Heatline SARGON 30 User guide

SARGON
SARGONSARGON
SARGON 2
2 2
24
44
4 / 30 / 35
/ 30 / 35 / 30 / 35
/ 30 / 35
PRE
PREPRE
PRE-
--
-MIX
MIXMIX
MIX CONDENSING
CONDENSINGCONDENSING
CONDENSING
COMBI
COMBICOMBI
COMBINATION BOILER
NATION BOILERNATION BOILER
NATION BOILER
Installation Servicing and User
Instructions

Natural Gas
Natural GasNatural Gas
Natural Gas
Heatline Sargon 24 / 30 / 35 Pre-mix Condensing Combination Boiler
British Gas Service Listing
SARGON 24 G.C.No. 47-157-15
SARGON 30 G.C.No. 47-157-16
SARGON 35 G.C.No. 47-157-17
Notified Body
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.
IMQ
51
BP2750
Directive 90/396/EEC
51BP2751DR Directive 92/42/EEC
The Heat Line™ range of heating boiler are
manufactured from high quality materials enabling
reliability and optimum performance.
Heat Line™ are 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 Boiler Registration & SEDBUK
'Benchmark' Log Book Boiler Registration & SEDBUK'Benchmark' Log Book Boiler Registration & SEDBUK
'Benchmark' Log Book Boiler Registration & SEDBUK
As part of the industry-wide initiative the boiler comes complete with an Installation
Commissioning and Service Record Log Book. Please read the Log book carefully and in
accordance with current legislation 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 which is found on pages 57&58 of the Installation manual 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. SARGON 24.

1
Page
Section Page
Preface
1. Installation Regulations 4
2. Technical Data 5
3. Boiler Characteristics 7
4. Operation 8
5. General Installation 8
6. Appliance Sitting 12
7. Flue Terminal Location 13
8. Flue (General) 13
9. Electrical Connections 16
Wiring Diagram 17
10. Boiler Installation 18
11. Gas Supply 22
12. Filling the System 22
13. Control Panel Functions 23
14. Commissioning 26
15. Onboard Adjustments 27
16. Safety Devices 29
17. Routine Servicing 30
18. Component Replacement 33
19. Gas Type Conversion 44
20. Fault Finding Chart 45
Appendices
Appendix 1. Spare Parts List 48
Appendix 2. User Instructions 49
Appendix 3.Benchmark Logbook 57-58
Contents
ContentsContents
Contents

2
Page
The Heat Line™ Gas fired combination boiler meets the requirements of Statutory
Instrument 'The Boiler (Efficiency) 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) and;
Electromagnetic Compatibility Directive 89/396 EEC (modified from 93/68)
Heat Line™ 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.
Heat Line™ 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 appliance is re-sold or installation transferred the appliance must be re-
registered with Heatline in order to maintain the warranty.
The boiler must be installed in accordance with these instructions and the regulations
currently in force. Read these instructions carefully before installing or using the
appliance.
Manual Handling
Manual HandlingManual Handling
Manual Handling: 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
PrefacePreface
Preface
Warnings
WarningsWarnings
Warnings

3
Page
230 V
The sign of approval.
This is a fragile piece of equipment: Do not drop.
The packed appliances may be stacked three high.
Do not crush the packaging as this may damage the appliance.
Store the appliance upright as indicated on the box.
Low Voltage
Low Voltage Low Voltage
Low Voltage Room Thermostat
Room ThermostatRoom Thermostat
Room Thermostat: This picture shows the terminal
block which is located at the bottom left hand side of the control
panel cover to which the room thermostat must be fitted.
NOTE:
NOTE:NOTE:
NOTE: This is a voltage free connection and no mains power must be
applied to these terminals. For mains powered thermostat
connection see section 9.5.
Warning High Voltage!
Warning High Voltage!Warning High Voltage!
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:
NOTE: NOTE:
NOTE: Take care as there may be residual voltage within some
components.
The
The The
The
Signs
SignsSigns
Signs
on Box
on Box on Box
on Box
Access
AccessAccess
Access
,
warnings
warningswarnings
warnings
and connect
and connectand connect
and connect
ions on the boiler
ions on the boilerions on the boiler
ions on the boiler

4
Page
1.1.
1.1.1.1.
1.1. This appliance must be installed in accordance with the Rules in Force by a
competent person or registered C.O.R.G.I. engineer in accordance with the Gas
Safety (Installation and Use) Regulations. Failure to install this appliance correctly
may invalidate your guarantee.
1.2.
1.2.1.2.
1.2. Your C.O.R.G.I. registered engineer should carry a C.O.R.G.I. ID card containing
their registration number which should be recorded in your BENCHMARK Log
Book which is supplied within the Instructions. You can check the validity of this ID
number by contacting C.O.R.G.I. on 0870 401 2300.
1.3.
1.3.1.3.
1.3. This appliance must be installed in accordance with the Gas (Safety 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.
1.4.1.4.
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 35mm (RI).
1.5.
1.5.1.5.
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.
1.6.1.6.
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.
For further information or advice contact HeatlineTM Service & Technical Enquiries in UK
& IE on:
Service: 0870 777 8341
Spares: 0870 777 8402
Technical Help Line: 0870 777 8318
E–mail via our web site: www.heatline.co.uk.
1. Installation Regulations
1. Installation Regulations1. Installation Regulations
1. Installation Regulations

5
Page
SARGON 24 30 35
Gas Category
II 2 H 3+
Gas inlet pressure G20
mbar
20
20
20
Gas inlet pressure Butane / Propane
mbar
28
-
30/
37
28
-
30/
37
28
-
30/
37
Heat Input (Q
max
) (CH)
kW
20.0
2
5
30.5
Heat Output (P
max
) (CH)
kW
19.5
24.4
29.8
Heat Input (Q
max
) (DHW)
kW
24.0
31.5
35.8
Heat Output (P
max
) (DHW)
kW
23.3
30
35
Heat Input (Q
min
) (CH/DHW)
kW
10.5
11.0
11.0
Heat Output (P
min
) (CH/DHW)
kW
10.1
10.6
10.6
Useful efficiency at 100% loa
d
%
97.5
97.5
97.6
Useful efficiency at 30% load
%
107.
0
107.0
106.9
Gas Rate (Max) (NG)
m³/h
2.12
2.54
3.18
Gas Rate (Max) (Butane)
kg/h
1.
57
1.97
2
.4
Gas Rate (Min) (NG)
m³/h
1.11
1.16
1.16
Gas Rate (Min) (Butane)
kg/h
0.83
0.867
0.867
Power suppl
y
Input
230 V 50 Hz
Gas Diaphragm (NG)
mm
7.1
7.0
7.0
Gas Diaphragm (LPG)
mm
4.9
5.0
4.9
Air Diaphragm (NG)
colour
Red
Red
Red
Air Diaphragm (LPG) colour
Red Red Red
Max. power consumption
Watts
175
175
175
Level of protection
IPX4D
Maximum heati
ng temperature
ºC
84~85
Max. domestic hot water
temperature
ºC 60
Operating pressure
PMS / Min
Bar 8 / 0.5
Domestic water supply pressure
PMS / Min
Bar 10 / 0.8
35
o
C
9.83
12.29
14.34
30
o
C
11.47
14.34
16 73
Domestic Water Supply Output
(litres/min.)
25
o
C
13.76
17.20
20.07
Expansion Vessel Capacity litres 7
Expansion Vessel Pre-charge bar 0.5
Air Intake Pipe Diameter mm 100
Flue Pipe Diameter mm 60/100 concentric & 80/80Twin
CO2 % at nom ±0.1% (NG) % 9.8 9.5 9.9
CO2 % at nom ±0.1% (Butane) % 10.4 11.0 10.8
CO2 % at min. ±0.1% (NG) % 10.0 10.0 10.0
CO2 % at min. ±0.1% (Butane) % 10.3 10.9 10.8
Output mass (NG) g/sec 8.77 11.17 12.94
Output mass (Butane) g/sec 8.76 10.69 12.70
Nitrogen oxide (NOx) emissions at
max. heat input
NOx
Class 5 5 5
Nitrogen oxide (NOx) emissions at
max. hot water input
NOx
Class 5 5 5
Combustion products temperature
(max.)
oC 75 71 71
Case Dimensions mm 330(d) x 430(w) x 720(h)
Shipping weight kg 38 39 40
Dry weight
kg 41 42 43
2. Technical Data
2. Technical Data2. Technical Data
2. Technical Data

6
Page
Figure 1
A B C D E
A B C D E A B C D E
A B C D E
Valves
A - Heating Flow (22mm) Red
B - D.H.W. Outlet (15mm) No Valve
C - Gas Inlet (22mm) Yellow
D - Cold Water Inlet (15mm) Blue
E - Heating Return (22mm) Blue (with filter)
Key
KeyKey
Key
1 – Flue Sensor
2 – Thermal Fuse
3 – Heat Exchanger
4 – Ionisation Electrode
5 – Ignition Electrode
6 – Fan Group (Fan Air gas mixer ring )
7 – Expansion Vessel
8 – Ignition Transformer
9 – Overheat Safety Thermostat
10 – Central Heating Temperature Sensor (Flow)
11 – Pressure Relief Valve
12 – Diverter Valve
13 – Secondary Heat Exchanger
14 - Gas Valve
15 – Pressure Sensor
16 – Return Hydroblock
17 – Pump
18 – Central Heating Temperature Sensor
(Return)
19 – Condensing Trap
20 – D.H.W. Flow Sensor
21 – Burner
22 – Plastic Flue Channel
23 – Automatic air vent
24 – D.H.W. Temperature Sensor

7
Page
3.1
3.13.1
3.1 The Sargon 24 / 30 / 35 are fan flued wall-mounted combination boilers that
supply both central heating and mains fed domestic hot water. Being room sealed
the boiler may be installed in any room 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 principal components is given in figure 1.
3.2
3.2 3.2
3.2 An electronic control unit consisting of a PCB and separate ignition module
provides direct burner ignition and flame supervision along with continuous
modulation of the burner’s gas supply.
3.3
3.3 3.3
3.3 An interface unit which includes boiler adjustment potentiometers and fault
display provides easy adjustment and fault diagnosis.
3.4
3.4 3.4
3.4 Heat transfer of heat to the boiler’s primary hydraulic circuit is obtained via a
primary gas to water heat exchanger within a hermetically sealed combustion
chamber. A 24 volt modulated speed fan blows the gas/air mixture into the
combustion chamber and expels the products of combustion to outside air via an
associated flue system.
3.5
3.5 3.5
3.5 A secondary heat exchanger allows the instantaneous transferral of heat from
the primary hydraulic circuit to water destined for domestic hot water use. The
secondary heat exchanger is sized so as to minimise thermal shock and is protected
against the build up of lime scale by limiting the D.H.W. outlet water temperature to
a maximum of 60°C.
3.6
3.63.6
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 or D.H.W.
heat exchanger depending on the demand. In the event of reduced or interrupted
water circulation in the central heating circuit an automatic 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
3.7 3.7
3.7 Room temperature can be controlled by the use of an external room thermostat
or thermostatic radiator valves. Note connection of the room thermostat is
dependant on the operating voltage of the thermostat. See section 9.4 & 9.5 for
details.
3.8
3.8 3.8
3.8 The boiler incorporates an integrated clock which allows the setting of central
heating periods (See the User Instructions Boiler Controls for details) and the
boiler’s control panel incorporates an LCD display which indicates the state of
operation and fault defect codes.
3. Boiler
3. Boiler3. Boiler
3. Boiler
Characteristics
Characteristics Characteristics
Characteristics

8
Page
4.1 Using the operating switch the boiler can be set to operate either on domestic
hot water only or domestic hot water and heating.
Note: Domestic hot water demand draws preference over heating. During
Note: Domestic hot water demand draws preference over heating. During Note: Domestic hot water demand draws preference over heating. During
Note: Domestic hot water demand draws preference over heating. During
heating periods the boiler will automa
heating periods the boiler will automaheating periods the boiler will automa
heating periods the boiler will automatically revert back to heating mode after a
tically revert back to heating mode after a tically revert back to heating mode after a
tically revert back to heating mode after a
draw off of hot water but there will be a 45sec delay if the No.
draw off of hot water but there will be a 45sec delay if the No.draw off of hot water but there will be a 45sec delay if the No.
draw off of hot water but there will be a 45sec delay if the No.S
SS
S3 dipswitch is set
3 dipswitch is set 3 dipswitch is set
3 dipswitch is set
to the OFF position. See fig
to the OFF position. See figto the OFF position. See fig
to the OFF position. See figure
ureure
ure 19
19 19
19 .
..
.
4.2
4.2 4.2
4.2 Depending on demand water is either diverted via the diverter valve to the
secondary water-to-water heat exchanger for domestic hot water or directly to
the heating system.
4.3 DOMESTIC
4.3 DOMESTIC 4.3 DOMESTIC
4.3 DOMESTIC HEATING
HEATING HEATING
HEATING MODE:
MODE: MODE:
MODE:
When the Control is set to “Winter” mode and a heating demand is requested
(power is on the timer and thermostat are calling for heat) the boiler will fire
automatically. The 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 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 or hot water 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. If during the heating period there is a call for
hot water this will take preference over heating. When satisfied the boiler will
then supply the heating demand as required. Note there will be a delay of 45sec
delay depending on how the boilers dipswitches are set. See section 15.3 for
details.
4.4 DOMESTIC HOT WATER MODE:
4.4 DOMESTIC HOT WATER MODE:4.4 DOMESTIC HOT WATER MODE:
4.4 DOMESTIC HOT WATER MODE:
When the Control is set to either the “Summer” or “Winter” mode and there is a
request for hot water (a hot water faucet is opened) the boiler will fire
automatically. The integral pump is then energised and hot water from the
boilers primary circuit is circulated around the water to water heat-exchanger
irrespective to any demand for heating giving up its heat to the domestic hot
water. When the faucet is closed the pump will continue to operate for a short
period of time to dissipate any excess heat within the boiler’s heat-exchanger
into the heating circuit and after a 45sec delay will revert back to the heating
mode if required.
5.1 Installer Testing & Commissioning Tips
5.1 Installer Testing & Commissioning Tips5.1 Installer Testing & Commissioning Tips
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 the location of the filling
the location of the filling the location of the filling
the location of the filling loop and
loop and loop and
loop and
how to re
how to rehow to re
how to re-
--
-pressurise the system if the water pressure falls.
pressurise the system if the water pressure falls.pressurise the system if the water pressure falls.
pressurise the system if the water pressure falls. The installer should
then hand over the instructions indicating the included Benchmark Logbook that
has been completed.
4. Operation
4. Operation4. Operation
4. Operation
5. General Installation
5. General Installation5. General Installation
5. General Installation

9
Page
•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.
•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. See Figure 1 for detail.
•Please ensure that you spin the pump rotor manually before firing the boiler.
•Remember to thoroughly flush the water circuits after isolating the boiler
Remember to thoroughly flush the water circuits after isolating the boiler Remember to thoroughly flush the water circuits after isolating the boiler
Remember to thoroughly flush the water circuits after isolating the boiler in
in in
in
order to remove any fluxes and debris from them.
order to remove any fluxes and debris from them.order to remove any fluxes and debris from them.
order to remove any fluxes and debris from them. This should be done
This should be done This should be done
This should be done
particularly where boilers are being fitted to existing radiator circuits.
particularly where boilers are being fitted to existing radiator circuits. particularly where boilers are being fitted to existing radiator circuits.
particularly where boilers are being fitted to existing radiator circuits.
•R
RR
Refer to BS 7593:
efer to BS 7593:efer to BS 7593:
efer to BS 7593:2006
20062006
2006 for the details to clean DHW and Central heating system.
for the details to clean DHW and Central heating system. for the details to clean DHW and Central heating system.
for the details to clean DHW and Central heating system.
•This boiler has been factory set
This boiler has been factory set This boiler has been factory set
This boiler has been factory set but adjustment may be required to the Heating
but adjustment may be required to the Heating but adjustment may be required to the Heating
but adjustment may be required to the Heating
input in order to match the heating demand. This can be done using
input in order to match the heating demand. This can be done using input in order to match the heating demand. This can be done using
input in order to match the heating demand. This can be done using
potentiometer R29
potentiometer R29potentiometer R29
potentiometer R29.
..
. See section
See section See section
See section 15 for details.
15 for details. 15 for details.
15 for details.
•To ensure that air is vented from the pump and heat exchanger as the system
fills release the small vent caps (1 turn) of the air vents which are located on top
of the pump and at the top left hand side of the heat exchanger before filling.
•Do not use the pressure relief valve as a means of flushing the system
Do not use the pressure relief valve as a means of flushing the systemDo not use the pressure relief valve as a means of flushing the system
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 system from the
pressure relief valve may allow debris to collect on the seating allowing water to
weep after you have left the job causing the boiler to lose pressure and shut
down.
•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 the tap it is likely that the
cold water inlet valve filter has become blocked whilst blockage of the filter on
central heating return valve will cause the heater to lock out at the overheat
thermostat as the water flow is reduced.
•If you are able to obtain hot water but not heating it is also advisable to check the
clock connections and that the room thermostat and time clock are calling for
heat.
•Remember that after hot water draw off there is a 45 sec delay before the
heating will fire up if No.S3 dipswitch is in the OFF position see fig 22 .
•When commissioning the boiler check the gas inlet pressure is 20mbar (NG) or
37mbar for LPG.
•Note an anti-cycle delay time can be set up to a maximum of 255 seconds by
adjusting potentiometer R28 as described in section 15.1 .
If you experience any problems please refer to the installation and commissioning
guidelines within the boiler instruction manual. If necessary please contact Heat
LineTM Service Enquiries in the UK on 0870 777 8341 for further advice or technical
assistance on 0870 777 8318
0870 777 83180870 777 8318
0870 777 8318.
NOTE
NOTE NOTE
NOTE –
––
– FOR INSTALLERS:
FOR INSTALLERS: FOR INSTALLERS:
FOR INSTALLERS:
REMEMBER IT IS A REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF
REMEMBER IT IS A REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF REMEMBER IT IS A REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF
REMEMBER IT IS A REQUIREMENT TO COMPLETE THE BENCHMARK CODE OF
PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION. YOU ARE ALSO
PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION. YOU ARE ALSO PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION. YOU ARE ALSO
PRACTICE LOGBOOK BEFORE LEAVING THE INSTALLATION. YOU ARE ALSO
REQUIRED TO REGISTER THE INSTALLATION WITH C.O.R.G.I.
REQUIRED TO REGISTER THE INSTALLATION WITH C.O.R.G.I.REQUIRED TO REGISTER THE INSTALLATION WITH C.O.R.G.I.
REQUIRED TO REGISTER THE INSTALLATION WITH C.O.R.G.I. OR YOUR LOCAL
OR YOUR LOCAL OR YOUR LOCAL
OR YOUR LOCAL
AUTHORITY.
AUTHORITY.AUTHORITY.
AUTHORITY.

10
Page
5.2
5.2 5.2
5.2 The boiler is designed to operate on fully pumped pressurised sealed systems
operating at a maximum of 3bar pressure and maximum design flow temperature of
850C.
5.3
5.35.3
5.3 The boiler’s integral expansion vessel is pre-charged to a pressure of 0.5bar and
will accommodate a system volume of 125l at an average water temperature of 750C
and maximum system pressure of 3bar. If the system volume is more than 125l an
additional expansion vessel must be fitted to suit the size of the system. A typical
installation of an additional pressure vessel is shown below in figure 2 below .
NOTE: The filter valve must be fitted to the boiler return at the right of the boiler.
NOTE: The filter valve must be fitted to the boiler return at the right of the boiler.NOTE: The filter valve must be fitted to the boiler return at the right of the boiler.
NOTE: The filter valve must be fitted to the boiler return at the right of the boiler.
5.4
5.4 5.4
5.4 The heating circuit should be designed and balanced to give a 200C temperature
rise across the boiler flow and return.
5.5
5.5 5.5
5.5 When fitting a new boiler to an existing system the system must be thoroughly
flushed in accordance with the recommendations of BS7593:2006 prior to
installation.
NOTE:
NOTE:NOTE:
NOTE: also that the gas supply pipe to the boiler from the meter should b
also that the gas supply pipe to the boiler from the meter should b also that the gas supply pipe to the boiler from the meter should b
also that the gas supply pipe to the boiler from the meter should be in 22mm
e in 22mm e in 22mm
e in 22mm
copper.
copper. copper.
copper.
5.6
5.65.6
5.6 It is recommended that the system should be protected by a proprietry
anticorrosion inhibitor.
5.7
5.7 5.7
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
5.85.8
5.8 The system’s water must always be allowed to circulate whenever the circulation
pump is running. An automatic by-pass must be provided.
Flow
control
valve
Bypass
valve
Filling
device
Cold water
supply
Domestic
hot
water
Heating outlet
Flow
control
valve
Boiler
Flow
co
ntrol
valve
Heating
return
Additional
expansion
vessel (if
required)
Figure 2

11
Page
NOTE
NOTE NOTE
NOTE –
––
– It is no longer permissible to use non
It is no longer permissible to use non It is no longer permissible to use non
It is no longer permissible to use non-
--
-thermostatic radiator valves to allow
thermostatic radiator valves to allow thermostatic radiator valves to allow
thermostatic radiator valves to allow
by
byby
by-
--
-pass through a radiator.
pass through a radiator.pass through a radiator.
pass through a radiator.
5
55
5.9
.9 .9
.9 In high water volume systems or under floor heating systems see section 15.2
where prolonged operation of the boiler is expected at temperatures below 600C a
by-pass must be installed on the boiler outlet in order to prevent condensation
forming inside the boiler body. Failure to comply with this requirement will
invalidate the manufacturer’s guarantee.
5.10
5.10 5.10
5.10 The pressure relief discharge must be directed away from any electrical
equipment or where it could cause a hazardous situation.
5.11
5.11 5.11
5.11 In order to drain the complete system efficiently it is recommended that drain
cocks (compliant to BS2879) are fitted at the lowest points in the system pipe-work.
5.12
5.12 5.12
5.12 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:
NOTE:NOTE:
NOTE: T
TT
The boiler will not operate
he boiler will not operatehe boiler will not operate
he boiler will not operate on DHW
on DHW on DHW
on DHW unless
unless unless
unless there is
there is there is
there is a minimum pressure of
a minimum pressure of a minimum pressure of
a minimum pressure of
0.25bar with a flow rate of 2.5l/min. Where inlet pressures exceed 10bar a
0.25bar with a flow rate of 2.5l/min. Where inlet pressures exceed 10bar a 0.25bar with a flow rate of 2.5l/min. Where inlet pressures exceed 10bar a
0.25bar with a flow rate of 2.5l/min. Where inlet pressures exceed 10bar a
pressure regulator must be fitted to the cold water supply.
pressure regulator must be fitted to the cold water supply.pressure regulator must be fitted to the cold water supply.
pressure regulator must be fitted to the cold water supply.
5.13
5.13 5.13
5.13 Where cold water mains are fitted with a water meter check valve(s) or loose
jumper stopcock you may need to fit a domestic hot water mini-expansion vessel in
order to avoid water hammer.
5.1
5.15.1
5.14
44
4 To obtain the best hot water performance from your boiler it is suggested that
supplies to taps are run in 15mm copper as short as possible and where practical
be insulated to reduce heat loss.
5.1
5.15.1
5.15
55
5 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.

12
Page
6.1
6.16.1
6.1 If the boiler is to be installed in any room or compartment it does not require any
purpose made ventilation for combustion air. If sited in a room containing a bath or
shower then particular reference is drawn to the current I.E.E. Wiring Regulations
local Building Regulations or any other local regulations currently in service.
6.2
6.26.2
6.2 The boiler is not suitable for external installation unless protected by a purpose
made building such as a boiler house.
6.3.
6.3. 6.3.
6.3. The following clearances are recommended for installation purposes; 200mm
above 300mm below and 20mm at each side. 600mm is required at the front but
this may be upon opening a cupboard door.
6.4
6.4 6.4
6.4 Flammable fluids and materials must be stored at least 1m away from the boiler.
6.5
6.56.5
6.5 The wall on which the boiler is mounted must be sufficiently strong to support
the weight of the boiler.
6.6
6.66.6
6.6 A corrosion resistant or plastic 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.
NOTE:
NOTE: NOTE:
NOTE: It is recommended that any external condensate pipe is insulated and
It is recommended that any external condensate pipe is insulated and It is recommended that any external condensate pipe is insulated and
It is recommended that any external condensate pipe is insulated and
increased to 32mm diameter in order to prevent the condensate from freezing.
increased to 32mm diameter in order to prevent the condensate from freezing.increased to 32mm diameter in order to prevent the condensate from freezing.
increased to 32mm diameter in order to prevent the condensate from freezing.
6.7
6.76.7
6.7 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 20mm of the boiler casing without
protection.
There must be 20mm 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 having a minimum clearance
of 20 mm between the flue pipe and sleeve. 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.
6.8
6.8 6.8
6.8 When the boiler is intended for use with LPG it must not be installed in a room or
internal space below ground level.
6. Appliance Sitting
6. Appliance Sitting6. Appliance Sitting
6. Appliance Sitting

13
Page
7.1
7.1 7.1
7.1 The flue terminal must be sited with minimum clearances as specified in
Figure 3 . Note if pluming becomes problematic or causes a nuisance a plume
management kit is available from your stockist.
7.2
7.2 7.2
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
7.3 7.3
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.
7.4
7.47.4
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 a “anti-plume management kit” which discharges the flue
products at a higher level.
8.1
8.18.1
8.1 The boiler utilises a concentric flue arrangement which consists of a 60mm-
diameter inner flue and 100mm-diameter outer air inlet duct which comes in either
horizontal or vertical arrangements. However for greater flexibility flues are
available as 80/80mm twin pipes and in circumstances where the plume may cause
a nuisance horizontal and vertical anti plume kits available. NOTE: Only use
approved Heatline flue products with this boiler which can be sourced from the
supplier of your boiler or Heatline stockist.
8.2
8.28.2
8.2. The standard 705+/-5mm flue ( figure 4 ) is not supplied with the boiler and
should be purchased separately from your supplier. This flue may be routed to the
rear left or right of the appliance by means of the 900 degree bend which is supplied
in the flue kit ( figure 5 ). The bend is connected to the boiler using the screws
provided and sealed with the gasket.
7. Flue Terminal Location
7. Flue Terminal Location7. Flue Terminal Location
7. Flue Terminal Location
8. Flue (General)
8. Flue (General)8. Flue (General)
8. Flue (General)
Figure 5
Figure
4

14
Page
Figure 3
Internal Corner
External Corner
Double Corners
TERMINAL POSITION MINIMUM
DISTANCE
A-
Directly below an openable window or other opening e.g. air brick 300 mm
B-
Below gutters soil pipes or drain pipes 75 mm
C-
Below eaves 200 mm
D-
Below balconies or car front roofs 200 mm
E-
From vertical drain pipes and soil pipes 150 mm
F-
From internal or external corners 300 mm
G-
Above ground roof or balcony level 300 mm
H-
From a surface facing a terminal 600 mm
I- From a terminal discharging towards another terminal 1200 mm
J- From an opening in a car port (e.g. door window) into a dwelling 1200 mm
K-
Vertically from a terminal on the same wall 1500 mm
L-
Horizontally from a terminal on the same wall 300 mm
M-
Above an opening air brick opening windows etc. 300 mm
N-
Horizontally to an opening air brick opening windows etc. 300 mm
P-
Above roof level (to base of terminal) 300 mm
Q-
From adjacent wall to flue 300 mm
R-
From an adjacent opening window 1000 mm
S-
From another roof terminal 600 mm
From an external boundary. Note if the terminal is facing a
boundary it is recommended that an anti-plume kit be fitted.
600 mm
Installation type C5 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.

15
Page
8.3.
8.3. 8.3.
8.3. The 60/100mm horizontal flue system may be extended up to a maximum of
5.0m excluding the initial 900 bend using additional spare components available
from the supplier of your boiler or Heatline stockist. Please note only use approved
Heatline flue products with this boiler. (Flue type: C13 – C33 – C43 - C53)
8.4.
8.4. 8.4.
8.4. A vertical 60/100mm flue kit is also available (figures 6 ) which can be extended
up to a maximum of 5.0m excluding the initial boiler connection using additional
components available from the supplier of your boiler or Heatline stockist. Please
note the terminal is suitable for a flat or pitched roof and only approved Heatline flue
products can be used with this boiler. The connection of the vertical flue system is
similar to the Horizontal flue connection. The system is connected with screws to
the boiler and the vertical extension pipes and roof terminal are connected by clips .
8.5.
8.5.8.5.
8.5. The 80/80mm twin flue pipe system may be extended up to a maximum of 20m
in any combination of horizontal or vertical configuration using additional spare
components available from your boiler supplier or Heatline stockist. NOTE: When
NOTE: When NOTE: When
NOTE: When
such a system is used it is necessary to have all joints accessible for inspection.
such a system is used it is necessary to have all joints accessible for inspection.such a system is used it is necessary to have all joints accessible for inspection.
such a system is used it is necessary to have all joints accessible for inspection.
8.6.
8.6.8.6.
8.6. The anti-plume kit comprises of a 710mm horizontal section with elbow to
connect the 1m vertical condensing tube which has a horizontal or vertical terminal
dependant on your requirements. The maximum length of horizontal flue including
the terminal but excluding the initial elbow from the boiler and 1m vertical
condensing tube is 4m.
Figure 6
NOTE. For each additional 90º elbow used the maximum flue length must be
NOTE. For each additional 90º elbow used the maximum flue length must be NOTE. For each additional 90º elbow used the maximum flue length must be
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 red
reduced by 1.5 m whilst the use of 2 x 45º bends warrants a redreduced by 1.5 m whilst the use of 2 x 45º bends warrants a red
reduced by 1.5 m whilst the use of 2 x 45º bends warrants a red
uction of 2m.
uction of 2m.uction of 2m.
uction of 2m.
WARNING
WARNINGWARNING
WARNING
!
! !
!
ONLY A HEATLINE APPROVED FLUE IS TO BE
ONLY A HEATLINE APPROVED FLUE IS TO BE ONLY A HEATLINE APPROVED FLUE IS TO BE
ONLY A HEATLINE APPROVED FLUE IS TO BE
USED WITH THIS PR
USED WITH THIS PRUSED WITH THIS PR
USED WITH THIS PRODUCT. FAILURE TO
ODUCT. FAILURE TO ODUCT. FAILURE TO
ODUCT. FAILURE TO
COMPLY WITH THIS REQUIREMENT WILL
COMPLY WITH THIS REQUIREMENT WILL COMPLY WITH THIS REQUIREMENT WILL
COMPLY WITH THIS REQUIREMENT WILL
INVALIDATE YOUR GUARANTEE AND MAY
INVALIDATE YOUR GUARANTEE AND MAY INVALIDATE YOUR GUARANTEE AND MAY
INVALIDATE YOUR GUARANTEE AND MAY
LEAD TO A DANGEROUS SITUATION
LEAD TO A DANGEROUS SITUATIONLEAD TO A DANGEROUS SITUATION
LEAD TO A DANGEROUS SITUATION
.
..
.

16
Page
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. or other local regulations.
9.2
9.2 9.2
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
9.3 9.3
9.3 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
9.4 9.4
9.4 The low voltage room thermostat terminal block is located behind the plastic
cover on the left hand side (figure 7). 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
then please refer to 9.5 below and the electric wiring diagram in figure 8.
figure 8.figure 8.
figure 8.
9.5
9.59.5
9.5 Mains powered thermostats must be connected directly to the mains circuit
board as indicated in Figure 8 where connection of the thermostat is to the terminal
block within the control box. If using this connection the link wire across the
terminal block shown in figure 7 must be removed
must be removedmust be removed
must be removed.
9.6
9.6 9.6
9.6 Ensure that the polarity of the mains connection is correct as reversed polarity
may cause the appliance to malfunction.
9.7
9.7 9.7
9.7 While the boiler's main pcb pump three-way valve and gas valve are supplied at
230V a.c. all other components and associated circuits are supplied at low voltage.
9.8
9.8 9.8
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
figure 8 .
9. Electrical Connections
9. Electrical Connections9. Electrical Connections
9. Electrical Connections
Warning: On no account
Warning: On no account Warning: On no account
Warning: On no account
must any mains voltage
must any mains voltage must any mains voltage
must any mains voltage
be applied to any of the
be applied to any of the be applied to any of the
be applied to any of the
terminals on the heating
terminals on the heating terminals on the heating
terminals on the heating
control connection plug.
control connection plug. control connection plug.
control connection plug.
Figure 7

17
Page
Fuse ratings: 2AT
Open Therm / On Off
Open Therm / On OffOpen Therm / On Off
Open Therm / On Off
Low Volt
Low Volt Low Volt
Low Voltage Room
age Room age Room
age Room
Thermostat
Thermostat Thermostat
Thermostat
Mains powered
Mains powered Mains powered
Mains powered
thermostat connection
thermostat connectionthermostat connection
thermostat connection
Figure 8

18
Page
10.1
10.1 10.1
10.1 Prior to installing the boiler check the contents of the carton: Appliance Valves
Wall Hanging Bracket Mounting Template Service Installation and User Manual
which includes the Benchmark Log Book and Guarantee Card. The boiler
dimensions are given in figure 10 .
10.2
10.210.2
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
10.3 10.3
10.3 Position the supplied template on the wall ensuring it is level both vertically
and horizontally (figure 10 ). Mark the boiler 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 3o decline back (if required see note below) towards the boiler to enable
condensate to drain back through the boiler. Mark the flue centre vertical line. (
figure 11)
NOTE
NOTENOTE
NOTE : Some flues may have the 3
: Some flues may have the 3: Some flues may have the 3
: Some flues may have the 3o
oo
o built in and as such these flues may be installed
built in and as such these flues may be installed built in and as such these flues may be installed
built in and as such these flues may be installed
in a horizontal position.
in a horizontal position.in a horizontal position.
in a horizontal position.
TOP
BOTTOM
10. Boiler Installation
10. Boiler Installation10. Boiler Installation
10. Boiler Installation
Figure 9
Figure 10 Figure 11
A: 430
mm
B: 166 mm