Heatrae Sadia 95 022 001 C-400 User manual

1
Amptec Electric Flow Boiler
Fitting Instructions and User Guide
Models:
95 022 001 C-400 GC No.EB-205-06
95 022 002 C-600 GC No.EB-205-02
95 022 003 C-900 GC No.EB-205-03
95 022 004 C-1100 GC No.EB-205-01
95 022 005 C-1200 GC No.EB-205-04
95 022 101 U-401 GC No.EB-205-08
95 022 102 U-601 GC No.EB-205-09
95 022 103 U-901 GC No.EB-205-10
95 022 104 U-1101 GC No.EB-205-11
95 022 105 U-1201 GC No.EB-205-12

2
THANK YOU FOR PURCHASING THIS HEATRAE SADIA AMPTEC FLOW BOILER. IT HAS BEEN
DEVELOPED TO PROVIDE YOU WITH MANY YEARS OF TROUBLE-FREE SERVICE WHEN
INSTALLED IN THE PROPER MANNER.
PLEASE READ AND UNDERSTAND THESE INSTRUCTION PRIOR TO INSTALLING YOUR HEATRAE
SADIA AMPTEC FLOW BOILER. FOLLOWING INSTALLATION AND COMMISSIONING, THE
OPERATION OF THE HEATER SHOULD BE EXPLAINED TO THE CUSTOMER AND THESE
INSTRUCTIONS LEFT WITH THEM FOR FUTURE REFERENCE.
FIGURE ONE: MAIN COMPONENTS OF AMPTEC ELECTRIC FLOW BOILER
OUTLET
RED IDENT
ELECTRICAL CABLE
ENTRY POINTS
EARTH CLAMP
TERMINAL BLOCK
MAIN PCB
BOILER ELEMENT
INSULATION
TEMPERATURE SWITCH
BLUE IDENT
INLET
FRONT COVER (TOP)
WARNING LABEL
INSULATION SHEET
FLYING LEAD
CONTROL PANEL
FRONT COVER (BOTTOM)
RATING LABEL
SERIAL NUMBER

3
DESCRIPTION
Th AMPTEC l ctric flow boil r is d sign d to h at r -circulat d wat r us d in w t c ntral h ating syst ms.
Th wat r is h at d wh n it is pass d ov r l ctric imm rsion l m nts, which ar contain d in a chamb r.
Th t mp ratur of th wat r is monitor d and controll d by a modulation t chniqu switching on th imm rsion
l m nts. Th switching of th l m nts is carri d out by solid-stat t chnology contain d in th control s ction
of th boil r. Th op ration of th boil r can b controll d by standard programm rs, room th rmostats, tc.
Th pump should b conn ct d to th boil r control, which provid s th run-on facility.
FEATURES
· El ctric flow boil r for w t c ntral h ating syst ms.
· Dom stic hot wat r is availabl from a cylind r.
· Can b us d in a s al d or op n v nt d syst m installations.
· No flu or fu l tank r quir d.
· Qui t in op ration.
· Op rat s from standard programm rs, room th rmostats, tc.
· Pump run-on facility.
· Solid-stat t chnology nabl s z ro volt switching.
· Soft start and soft modulation.
· Front pan l op ration indicators.
· Us r adjustm nt of th op rating t mp ratur on th front pan l.
· S lf ch ck v ry tim it op rat s.
· Optical isolation to nabl conn ction of mor boil rs on singl or thr phas suppli s.
· El ctrical tails t rminations insid th boil r.
· Saf ty trip for no wat r or no flow situations.
TECHNICAL SPECIFICATION
Output T mp ratur Control Rang : (C s ri s) 650C to 800C.
(U S ri s) 300C to 600C
Op rating voltag 200V - 245V 50Hz
Pump supply fus (int rnal) T 2A 240V - 20x5mm.
RUN control input signal r quir s  200V - 245V 50Hz
RUN control input signal draws l ss than 0.25A. 10mA typical.
Optical isolation B tw n th control signals
and th boil r supply.
Ov r t mp ratur trips 95 and 1000C
Wat r cont nt 1.3 litr s
Product cod Boil r typ 220V / Btu 240V / Btu Siz
95 022 001 C400 3.5kW / 11,900Btu 4kW / 13,600Btu 1050 x 90 x 90mm
95 022 101 U401 3.5kW / 11,900Btu 4kW / 13,600Btu 1050 x 90 x 90mm
95 022 002 C600 5kW / 17,000Btu 6kW / 20,400Btu 1050 x 90 x 90mm
95 022 102 U601 5kW / 17,000Btu 6kW / 20,400Btu 1050 x 90 x 90mm
95 022 003 C900 7.5kW / 25,600Btu 9kW / 30,700Btu 1050 x 90 x 90mm
95 022 103 U901 7.5kW / 25,600Btu 9kW / 30,700Btu 1050 x 90 x 90mm
95 022 004 C1100 9kW / 30,700Btu 11kW / 37,500Btu 1050 x 90 x 90mm
95 022 104 U1101 9kW / 30,700Btu 1kW / 37,500Btu 1050 x 90 x 90mm
95 022 005 C1200 10kW / 34,000Btu 12kW / 40,900Btu 1050 x 90 x 90mm
95 022 105 U1201 10kW / 34,000Btu 12kW / 40,900Btu 1050 x 90 x 90mm

4
INSTALLATION
Car must b tak n wh n handling and conn cting th boil r not to damag or str ss it in any way. Prior to
installation th boil r must b stor d in a dry, saf plac .
Th boil r must b mount d in an UPRIGHT position. Th boil r must b fix d to a wall b for conn cting
pip work. Wh n choosing th position for th boil r, nsur suffici nt cl aranc s to hous th unit and for
s rvicing. 50mm minimum cl aranc ach sid of th boil r is r quir d. A drain valv at th bas of th
boil r is strongly r comm nd d. It must b sit d in a dry, v ntilat d position, frost fr and not subj ct d to
xtr m s of t mp ratur .
Not . B for conn cting th pip work, nsur th rubb r s al at th top of th boil r is firmly in plac ;
ch ck it has not b com loos in transit. Th warranty will b invalid if wat r l aks into th boil r.
TOP HAUT ALT O OBEN
WARN IN G
Before obta ining ac ce ss to ter m ina ls all su p ply
circuitsm ust be di sconnected
Donot so lder directly onto flow a nd return pipe work
Thegua rantee will be withdra wn if this produc t is
N
otins talle d in acco rdanc e with the in stalla tion
instructio ns
Electroheat
AMP TEC
AMPTEC BOILER C60 0
GCNO. E B-205-02
OPERATINGTEMPERATURE 65-80C
PRESSURE 3BARMAX
220-240V~ 5-6KW
BEAB CE N C CA
COPYRI GHT RE SE RVE D P AT ENT AP P LIE D
FOR
Electroheat
Basingstoke UK RG24 9RA
BOTTOM BAS BASSO U NTEN
FIGURE TWO: DIMENSIONS
BACK VIEW
FRONT VIEW
SIDE VIEW
ENTRY PORTS
SUPPLY AND
CONTROL ON
BOTH SIDES
20mm 25.4mm
FLOW PIPEWORK
RED IDENT
RETURN PIPEWORK
BLUE IDENT
5mm SECURING
HOLE
900mm FIXING CENTRES
30mm
1050mm
20mm
30mm
100mm
90mm

5
INSTALLATION PLUMBING
IT IS THE INSTALLERS RESPONSIBILITY TO ENSURE THAT THE INSTALLATION DOES NOT
CONTRAVENE THE REQUIREMENTS OF THE WATER SUPPLY REGULATIONS, BUILDING
REGUALTIONS OR LOCAL AUTHORITY REGULATIONS.
Th boil r must b install d by a qualifi d, comp t nt trad sman who is awar of and will comply with all
r l vant standards that ar applicabl : .g. Building R gulations, th Local Authority R gulations, th Wat r
Supply R gulations and und rtaking th r l vant British Standards. Th syst m must b flush d in
accordanc with BS 7593 and in accordanc with th suppli d instructions and drawings to nsur prop r
op ration.
Th boil rs contain a v ry small amount of wat r, and so r quir a suffici nt flow rat of wat r to nsur
prop r op ration. Mod ls 400 and 600 r quir a minimum flow of 6 litr s/minut , and mod ls 900, 1100 &
1200 r quir a minimum flow of 12 litr s/minut . Insuffici nt flow of wat r through th boil r will caus
nuisanc trip outs. Th maximum t mp ratur diff r ntial b tw n input and output of th boil r must not
xc d 140C. If th t mp ratur across th boil r xc ds this th n th flow rat is too low and will
pot ntially damag th boil r. S t th flow rat to giv 5 - 100C across th boil r on full h at.
Th output FLOW pip at th TOP of th boil r is id ntifi d RED. Th input RETURN pip at th BOTTOM
is id ntifi d BLUE. Ensur that th dir ction of flow is corr ct through th boil r aft r installation. S t th
pump on maximum flow rat .
Pip work conn ctions on all mod ls ar 22mm.
Us standard siz pip work. DO NOT SOLDER DIRECTLY ONTO THE BOILER TAILS. Push-on or
compr ssion fittings ar suitabl for conn cting dir ctly onto th boil r tails. Fit a 22mm lbow to th top of
th boil r, and aft r 100  150mm of horizontal pip work fit an automatic air v nt, or conn ct th xpansion
pip work on op n v nt d syst ms to provid a rout for air to v nt. DO NOT FIT THE AAV DIRECTLY
ABOVE THE BOILER.
Th Ampt c boil r is suitabl for op ration in s al d or op n v nt d syst ms. It is also suitabl for sch m s
such as h ating only, W plan, S plan, zon h ating, und r floor h ating, micro-bor via a manifold, tc. If
you ar unsur about your application r garding suitability of th boil r pl as do not h sitat to contact your
local suppli r or H atra Sadia dir ctly.
Th cost of installation can b r duc d if th l ctric flow boil r is us d for h ating only. Us a dir ct typ
cylind r with imm rsion l m nts and a tim clock for th dom stic hot wat r, th n conn ct th l ctric flow
boil r dir ctly to th h ating circuit and control it by a programmabl room th rmostat. If th radiator circuit
has a continuously op n rout for th wat r flow, th n a bypass is not r quir d. Th boil r sizing is for
h ating only in this cas and do s not hav to b incr as d to allow for dom stic hot wat r as w ll.
Ensur th r is always an op n rout for th wat r to flow in any installation, to m t th r quir d minimum
flow rat of th boil rs and to allow for th pump ov r run. If an op n rout through th h ating circuit can
not b guarant d, th n a bypass, fitt d with an automatic bypass valv , must b fitt d which m ts th
r quir d minimum flow rat s for th boil r.
Th bypass must hav a minimum of ith r 2 m tr s of 22mm continuous pip work, or b rout d through a
radiator with minimum dim nsions of 600 x 600mm. Automatic pr ssur op ning valv s must b us d with
th bypass circuit, nsur th y ar install d corr ctly as p r th manufactur rs instructions. Gat valv s ar
not suitabl . DO NOT FIT A VALVE BETWEEN THE BOILER AND THE SAFETY PRESSURE RELIEF
VALVE OR EXPANSION RELIEF SYSTEM.
Th boil rs ar suitabl for op rating pr ssur s up to 3 bar. Normal s al d syst ms op rat at 1 to 1.5 bar.
Ensur a saf ty pr ssur r li f valv is fitt d to all s al d syst ms. With op n v nt d installations, nsur
th r is a suffici nt h ad of wat r for th pump to supply th full flow through th boil r of at l ast 1½ m tr s
b tw n th bottom of th F & E tank and th top of th boil r.

6
NOTE: TO COMPLY WITH BUILDING REGULATIONS, PART L (PART J IN SCOTLAND), WHEN THE
AMPTEC IS USED FOR CENTRAL HEATING PURPOSES, A ROOM THERMOSTAT MUST BE FITTED TO
CONTROL THE BOILER (SEE PAGE 15).
Do not fit th rmostatic radiator valv s to th room with th control th rmostat, oth r rooms may b fitt d with
th rmostatic radiator valv s. DO NOT OPERATE UNDER THERMOSTATIC RADIATOR VALVES ONLY.
Us standard pumps, controls, room th rmostat, valv s, tc. Th main l ctrical pow r (high curr nt) must
b rout d dir ctly to th boil r via an MCB and RCD, not through th controls. Only a control signal to th
boil r com s from th programm r. Th switching of th high pow r curr nt is don insid th boil r.
For installations with mor than on boil r, mount th boil rs sid -by-sid with a minimum of 50mm gap
b tw n ach boil r, output flow tails at th top and th r turns at th bottom. T  in th flows tog th r,
incr asing in pip siz at ach boil r to nsur full flow to ach boil r. E.g. for 3 x 1200 boil rs, first boil r
us a 22mm lbow to th s cond boil r. S cond boil r t 22mm in from first boil r, 22mm branch to
s cond boil r, 28mm to third boil r. Third boil r t 28mm in from s cond boil r, 22mm branch to third
boil r, 35mm away to h ating circuit. R p at for th r turn conn ctions. Singl pump in th 35mm flow lin ,
nsur suffici nt flow for all 3 boil rs, i. . (for 3 x 1200 boil rs r quir s 3 x 12 l/m = 36 litr s/minut
minimum). Do not r duc pip work b for t ing. S figur four on pag 8.
Wh n filling th syst m ch ck for l aks. THE WARRANTY WILL BE INVALIDATED IF WATER LEAKS
INTO THE BOILER. ENSURE ALL JOINTS ABOVE THE BOILER ARE SOUND.
Aft r installation th syst m must first b flush d out in accordanc with BS 7593:1992 b for adding th
inhibitor. F rnox Sup rfloc, or B tzD arborn S tin l X300 or X400 ar id al flushing ag nts for n w and
xisting syst ms. Aft r flushing th corr ct amount of inhibitor must b add d b for us . F rnox
Sup rconc ntrat , or MB-1, or B tzD arborn S ntin l X100 can b us d for most wat r ar as, how v r
w r comm nd you should ch ck with your local wat r authority to nsur suitability. Ch ck th inhibitor
conc ntration aft r installation and p riodically th r aft r to nsur corr ct prot ction.
FAILURE TO FLUSH PROPERLY OR INADEQUATE INHIBITOR IN THE SYSTEM WILL INVALIDATE THE
WARRANTY.

7
FIGURE THREE: BASIC PLUMBING LAYOUT
AUTOMATIC AIR VENT EXPANSION / SAFETY
RELIEF SYSTEM
SERVICE VALVE
PUMP
ISOLATING VALVE
150mm MINIMUM
2 METRES MINIMUM
AMPTEC BOILER
AUTOMATIC
PRESSURE
BYPASS VALVE
FLOW
RETURN
DRAIN VALVE
ALTERNATIVE BY-PASS ARRANGEMENT
USING THE BATHROOM RADIATOR FITTED
WITH TWO LOCKSHIELD VALVES
OPEN VENTED SYSTEMS MUST
HAVE A MINIMUM HEAD OF
1.5 METRES AND MAXIMUM
HEAD OF 30 METRES

8
A typical plumbing sch matic conn cting 3 x 1200 boil rs tog th r.
NOTE th incr as in pip work sizing to nsur prop r flow through th boil rs.
Ensur th r ar no r strictions in th h ating circuit such as th rmostatic radiator valv s tc.
Expansion v ss l tc. has not b n shown on this sch matic.
For 2 x 1200 boil rs, 28mm pip work flow and r turn is r quir d.
A bypass must b fitt d. Pr f r nc should b mad for a 600 x 600 radiator.
FIGURE FOUR: THREE BOILER PLUMBING SCHEMATIC
AUTOMATIC AIR VENT EXPANSION / SAFETY
RELIEF SYSTEM
SERVICE
VALVE
PUMP
AMPTEC BOILER
FLOW
DRAIN VALVE
AMPTEC BOILER
AMPTEC BOILER
35mm PIPE
FLOW
36 LITRE/
MIN
28mm PIPE
FLOW
24 LITRE/
MIN
22mm PIPE
FLOW
12 LITRE/
MIN
35mm PIPE
FLOW
36 LITRE/
MIN
28mm PIPE
FLOW
24 LITRE/
MIN
22mm PIPE
FLOW
12 LITRE/
MIN
RELAY
SYSTEM
95970136
RETURN

9
INSTALLATION ELECTRICAL REQUIREMENTS
ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS.
Th AMPTEC boil r must b install d by a qualifi d comp t nt trad sman in accordanc with suppli d
instructions and drawings to nsur corr ct op ration.
Ch ck th main incoming supply to th prop rty to nsur th r is suffici nt curr nt and voltag for th siz of
th boil r or boil rs to b install d. R m mb r to also tak account of th supply r quir m nts for th r st of
th prop rty. Ensur th corr ct cabl siz is us d to f d th boil r (r f r to IEE wiring r gulations).
A doubl pol RCD with a trip l v l s nsitivity of 30mA and capabl of br aking th full load curr nt to BS EN
61008:1994, must b us d.
In ord r to provid a m ans of isolation, th boil r must b conn ct d to th supply through a doubl pol
link d switch with a minimum contact gap of 3mm in all pol s. Th RCD is suitabl for this r quir m nt if it is
mount d in clos proximity to th boil r.
A corr ctly rat d MCB must b us d in th supply, s T chnical Sp cifications. An additional 3A supply is
r quir d for th controls tc. NOTE, a blank must b fitt d b tw n ach MCB to provid v ntilation, ch ck
with th MCB manufactur /suppli r.
NOTE: Th high curr nt mains supply MUST NOT b rout d through th programm r, controls tc. Follow th
wiring diagrams. Us a standard programm r, room th rmostat, tc. Th high curr nt switching is carri d out
insid th boil r, only standard switch d liv (low curr nt) control signals ar suppli d by th programm r tc.
El ctrical Conn ctions
Acc ss can b gain d to th l ctrical conn ctions by r moving th top front pan l.
1 CONN5: MAIN POWER.Main pow r-supply cabl s. Conn ct th pow r cabl s from th
pow r supply (CONN5) t rminals on th PCB ass mbly in th boil r dir ctly to th isolation switch,
liv , n utral and arth. Us th corr ct rat d cabl . Do not conn ct th pow r through th
programm r, th rmostats tc. Th main pow r PCB t rminals in th boil r ar suitabl for cabl s up
to 10mm2. NOTE: THESE CONNECTIONS MUST BE TIGHT. LOOSE CONNECTIONS WILL
CAUSE A FIRE. BURNING AT CONN5 CONNECTOR IS NOT COVERED BY THE WARRENTY.
2 CONN1, pins 2 & 3: CONTROL SIGNAL.Conn ct switch d liv to R and n utral to N on
th control t rminal block in th boil r to th switch d liv and n utral from th programm r control
circuit. A n utral must b conn ct d, as this control signal is optically isolat d from th main supply
in th boil r and will not run without a n utral. Do not conn ct any wir s to th t rminal mark d N/C.
3 CONN1 pins 4, 5 & 6: PUMP CONNECTIONS. Th supply to th pump must b conn ct d to th
PUMP t rminal on th control t rminal block in th boil r. This supply is fus d in th boil r at 2A.
Conn ctions for 2 or mor boil rs.
1 CONN5: Main pow r-supply cabl s. Conn ct ach boil r to its supply liv , n utral, and arth, as
d scrib d abov . Th suppli s to ach boil r can b on diff r nt phas s if using a 3-phas
supply.
2 CONN1 pins 2 & 3: Control signal. Join all th boil r R t rminals on th control t rminal block
tog th r, and th n conn ct th m to th switch d liv control signal to th programm r control circuit.
Conn ct all th boil r N t rminals on th control t rminal block tog th r and th n to n utral on th
programm r control circuit.
3 CONN1: Pump conn ctions. Th pump must b conn ct d through a r lay ass mbly to nsur
that th pump always op rat s if any on boil r is running. S pag 26. R lay box 95970135 is
r quir d for a two boil r syst m and 95970136 is r quir d for a 3 boil r syst m.
Ch ck th main l ctrical pow r conn ctions ar tight. Support th back of th PCB b hind th pow r t rminals
wh n tight ning th main pow r t rminals. Loos conn ctions can caus a fir and will invalidat th warranty.
Th control RUN signal is optically isolat d from th main boil r supply to nabl diff r nt phas s to b us d
b tw n boil rs. Th control signal r quir d to op rat th boil r is 220V - 240V at a v ry low curr nt, typically
10mA.

10
WARNING: THIS APPLIANCE MUST BE EARTHED.
All xpos d pip work must b arth d in accordanc with IEE R gulations.
Aft r installation, pr liminary l ctrical ch cks i. . short circuit, arth continuity, r sistanc to arth and
ch ck for corr ct polarity tc. must b carri d out.
B for conn cting th l ctrical supply, nsur th syst m is full of wat r and s t to th corr ct pr ssur
(s al d syst ms), ch ck for l aks. It is ss ntial that all th air is purg d from th syst m. Only th n can
th supply b switch d on.
On compl tion of th work th installation must b t st d to IEE R gulations and an NICEIC Insp ction and
Compl tion C rtificat must b issu d.
Pl as tak not of th installation information. If in doubt pl as contact your local suppli r or H atra
Sadia.
FIGURE FIVE: BOILER INTERNAL SCHEMATIC
NEL
CONN5
N R E N L
CONN1
CONTROL
ELEMENT

11
FIGURE SIX: BOILER SUPPLY USING EXISTING CONSUMER UNIT
NEL
N R E N L
CONN1 CONN5
CONSUMER UNIT
MCB MCB MCB
AIR
GAP
PUMP
AMPTEC BOILER
NL
MAINS SUPPLY
DOUBLE POLE
RCD OR DOUBLE
POLE ISOLATION
LOCAL TO BOILER
DOUBLE POLE
ISOLATION SWITCH
OR DOUBLE POLE
RCD
3A FUSED
SPUR OR MCB
HEAT RESISTANT
CABLE
DEMAND SIGNAL
FROM CONTROLS/
PROGRAMMER ETC
(SEE TYPICAL
WIRING DIAGRAMS)
TO CONTROLS
PROGRAMMER / ETC
EARTH BONDING
TO BE PERFORMED
IN ACCORDANCE
WITH BS7671
BOILER SUPPLY
MCB
L
N

12
FIGURE SEVEN: BOILER WIRING DIAGRAM
NO CONNECTION
PUMP SUPPLY CABLE
0.5mm - 1mm
MAINS SUPPLY CABLE
BOILER CONTROL CABLE
0.5mm - 1mm
SUPPORT BACK
OF PCB WHEN
TIGHTENING SCREWS
ENSURE SCREWS
ARE TIGHT.
LOOSE CABLE
CONNECTIONS
CAN CAUSE A
FIRE
SUPPLY
CONN 5
CONN 1
FS 1 2A 240V
(5 X 20mm)
REMOVE TOP COVER ONLY TO
GAIN ACCESS TO THE
CONNECTIONS ON THE PRINTED
CIRCUIT BOARD INSIDE THE
BOILER HOUSING
LIVE EARTH NEUTRAL
LIVE EARTH NEUTRAL RUN NEUTRAL
NEL
CONTROL PUMP
CONTROL PUMP
NC N R E N L
NC N R E N L
CASE EARTH
22
2 2

13
FIGURE EIGHT: TYPICAL S PLAN WIRING DIAGRAM
ROOM STAT CYLINDER STAT
BLUE
GRN/YLW
BROWN
GREY
ORANGE
2 1 3 C 1 2
E
N
L
N
RUN
TO
BOILER
L N CH ON HW ON CH OFF HW OFF
FROM 3A
FUSED SPUR
OR MCB
1 2 3 4 5 6 7 8 9 10
TIME CONTROLLER
BLUE
GRN/YLW
BROWN
GREY
ORANGE
2 PORT VALVES

14
FIGURE TEN: TYPICAL HEATING ONLY WIRING DIAGRAM
ROOM STAT
CYLINDER
STAT
BLUE
G/YELLOW
BROWN
GREY
ORANGE
2 1 3 C 1 2
E
N
L
N
RUN
TO
BOILER
L N CH ON HW ON CH OFF HW OFF
FROM 3A
FUSED SPUR
OR MCB
TIME CONTROLLER
FIGURE NINE: TYPICAL Y PLAN WIRING DIAGRAM
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
MID POSITION
VALVE
E
N
L
N
RUN
TO
BOILER
FROM 3A
FUSED SPUR
OR MCB
PROGRAMMABLE ROOM
THERMOSTAT
A B C

15
INSTALLATION REVISED BUILDING REGULATIONS
H ating Controls To Comply With Th R vis d Building R gulations (Part L For England. Part J for
Scotland).
N w Dw lling
1. Th installation must b a fully pump d syst m.
2. Ind p nd nt t mp ratur and tim controls for both h ating and dom stic hot wat r.
3. Controls to int rlock with th boil r. TRVs alon do not comply.
4. An automatic bypass must b us d if a bypass is r quir d. Gat -valv s do not comply.
5. Split h ating circuits into zon s: -
a. Room th rmostat or programmabl room th rmostats in all zon s.
b. A room th rmostat or programmabl room th rmostats in th main zon and TRVs in all oth r
zon s.
6. Cylind r th rmostat and zon valv to control stor d hot wat r. Non- l ctric hot wat r controll rs do not
comply.
7. Tim d controll r for h ating and hot wat r must b provid d.
8. A minimum of 2 zon s for h ating floor spac s gr at r than 150m2.
9. Boil r manag m nt control syst ms m ting sp cific zoning, timing and t mp ratur r quir m nts ar
acc ptabl .
Existing Dw llings
Wh n a n w installation is fitt d, th controls must b as for a n w dw lling.
Wh n r placing th boil r and/or hot wat r v ss l, th opportunity to improv th controls should b consid r d
to b confid nt that th r quir m nts of th Building R gulations ar m t.

16
COMMISSIONING
Th boil r controls ar fully automatic, making th op ration v ry simpl .
Only aft r th syst m has b n flush d through and th n fill d with wat r, inhibitor and s t to th corr ct
pr ssur (s al d syst ms), can th l ctrical supply b switch d on.
Ch ck 1. Wh n filling th syst m ch ck for l aks. Th warranty will b invalidat d if wat r l aks into th
boil r. Ensur th joints abov th boil r ar sound.
Ch ck 2. B for switching on th mains supply, ch ck th main l ctrical pow r conn ctions ar tight.
Support th back of th PCB b hind th pow r t rminals wh n tight ning th main pow r
t rminals. Loos conn ctions can caus a fir .
Initial set up procedure: -
1. Ensur th main l ctrical supply and th programm r controls to th boil r ar off and isolat d.
2. R mov th pump liv and n utral conn ction from th control t rminal block in th boil r, and
r conn ct th pump liv wir into th control t rminal R tog th r with th control signal wir .
Conn ct th pump n utral wir into th control t rminal N tog th r with th control n utral wir .
3. Unplug th control block from th main PCB, nsur it is saf and not touching anything. Th pump
is now f d from th control signal.
4. Ch ck all air is purg d from th syst m, and s t th pump to maximum.
5. Switch on th control supply only (3 amp or 6 amp) MCB.
6. With th programm r and room th rmostat on, ch ck th pump is running and wat r is flowing.
Ensur th whol syst m, valv s tc. ar op rating corr ctly. Continu to run th pump for som
tim to purg any air. Dont forg t to bl d th pump.
7. Switch off th main supply RCD and MCBs. Ensur it is all saf b for r conn cting th pump
conn ctions to th pump t rminals as was originally wir d. R conn ct th control t rminal block
onto th PCB. Ch ck all conn ctions ar mad corr ctly, ch ck th main supply t rminals in th
boil r ar tight, clos and s cur th top front cov r of th boil r.
Main test procedure: -
Only aft r a satisfactory initial t st, proc d as follows; -
1. Switch on th main boil r MCB.
Switch on th programm r control (3 amp or 6 amp) MCB.
Switch on th RCD unit / Isolation switch.
Ch ck th boil r front pan l SUPPLY indicator is illuminat d (gr n).
2. S t th programm r for c ntral h ating to ON.
S t th room th rmostat to b ON.
Th boil r front pan l CALL indicator will flash (gr n).
This indicator will illuminat as a st ady gr n aft r approximat ly 2-3 minut s.
Following th st ady gr n, th HEAT indicator will build up gradually.
3. Ch ck th t mp ratur of th FLOW pip work from th boil r. This pip work should start to ris in
t mp ratur . Th rat of ris will d p nd upon th siz of th boil r and syst m.
4. Ch ck th full syst m op rat s corr ctly. If at any tim th t mp ratur diff r nc b tw n th
boil r r turn and flow is gr at r that 140C, th n th r is a flow r striction probl m, and must b
r ctifi d imm diat ly. S t pump sp d to giv 5-100C diff r ntial b tw n r turn and flow on th
boil r wh n op rating at maximum pow r output.

17
5. Th pump is op rat d from th boil r control. It should b conn ct d to th pump t rminals on th
boil r control board. Th pump will run wh n v r th CALL indicator is illuminat d (gr n) ith r
flashing or st ady, and it will also continu to run if th boil r is hot, v n aft r th d mand has
c as d. It will turn off th pump wh n th boil r t mp ratur falls b low approximat ly 750C. It will
also turn th pump back on if th wat r t mp ratur ris s abov 750C again. A bypass must b
incorporat d in syst ms wh r th h ating load can shut down, i. . wh n valv s or th rmostatic
radiator valv s ar fitt d. S not on th bypass (pag 5).
6. Th ALARM indicator flashing (r d) will only illuminat if th r is a probl m. If th r is a wat r
probl m th HEAT and th CALL (gr n) indicators will turn off. Th boil r will r main in this
tripp d stat until th fault is corr ct d and th boil r is r -s t.
7. An ALARM indicator flashing(r d) tog th r with th CALL indicator (r d) indicat s an ov r
t mp ratur probl m.
FIGURE ELEVEN: INITIAL TEST SET UP
NO CONNECTION
PUMP SUPPLY CABLE
0.5mm - 1mm
MAINS SUPPLY CABLE
BOILER CONTROL CABLE
0.5mm - 1mm
SUPPORT BACK
OF PCB WHEN
TIGHTENING SCREWS
ENSURE SCREWS
ARE TIGHT.
LOOSE CABLE
CONNECTIONS
CAN CAUSE A
FIRE
SUPPLY
CONN 5
CONN 1
FS 1 2A 240V
(5 X 20mm)
REMOVE TOP COVER
ONLY TO GAIN ACCESS
TO THE CONNECTIONS
ON THE PRINTED
CIRCUIT BOARD
INSIDE THE BOILER
HOUSING
LIVE EARTH NEUTRAL
LIVE EARTH NEUTRAL RUN NEUTRAL
NEL
CONTROL PUMP
CONTROL PUMP
NC N R E N L
NC N R E N L
CASE EARTH
INITIAL TEST SET UP
REMOVE PUMP LIVE AND PUMP
NEUTRAL WIRES FROM CONN1 BLOCK.
RECONNECT PUMP LIVE TO RUN WIRE.
RECONNECT PUMP NEUTRAL TO
NEUTRAL.
UNPLUG CONN1 BLOCK FROM PCB.
ENSURE IT IS SAFE BEFORE CARRYING
OUT TEST.
POWER UP SYSTEM WITH ALL
CONTROLS SET TO RUN.
ENSURE THE BOILER SUPPLY LIGHT IS
ON, CALL LIGHT IS OFF AND PUMP
IS RUNNING.
THIS COMPLETES THE TEST.
SWITCH OFF ALL POWER TO BOILER
AND RECONNECT PUMP NEUTRAL
AND PUMP LIVE WIRES BACK TO
THEIR ORIGINAL POSITIONS.
PLUG THE TERMINAL BLOCK
BACK INTO CONN1 ON THE PCB.
ENSURE CONNECTION SCREWS ARE
TIGHT
22
22

18
FIGURE TWELVE: OPERATION OF THE C SERIES ISSUE 5 BOILER
MAIN POWER ON
CONTINUE CHECK FOR ALL AS
LONG AS BOILER IS POWERED
RUN TO ON
PUMP ON AND PRE-HEAT ON
THEN WAIT FOR 1 - 1.5 MINUTES
CALL LED RED
ALARM LED FLASHING
IS TEMP
SWITCH OPEN
I.E. FAULTY OR
BOILER OVER
TEMP
DO BOTH
THERMISTOR BEADS
READ SAME VALUE I.E.
TEMPERATURE
CONTINUE CHECK FOR A
FURTHER 2 MINUTES
SWITCH OFF PRE-HEAT ,POWER
UP AND MODULATE BOILER
RUN TO OFF
BOILER POWERS DOWN
IS WATER IN
BOILER BELOW
70ºC/75ºC
KEEP PUMP RUNNING
OR PUMP ON
ALARM LED FLASHING
(NO WATER OR INSUFFICIENT
WATER FLOW)
PUMP OFF
YES
NO
NO
YES
NO
YES

19
OPERATION AND INDICATORS
Th SUPPLY indicator (gr n) will r main illuminat d all th tim th supply is pr s nt to th boil r.
Th CALL indicator will illuminat (gr n) on d mand from th programm r and th rmostats or (r d) for an
alarm ov rh at condition. It will flash (gr n) for 2 to 3 minut s during which it carri s out s lf-t sts b for
allowing th boil r to produc h at. At th nd of this p riod it will r main on st ady (gr n), until th
h ating d mand is satisfi d.
Th HEAT indicator will illuminat wh n th boil r actually
produc s h at, this is only wh n th CALL indicator (gr n)
is st ady. Th gradual build up in h ating pow r of th boil r
can b s n on th front pan l. Th HEAT indicator also shows
th boil r modulating wh n it r ach s op rating t mp ratur .
Th ALARM indicator flashing (r d) will only illuminat if th r is
a probl m. Th HEAT and th CALL (gr n) indicators will turn
off. Th boil r will r main in this tripp d stat until it is r -s t.
To r s t an ALARM follow th Alarm R s t proc dur .
TEMPERATURE CONTROL. Th boil r output t mp ratur can
b adjust d from th front pan l. Minimum s tting for C s ri s is
approximat ly 650C and U s ri s 300C. Maximum s tting for C
s ri s is approximat ly 800C and U s ri s is 600C.
CLEANING
Us only a damp cloth and mild d t rg nt to cl an th boil r out r
casing. Do not us abrasiv cl an rs. Do not allow wat r insid
th boil r. Do not imm rs in wat r.
SERVICING
IT IS ESSENTIAL THAT THE BOILER IS CHECKED ANNUALLY, Ch cks must includ th l ctrical
conn ctions and inhibitor conc ntration.
B for any s rvicing or maint nanc is carri d out on th syst m, nsur that th l ctrical supply has b n
disconn ct d first. Car must also b tak n as th wat r may b scalding hot and at a high pr ssur .
Ch ck th main l ctrical pow r conn ctions ar tight. Loos conn ctions can caus a fir .
Part Locations and comments (see page 2)
Fus FS1 is found n ar th top of th main pow r PCB ass mbly.
Th t mp ratur switch conn ct d to Conn 3 is situat d on th body of th boil r approximat ly 1/3rd of th
distanc up from th bottom b tw n insulation and boil r.
Th th rmistor ass mbly plugs into th main pow r PCB ass mbly through Conn 4, and is clamp d at th
top of th boil r. Car must b tak n not to br ak th fin wir s.
Th control PCB ass mbly is mount d on th back of th bottom front pan l, and plugg d into th main
pow r PCB Conn 2. Gr at car must b tak n wh n changing this board ass mbly not to damag any of
th compon nts, sp cially thos adjac nt to th mountings.
To chang th main pow r PCB, follow R placing th Main Pow r PCB proc dur (s pag 20).
Each of th main l ctrical l m nts should hav a r sistanc of approximat ly 19 ohms t rminal to
t rminal, (r d to r d, y llow to y llow, blu to blu and black to black) and an insulation r sistanc gr at r
than 2 M g ohms b tw n t rminal and cas . If th l m nts ar op n circuit t rminal to t rminal, or hav
short circuit insulation r sistanc t rminal to cas , th n th boil r must b r plac d.
FIGURE THIRTEEN: CONTROL PANEL

20
REPLACING THE MAIN POWER PCB
Not . B for any maint nanc is carri d out on th syst m, nsur that th l ctrical supply has b n
disconn ct d first. Car must b tak n as th wat r may b scalding hot and at high pr ssur .
Maint nanc on th boil r can only b carri d out by a qualifi d and comp t nt trad sman in accordanc
with suppli d instructions.
R moval of th Main Pow r PCB
1 Switch OFF l ctrical suppli s to th boil r. Both Main, Liv and N utral, and Control R and N
must b isolat d
2 R mov th front top pan l.
3 Disconn ct th control PCB and car fully r mov th high t mp ratur insulation and th
front bottom pan l.
4 Unplug th control conn ctor (Conn1), th t mp ratur switch conn ctor (Conn3), and th
th rmistor conn ctor (Conn4).
5 Unplug th pow r conn ctors on th l m nts.
6 Disconn ct th main pow r cabl to Conn5.
7 R mov th 4 scr ws id ntifi d by th black triangl s, s figur fourt n b low.
8 Car fully r mov th PCB ass mbly from th pip work. This may b stiff and g ntl prising at th
top may b r quir d.
R placing th Main Pow r PCB
1 Ensur h at sink compound is us d on th h at sinks.
2 Id ntify and plug th pow r conn ctors onto th l m nts, colour for colour, as it is asi r to mak
th s conn ctions b for fitting th PCB.
3 Holding th back plat lin up th pillars with th PCB and position it onto th pip work.
4 Loos ly add th 4 fixing scr ws.
5 Tight n up th s scr ws in th ord r shown b low in figur fourt n. It is important to nsur that
th PCB ass mbly is tight on th pip work.
6 R conn ct th control PCB and r plac th high t mp ratur insulation.
7 Ensur th main pow r conn ctions ar tight. Loos conn ctions can caus a fir .
12
3
4
FIGURE FOURTEEN: MAIN POWER PCB