Heatline solaris 24PC User guide

solaris 24PC, 30PC
solaris
24PC
30PC
Installation,Servicing
&UserInstructions
Pre-Mix Condensing
Combination Boiler
Supplied by HeatingSpares247.com

solaris 24PC, 30PC
Natural Gas
Heatline Solaris 24PC/30PC Pre-mix Condensing
Combination Boiler
British Gas Service Listing
Solaris 24PC G.C.No 47-157-04
Solaris 30PC G.C.No 47-157-05
Notified Body IMQ 51BP2750
CE Directive 90/396/EEC
CE Directive 92/42/EEC
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.
For further information or advice (UK) contact
Heatline TM:
Service please call:
0870 777 8341
Spares please call:
0870 777 8402
Technical assistance please call:
0870 777 8318
Or by E mail on our Web Site on
www.heatline.co.uk
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
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 46 & 47
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. SOLARIS 24PC.
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solaris 24PC, 30PC
Section Page
Preface
1. Installation Regulations 5
2. Technical Data 6
3. Boiler Characteristics 8
4. Operation 8
5. General Installation 9
6. Appliance Siting 11
7. Flue Terminal Location 12
8. Flue (General) 14
9. Electrical Connections 15
10. Boiler Installation 17
11. Gas Supply 19
12. Filling the System 20
13. Control Panel Functions 20
14. Commissioning 22
Section Page
15. Onboard Adjustments 23
16. Safety Devices 24
17. Routine Servicing 24
18. Component Replacement 27
19. Gas Type Conversion 34
20. Fault Finding Chart 34
Appendices
Appendix 1. Spare Parts List 39
User Instructions 40
Contents
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solaris 24PC, 30PC
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 a dangerous situation.
If the appliance is sold on to another customer all
documentation must be passed on and the
appliance re-registered with Heatline in order to
maintain the guarantee.
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:
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 Warnings
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solaris 24PC, 30PC
The sign of approval.
This appliance has been certified
by IMQ
This is a fragile piece of equipment:
Do not drop.
Avoid getting the carton 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.
This picture shows the terminal
block, which is located at the
Room Thermostat bottom left
hand side of the control panel
cover, to which the room
thermostat must be fitted.
NOTE: This is a voltage free connection and no
power must be applied to these terminals. For
mains powered thermostat connection, 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.
The Signs on Box Access, warnings and connections on the boiler
230 V
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Page 5
1.1. This appliance must be installed by a
competent person as defined by the Gas
Safety (Installation and Use) Regulations.
Failure to install this appliance correctly
may invalidate your guarantee and may
lead to a dangerous situation.
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 with the Instructions. You can
check the validity of this ID number by
contacting C.O.R.G.I. on 0870 401 2300.
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. 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 (RI).
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.
1.7. Your boiler comes with a statutory 1 year
guarantee. In order to claim your 2nd years
free warranty you must completes and return
your guarantee card within one month of the
date of installation or ring the telephone
number on the label on the front of your
appliance.
Note: Your second year of warranty is only
valid if there is evidence of service after the
first year of installation. It is recommended
that the appliance be serviced annually by a
competent person, as defined in the Gas
(Safety and Use) Regulations, and the service
record maintained in the Benchmark
Logbook.
For further information or advice (UK) contact
HeatlineTM:
Service please call: 0870 777 8341
Spares please call: 0870 777 8402
Technical assistance please call: 0870 777 8318
or
E–mail via our web site www.heatline.co.uk.
1. Installation Regulations
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solaris 24PC, 30PC
Page 6
24PC 30PC
Gas Category II2H3+
Gas inlet pressure G20 mbar 20
Heat Input (Qmax) (CH) kW
(Btu/h) 25.03 30.5
Heat Output (Pmax) (CH) kW
(Btu/h) 24.42 29.8
Heat Input (Qmax) (DHW) kW
(Btu/h) 31.05 35.8
Heat Output (Pmax) (DHW) kW
(Btu/h) 30.3 35.01
Heat Input (Qmin) (CH/DHW) kW
(Btu/h) 9.26 10.00
Heat Output (Pmin) (CH/DHW) kW
(Btu/h) 9.35 10.09
Useful efficiency at
100% load % 97.6 97.8
Useful efficiency at 30%
load % 107.4 107.5
Inlet Pressure
(Natural Gas) mbar 20
Gas Rate (Natural Gas) m³/h Max
2.65
Max
3.2
Power supply Input 230 V
50 Hz
Gas Diaphragm mm 6.5 7.0
Air Diaphragm colour Red Red
Max. power
consumption Watts 140
Level of protection IPX4D
Maximum heating
temperature ºC 85º
Max. domestic hot water
temperature ºC 64º
Operating pressure
(Bar)
PMS
(Min)
3
(0·8)
Domestic water supply
pressure (Bar)
PMS
(Min)
8
(0·25)
Domestic Water Supply
Output (liters/min.)
35 oC ∆T
30 oC ∆T
25 oC ∆T
12.20
14.24
17.08
14.35
16.73
20.10
Expansion Vessel Capacity
(litres) 7
Expansion Vessel Pre-Charge
(bar) 0·5
Flue Extraction Diameter
(mm) 60/100
CO2% at max. input
±0.1% ppm 9
Nitrogen oxide (NOx)
emissions at max. input
(NOx Class 5)
ppm 20.6 22
Nitrogen oxide (NOx)
emissions at max. input
(NOx Class 5)
ppm 22.6 26
Combustion products
temperature (max.)
oC 70 72
Case Dimensions (mm) 330d x 430w x 720h
Shipping weight kg 44 45
Dry weight kg 41 42
G30/G31 VERSION
Gas Inlet Pressure mbar 28-30/37 28-
30/37
Gas Diaphragm mm 4.70 5.35
Air Diaphragm colour Orange Red
Gas rate (LPG) kg/h 1.29 1.52
CO2% at min. input
±0.1% 10
2. Technical Data
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solaris 24PC, 30PC
Page 7
Figure 1
1 - D.H.W. Flow Sensor
2 - Water Pressure Sensor
3 -Pump
4 - Pressure Relief Valve
5 - Fan
6 - Air/gas mixer
7 - Air/gas mixer ring
8 - Supply transformer
9 - Expansion Vessel
10- Heat exchanger
11 - Ionisation electrode
12 - Burner
13 - Plastic flue duct
14 - Plastic flue safety thermostat
15 - Gas valve
16 - Diverter Valve
17- DHW temperature sensor
18 - Condensate trap
19 - Overheat Safety thermostat
20 - Secondary Heat Exchanger
21 - Condensate drain pipe
22 - Central heating temperature sensor
23 - Ignition electrode
24 - Manual air vent
A - Heating Flow (22mm)
B - D.H.W. Outlet (15mm)
C - Gas Inlet (22mm)
D - Cold Water Inlet (15mm)
E - Heating Return (22mm)
A B C D E
5
6
7
8
9
10
12
14
4
2
1
16
15
18
19
21
23
22
11
20
13
3
17
24
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Page 8
3.1 The Heat Line boiler is a fan flued, wall-
mounted combination boiler that supplies 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, page 7.
3.2 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.
3.3 An interface unit, which includes boiler
adjustment potentiometers and fault display
codes provides easy serviceability of the
boiler.
3.4 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 24
volt, modulated speed fan blows the products
of combustion from the combustion chamber
to outside air via an associated flue system.
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 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, a
system by-pass should be fitted, in accordance
with current legislation 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 9.4 & 9.5 for details.
3.8 The C H system temperature can be adjusted
automatically to balance heat demand, dependant
on the outside temperature, if an outdoor sensor is
connected directly to the main PCB. Call Heatline
Technical Services for further assistance.
3.9 The boiler incorporates an integrated clock,
which allows the setting of central heating periods
and the boiler’s control panel incorporates an LCD
display, which indicates the state of operation and
fault defect codes.
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 heating
periods the boiler will automatically revert
back to heating mode, after a draw off of hot
water, but there will be a 45sec delay if the
No.3 dipswitch is set to the OFF position.
See fig 19 page 27.
4.2 Depending on demand water is either diverted
via the three port valve to the secondary water-
to-water heat exchanger for domestic hot
water or directly to the heating system.
4.3 DOMESTIC HOT WATER MODE:
On opening a hot water faucet the boiler
automatically responds to fire the boiler and
supply the water-to-water heat exchanger with
hot water via the three port valve, located on
the hydro-block. The boilers electronic
control unit automatically modulate the
burner’s output to maintain the required
temperature at the faucet. Hot water will
3. Boiler Characteristics.
4. Operation
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solaris 24PC, 30PC
Page 9
continue to flow until the faucet is closed
and the boiler automatically shuts down.
Note that the pump will continue to run for
a further 10secs to dissipate the residual
heat from the boiler.
4.4 DOMESTIC HOT WATER AND
CENTRAL HEATING MODE:
When heating demand is required, i.e. the
timer and thermostat are calling for heat,
then providing the power is on 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 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 may be a 45sec delay
depending on how the boilers dipswitches
are set. See section 14.3 for details.
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 and
completed Benchmark Logbook.
•The user should be instructed to keep the
instructions and logbook 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.
•Remember to thoroughly flush the water
circuits in order to remove any fluxes and
debris from them. This should be done
particularly where boilers are being fitted to
existing radiator circuits.
•Refer to BS 7593:1992 for the details to clean
DHW and Central heating system.
•This boiler has been factory set and does not
require any adjustments to the gas valve or
fan speed.
•Remember to release the small cap, 1 turn, on
top of the automatic air vent, located on top of
the pump, before filling. This will ensure that
air is vented from the pump 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 system via the pressure relief valve may
leave debris on the valve seat allowing water to
seep after you have left the job. This will cause
the boiler to lose pressure and the boiler to
lockout.
•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
faucet 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.
5. General Installation
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Page 10
•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.3 dipswitch is in the OFF
position, see fig 19 on page 27.
•When commissioning the boiler check the
inlet pressure is at 20mbar and burner
pressure against the Technical data on page
6.
•Note an anti-cycle delay time can be set up
to a maximum of 255 seconds by adjusting
potentiometer 2 as described in section 15.4
on page 27.
If you experience any problems please refer to
the installation and commissioning guidelines
within the boiler instruction manual. If
necessary, please contact Heat LineTM
Enquiries:
For further information or advice (UK) contact
HeatlinTM:
Service please call:
0870 777 8341
Spares please call:
0870 777 8402
Technical assistance please call:
0870 777 8318NOTE – FOR
INSTALLERS:
REMEMBER IT IS A LEGAL
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 3bar pressure and maximum design
flow temperature of 850C.
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.
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.
5.7 On installation it is important to ensure that
the heat exchanger is not a natural collection point
Figure 2 – Note the filter valve supplied should
be fitted to the heating return pipe, which is on
the extreme rightof the boiler as shown below.
Flow
control
valve
Bypass
valve
Filling
device
Cold water
supply
Domestic
hot
water
Heating outlet
Flow
control
valve
Boiler
F
low
control
valve
Heating return
Additional
expansion
vessel (if
required)
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solaris 24PC, 30PC
Page 11
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 The system’s water must always be
allowed to circulate whenever the circulation
pump is running. A return by-pass must be
provided.
NOTE – It is no longer permissible to use
non-thermostatic radiator valves to allow
by-pass through a radiator.
5.9 In high water volume systems or under
floor heating systems 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 The pressure relief discharge must be
directed away from any electrical equipment
or where it could cause a hazardous situation
and terminated in a safe but visible position.
5.11 To enable adequate drainage of the
system drain cocks compliant with BS2879
must be fitted at the lowest points in the
system pipe-work.
5.12 To obtain the best hot water performance
from your boiler it is suggested that the cold
water supply to the boiler is taken directly
from the incoming mains water 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.
5.13 Where cold water mains are fitted with a
water meter, check valve(s) or loose jumper
stopcock it is recommended that a domestic
hot water mini-expansion vessel may need to
be fitted.
5.14 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.
5.15 To obtain the best hot water performance
from your boiler it is suggested that supplies to
faucets are run in 15mm copper, as short as
possible and where practical, be insulated to
reduce heat loss.
5.16 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 current I.E.E. Wiring
Regulations and local Building Regulations.
.
6.2 The boiler is not suitable for external
installation unless protected by a purpose made
building such as a boiler house.
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 The boiler must be sited at least 1m away from
flammable materials and combustible walls must
be protected with appropriate insulation.
.
6.5 The wall on which the boiler is mounted must
be sufficiently strong enough to support the
weight of the boiler.
6. Appliance Sitting
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Page 12
6.6 A condensate drain pipe must be fitted to
allow discharge of condensate to a drain or
soakway. Note condensate is acidic and
should be discharged through plastic or
suitable corrosion resistant pipes.
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 soakway.
It is recommended that any external
condensate pipe is insulated and increased
to 32mm diameter in order to prevent the
condensate from freezing.
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 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 3. 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.
7.4 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 or a deflection elbow, which
deflects the plume to the left or right.
7. Flue Terminal Location
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Figure 3
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
Internal Corner
External Corner
Double Corners
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8.1 The boiler utilises a concentric flue
arrangement which consists of a 60mm-
diameter inner flue and 100mm-diameter outer
air inlet duct.
8.2. A standard 700+/-5mm flue kit (figure 4)
is supplied with the boiler, which can be
routed to the rear, left or right of the appliance
by means of a 900degree bend (figure 5). The
bend is connected to the boiler using the
screws provided and sealed with the gasket.
Figure 4
Figure 5
8.3. The horizontal 60/100cm flue pipes may
be extended up to a maximum of 7m using
additional spare components available from
your supplier.
8.4. A vertical 60/100cm flue kit is also
available (figures 6a & 6b) from your supplier
up to a maximum length of 8m. The terminal
is suitable for a flat or pitched roof.
8.6. The connection of the vertical flue system
is similar to the Horizontal flue connection.
However, the 80/125 system is connected with
screws to the boiler and the vertical extension
pipes and roof terminal are connected by clips
as shown in figure 6b, item 3.
8. Flue (General)
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.
WARNING!
ONLY A HEATLINE APPROVED FLUE IS
TO BE USED WITH THIS PRODUCT.
FAILURE TO COMPLY WITH THIS
REQUIREMENT WILL INVALIDATE
YOUR GUARANTEE AND MAY LEAD TO
A DANGEROUS SITUATION.
Figure
6a
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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 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 5
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 5 amp.
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 The low voltage room thermostat terminal
block is located on the back left side of the
control box (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 the please refer to figure 8.
9.5 Mains powered thermostats must be connected
directly to the mains circuit board as indicated in
Figure 8.
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 a.c., 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 in figure 8.
9.9 Fuse Ratings F1 and F2 are 3.15A fast
Bertelli & Partners Circuit Board
F1 – 3.15A fast
F2 – 3.15A fast
F3 – 3.15A fast
SIT Circuit Board not used
F1 – not used
F2 – not used
Figure 6b
9. Electrical Connections
Warning: On no account must any
external voltage be applied to any of the
terminals on the heating control
connection plug.
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Important Note.
Connection to the mains electrical supply must be maintained at all times in order to provide
domestic hot water, frost protection, anti seizure protection of the pump and pump over-run
facility. Ensure that the boilers electrical supply is not interrupted by any external controls.
This diagram is illegible and requires
that the thermostat connections are
clearly marked showing the live
terminal of the mains thermostat
connection clearly differenciated.
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10.1 Manual Handling: This appliance is
heavy and it is suggested that it should be
lifted by two people. When manoeuvring the
boiler always use safe techniques truck if
possible and obtain assistance if required –
when lifting 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.
To remove the appliance:
1. Carefully slit or remove the sealing tape
being careful not to scratch the appliance
door.
2. Fully open the carton lid and remove the
condensate hose and mounting bracket.
3. Roll the carton onto its open face.
4. Lift the carton free of the inner packaging.
5. Remove and valve package and
instructions.
6. Stand the boiler on its base within the
styrene block and remove the top
packaging piece.
7. If you wish to remove the styrene base lie
the appliance on its back to do so.
8. Read the instructions carefully before
installation of the appliance.
10.2 Prior to installing the boiler check the
contents of the carton: Appliance, Valves,
Condensate hose, 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 9.
10. Boiler Installation
Figure 10
Bottom
Fixing Jig (Optional)
Give dimensions between valves
Figure 9
A: 430 mm
B: 128 mm
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10.4 Position the supplied template on the
wall, ensuring it is level both vertically and
horizontally (figure 10). Mark the boiler fixing
jig locations (if used), 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 3% decline back towards the
boiler, to enable condensate to drain back
through the boiler. Mark the flue centre line.
(figure 11.)
Figure 11 (vertical Centre??)
10.5 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).
10.6 Using a 8·5mm drill bit, drill the holes for
fixing jig (optional) and hanging bracket.
Locate and secure the supplied wall mounting
bracket and fixing jig (if obtained) in position
(figure 12).
10.7 Mount the boiler onto the fixing bracket via
the boiler mounting tabs, (figure 12).
10.8 Connect the isolation valves to the boiler
ensuring the filter valve is at the extreme right and
the sealing washers are fitted correctly.
10.9 On installing the flue, determine the
required length of the outer air duct by
measuring the distance 'L' (figure 13) 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
10.10 Measuring from the back of the terminal
connection, mark distance 'L' onto the outer air
duct. (figure 13)
10.11 Cut the outer air duct only to the required
length ensuring that the cut is square and free from
burrs.
10.12 Measuring from the back of the terminal
connection, mark distance 'L' + 20mm (figure 14)
onto the inner flue duct and cut the duct to size,
ensuring that the cut is square and free from burrs.
10.13 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.
10.14 With the flue tilted at 30, allowing
condensate to drain back into the boiler, and joints
secured fit the flue trim to the external wall
surface using a 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.
Figure 12
Waste
L
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10.15 The vertical system diagram is shown in
figure 15a and 15b. Note: Maximum vertical
flue length is 8m with a 60/100mm flue
system.
Figure 15b
Figure 15a
10.16 Provisions to fill the boiler and system
must be made by the Installer, using an
approved filling loop. The filling loop used
must be approved to current water byelaws
and fitted as close to the boiler as practicable.
If it is not practicable to install the filling loop in
an obvious position please add a label on the
boiler to state where the filling loop can be found
for future reference. Please instruct the user how
to top up the system water pressure.
10.17 Connect the domestic hot water, cold water
inlet, heating system flow & return and pressure
relief valve pipework to the supplied boiler
fittings, ensuring that the pipework has been
correctly power flushed before final connection.
10.18 Condensing boilers of this type must have
the condensate drain connected to drainage
system. Due to the acidic nature of the condensate
the drainage system must be made of non-
corrosive material such as plastic tubing..
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 soak away containing lime chippings.
Note if a soak away is used the drain must
terminate at least 500mm from the external wall.
10.19 The electrical connections to the boiler must
be in accordance with Section 9 of these
instructions.
11.1 The gas supply pipe must be of 22mm copper
from the meter to the boiler and capable of
delivering 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 meter governor must be capable of
delivering a pressure of either 20mbar for natural
gas or 37mbar for propane gas, dependant on the
gas being used.
11.3 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.
L
L+20mm
11. Gas Supply
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