Heatline capiz 25s. capiz 28s User guide

capiz 25 & capiz 28
capiz 25s
capiz 28s
&
Installation,Servicing
&UserInstructions
w w w . h e a t l i n e . c o . u kw w w . h e a t l i n e . c o . u k
Condensing
Wall Mounted
Combination Boiler

capiz 25 & capiz 28
Type test for purpose of EEC Regulations certified by:
Notified Body IMQ
51BP2727 CE Directive 90/396/EEC
51BP2728DR CE Directive 92/42/EEC
CE Directive 73/23/EEC
CE Directive 89/396 EEC
(modified from 93/68)
The manufacturer, in the continuous process to
improve his products, reserves the right to modify the
data expressed in the present documentation at any
time and without prior notice.
The present documentation is an informative support
and it cannot be considered as a contract towards
third parties.
Natural Gas / LPG
The HeatlineTM range of heating boilers is
manufactured from hight quality materials,
enabling reliability and optimum performance.
HeatlineTM is committed to the continual
development of their appliances to ensure their
customers benefit from the latest advances in
combustion technology and energy savings.
‘Benchmark’ Log Book
As part of the industry - wide initiative the
CAPRIZ 25S / CAPRIZ 28S boilers
come complete
with an Installation, Commissioning
and Service
Record Log Book. Please read the Log book
carefully and in accordance with current regulations
complete all sections relevant to the appliance and
installation. The details within the Log Book will be
required in the event of any warranty work.On
completion, the Log Book must be left with the end
user and the relevant sections completed on each
subsequent Service visit.
NOTE: You are also obliged to register the
installation of this boiler with C.O.R.G.I. Should
you wish to check the SEDBUK website for the
rating of this boiler search under DD HEATING
or the boiler name and designation, e.g. CAPRIZ 25S.
HEATLINE™ CAPRIZ 25S / CAPRIZ 28S
Condensing System Boilers
British Gas Service Listing
CAPRIZ 25S Condensing System Boiler
G.C.No 41-157-10
CAPRIZ 28S Condensing System Boiler
G.C.No 41-157-11

capiz 25 & capiz 28
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Appendices
13tsiLstraPerapS
User Instructions 32
Benchmark Log Book 36- 37
Contents
Page 1

capiz 25 & capiz 28
The Heatline™ gas fired, condensing system
boiler meets the requirements of all appropriate
regulations and is deemed to meet the requirements of:
Gas Appliance Directive 90/396/EEC
Efficiency Directive 92/42/EEC
Low Voltage Directive 73/23 EEC (modified from 93/68)
Electromagnetic Compatibility Directive 89/396 EEC
(modified from 93/68)
Heatline™ declares that the materials used in the
manufacturer of this appliance are non-hazardous and
that no substances harmful to health are contained
within the appliance.
Heatline™ accepts no responsibility for the
unsatisfactory performance of the appliance or flue
arising from the failure to comply with the installation
and user instructions. Incorrect installation could
invalidate your guarantee and may lead to prosecution.
If the boiler is sold to another customer, all documents
must be transferred from existing customer to the new
one and the appliance must be re-registered with
Heatline™ in order to maintain the guarantee.
The boiler must be installed in accordance with these
instructions and all the regulations currently in force.
Read these instructions carefully before installing or
using the appliance.
Manual Handling:
As this appliance is heavy it is recommended that you
get assistance when lifting. When manoeuvring the
boiler always use safe techniques – keep your back
straight, bend your knees, don’t twist, move your feet.
Avoid bending forwards or sideways and keep the load
as close to your body as possible. Where possible
transport the boiler using a suitable trolley, sack truck
or get some assistance. Grip the boiler firmly and
before lifting establish where the weight is concentrated
to determine the centre of gravity, repositioning yourself
if necessary
Preface Warnin
g
s
IMPORTANT NOTE
Speed 2 is the factory default setting
for the Pump.
This setting should be suitable for
most of your applications.
SHOULD YOU SMELL GAS: Turn the gas valve off at the
Gas Meter or Gas Cylinder, ventilate the room by opening
windows and doors (EXTINGUISH ANY NAKED FLAMES,
DO NOT OPERATE ANY ELECTRICAL SWITCHES) and call
Transco on 0800 111 999 or if you use LPG call your gas
supplier.
Page 2
NOTE: Cables on the cap ; 1- Ionisation cable
2 - Earth cable
3 -
Condensate hose
3
12
02

capiz 25 & capiz 28
This is a fragile piece of equipment: Do not
drop.
Avoid getting the box damp or wet.
The packed appliances may be stacked
five high.
Do not crush the packaging as this may
damage the appliance.
Store the appliance upright as indicated on
the box.
The Signs on Box
The Signs on Boiler
5
1 2
4
3
Handling
This appliance is heavy, truck if possible and obtain assistance if required.
To remove the appliance :
1. Carefully slit or remove the scaling tape being careful not to scratch the appliance door.
2. fully open the carton lid and remove any instructions & components.
3. Read the instructions carefully before installation of the appliance.
4. Roll the carton onto its open face.
5. Lift the carton free of the inner packaging.
6. Remove the mounting bracket and valve package.
7. Stand the boiler on its base within the styrene block and remove the top packaging piece.
8. If you wish to remove the stryene base lie the appliance on its back to do so.
Page 3
The sign of approval the
Capriz 25S & Capriz 28S
boilers have been
certified by IMQ Italy.
LOW VOLTAGE ROOM THERMOSTAT – This
picture shows the terminal block, which is
located at the left corner on the rear of the
drop down control box. Note these
terminals are not intended to drive the
thermostat but simply connect across the
switch that opens and closes as the
thermostat operates.
NOTE – This is a voltage free connection
and no power (AC or DC) should be applied to
these terminals. For mains powered
thermostats see section 9.5.
Warning! High Voltage: This sign is
located on the back of the control box
housing warning of high voltages within
the control box. Turn off and isolate the
appliance before removing this cover.
NOTE: Take care as there may be residual voltage within
some components
Potentiometer Cover: Removal of the
cover, which is found on the back of the
control box, gives access to the
adjustment potentiometers. NOTE: Do not
make any adjustments without reading the
instructions carefully.
03

capiz 25 & capiz 28
Correctly may invalidate your guarantee and may
lead a dangerous situation.
1.2.
1.1.
Your CORGI registered engineer should carry a
CORGI ID card containing their registration
number, which should be recorded in your
BENCHMARK Log Book, which is supplied with
the Instructions. You can check the validity of
this ID number by contacting CORGI on 0800 915
0480.
1.3. This appliance must be installed in accordance
with the Gas Safety (Installation and Use)
Regulations, current Building Regulations,
Building Standards (Scotland), I.S.813 Installation
of Gas Appliances (Ireland), IEE Wiring
Regulations (BS 7671), Health and Safety
Document No. 635 (Electricity at Work
Regulations) and Local Water Authority Bye
Laws.
1.4. On installation the following British Standards
must also be considered:
BS 6798 Specification for installation of gas
fired hot water boilers of rated input not
exceeding 70kW.
BS 5449 Central heating for Domestic
Premises.
BS 5546 Installation of gas hot water supplies
for domestic purposes.
BS 5440 Flues and Ventilation for gas
appliances of rated input not exceeding 70kW
(Part 1 Flues)
BS 5440 Flues and Ventilation for gas
appliances of rated input not exceeding 70kW
(Part 2 Air Supply)
BS 6891 Installation of low pressure gas pipe-
work installations up to 28mm (R1!).
Reference should also be made to British Gas
Guidance Notes for Installation of Domestic Gas
Fired Boilers.
1.5. Due to the manufacturer’s continuous
improvement policy the manufacturer reserves
the right to change any specification of the
appliance or make modifications to these
instructions, which meet current regulations at
the time of print. However, the instructions must
not be taken as overriding statutory
requirements.
1.6. To ensure reliability and continued performance
ensure that other components in the system are
also approved to relevant standards and that the
appliance and system is adequately protected
and maintained on an annual basis.
1. Installation Regulations
Page 4
For further information or advice (UK) contact HeatlineTM:
Service please call: 0870 609 2091
Spares please call: 0870 777 8402
Technical assistance please call : 0870 777 8318
Or by E mail on our Web Site at www.heatline.co.uk
04

capiz 25 & capiz 28
Heat Input (max)
kW 25.7
Heat Output (max)
kW 24.7
Heat Input (min)
kW 11
Heat Output (min)
kW 10.2
Useful efficiency at
100% load
% 96
Useful efficiency at 30%
load
% 102.4
Burner injector
mm. 1.20 NG
0.75 LPG
Burner Pressure
(Natural Gas)
mbar Max 12.5
Min 2.5
Burner Pressure
(Propane)
mbar Max 28.5 /36.5
Min 6 / 7.8
Power Supply
Input 220~240V-50Hz
Max. power
consumption
Watt 220
Level of Protection
IPX 4 D
Case Dimensions
mm 330d x 405w x 720h
Maximum heating
temperature ºC 85
Operating pressure (Bar)
PMS
Nominal
(Min)
3
1.5
(0.8)
3
1.5
(0.8)
Expansion Vessel Capacity Litres 7
Expansion Vessel
Pre-charge Pressure bar 1
Air Intake Pipe Diameter mm 100/125 100/125
60/80
Flue Pipe Diameter mm 60/80
Max. Flue Length C12 – C32 m
3.0
(60/100)
7.0
(80/125)
3.0
(60/100)
7.0
(80/125)
Max. Flue Length
C42 – C52 m 20 (80/80)
22
(80/80)
Equivalent Length 45
0
Bend m 1.0
m 1.5
Equivalent Length 90
0
Bend
Net weight kg 35
kg 38
Gross Weight
2. Technical Data
Page 5
28.5
27.6
11
10.2
96.8
103.3
1.15 NG
0.75 LPG
Max 14
Min 2.3
Max 28.2 /36.2
Min 4.5 / 6
220~240V-50Hz
220
IPX 4 D
Capriz 25S
(25 kW)
Capriz 28S
(28 kW)
Capriz 25S
(25 kW)
Capriz 28S
(28 kW)
85
7
1
36
1.5
1.0
39
330d x 430w x 720h
05

capiz 25 & capiz 28
Page 6
A - Heating Flow (22mm)
B- Gas Inlet (22mm)
C- Cold Water Inlet (15mm)
D- Heating Return (22mm)
D
C
B
A
1
2
3
4
5
6
7
8
9
10 11 12
13
14
15
16
17
18
19
20
A
t
t
h
e
r
e
a
r
A
t
t
h
e
r
e
a
r
A
t
t
h
e
r
e
a
r
11 - Air Pressure Switch
12 - Condensing Unit (Turbo heat exchanger)
13 - Overheat Safety Thermostat
14 - Ignition Electrode
15 - Heating Circuit– Pressure Safety Valve
16 - Automatic Air Vent
17 - Water Pressure Switch/Sensor
18 - Pump
19 - Gas Valve
20 - Filter Valve (Below the pump)
Key
1 - Condensate Trap
2 - Limit Safety Thermostat
3 - Expansion Vessel (At rear of the boiler)
4 - Burner
5 - Flame Sensor (Ionisation) Electrode
6 - C.H. Sensor (Heating Sensor)
7 - Combustion Chamber
8 - Primary Heat Exchanger
9 - Fan Hood
10 - Fan
Figure 2.1
06

capiz 25 & capiz 28
3.2
Range rated from 25kW and 28kW the Capriz 25/
Capriz 28 heat output can be focused to match the
designed heating systems adjustments.
3.3 An electronic control unit, consisting of a PCB,
which includes ignition module, provides direct burner
ignition and flame supervision along with continuous
modulation of the burner’s gas supply.
3.4 An interface unit, which includes boiler adjustment
potentiometers and fault display provides easy service
ability to the boiler.
3.5 Heat transfer to the boiler’s primary hydraulic
circuit is obtained via a primary, gas to water heat
exchanger contained within a hermetically sealed
combustion chamber. A 230 volt, duel speed fan
expels the products of combustion from the
combustion chamber to outside air via an associated
flue system. The fan is activated at the beginning of
each ignition cycle and its operation monitored by
means of negative and positive sensing points
connected to an air pressure switch.
3.6 An integral pump located in the boilers main
hydraulic circuit circulates water through the primary
heat exchanger to either the central heating circuit
,depending on the demand. In the event of reduced or
interrupted water circulation in the central heating
circuit , a system by-pass should be fitted as far away
from the boiler as possible.
Note: It is no longer permissible to utilise
a non-thermostatic controlled radiator as a by-pass.
3.7
Room temperature can be controlled by the use of an
external room thermostat or temperature regulator.
Note connection of the room thermostat is dependant on
the operating voltage of the thermostat. See section 9
for details
3.8
The boiler boiler’s control panel incorporates an LED
display, which indicates the state of operation and fault
defect codes.
4.1 Using the operating switch the boiler can be
switched on.
3. Boiler Characteristics 4. O
p
eration
CENTRAL HEATING HYDRAULIC CIRCUIT
Figure 4.1
Page 7
3.1 The CAPRIZ 25S & CAPRIZ 28S are fan flued,
wall-mounted condensing type system boilers that
supply domestic central heating. Being room sealed
the boiler may be installed in any room or internal
compartment without the need for purpose made
ventilation. However, if the boiler is installed in a
compartment it is recommended that the compartment
is ventilated for cooling purposes. A functional diagram
of the boiler’s components is given as VENTILATION
section in user manual.
4.2 CENTRAL HEATING DEMAND:
When heating demand is requested and power is on
with the timer and thermo stat calling for heat, the
boiler will fire automatically. An integral pump is then
energised and hot water from the boilers primary
circuit is circulated around the central heating
systems pipe-work and radiators. When the demand
for central heating is no longer present, either the
thermostat reaches temperature or the time clock
reaches temperature or the time clock reaches the
end of its set period, the burner will shut down and
the boiler will revert to stand-by, waiting to respond
to the next heating demand. The pump will continue
to operate for a short period of time to dissipate any
excess heat from within the boiler’s heat-exchanger.
07

capiz 25 & capiz 28
5.1 Installer Testing & Commissioning Tips
•The installer shall instruct the user in the operation
of the boiler, safety devices contained within the
boiler and instruction on how to re-pressurise the
system if the water pressure falls. The installer
should then hand over the instructions with the
Benchmark Logbook that has been completed.
•The user should be instructed to keep the
instructions in a safe place for servicing and future
reference.
•It is important to keep the boiler clear of dust during
the installation. In particular, do not allow debris to
enter the top of the boiler where the flue connection
is made. This may cause the fan outlet to get blocked
or combustion chamber to fill with debris and will, of
course, cause the boiler to fail to ignite on first
ignition. It is recommended that you check the fan
outlet before you light the boiler.
•Before you fit the boiler ensure that the pipe work
that you are installing is connected to the appropriate
connections on the boiler i.e. cold water pipe to cold
water inlet, hot water outlet to the hot water tap etc.
•Because the boiler is actually operated, at the end of
each production stage, a small amount of water is
retained within the boiler when packed. Please
ensure that you spin the pump rotor manually before
firing the boiler.
•It is important that the boiler must be used in
conjunction with a Heatline approved flue and all
flue connections are correctly sealed.
•Remember to flush out the system, both cold and
hot, in order to remove the debris from the system.
This should be done particularly where boilers are
being fitted to existing radiator circuits.
•Refer to BS 7593: 1992 for the details to clean
Central heating systems.
•This boilers central heating output has been set to a
mid range position. However you may choose to
adjust this using potentiometer P2 to meet the
requirement of the system.
•Remember to release the small cap on top of the
auto air purge device on the pump, 1 turn, before
filling. This will ensure that air is removed as the
system fills.
•Do not use the pressure relief valve as a means of
flushing the system, please use the valve below the
pump. Discharging water from the pressure relief
valve may allow water to seep after you have left the
job, causing the boiler to lose pressure and debris to
collect on the seating.
5. General Installation
Page 8
will cause the heater to lock out at as the water
flow is reduced.
•If you are able to obtain hot water but not heating it
is also advisable to check that the room thermostat
and any external time clock that may be fitted are
calling for heat.
•When commissioning the boiler check the inlet
pressure is at 20mbar and burner pressure against
the Technical data, section 2.
•
NOTE – FOR INSTALLERS:
REMEMBER IT IS A REQUIREMENT TO COMPLETE
THE BENCHMARK CODE OF PRACTICE LOGBOOK
BEFORE LEAVING THE INSTALLATION.
5.2 The boiler is designed to operate on fully pumped,
pressurised sealed systems operating at a maximum
of 3 bar pressure and maximum design flow
temperature of 850C.
5.3 The boiler’s integral expansion vessel is pre-
charged to a pressure of 1 bar and will accommodate
a system volume of 125 litres. at an average water
temperature of 75°C and maximum system pressure
of 3 bar. If the system volume is more than 125 litres.
an additional expansion vessel must be fitted to suit
the size of the system. A typical installation of an
additional pressure vessel is shown in Figure 5.1
5.4 The heating circuit should be designed and
balanced to give a 200C temperature rise across the
boiler flow and return.
5.5 When fitting a new boiler to an existing system the
system must be thoroughly flushed in accordance with
the recommendations of BS7593 prior to installation.
5.6 It is recommended that the system should be
protected by an anticorrosion inhibitor. Failure to
comply with this requirement may invalidate your
guarantee.
If you experience any problems please refer to the
installation and commissioning guidelines within the
boiler instruction manual. If necessary, please contact
HeatlineTM Service Enquiries, in the UK, for further
advice and assistance on 0870 777 8318
•The boiler is fitted with inlet filters both on the cold
water inlet and the central heating return. If you are
unable to obtain hot water at an outlet.
It is likely that the cold water inlet valve filter has
become blocked, whilst blockage of the filter on
central heating return valve, the overheat thermostat
Boiler
Flow
control
valve
Flow
control
valve
Flow
control
valve
Filling
device
Heating return
Heating outlet
Cold water
supply
Additional
expansion
vessel (if
required)
Figure 5.1
08

capiz 25 & capiz 28
Page 9
5.7 On installation it is important to ensure that the heat
exchanger is not a natural collecting point for air and
where possible, the system pipe work should have a
gradient to ensure any excess air is carried naturally to
other purpose made, air release points.
5.8 In high water volume systems or under floor heating
systems where prolonged operation of the boiler is
expected at temperatures below 60°C, a by-pass must
be installed on the boiler outlet in order to prevent
condensation forming inside the combustion chamber.
Failure to comply with this requirement will invalidate
the manufacturer’s guarantee.
5.9 The pressure relief discharge must be directed away
from any electrical equipment or where it could cause a
hazardous situation.
5.10 To enable adequate drainage of the system drain
cocks compliant with BS2879 must be fitted at the
lowest points in the system pipe-work.
5.11 To obtain the best hot water performance from your
boiler it is suggested that the cold water supply to the
boiler is the first draw off from the incoming mains
supply. Note that the boiler will not operate unless
there is a minimum pressure of 0.25bar with a flow rate
of 2.5l/min. Where inlet pressures exceed 8bar, a
pressure regulator must be fitted to the cold water
supply.
5.12 Where cold water mains are fitted with a water
meter, check valve(s) or loose jumper stopcock, a
domestic hot water mini-expansion vessel may need to
be fitted.
5.13 Although the boiler is designed to inhibit the
formation of scale, in hard water areas above 200mg/l, a
proprietary scale reduced should be fitted in the cold
water supply to the boiler. Failure to comply may
invalidate your guarantee. The local water undertaking
will advise on water hardness.
5.14 To obtain the best hot water performance from your
boiler it is suggested that supplies to outlets are run in
15mm copper, as short as possible and where practical,
be insulated to reduce heat loss.
5.15 The boiler incorporates a frost protection
thermostat. Therefore if the boiler will not be used for
long periods of time during cold weather, in order to
avoid freezing the electric supply must be left ON and all
the central heating isolation valves must be left open.
The internal frost thermostat will then operate the boiler
if the temperature falls too low. However, if the
electrical supply is to be turned off the boiler, the
heating system and domestic hot water circuit must be
drained.
6.1 If the boiler is to be installed in any room or
compartment, it requires no purpose made ventilation
for combustion air. If sited in a room containing a bath
or shower then particular reference is drawn to the
requirements of British Standard 7267 (confirm)
(I.E.E. Wiring Regulations) and Building Regulations.
6.2
6.3 The boiler is not suitable for external installation
unless protected by a purpose made building such as a
boiler house.
6.4 The following clearances are recommended for
installation purposes; 200mm above, 300mm below
and 50 mm at each side. 600 mm is required at the
front but this may be provided by opening a cupboard
door.
6.5 The boiler must be sited at least 1m away from
flammable materials and heat sensitive walls must be
protected by an appropriate insulating material.
6.6 The wall on which boiler is mounted must be non
combustable and sufficient strong to support the
weight of the boiler.
6.7 A condensate drain pipe must be fitted to allow
discharge of condensate to a drain or soak way.
Where possible condensate should be discharged into
the household internal drainage system. If this is not
practical, discharge can be made into an external
drain. If neither of the above options are possible then
condensate must be discharged into a purpose
designed soak way.
It is recommended that any external condensate pipe
is insulated and increased to 32 mm diameter in order
to prevent the condensate from freezing.
6. Appliance Siting
If the boiler is installed in a compartment there
must be purpose made ventilation for cooling purposes .
09

capiz 25 & capiz 28
To avoid excessive condensation occurring within
the boiler flue the boiler should wherever possible, be
sited to ensure the shortest possible flue run is
utilised.
6.8 For compartment installation the requirements of
BS6798 and BS5440: Part 2 must be met.
The compartment must be of sufficient size to
permit access for inspection and servicing or the
removal of the boiler and any ancillary equipment.
Any space used for airing clothes or storage must be
separated from the appliance by a non-combustible
partition. Where the partition is formed from
perforated material, then the major dimension of the
apertures shall not exceed 13mm.
No combustible surface must be within 50mm of the
boiler casing without protection.
There must be 50 mm clearance between the
compartment door and boiler case.
Where the boiler’s flue pipe passes through the
airing space, it must be protected by a non-
combustible sleeve or fire stop which has a
minimum clearance of 25 mm from the flue pipe. In
addition, if the flue pipe passes through the partition
then the clearance gap of the flue pipe or its guard
with the partition must not exceed 13 mm.
6.9 When the boiler is intended for use with LPG it must
not be installed in a room or internal space below
ground level.
7.1 The flue terminal must be sited with minimum
clearances as specified in
Figure 7.1
. Note if pluming
becomes problematic or causes a nuisance a plume
management kit is available from your stockist.
7.2 Current regulations and standards require a terminal
guard to be fitted where the terminal is accessible to
touch or at risk of being damaged. All wall mounted
terminals sited within 2m of the level which people have
normal access, should be adequately protected with a
suitably sited guard.
7.3 Where the flue terminates within 1m of a plastic or
painted gutter or within 500mm of painted eaves then
protection should be provided in the form of an
aluminium shield at least 1m in length, fitted to the
underside of the gutter or painted surface.
7. Flue Terminal Location
Page 10
10

capiz 25 & capiz 28
Internal Corner External Corner Double Corners
)mm(ecnaraelC
)margaideeS(noitpircseDnoitacoL
003)1etoNeeS(gnineponawoleBA
003gnineponaevobAB
003gnineponaotyllatnoziroHC
57sepipniardrosepiplios,srettugwoleBD
002sevaewoleBE
002foortropracroynoclabwoleBF
051epipliosroepipniardlacitrevamorFG
H From an internal or external corner or to a boundary alongside the
terminal (See Note 2)
300
003levelynoclabrofoor,dnuorgevobAI
J From a surface or a boundary facing the terminal (See Note 2) 600
0021lanimretehtgnicaflanimretamorFK
0021gnidliubehtotnitropracehtnignineponamorFL
0051llawemasehtnolanimretamorfyllacitreVM
003llawemasehtnolanimretamorfyllatnoziroHN
P 006
lanimretfoorrehtonarofoorehtnoerutcurtsamorF
Q 003llawtnecajdanaotlanimreteulflacitrevamorF
R From a vertical ue terminal to an adjacent wall which includes an
opening window (See Note 3)
1000
Notes: 1. An opening here means an opening element, such as an openable window, or a
xed opening such as a air vent. However, in addition, the outlet should not be
nearer than 150mm to an opening into the building fabric formed for the purpose
of accommodating a built in element, such as a window frame.
2. Boundary as dened in the Building Regulations (England & Wales) or the
Building Standards (Scotland) Regulations.
3. Where the wall adjacent to a vertical ue terminal includes an opening window,
the clearance between the terminal and any part of the opening window must
not be less than 1000 mm.
Page 11
Figure 7.1
11

capiz 25 & capiz 28
7.4 The flue should not be sited where the condensate
plume may give rise to a nuisance factor under
certain weather conditions.
NOTE: If you have difficulty siting the flue in an
appropriate location your supplier will be happy to
supply an “anti-plume management kit”, which
discharges the flue products at a higher level.
8.1 The boiler utilises a concentric flue arrangement
which consists of a 60mm-diameter inner flue and
100mm-diameter outer air inlet duct.
8.3. The 60/100 mm flue pipes may be extended up to a
maximum of 2.5 m using additional spare components
available from your supplier. This length can be
increased to 7 m using the 80/125 mm flue kit.
8.4. A vertical 60/100 mm flue kitis also available from
your supplier up to a maximum length of 3m. The
terminal is suitable for a flat or pitched roof. This
length can be increased to 7 m using the 80/125mm
flue kit.
8.5. If horizontal and vertical flue lengths are less than
1m,the restrictor (air diaphragm)–Figure 8.2 must be
fitted on the combination boiler.
Please find the information sheet for the installation
of restrictor given with documentation group.
The diameter of air diaphragm changes according to
the installation types.
C12-C32 C42-C52
60/100 80/125 80/80
24 kW Ø80 Ø80 Ø80
28 kW Ø82 Ø82 Ø82
8.6 The air restrictor should not be fitted if the length of
the flue pipe installation is below:
C12-C32 C42-C52
60/100 80/125 80/80
24 kW >1 m >2 m
28 kW >1 m >2 m
8.7. The connection of vertical flue system is similar to
the Horizontal flue connection. The flue is connected to
the boiler via connection screws whilst the sections are
held together with the clamps provided.
8.8. To avoid condensate dripping from the terminal the
flue should be installed with an upward gradient (from
the boiler) of 3o. Note that some new flue may have the
3obuilt in.
8.9. The installation types for room sealed versions are
C12-C32-C42-C52.
8.10. The boiler can be used with separate ducts such as
80/80 to fit required type of installations.
8. General Flue Info
Note. For each additional 90º elbow used the
maximum flue length must be reduced by 1.5 m,
whilst the use of 2 x 45º bends warrants a
reduction of 2m.
Figure 8.2
Figure 8.1
WARNING!
Page 12
ONLY A HEATLINE APPROVED FLUE IS TO BE
USED WITH HIS PRODUCT.FAILURE TO COMPLY
WITH THIS REQUIREMENT WILL INVALIDATE YOUR
GUARANTEE AND COULD LEAD TO A DANGEROUS
SITUATION.
8.2 The standard 700 +/-5 mm flue kit (Figure 8.1) can
be routed to the rear, left or right of the appliance by
means of a 90° degree bend .This can be purchased
with the boiler but there are other various types of flue
available if required. The bend is connected to the boiler
using the screws provided and sealed with the gasket.
12

capiz 25 & capiz 28
9.1 The boiler is supplied factory wired complete with
1.5 m of mains fly lead. All electrical connections to
the mains supply must be made in full accordance
with the current I.E.E. regulations.
9.2 The boiler must be connected to an effective earth
system. Using the cable supplied the boiler may be
connected via a 3 amp fused three pin plug to an
unswitched shuttered socket outlet. However if the
boiler is installed in a room containing a bath or
shower regulations dictate that disconnection must be
incorporated in the fixed wiring with a switch provided
for disconnection from the mains supply having a
contact separation of at least 3 mm on all poles and
fused at 3 amp.
9.3 Other than for a bathroom installation the point of
connection must be readily accessible, at a distance no
further than 1.5m adjacent to the appliance and provide
complete electrical isolation for the boiler and control
system.
9.4 The low voltage room thermostat terminal block is
located to behind of left side of the plastic cover
(Figure 9.1)
Figure 9.2.
Figure 9.3.
On connection of a voltage free room
thermostat to the boiler, the factory fitted bridge across
the room thermostat terminal connectors must be
removed. If a mains voltage thermostat is to be used
please refer to
9.5 Mains powered thermostats must be connected
directly to the mains circuit board as indicated in
Figure
9.2
Cut the existing link and connect the wires into the
thermostat circuit.
9.6 Ensure that the polarity of the mains connection is
correct as reversed polarity may cause the appliance to
malfunction.
9.7 While the boiler's main pcb, pump, three-way valve
and gas valve are supplied at 230V AC., all other
components and associated circuits are supplied at low
voltage.
9.8 On connecting the mains electrical supply to the
boiler, it is essential to ensure that electrical safety
checks for earth continuity, earth resistance, polarity
and short circuit are carried out prior to making the final
connection. A diagram of the boiler's electrical circuit is
given as
9.9 Fuse Ratings
Circuit Board
F1 – 2 amp fast blow
F2 – 2 amp fast blow
9. Electrical Connections
FOR CONDENSING BOILERS IT IS RECOMMENDED
THAT AN ANTI PLUME KIT IS FITTED IF THE
TERMINAL IS LESS THAN 2.5 m FROM A BOUNDARY.
IN ADDITION THERE IS 45oELBOW AVAILABLE TO
DEFLECT THE PLUME AWAY FROM WINDOWS ETC.
Warning: On no account must any external voltage be
applied to any of the terminals on the heating control
connection plug. Figure 9.1
Connection to the mains electrical supply must be
maintained at all times in order to provide frost
protection and pump over - run facility. Ensure
that the boilers electrical supply is not interrupted
by any external controls.
Figure 9.1
Figure 9.2
Page 13
Important Note
FITTED
BRIDGE
24V LOW VOLTAGE
ROOM THERMOSTAT
TERMINAL BLOCK
BRIDGE PLUG
PRINTED CIRCUIT
BOARD
13

capiz 25 & capiz 28
Figure 9.3
FUSE RATINGS:
F1: 2 A
F2: 2 A
Page 14
5 4 3 2 1
br BROWN
b BLUE
g/y GREEN/YELLOW
gn GREEN
g GREY
bk BLACK
m MAUVE
w WHITE
r RED
KEY
IGNITION
ELECTRODES
FLAME
(IONISATION)
ELECTRODE
OVERHEAT
THERMOSTAT
FUSES (2A)
AIR PRESSURE
SWITCH
GAS CONTROL
VALVE
CENTRAL HEATING
SENSOR
PUMP
FAN
PRINTED
CIRCUIT
BOARD
L E N
230V~50Hz PERMANENT
MAINS SUPPLY
FUSED AT 3A
24V ROOM
THERMOSTAT
CONNECTION
(low voltage)
24V TIME
CLOCK
(low voltage)
230V ROOM
THERMOSTAT
CONNECTION
(high voltage)
USER
INTERFACE
WATER
PRESSURE
SENSOR
r
r
r
r
F1 F2
CHASSIS
EARTH
br
br
br
br
b
b
b
b
g/y
g/y
g/y
g/y
g/y
g/y
g/y
g g
m
w
w
w
g
w
w
w
w
ww
ww
w w
r
rr
r
r
r
r
r
r r
r r
LIMIT
SAFETY
THERMOSTAT
HALL
EFFECT SENSOR
14

capiz 25 & capiz 28
10.1 Prior to installing the boiler check the contents of
the carton: Appliance, Valves (Fixing Jig Optional), Wall
Hanging Bracket, Mounting Template Service,
Installation and User Manual, Guarantee Card and
Benchmark Log Book. The boiler dimensions are given
in
10.2 Ensure that the boiler is suitable for the gas
supply by checking the data plate, which is situated on
the inside of the control panel door, and that the
system and chosen boiler position is in accordance to
Sections 5, 6 and 7 of these instructions.
10.3 Position the supplied template on the wall,
ensuring it is level both vertically and horizontally
(Figure10.2).
Figure10.1.
(Figure10.3).
Mark the boiler fixing jig (if required), wall
bracket fixing positions and flue outlet position (rear
flue only). For flue side exit from the boiler - Mark the
horizontal flue centre line on the rear wall. Extend the
horizontal line to the side wall allowing a 30decline
back towards the boiler, to enable condensate to drain
back through the boiler. Mark the flue centre vertical
line.
Figure 10.1
Figure 10.2
Dimension
A 405 430
169
60/100
B 169
C 60/100
10.4 When cutting the flue hole it is recommended that a
105mm diameter core drill is used where both internal
and external access for the flue installation is available.
Where only internal access is available a 125mm
diameter core drill should be used. (Note: Please take
adequate precautions to prevent debris entering the
boiler via the flue outlet).
10.5 Using a 8·5mm drill bit, drill the holes for fixing jig
(optional) and hanging bracket. Locate and secure the
supplied wall mounting bracket in position
(Figure 10.4).
(Figure 10.4).
10.6 Mount the boiler onto the fixing bracket via the
boiler mounting slots
10.7 Connect isolation valves assembled to the boiler
ensuring the washers are fitted correctly.
10.8 On installing the flue, determine the required
length of the outer air duct by measuring the distance 'L'
(Figure 10.6)
from the face of the external wall to the back
of boiler's elbow connecting collar. The measurement
for the inner flue duct will be 'L' + 20mm
10. Boiler Installation
Figure 10.3
30
130 130
CONDENSATE
CONNECTION
SDV
outlet
86
50 98
151151
027
BOILER
CENTRAL HEATING
Page 15
B
033
A
C
= =
A
Bracket Fixing Slots
Boiler Mounting Tabs
(CONDENSING)
(NON-CONDENSING)
Figure 10.4
Distance to centre line 169 mm
Capriz 25S Capriz 28S
15

capiz 25 & capiz 28
Cut the outer air duct only to the required length
ensuring that the cut is square and free from burrs.
Measuring from the back of the terminal
connection, mark distance 'L' + 20 mm
(Figure 10.5).
Pass the flue assembly through the wall and
connect the assembly to the boiler, ensuring that both
the air and flue duct joints are fully pushed home into
the connecting elbow's collar.
With the flue and joints secured fit the flue trim
to the external wall surface using suitable mastic.
Note. Where internal access only is available, the flue
trim must be attached to the flue assembly prior to
passing the assembly through the wall.
For maximum flue lengths refer to the Technical
Data, section 2 in this manual
Condensing type boilers must be connected to
the drainage system. A plastic drain must be fitted to
allow discharge of condensate to a drain.
Condensate should, if possible, be discharged into the
internal household draining system. If this is not
practical, discharge can be made externally into the
household drainage system or a purpose designed
Extract the bottom part of condensate trap, by
turning anti-clockwise and fill it with approximately 50
cc water re-connecting it to the boiler.
(Figure10.7).
(Figure 10.5).
Connect the condensate drainage pipe to the
drainage system
(Figure10.7).
of the condensate the drainage system must be made of
non-corrosive material such as plastic tubing. More
detailed information on condensate discharge is provided
in BS 6798 (Specification for installation of gas fired hot
water boilers of rated input not exceeding 70kW)
Connect the domestic hot water, cold water inlet,
heating system flow & return and pressure relief valve
pipework to the boiler fittings, ensuring that the
pipework has been correctly flushed before final
connection. The electrical connections to the boiler must
be in accordance to Section 9 of these instructions.
11.1 The gas supply pipe must be capable of supplying
the quantity of gas required by the boiler (see Technical
Data, section 2) in addition to the demand of any other
gas appliances being serviced from that supply.
11.2 The internal diameter of the gas supply from the
meter to the boiler's gas inlet connection must not be
less than 22mm.
11.3 The meter governor must be capable of delivering a
nominal pressure of 20mbar (for natural gas).
11.4 On final connection of the gas supply to the boiler,
the complete gas installation including the gas meter,
must be tested for tightness and purged.
NOTE: Place the filling loop in a visible accessible
position and instruct the user how to pressurise the
system if there is a fall in pressure.
11. Gas Supply
Figure 10.7
Page 16
CONDENSATE
OUTLET PIPE
CONDENSATE
TRAP
Figure 10.6
Figure 10.5
L+20 mm
L
L
!
!
!
!
Waste
External
wall face
10.9 Measuring from the back of the terminal
connection, mark distance 'L' onto the outer air duct.
10.10
10.11
10.12
10.13
10.14
10.15
soak away. Note if a soak way is used the drain must
terminate at least 500 mm from the external wall.
10.16
10.17
10.18
onto the inner flue duct and cut the duct to size,
ensuring that the cut is square and free from burrs.
Note due to the acidic nature
16

capiz 25 & capiz 28
12.1 The boiler must not be operated without water.
12.2 On completion of the boiler installation and
ensuring that all water connections are correctly
made the boiler may be filled with water via the filling
loop (not supplied with the boiler). Ensure that manual
feed valves and boiler isolation valves are open.
12.3 Release the cover cap of the boiler's automatic air
vent situated on top of the pump.
(Figure 12.1)
12.4 The manual feed valves must be closed and the
filling loop disconnected once the pressure gauge,
sited on the boiler’s control panel, indicates a system
pressure between 1.0 and 1.5 bar.
12.5 Check that all the water connections throughout
the system are sound and bleed each of the heating
system’s radiators in turn. As air is vented the system
pressure may need topping back up to 1.0 bar.
12.6 Air must be vented from the boiler's pump by
unscrewing the pump’s integral vent plug and allowing
water to bleed for a few seconds. Take care not to
allow water to splash onto any electrical components.
12.7 When the system is bled of any air it must be re-
filled until the pressure shown on the display gauge
indicates a system pressure of 1.5 bar.
12.8 If the pressure shown on the gauge exceeds 1.5
bar discharge the excess pressure from the system via
a radiator valve or pipe connection. Do not use the
safety discharge valve as the valve seat may become
contaminated with debris and fail to re-seal.
Figu
Figure 13.2
re 13.1
1- Timer
2- Function switch
3- C.Heating temperature control
4- System pressure gauge
5- LED display
12. Filling the System
Release the cover cap
(behind the pump) when
the filling complete
Figure 12.1
13. Control Panel Functions
Page 17
1
0
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
24
23
bar
1
2
3
4
bar
0
1
23
4
5
ON
bar
Boiler Stand-by
Indicator
Water
Temperature
Flashing
Fault on CH
sensor
Flashing
Fault on
Outdoor sensor
Flashing
Fault on Air
Pressure Switch
Flashing
Flames or Gas
Failure
Flashing
Fault on
DHW sensor
Flashing
Low System
Pressure
Flashing
Overheat
Themostat
30 40 50 60 70 80 90
bar
13.1 C/heating temperature controls: The boiler's
integral control unit monitors and adjusts the boiler’s
hydraulic circuit water outlet temperature by means
of a sensor located on the C/heating flow outlet. The
sensor’s electrical resistance is dependant on
temperature and determines the current passing through
the control potentiometer located on the control panel.
The potentiometer control dial allows manual setting
of the maximum required temperature (reference value)
being between 30º and 85ºC. When the boiler operates
the current received is compared to the manually set
reference value. The difference of the two values
operates the modulation of the gas valve adjusting the
useful heat output generated and stabilising the
temperature to within ±1ºC.
13.2 Re-set function: Should the boiler lock out at any
time, please check the gas supply and ionisation probe
position, the boiler may be re-started by switching to
standby “O” position (Switch 2 Figure 13.1) waiting 15-30
seconds and switching back to its previous position
once the fault has been eliminated.
17

capiz 25 & capiz 28
Important Note.
In order to maintain the appliance’s warranty and
so as to comply with the Domestic Heating
Compliance Guide; when the boiler is to be
installed to an existing central heating system,
the system must be properly cleansed using a
proprietary cleanser before the boiler is
connected to the system. On all installations,
after connecting the boiler to the system and
initially filling with water, a proprietary inhibitor
must be added to the system water to prevent
corrosion.
14. Commissioning
Important Notice
•Failure to thoroughly power flush the heating
system with the boiler disconnected or to add an
anti corrosion inhibitor to the system water will
invalidate the boiler's warranty.
•The condensate trap must be filled with water and
plastic discharge pipe connected to drain before
operating the boiler.
15. Onboard Adjustments
Figure 15.2Figure 15.1
POTENTIOMETER
ADJUSTMENT
COVER
7654321
NO
7P
5P
2P
4P
4 OFF
POTENTIOMETERS
Page 18
14.1 The CAPRIZ 25S & CAPRIZ 28S boilers have been
tested and pre-set at the factory and is dispatched
with its on board controls set to provide maximum
central heating output. Consequently, once all the
connections have been made and the boiler has been
filled with water to the designed system operating
pressure, the boiler may be fired prior to adjusting it’s
on board controls set to a mid heating output position.
14.2 Prior to firing, check that the electrical supply to
the boiler is 'On' (The green boiler ‘Stand by’ indicator
will light) and the gas service cock is in the open position.
Set the boiler's central heating water temperature
control to maximum by turning fully clockwise.
Set the external room thermostat to maximum and
open the thermostatic radiator valves to maximum.
14.3 Switch the boilers function switch to the heating
position.The boiler's control unit will now automatically
carry out pre-ignition safety checks before igniting the
burner.
14.4 During the 10 second burner ignition attempt
visually check that all of the burner blades ignite
correctly.
If necessary, adjustments to the ignition rate may be
made using potentiometer P4. Turning P4 clockwise
increases the ignition rate and anti-clockwise decreases
the rate. After successful ignition check the integrity
of the boiler's flue for soundness and correct operation.
14.5 In order to maintain the appliance warranty after
initial filling the heating system must be thoroughly
flushed using a propriety cleanser to remove foreign
material and contaminants.
14.6 Restart the boiler and again allow the central
heating system to reach maximum operating temperature.
Check that all the water connections throughout the
system are sound and bleed each of the heating systems
radiators and purpose made air release points in turn.
Isolate the boiler before carrying out this operation.
14.7 Check the system pressure and top up if necessary.
14.8 Reset the central heating water temperature control
and room thermostat to the desired temperature
settings.
15.1 The boiler incorporates 4 potentiometers and
a bank of dip switches to allow adjustment to its pre-set
parameters. These are situated on the rear of the control
panel.(Figure 15.1) The potentiometers can easily be
accessed by removing the cover on the rear of control
panel (Figure 15.1).However,to reach the dip switches,
the control panel must be opened. Factory settings for
potentiometers shown below
15.2 Setting the maximum c/heating flow temperature:
The boiler is dispatched with a maximum flow temperature
factory set to 85°C. Where a lower maximum temperature
is required such as in the case of under-floor heating,
the factory setting can be altered between a maximum
of 50°C and a minimum of 30ºC, by fitting dip switch '6'
into ON position.
15.3 255 seconds delay setting: The boiler is capable of
up to 255 seconds ignition delay (anti cycling time) before
re-ignition following burner shut down on the primary
hydraulic water reaching its set temperature.This delay
can be increased up to a maximum of 255 seconds by
turning potentiometer P5 (Figure 15.2) clockwise.
CAPRIZ 25S
CAPRIZ 28S
6th line
6th line
6th line
6th line
4th line
4th line
4th line
4th line
P7 P5 P2 P4
18