.

13.5 INSULATION

1. Remove the electrode leads, noting their positions. Remove

the electrodes as described in section 13.2.

2. Remove the valve and fan assembly as described in Section

13.3.

3. Examine the gasket and replace if necessary.

4. Undo the four nuts securing the burner door and remove

from the heat exchanger.

5. Slowly withdraw the burner from the burner door.

6. Replace the insulation if necessary.

7. Check the burner door seals.

8. The rear insulation is retained by a screw and large washer,

remove these and draw the insulation out of the heat

exchanger (Fig. 59).

9. Reassemble in reverse order.

Burner

Insulation

Gasket

Air/Gas Channel

Rear Insulation

Washer

Insulation

Retaining Screw

Burner Assembly

Burner Door

Burner Door Seal

Fig. 58

Fig. 59

Inner Seal

7.0 SITE REQUIREMENTS

7.3 VENTILATION OF COMPARTMENTS

1. Where the appliance is installed in a cupboard or

compartment, no air vents are required.

Where an open flued system is used - Flue kit E (B23

classification) then an air vent communicating directly with

outside air must be provided in the same room or internal

space of the flue duct air inlet. Minimum free area:

Dimplex 24 = 88cm2

Dimplex 30 = 121.5cm2

Dimplex 38 = 159cm2

In addition if an open flued system is used - Flue kit (B23

classification) and the boiler is fitted in a compartment, then

high and low level ventilation is required.

BS 5440-2:2000 gives guidance on compartmental ventilation.

2. When the boiler is installed in a cupboard or compartment

and either flue kit A, B, C, D or F (Classification C13, C33, C53)

is used, then no compartmental ventilation is required.

7.4 GAS SUPPLY

1. The gas installation should be in accordance with the

relevant standards. In GB this is BS 6891. In IE this is the

current edition of I.S. 813 “Domestic Gas Installations”.

2. The connection to the appliance is a 22mm copper tail

located at the rear of the gas service cock (Fig. 13).

3. Ensure that the pipework from the meter to the appliance is

of adequate size, and the demands of any other gas appliance

in the property are taken into consideration. Do not use pipes

of a smaller diameter than the boiler gas connection (22mm).

4. For boilers connected to use LPG (propane), the inlet

pressure must be 37mbar.

NOTE:

The completed installation should always be tested

for gas tightness

7.5 ELECTRICAL SUPPLY

1. External wiring must be correctly earthed, polarised and in

accordance with relevant regulations/rules. In GB this is the

current I.E.E. Wiring Regulations. In IE reference should be

made to the current edition of the ETGI rules.

2. The mains supply is 230V - 50Hz fused at 3A

NOTE:

The mains supply connection must allow complete

electrical isolation of the appliance and system controls

only.

Connection may be via a fused double-pole isolator with a

contact separation of at least 3mm in all poles and servicing

the boiler and system controls only.

Any additional mains cable should comply fully with the

current I.E.E. wiring regulations.

Fig. 13

Gas Service

Cock

48pp MANUAL SPREADS 19/10/10 08:36 Page 15

7.0 SITE REQUIREMENTS

7.6 CONDENSATE DRAIN

NOTE:

The appliance is fitted with a trap the depth of

which is >= 75mm, therefore no other traps are required in

the condensate run.

The condensation discharge pipe must not rise at any point

along its length. There MUST be a fall of AT LEAST 2.5° (50mm

per metre) along the entire run.

1. The condensate outlet will accept 21.5mm (3/4in) plastic

overflow pipe which should discharge internally into the

household drainage system, downstream of all other traps. if

this is not possible, discharge into an outside drain is

acceptable.

2. Ensure the discharge of condensate complies with any

national or local regulations in force.

BS 6798:2000 & Part HI of the Building Regulations give

further guidance.

3. Metal pipework is NOT suitable for use in condensate

discharge systems.

4. The pipe should be a minimum of 21.5mm diameter and

must be supported properly.

5. I

It is advisable to keep the condensate pipe internal.

6. E

External runs greater than 3 metres or runs in cold areas

should use 32mm waste pipe.

7. If the boiler is fitted in an unheated location the entire

condensate discharge pipe should be treated as an external

run.

8. In all cases discharge pipe must be installed to aid disposal

of the condensate.

9. When discharging condensate into a soil stack or waste pipe

the effects of existing plumbing must be considered. If soil

pipes or waste pipes are subjected to internal pressure

fluctuations when WC’s are flushed or sinks emptied then

back-pressure may force water out of the boiler trap and

cause appliance lockout.

Examples are shown of the following methods of

terminations:-

i) to an internal soil & vent pipe

ii) via and internal discharge branch (e.g. sink waste)

iii) to a drain or gully

iv) to a purpose made soakaway

10. In exceptional circumstances, such as when a boiler is

installed in a basement without drainage, it may be necessary

to install a condensate pump to carry condensate up to ground/

drain level. Such products are available from most plumbing

merchants. For help with selecting a condensate pump contact

Dimplex Boilers - Tel: 0844 3711121.

WARNING:

There must be no air breaks in the condensate

pipework or drainage system.

50mm per metre of pipe run

2.5° Minimum fall

450mm min

Termination to an internal soil and vent pipe

50mm per metre of pipe run

2.5° Minimum fall

External termination via internal discharge branch

e.g sink waste - downstream

Sink

Pipe must terminate

above water level but

below surrounding surface.

50mm per metre of pipe run

2.5° Minimum fall

Termination to a purpose made soak-away

Holes in the soak-away must

face away from the building

500mm min

NOT ALLOWED

There should be

no air gap

Fig. 14

Fig. 15

Fig. 17

Fig. 16

13.0 CHANGING COMPONENTS

13.3 GAS VALVE AND FAN

1. Disconnect the two leads to the fan and one lead to the gas

valve.

2. Undo the nut on the gas inlet pipe to the valve and retain

the sealing washer.

3. Remove the three securing screws holding the air/gas

Channel to the burner door plate and remove the valve and fan

assembly (Fig. 57).

4. Remove the three screws holding the valve and swirl plate

to the fan adaptor plate.

NOTE:

Mark on the adaptor plate which holes are being

used by the screws. Using the wrong holes on

re-assembly will cause mis-alignment of the gas valve.

Fan Only

6. Remove the three screws holding the fan adaptor to the fan.

7. Remove the four screws securing the fan to the air/gas

channel. Reassemble in reverse order ensuring all seals are in

place.

NOTE:

The gas valve throttle should be adjusted in

accordance with the instructions supplied in the spares kit

See Section 10.

NOTE:

Dimplex Combi 38 will also be fitted with a black

plastic air cowl which encases the swirl plate.

Fig. 57

Swirl Plate

Fan

Fan Gasket

Burner Door

Air/Gas Channel

Fan Adaptor Plate

Injector Plate

Injector

Injector ‘O’ Ring

Gas Valve

48pp MANUAL SPREADS 19/10/10 08:36 Page 16

13.0 CHANGING COMPONENTS

IMPORTANT:

When changing components ensure that both

the gas and electrical supplies to the boiler are isolated

before any work is started.

See Section 12 : “Annual Servicing” for removal of case, panel,

door etc.

13.1 IGNITER

1. Disconnect the two feed wires, earth wire and electrode

lead noting their positions (Fig. 53).

2. Undo the two screws securing the igniter to its bracket and

remove the igniter. Reassemble in reverse order.

13.2 SPARK AND SENSING ELECTRODES

1. Disconnect the electrode leads, noting their positions

(Fig. 56).

2. Using a 3mm Hex key, remove the retaining screws securing

each of the electrodes to the burner door and remove the

electrodes.

3. Check the condition of the sealing gaskets and replace if

necessary. Reassemble in reverse order and then check that

the electrode gaps are as shown in Fig. 54 & 55.

Fig. 53

Fig. 54

Fig. 55

Fig. 56

Igniter

Gasket

6mm ± 0.5

to Burner

4mm ± 0.5

10mm ± 0.5

7.0 SITE REQUIREMENTS

7.7 FLUE

1. This high efficiency boiler will discharge a plume of water

vapour from the flue. This should be considered when siting

the flue terminal.

2. The following guidelines indicate the general requirements

for siting balanced flue terminals. For GB recommendations are

given in BS 5440 Pt 1. For IE recommendations are given in

the current edition of I.S. 813 “Domestic Gas Installations”.

3. If the terminal discharges onto a pathway or passageway,

check that combustion products will not cause a nuisance and

that the terminal will not obstruct the passageway.

4. If a terminal is less than 2 metres above a balcony,above

ground or above a flat roof to which people have access, then

a suitable terminal guard must be provided - Part No: 951507.

IMPORTANT:

• Only O

ONE

of the 25mm clearances (Positions ‘O’ to ‘S’ in

the chart below) is allowable per installation.

• Under car ports we recommend the use of the plume

displacement kit.

• The terminal position must ensure the safe and nuisance

- free dispersal of combustion products.

NOTE: The minimum distance from a flue terminal to a boundary line is 300mm.

If fitting a plume diverter kit, the air inlet should be a minimum of 100mm from

any opening windows or doors.

NOTE A: A terminal should

be no closer than 150mm

to an opening in the

brickwork intended to

accommodate a fitting

such as a window frame.

NOTE: Fitting of the deflector

elbow is recommended when

installing boiler to minimum

clearance of 25mm as

detailed in positions O & P.

M,L

Flue terminals that require a guard fitting

Position Description Minimum Distance (mm)

A Horizontally to an opening, air brick, opening window - see note A 300

B Above an opening, air brick, opening window etc. - see note A 300

C Below an opening, air brick, opening window etc. - see note A 300

D Below windows or openings on pitched roofs 2000

E Adjacent to windows or openings on pitched and flat roofs 600

F From an adjacent opening window (vertical only) 1000

G From an adjacent wall to flue (vertical only) 300

H Horizontally from a terminal on the same wall 300

J Vertically from a terminal on the same wall 1500

K From an opening in a carport (e.g. door, window) into the dwelling 1200

L From a terminal facing a terminal (horizontal flue) 1200

From a terminal facing a terminal (vertical flue) 600

M From a surface or boundary line facing a terminal 600

N Above ground, roof or balcony level 300

O From an internal or external corner 25

P From a vertical drain pipe or soil pipe 25

Q Below balconies or car port roof 25

R Below eaves 25

S Below gutters, soil pipes or drain pipes 25

300mm Min 300mm Min

Adjoining Properties Boundary Line

TERMINAL POSITION

Fig. 18

Fig. 19

48pp MANUAL SPREADS 19/10/10 08:36 Page 17

8.0 FLUE OPTIONS

8.1 CONCENTRIC AIR/FLUE DUCT SPECIFICATIONS

The Dimplex Combi 24, Dimplex Combi 30 and Dimplex Combi

38 can be installed to a number of different concentric flue

systems. The different flue applications as shown in Fig. 20 are

available as kits comprising the connecting parts to the

appliance and end terminal. Flue extension ducts and extension

elbows are available as accessories.

Note:

Dimplex Combi 38 only, with maximum concentric

flue length of 10m, the heat input will be reduced by 6.1%

8.2 Kit A + Telescopic Horizontal Wall Terminal

(C13) - Part No. 956120

Traditional concentric flue system, Fig. 21, with a maximum

length of 10000mm. The flanged flue elbow is designed with a

3° slope towards the appliance so that the condensate can

easily drain off. It has to be considered that for every metre

horizontal flue length the terminal exit centreline is approx.

45 mm higher than the elbow’s centreline.

The standard telescopic terminal is 615mm max length and

430mm min length, but can be cut to a minimum flue length of

250mm, which is suitable for single, 100mm (4”), brick walls.

8.3 Kit B Vertical Concentric Flue Terminal

(C33) - HBL Part 956081

Standard concentric (100/60) vertical flue application, Fig. 22,

through roof attics with a maximum length of 12000mm.

The kit comprises of the roof terminal, flashing kit, vertical

adaptor with sampling point and bracket.

The maximum length is measured from the top of the

appliance casing to the underside of the air cowl.

For installation details refer to the flue kit instructions.

Chimney flue liner kit

- Part no. 956082

Vertical flue kit - Part no. 956081

with flat roof flashing plate

Split pipe vertical flue outlet kit

- Part no. 956080

with flat roof flashing plate

Raised external flue outlet kit

- Part no. 956084

Vertical flue kit - Part no. 956081

External vertical flue kit

- Part no. 956085

Standard telescopic

horizontal flue kit

- Part no. 956120

Flue system application

The pluming from the flue may

cause nuisance to neighbours

or other buildings.

60/100 flue accessories:

0.5m flue extension duct - 956092

1m flue extension duct - 956093

93 flue extension elbow - 956091

45 flue extension elbow (2x) - 956090

Vertical flue turret - 956087

Ø60/100mm concentric

standard horizontal wall

terminal.

Max. length 10,000mm.

Min. length 250mm.

Standard telescopic horizontal flue kit - Part no. 956120

Horizontal terminal has a

built-in fall in the flue to allow

condensate to drain away.

If horizontal flue requires

extension pipe. the flue

should be installed such

that there is no section less than

2.5° - 3° to the horizontal,

falling back towards the boiler.

93 flanged elbow (concentric)

with sampling point

Kit A +

Vertical flue kit - Part no. 956081

Suitable for 25 - 45°

Pitch Angle

Length

Kit B

60/100 flue accessories:

0.5m flue extension duct - 956092

1m flue extension duct - 956093

93 flue extension elbow - 956091

45 flue extension elbow (2x) - 956090

Flat roof flashing plate - 840512

93 flanged flue elbow - 956086

Max. length12m.

Min. length 0.6m.

Roof terminal

with rain cover

and pitched roof

flashing kit.

Vertical flue socket

with sampling point.

Top of Boiler

to underside of Cowl

Fig. 20

Fig. 21

Fig. 22

12.0 SERVICING AND MAINTENANCE

12.1 ANNUAL SERVICING

8. Remove the two screws securing the front panel to the

underside of the boiler. Lift the panel upwards off its retaining

studs on top of the appliance.

9. Disconnect the two leads to the fan and one lead to the gas

valve.

10. Undo the nut on the gas inlet pipe to the valve and retain

the sealing washer.

11. Remove the four nuts holding the burner door plate and

remove the valve and fan assembly (Fig. 51).

12. Clean any debris from the heat exchanger using a soft

brush and check that the gaps between the tubes are clear.

13. Inspect the burner, electrode positions and insulation,

cleaning or replacing if necessary.

14. Check the condition of the burner door seals, replacing if

necessary.

15. Reassemble in reverse order.

16. Complete the relevant Service Interval Record section of

the Benchmark Commissioning Checklist at the rear of this

publication and then hand it back to the user.

Fig. 51

Fig. 49

Fig. 50

Fig. 52

Gas Inlet Nut

Front Panel

Retaining Stud

X 4

X 2

Burner Door Seal

Inner Seal

48pp MANUAL SPREADS 19/10/10 08:36 Page 18

12.0 SERVICING AND MAINTENANCE

12.2 COMBUSTION CHECKS

COMBUSTION CHECKS AT MAXIMUM RATE

9. Set the boiler to Maximum gas rate.

10. Check the Carbon Monoxide (CO) and Carbon Dioxide (CO2)

readings are within the range quoted in the tables opposite

(Table 2).

11. If the combustion value(s) is outside the values specified

in Tables 1 and 2 and the integrity of the full flue system and

combustion circuit seals, the inlet gas pressure and gas rate

have been verified, it is possible to make an adjustment to the

combustion settings by adjustment of the air/gas ratio valve.

See Section 12.3 Adjustment of the Gas Valve.

12.3 ADJUSTMENT OF THE GAS/AIR RATIO VALVE

COMBUSTION SETTING ADJUSTMENT

1. It is only possible to adjust the valve at Maximum rate. No

adjustment at Minimum rate is allowed.

2. If the maximum rate setting is adjusted, then the

combustion values must be checked at minimum rate.

NOTE:

DO NOT ATTEMPT TO ADJUST THE GAS/AIR RATIO

VALVE UNLESS;

• The person carrying out the measurement has been

assessed as competent in the use of a flue gas analyser

and the interpretation of the results.

• The flue gas analyser used, meets the requirements of

BS7927 or BS-EN50379-3.

• The flue gas analyser is calibrated in accordance with the

manufacturers requirements.

3. At Maximum Gas Rate; put the appliance into Service Mode

at Maximum Gas Rate (see Section 11.2).

4. Wait 5 minutes to allow the boiler to stabilise.

5. If the Carbon Dioxide (CO2) level is outside the required

values given in Section 12.2 (Table 2) then adjust the throttle

screw (Fig. 48) until the CO2is at the correct setting level. See

Table 4. Clockwise to decrease CO2, anti-clockwise to increase

CO2.

NOTE:

Only turn the throttle in small steps of n

no more than

1/8th of a turn

and wait 1 minute after each adjustment for

the combustion reading to stabilise.

IMPORTANT:

After any adjustment of the gas valve, it is

essential to check the combustion levels at minimum gas

rate (Table 1). If the Carbon Monoxide or Carbon Dioxide

levels are outside the range quoted, call Dimplex Boilers Ltd

Technical Helpline on 0844 3711121. If in doubt ASK!

Table 4

Fig. 48

NOTE:

Factory set - warranty

void if adjusted

Throttle Adjuster Screw

Gas Valve

Inlet Test Point

Carbon Dioxide (CO2) acceptable setting level at Maximum

Gas Rate after 5 minutes operation

Natural Gas %Boiler Model

Combi 24

9.0 10.7

Combi 30

9.3 10.9

Combi 38

9.1 10.7

LPG (Propane) %

8.0 FLUE OPTIONS

8.5 Kit C Horizontal Anti-Plume Flue Kit

(C13) - Part No. 956084

If the standard horizontal terminal is likely to cause nuisance to

a neighbour or buildings, because of excess pluming, then this

particular flue kit raises the flue gas outlet point to a higher

elevation with the minimum amount of changes. The flue gas

duct is teed-off from the concentric part and covered by an

80mm outer tube to protect the flue duct from freezing. The

air in-take remains at the lower level (see Fig. 24).

If choosing this option then the external flue duct length

should be taken into account when calculating equivalent flue

length.

For installation details refer to the flue kit instructions.

Dimensions from vertical terminals to opening windows should

be in line with Fig. 19.

(For use with Standard horizontal telescopic flue kit - Part no.

956120 - only).

This kit is provided to assist in fitting a condensing boiler with

reduced clearances when fitted in good practice according to

the Guide to Condensing Boiler Installation published by

DEFRA/HMSO.

This kit allows the boiler flue outlet to be directed to the left

or to the right only.

Suitable for installations if the appliance cannot be repositioned

and where other horizontal flue options may cause some

nuisance to neighbours or buildings. The flue kit contains some

additional 45° elbows and extension ducts as well as a special

wall bracket to pass the guttering (see Fig. 26). The concentric

flue will be routed vertically alongside the outside wall to

above the roofline. Special seals are required to prevent

rainwater penetrating the pipe joints.

For installation details refer to the flue kit instructions.

8.6 Plume Diverter Terminal Kit

Part No. 956103

8.7 Kit D External Vertical Flue

(C33) - Part no. 956085

93 flanged elbow (concentric)

with sampling point

Raised external flue outlet kit -

Part no. 956084

Kit C

Raised Ø60mm flue

outlet duct with

Ø80mm anti-freeze

pipe.

Max height of raised

flue from top of boiler

to centre of outlet 8.5m

Min height 1m.

Standard horizontal flue

adaptor has an already

built-in fall in the flue to

allow the condensate to

drain away.

93 flanged elbow (concentric)

with sampling point

Max. lengths (from top of

boiler to AIR COWL 8m

Min. length 1m.

Kit D

Ø60/100mm concentric

air/flue pipe -

Part no. 956093

(1m extension)

and

Part no, 956092

(0.5m extension)

For outside installations

the pipe joints have to

be covered with special

“lip-seal” to prevent

rain ingress.

Ensure all horizontally fitted

pipes are routed with a

2.5-3° fall towards the boiler.

External vertical flue kit - Part no. 956085

Roof terminal

with rain cover.

Roof terminal

with rain cover

and pitched roof

flashing kit. b

8.4 Offset Vertical Flue Terminal

(C33) - HBL Part 956081

‘a’ measured from boiler flue outlet centre line to the centre

line of the extension elbow.

‘b’ measured from the top of the boiler to the underside of the

air cowl.

Maximum allowable length of a + b = 8900mm

Fig. 23

Fig. 24

Fig. 25

Fig. 26

48pp MANUAL SPREADS 19/10/10 08:36 Page 19

8.0 FLUE OPTIONS

8.8 Kit E Chimney Flue Liner Kit

(B23) - Part no. 956082

Note:

Dimplex Combi 38 - Maximum flue length 21m, and 30m

for all other appliances.

This kit is suitable for open flue application in accordance with

BS5440 where a room sealed flue installation is impractical.

The kit comprises of a flue adaptor from the appliance to the

chimney, a flexible plastic flue liner with connection parts and

chimney terminal (see Fig. 27). Where an open flue system is

used, then an air vent must be provided in the same room or

internal space as the flue duct air inlet, see section 7.3.

For installation details refer to the flue kit instructions.

Maximum flue resistive length = 30m.

A flue system can be built up from the components detailed in

table 8.10, but the total flue resistance must not exceed the

maximum stated.

8.9 Kit F: Twin Flue System

(C53) - Part no. 956080

Note:

Dimplex Combi 38 - Maximum flue length 21m, and 30m

for all other appliances.

This flue system kit is designed for installations where the air

intake position is different than the flue duct exit point. The kit

comprises of a twin adaptor from which the air intake is taken

from the adjacent outside wall (see Fig. 28) and the flue duct

is routed vertically through the roof.

It has to be noted that the flue duct is under pressure when

the appliance is in operation and the duct can leak poisonous

carbon monoxide if the duct components are not correctly

assembled. It is n

not

recommended to route the flue duct

through living space areas, i.e. bedrooms, living rooms etc.

For installation details refer to the instructions provided with

the twin flued kit.

For C53 flue systems the terminal for the supply of

combustion air and for the evacuation of combustion products

shall not be installed on opposite walls of the building.

Maximum flue resistance permitted for a twin flued system

= 52 Pa

Minimum flue resistance permitted for a twin flued system

= 23.5 Pa

Centralising brackets

Chimney terminal

93 flanged elbow (concentric)

with sampling point

Ø60/100mm concentric

chimney adaptor pipe.

In replacement installations,

the chimney has to be

cleared of debris and

all flue parts.

Chimney

plate

Flexible corrugated plastic flue liner

Ø80mm according to EN 14471

Max. length 30m.

Min. length 5m.

KIT E

Chimney flue liner kit - Part no. 956082

Flue Component Flue Resistance (Pa) Part Number

Twin Flue Adaptor (required) 9.5 -

Air Inlet Terminal (required) 3 -

Chimney Terminal (required) 0.5 -

80 mm dia straight duct 1 metre 1 956101

80 mm dia straight duct 2 metre 2 956102

90° Elbow (80/80) 8 956100

45° Elbow (80/80) 4 956099

A flue system can be built up from the components detailed in the table, but the total flue

resistance must not exceed the maximum stated.

Ø80mm air intake

Split flue system

Roof terminal with pitched

roof flashing kit.

If the flue pipe passes

through compartment

from wall/floors, the

requirements set out

in Building Regulations

Part B must be followed.

Ø80mm twin adaptor

with sampling point.

If the flue pipe passes

through habitable rooms

within the same dwelling,

the flue pipe must be

routed through vented

ducts.

The flue resistance for the

following accessories has

to be considered.

Ø80mm flue extension

90 elbow

45 elbow

Split pipe vertical

flue outlet kit -

Part no. 956080

Kit F

Fig. 27

Fig. 28

12.0 SERVICING AND MAINTENANCE

12.1 ROUTINE SERVICING AND ALL MAINTENANCE THAT

INVOLVES THE EXCHANGE OF PART OF THE

COMBUSTION CIRCUIT

1. During routine servicing, e.g. an annual service check, and

after all maintenance that involves the exchange of parts of

the combustion circuit, we recommend that (in this order) the

integrity of the full flue system and combustion circuit seals,

the inlet gas pressure, gas rate and combustion performance is

verified.

NOTE:

The combustion circuit on this appliance comprises

of the PCB, fan, air/gas ratio valve, burner, burner door,

combustion box door, injector and flue system.

2. To ensure continued safe and efficient operation of the

appliance it is recommended that the boiler is serviced at least

annually. Servicing must be performed by a competent person.

BS 7967-1 gives guidance on identifying and managing

sources of fumes, smells, spillage/leakage of combustion

products and carbon monoxide detector activation.

Safety Checks

On any service visit always check;

a. Condition of flue system, both air and combustion products

ducts.

b. Condition of seals and joints.

c. For evidence of leakage of combustion products.

d. For evidence of heat staining.

e. For operation at maximum heat input.

f. The general condition of the boiler and its components.

1. Combustion checks must be carried out with the outercase

fitted.

2. Remove the sampling cap from the boiler flue elbow or

boiler vertical flue adaptor.

3. Insert the probe from the portable electronic combustion

analyser into the sampling point.

4. With the appliance operational, connect the flue gas

analyser to the flue sampling point as shown in Fig. 47.

NOTE:

The outercase must be fitted for all combustion

checks.

5. With the boiler at minimum rate and then at maximum rate

(allowing the combustion to stabilise at each rate before taking

a reading) carry out the combustion checks as follows:

COMBUSTION CHECKS AT MINIMUM RATE

6. The combustion values at minimum gas rate and maximum

gas rate must be checked using a suitable calibrated flue gas

analyser. Further guidance is detailed in BS7967 parts 1 to 4.

7. Set the boiler into Service Mode at Min Rate

(see section 11.1).

8. Check the Carbon Monoxide (CO) and Carbon Dioxide (CO2)

readings are within the range quoted in the tables opposite

(Table 1).

12.2 COMBUSTION CHECKS

Comfort+

bar

Fig. 47

Flue Gas Sampling Point

Minimum Gas Rate

Boiler

Model

(kW)

Carbon

Monoxide

p.p.m

0 - 40

0 - 30

Carbon

Dioxide

CO2%

8.2 - 8.6

8.7 - 9.1

8.3 - 8.7

LPG

Carbon

Monoxide

p.p.m

0 - 40

Carbon

Dioxide

CO2%

10.2 - 10.6

10.4 - 10.8

Maximum Gas Rate

Boiler

Model

(kW)

Carbon

Monoxide

p.p.m

40 - 120

Carbon

Dioxide

CO2%

8.8 - 9.2

9.1 - 9.5

8.9 - 9.3

LPG

Carbon

Monoxide

p.p.m

80 - 160

100 - 180

70 - 150

Carbon

Dioxide

CO2%

10.5 - 10.9

10.7 - 11.1

10.5 - 10.9

Table 1

Table 2

48pp MANUAL SPREADS 19/10/10 08:36 Page 20

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