Heatrae Sadia Amptec Mounting instructions

1
Amptec Electric Flow Boiler
Installation Instructions and User Guide

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Thank you for purchasing your Heatrae Sadia Amptec ow boiler. It has been developed to
provide you with many years of trouble-free service when installed in the correct manner.
Please read and understand these instructions prior to installing your Heatrae Sadia Amptec
ow boiler. This Amptec electric boiler must be installed (sections 1.0 - 7.0), Commissioned
(section 8.0) and maintained (section 10.0) by a competent person only. Particular attention
should be paid to the section headed important installation points. Following installation
and commissioning the operation of the boiler should be explained to the user (section 9.0)
and these instructions left with them for future reference.
This appliance can be used by children aged from 8 years and above and
persons with reduced physical sensory or mental capabilities or lack of
experience and knowledge if they have been given supervision or instruction
concerning use of the appliance in a safe way and understand the hazards
involved. Children shall not play with the appliance. Cleaning and user
maintenance shall not be made by children without supervision.
Children must be supervised to ensure they do not play with the appliance.
WARNING: Do not switch on if there is a possibility that the water in the heater is frozen.

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1.0 DESCRIPTION
The AMPTEC electric ow boiler is designed to heat re-circulated water used in wet central heating systems.
The water is heated when it is passed over electric immersion elements, which are contained in a chamber. The
temperature of the water is monitored and controlled by a modulation technique switching on the immersion
elements. The switching of the elements is carried out by solid-state technology contained in the control section
of the boiler. The operation of the boiler can be controlled by standard programmers, room thermostats, etc.
The pump should be connected to the boiler control, which provides the run-on facility and pump exerciser.
2.0 FEATURES
· Electric ow boiler for wet central heating systems.
· Domestic hot water is available from a cylinder.
· Can be used in sealed or open vented system installations.
· No ue or fuel tank required.
· Quiet in operation.
· Operates from standard programmers, room thermostats, etc.
· Pump run-on facility and pump exerciser.
· Solid-state technology enables zero volt switching.
· Soft start and soft modulation.
· Front panel operation indicators.
· User adjustment of the operating temperature on the front panel.
· Self check every time it operates.
· Optical isolation to enable connection of more boilers on single or three phase supplies.
· Electrical tails terminations inside the boiler.
· Safety trip for no water or no ow situations.
FIGURE 1 : MAIN COMPONENTS OF AMPTEC ELECTRIC FLOW BOILER
OUTLET
RED IDENT
ELECTRICAL CABLE
ENTRY POINTS
EARTH CLAMP
TERMINAL BLOCK
MAIN PCB
INSULATION
BOILER ELEMENT
TEMPERATURE SWITCH
INLET
FRONT COVER (TOP)
WARNING LABEL
INSULATION SHEET
FLYING LEAD
CONTROL PANEL
FRONT COVER (BOTTOM)
RATING LABEL
SERIAL NUMBER

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3.0 TECHNICAL SPECIFICATION
Output temperature control range: (C series) 650C to 800C.
(U Series) 300C to 600C
Operating voltage 200V - 245V 50Hz
Pump supply fuse (internal) T 2A 240V - 20x5mm.
‘RUN’ control input signal requires 200V - 245V 50Hz
‘RUN’ control input signal draws less than 0.25A. 10mA typical.
Optical isolation Between the control signals
and the boiler supply.
Over temperature trips 1000C
Water content 1.3 litres
Product code Boiler type 220V / Btu 240V / Btu Size
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 11kW / 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

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4.0 INSTALLATION - GENERAL
Care must be taken when handling and connecting the boiler not to damage or stress it in any way. Prior
to installation the boiler must be stored in a dry, safe place.
The boiler must be mounted in an UPRIGHT position. The boiler must be xed to a wall before connecting
pipework. The wall must be able to take the weight of the unit when full with the use of suitable xings
and also suitable for the operating temperature of the boiler. When choosing the position for the boiler,
ensure sufcient clearances to house the unit and for servicing. 50mm minimum clearance each side of the
boiler is required. A drain valve at the base of the boiler is strongly recommended. It must be sited in a
dry, ventilated position, frost free and not subjected to extremes of temperature.
Note. Before connecting the pipework, ensure the rubber seal at the top of the boiler is rmly in place;
check it has not become loose in transit. The warranty will be invalid if water leaks into the boiler.
TOP HAUT ALTO OB EN
W
ARNING
B
efore obtaining acc ess to ter minals all supply
ci
rcuitsm ust be disc onnected
D
onot solde r directly onto f low and return pipew ork
T
hegua rantee will be withdrawn if this product is
N
otinstalled in a ccordanc e with the instal lation
ins
tructions
HEATRAESADIA
AMPTECBOILER C600
GC
NO. EB-205- 02
OP
ERATING TEMPERATU RE 65-80C
PR
ESSURE 3BAR MAX
220
-240V~ 5-6KW
BE
AB CE N CCA
CO
PYRIGHT RE SERVED PAT ENT APPL IED
FO
R
Ele
ctroheat
Ba
singstokeU K RG24 9RA
BO
TTOM BAS BASSOU NTEN
FIGURE 2 : DIMENSIONS
BACK VIEW
FRONT VIEW
SIDE VIEW
ENTRY PORTS
SUPPLY AND
CONTROL ON
BOTH SIDES
20mm
25.4mm
FLOW PIPEWORK
RED IDENT
RETURN PIPEWORK
5mm SECURING
HOLE
900mm FIXING CENTRES
30mm
1050mm
20mm
30mm
100mm
90mm

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5.0 INSTALLATION PLUMBING
The installation must be carried out in accordance with the relevant requirements of:
The appropriate Building Regulations, either The Building Regulations, The Building Regulations (Scotland)
or Building Regulations (Northern Ireland)
The Water Fittings Regulations or Water Byelaws in Scotland.
IT IS THE INSTALLER’S RESPONSIBILITY TO ENSURE THAT THE INSTALLATION DOES NOT CONTRAVENE
THE REQUIREMENTS OF THE WATER SUPPLY REGULATIONS, BUILDING REGULATIONS OR LOCAL AU-
THORITY REGULATIONS.
The boiler must be installed by a qualied, competent tradesman who is aware of and will comply with
all relevant standards that are applicable: e.g. Building Regulations, the Local Authority Regulations, the
Water Supply Regulations and undertaking the relevant British Standards. The system must be ushed in
accordance with BS 7593 and in accordance with the supplied instructions and drawings to ensure proper
operation.
The boilers contain a very small amount of water, and so require a sufcient ow rate of water to ensure
proper operation. Insufcient ow of water through the boiler may cause nuisance trip outs. The maximum
temperature differential between input and output of the boiler must not exceed 140C. If the temperature
across the boiler exceeds this then the ow rate is too low and will potentially damage the boiler. Set the
ow rate to give 50C - 100C across the boiler on full heat.
The output FLOW pipe at the TOP of the boiler is identied RED. The input RETURN pipe is located at the
BOTTOM. Ensure that the direction of ow is correct through the boiler after installation. Set the pump on
maximum ow rate.
Pipework connections on all models are 22mm.
Use standard size pipework. DO NOT SOLDER DIRECTLY ONTO THE BOILER TAILS. Push-on or
compression ttings are suitable for connecting directly onto the boiler tails. Fit a 22mm elbow to the top
of the boiler, and after 100 – 150mm of horizontal pipework on the positive pressure side of pump t an
automatic air vent, or connect the expansion pipework on open vented systems to provide a route for air to
vent. DO NOT FIT THE AAV DIRECTLY ABOVE THE BOILER.
The Amptec boiler is suitable for operation in sealed or open vented systems. It is also suitable for schemes
such as heating only, W plan, S plan, zone heating, under oor heating, micro-bore via a manifold, etc. If you
are unsure about your application regarding suitability of the boiler please do not hesitate to contact your
local supplier or Heatrae Sadia specication team on 01603 420220.
The cost of installation can be reduced if the electric ow boiler is used for heating only. Use a direct type
cylinder with immersion elements and a time clock for the domestic hot water, then connect the electric
ow boiler directly to the heating circuit and control it by a programmable room thermostat. If the radiator
circuit has a continuously open route for the water ow then a bypass is not required. The boiler sizing is for
heating only in this case and does not have to be increased to allow for domestic hot water as well.
Ensure there is always an open route for the water to ow in any installation, to meet the required minimum
ow rate of the boilers and to allow for the pump over run. If an open route through the heating circuit can
not be guaranteed, then a bypass, tted with an automatic bypass valve must be tted, which meets the
required minimum ow rates for the boiler.
The bypass must have a minimum of either 2 metres of 22mm continuous pipework, or be routed through a
radiator with minimum dimensions of 600 x 600mm. Automatic pressure opening valves must be used with
the bypass circuit, ensure they are installed correctly as per the manufacturer’s instructions. Gate valves are
not suitable. DO NOT FIT A VALVE BETWEEN THE BOILER AND THE SAFETY PRESSURE RELIEF VALVE OR
EXPANSION RELIEF SYSTEM.
The boilers are suitable for operating pressures up to 3 bar. Normal sealed systems operate at 1 to 1.5 bar.
Ensure a safety pressure relief valve is tted to all sealed systems. With open vented installations, ensure
there is a sufcient head of water for the pump to supply the full ow through the boiler of at least 1½ Metres
between the bottom of the F & E tank and the top of the boiler.

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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 t thermostatic radiator valves to the room with the control thermostat, other rooms may be tted
with thermostatic radiator valves. DO NOT OPERATE UNDER THERMOSTATIC RADIATOR VALVES ONLY.
Use standard pumps, controls, room thermostat, valves, etc. The main electrical power (high current) must
be routed directly to the boiler via an MCB and RCD, not through the controls. Only a control signal to the
boiler comes from the programmer. The switching of the high power current is done inside the boiler.
For installations with more than one boiler, mount the boilers side-by-side with a minimum of 50mm gap
between each boiler, output ow tails at the top and the returns at the bottom. ‘Tee’ in the ows together,
increasing in pipe size at each boiler to ensure full ow to each boiler. E.g. for 3 x 1200 boilers, rst boiler
use a 22mm elbow to the second boiler. Second boiler tee 22mm in from rst boiler, 22mm branch to
second boiler, 28mm to third boiler. Third boiler tee 28mm in from second boiler, 22mm branch to third
boiler, 35mm away to heating circuit. Repeat for the return connections. Single pump in the 35mm ow
line, ensure sufcient ow for all 3 boilers, i.e. (for 3 x 1200 boilers requires 3 x 12 l/m = 36 litres/minute
minimum). Do not reduce pipework before ‘teeing’. (g 4, page 8) this is to ensure equal ow through
each boiler. Total pipework size can then be reduced after Tees back down to 22mm suitable for pump etc,
provided it meets BS specication
When lling the system check for leaks. THE WARRANTY WILL BE INVALIDATED IF WATER LEAKS INTO
THE BOILER. ENSURE ALL JOINTS ABOVE THE BOILER ARE SOUND.
After installation the system must rst be ushed out in accordance with BS 7593:1992 before adding the
inhibitor. Fernox “Superoc”, or BetzDearborn Setinel X300 or X400 are ideal ushing agents for new
and existing systems. After ushing the correct amount of inhibitor must be added before use. Fernox
“Superconcentrate”, or MB-1, or BetzDearborn Sentinel X100 can be used for most water areas, however
we recommend you should check with your local water authority to ensure suitability. Check the inhibitor
concentration after installation and periodically thereafter to ensure correct protection.
FAILURE TO FLUSH PROPERLY OR INADEQUATE INHIBITOR IN THE SYSTEM WILL INVALIDATE THE
WARRANTY.
WARNING: THIS APPLIANCE IS NOT TO BE USED FOR A POTABLE WATER SUPPLY.

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FIGURE 3 : BASIC PLUMBING LAYOUT
AUTOMATIC AIR VENT
EXPANSION / SAFETY
RELIEF SYSTEM
INC EXP VESSEL,
FILLING LOOP, SAFETY
RELIEF VALVE, GAUGE
SERVICE VALVE
PUMP
2 METRES MINIMUM
AMPTEC BOILER
AUTOMATIC
PRESSURE
BYPASS VALVE
FLOW
DRAIN VALVE
ALTERNATIVE BY-PASS
ARRANGEMENT USING THE
RADIATOR FITTED WITH TWO
LOCKSHIELD VALVES
NOTES
1. OPEN VENTED SYSTEMS MUST HAVE
A MINIMUM HEAD OF 1.5 METRES AND
MAXIMUM HEAD OF 30 METRES
2. FIT THE AUTOMATIC AIR VENT (AAV)
AS SHOWN WITH 150mm MINIMUM
DISTANCE FROM BEND.
3. ENSURE NO VALVE IS FITTED BETWEEN
THE AMPTEC BOILER & THE EXPANSION
KIT/SAFETY DISCHARGE VALVE.
4. THE BOILER CAN BE ISOLATED BY
CLOSING THE PUMP VALVES & THE SERVICE
VALVE ON THE RETURN PIPEWORK TO THE
BOILER.
RETURN

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A typical plumbing schematic connecting 3 x 1200 boilers together.
NOTE the increase in pipework sizing to ensure proper ow through the boilers.
Ensure there are no restrictions in the heating circuit such as thermostatic radiator valves etc.
Expansion vessel etc. has not been shown on this schematic.
For 2 x 1200 boilers, 28mm pipework ow and return is required.
A bypass must be tted. Preference should be made for the equivalent of a 600 x 600 radiator per boiler.
FIGURE 4 : THREE BOILER PLUMBING SCHEMATIC
AUTOMATIC
AIR VENT
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
150mm
min
EXPANSION
SAFETY
RELIEF
SYSTEM

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6.0 INSTALLATION - ELECTRICAL REQUIREMENTS
ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS.
The AMPTEC boiler must be installed by a qualied competent tradesman in accordance with supplied
instructions and drawings to ensure correct operation.
Check the main incoming supply to the property to ensure there is sufcient current and voltage for the size
of the boiler or boilers to be installed. Remember to also take account of the supply requirements for the
rest of the property. Ensure the correct cable size is used to feed the boiler (refer to IEE wiring regulations).
A double pole RCD with a trip level sensitivity of 30mA and capable of breaking the full load current to BS
EN 61008:1994, must be used.
In order to provide a means of isolation, the boiler must be connected to the supply through a double pole
linked switch with a minimum contact gap of 3mm in all poles. The RCD is suitable for this requirement if it
is mounted in close proximity to the boiler.
A correctly rated MCB must be used in the supply, see Technical Specications p.3. An additional 3A supply
is required for the controls etc. NOTE, a blank must be tted between each MCB to provide ventilation,
check with the MCB manufacture/supplier.
NOTE: The high current mains supply MUST NOT be routed through the programmer, controls etc. Follow the
wiring diagrams. Use a standard programmer, room thermostat, etc. The high current switching is carried out
inside the boiler, only standard switched live (low current) control signals are supplied by the programmer etc.
Electrical Connections
Access can be gained to the electrical connections by removing the top front panel.
1 CONN 5: MAIN POWER. Main power-supply cables (HOFR cable to be used). Connect the power
cables from the power “supply” (CONN 5) terminals on the PCB assembly in the boiler directly to
the isolation switch, live, neutral and earth. Use the correct rated cable. Do not connect the power
through the programmer, thermostats etc. The main power PCB terminals in the boiler are suitable
for cables up to 10mm2. NOTE: (These connections must be tight. Loose connections will cause a
re. Burning at CONN 5 connector is not covered by the warranty).
2 CONN 1, pins 2 & 3: CONTROL SIGNAL. Connect switched live to ‘R’ and neutral to ‘N’ on the control
terminal block in the boiler to the switched live and neutral from the programmer control circuit. A
neutral must be connected as this control signal is optically isolated from the main supply in the boiler
and will not run without a neutral. Do not connect any wires to the terminal marked N/C.
3 CONN 1 pins 4, 5 & 6: PUMP CONNECTIONS. The supply to the pump must be connected to the
‘PUMP’ terminal on the control terminal block in the boiler. This supply is fused in the boiler at 2A.
4. Cable access is made from either the right or left hand side via the X3 knockouts provided
(x1 25mm for power and x2 20mm for pump and thermostat cables). Having decided which side to
route the cables, remove x3 knockouts only. (This can be achieved with a small tap from a ball
nosed hammer, then twisting the knockout until it is removed. NOTE: Take care not to damage the
casing, ensure the metal discs are retrieved and no sharp edges are present. The cables should be
installed using a suitable strain relief bush (not supplied).
X3 KNOCKOUTS
LEFT HAND SIDE
X3 KNOCKOUTS
RIGHT HAND SIDE
FIGURE 5: FIGURE 6:

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Connections for 2 or more boilers.
1 CONN 5: Main power-supply cables. Connect each boiler to its supply live, neutral, and earth, as
described on p.10. The supplies to each boiler can be on different phases if using a 3-phase
supply. Safe isolation warning notices must be tted to units where multiple phase supplies are
used.
2 CONN 1 pins 2 & 3: Control signal. Join all the boiler ‘R’ terminals on the control terminal block
together and then connect them to the switched live control signal to the programmer control
circuit. Connect all the boiler ‘N’ terminals on the control terminal block together and then to
neutral on the programmer control circuit.
3 CONN 1: Pump connections. The pump must be connected through a relay assembly to ensure
that the pump always operates if any one boiler is running. (section 14, p.27). Relay box 95970135
is required for a two boiler system and 95970136 is required for a 3 boiler system.
Check the main electrical power connections are tight. Support the back of the PCB behind the power
terminals when tightening the main power terminals. Loose connections can cause a re and will invalidate
the warranty.
The control RUN signal is optically isolated from the main boiler supply to enable different phases to be
used between boilers. The control signal required to operate the boiler is 220V - 240V at a very low current,
typically 10mA.
WARNING: THIS APPLIANCE MUST BE EARTHED.
All exposed pipework must be earthed in accordance with IEE Regulations.
After installation, preliminary electrical checks i.e. short circuit, earth continuity, resistance to earth and
check for correct polarity etc. must be carried out.
Before connecting the electrical supply, ensure the system is full of water and set to the correct pressure
(sealed systems), check for leaks. It is essential that all the air is purged from the system. Only then can the
supply be switched on.
On completion of the work the installation must be tested to IEE Regulations and an NICEIC Inspection and
Completion Certicate must be issued.
Please take note of the installation information. If in doubt please contact your local supplier or Heatrae
Sadia Technical Team on 0344 871 1535, option 1.
FIGURE 7 : BOILER INTERNAL SCHEMATIC
N E L
CONN5
N R E N L
CONN1
CONTROL ELEMENT
MAIN SUPPLY
CONTROL DEMAND PUMP OUTPUT

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FIGURE 8 : BOILER SUPPLY USING EXISTING CONSUMER UNIT
N E L
N R E N L
CONN1
CONN5
CONSUMER UNIT
MCB MCB MCB
AIR
GAP
PUMP
AMPTEC BOILER
N L
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

13
FIGURE 9 : BOILER WIRING DIAGRAM
NO CONNECTION
OUTGOING PUMP
SUPPLY CABLE
0.5mm - 1mm
INCOMING
MAINS SUPPLY CABLE
INCOMING
PROGRAMMER
CONTROL CIRCUIT
FUSED 3A
0.5mm - 1mm
SUPPORT BACK
OF PCB WHEN
TIGHTENING
SCREWS
ENSURE SCREWS
ARE TIGHT.
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
NL
CONTROL PUMP
CONTROL PUMP
NC N R E N L
NC N R E N L
CASE EARTH
22
22
LOOSE CABLE CONNECTIONS
CAN CAUSE FIRE

14
FIGURE 10 : 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

15
FIGURE 12 : 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 11 : 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
OPTIONAL
CAPACITOR
0.47uF 240v AC

16
7.0 INSTALLATION - REVISED BUILDING REGULATIONS
Heating Controls to comply with the revised Building Regulations (Part L For England. Part J for Scotland).
New Dwelling
1. The installation must be a fully pumped system.
2. Independent temperature and time controls for both heating and domestic hot water.
3. Controls to interlock with the boiler. TRV’s alone do not comply.
4. An automatic bypass must be used if a bypass is required. Gate-valves do not comply.
5. Split heating circuits into zones: -
a. Room thermostat or programmable room thermostats in all zones.
b. A room thermostat or programmable room thermostats in the main zone and TRV’s in all other
zones.
6. Cylinder thermostat and zone valve to control stored hot water. Non-electric hot water controllers do not
comply.
7. Timed controller for heating and hot water must be provided.
8. A minimum of 2 zones for heating oor spaces greater than 150m2.
9. Boiler management control systems meeting specic zoning, timing and temperature requirements are
acceptable.
Existing Dwellings
When a new installation is tted, the controls must be as for a new dwelling.
When replacing the boiler and/or hot water vessel, the opportunity to improve the controls should be considered
to be condent that the requirements of the Building Regulations are met.

17
8.0 COMMISSIONING
The boiler controls are fully automatic, making the operation very simple.
Only after the system has been ushed through and then lled with water inhibitor and set to the correct pressure
(sealed systems), can the electrical supply be switched on.
Check 1. When lling the system check for leaks. The warranty will be invalidated if water leaks into the
boiler. Ensure the joints above the boiler are sound.
Check 2. Before switching on the mains supply, check the main electrical power connections are tight.
Support the back of the PCB behind the power terminals when tightening the main power
terminals. Loose connections can cause a re.
Initial set up procedure: - (See gure. 13, page.18)
1. Ensure the main electrical supply and the programmer controls to the boiler are off and isolated.
2. Remove the pump live and neutral connection from the control terminal block in the boiler, and
reconnect the pump live wire into the control terminal ‘R’ together with the control signal wire.
Connect the pump neutral wire into the control terminal ‘N’ together with the control neutral wire.
3. Unplug the control block from the main PCB, ensure it is safe and not touching anything. The pump
is now fed from the control signal.
4. Check all air is purged from the system and set the pump to maximum.
5. Switch on the control supply only (3 amp or 6 amp) MCB.
6. With the programmer and room thermostat on, check the pump is running and water is owing.
Ensure the whole system, valves etc. are operating correctly. Continue to run the pump for some
time to purge any air. Don’t forget to bleed the pump.
7. Switch off the main supply RCD and MCB’s. Ensure it is all safe before reconnecting the pump
connections to the pump terminals as was originally wired. Reconnect the control terminal block
onto the PCB. Check all connections are made correctly, check the main supply terminals in the
boiler are tight, close and secure the top front cover of the boiler.
Main test procedure: -
Only after a satisfactory initial test, proceed as follows; -
1. Switch on the main boiler MCB.
Switch on the programmer “control” (3 amp or 6 amp) MCB.
Switch on the RCD unit / isolation switch.
Check the boiler front panel SUPPLY indicator is illuminated (green).
2. Set the programmer for central heating to ON.
Set the room thermostat to be ON.
The boiler front panel CALL indicator will ash (green).
This indicator will illuminate as a steady green after approximately 2-3 minutes.
Following the steady green, the HEAT indicator will build up gradually.
3. Check the temperature of the FLOW pipework from the boiler. This pipework should start to rise
in temperature. The rate of rise will depend upon the size of the boiler and system.
4. Check the full system operates correctly. If at any time the temperature difference between the
boiler return and ow is greater than 140C, then there is a ow restriction problem and must be
rectied immediately. Set pump speed to give 50C-100C differential between return and ow on
the boiler when operating at maximum power output. The heat may be seen to modulate if the
temperature rise is to quick.

18
5. The pump is operated from the boiler control. It should be connected to the pump terminals on
the boiler control board. The pump will run whenever the CALL indicator is illuminated (green)
either ashing or steady, and it will also continue to run for 1 minute after the demand has ceased.
A bypass must be incorporated in systems where the heating load can shut down, i.e. when valves
or thermostatic radiator valves are tted. See note on the bypass (page 6).
6. Pump exerciser: If the boiler is not operated during a 24Hr period the pump is energised for 20
seconds every 24Hrs to ensure it is ready for operation, provided that power is supplied to the
boiler.
7. An ‘ALARM’ indicator (RED) indicates a problem. See fault nding section 12 page 22.
FIGURE 13 : INITIAL TEST SET UP
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.
PURGE ALL AIR FROM SYSTEM.
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
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.
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
NL
CONTROL PUMP
CONTROL PUMP
NC N R E N L
NC N R E N L
CASE EARTH
22
22
LOOSE CABLE CONNECTIONS
CAN CAUSE FIRE
DISCONNECT
FROM PCB

19
FIGURE 14 : OPERATION OF THE C SERIES BOILER
MAIN POWER ON
SHORT/OPEN
CIRCUIT
SHORT/OPEN
CIRCUIT AT CONTROL
THERMISTOR
YES
NO
OVER
TEMPERATURE?
(TEMPERATURE
SWITCH)
ALARM 2
HEATING
DEMAND?
WATER PRESENT?
(WATER CHECK)
WATER
TEMPERATURE <
SETPOINT
PREVIOUS
HEATING DEMAND
ON?
WATER
TEMPERATURE >
85°C
WATER
TEMPERATURE <
10°C
ALARM 1 OVER RUN PUMP
(1MINUTE)
HEATING OFF
SEQUENCE
HEATING ON
SEQUENCE
LOWER WATER
TEMPERATURE TO 80°C
FROST PROTECTION
PROCESS
YES
YES
YES
YES
YES
YES
YES
NO
NO NO
NO
NO
NO
NO

20
9.0 OPERATION AND INDICATORS
The SUPPLY indicator (green) will remain illuminated all the time the supply is present to the boiler.
The CALL indicator will illuminate (green) on demand from the programmer and thermostats or (red) for
an alarm overheat condition. It will ash (green) for 2 to 3 minutes during which it carries out self-tests, the
bottom heat indication can be seen to operate during this time. At the end of this period the call light will
remain on steady (green), until the heating demand is satised.
The HEAT indicator will illuminate when the boiler actually produces
heat, when the CALL indicator (green) is illuminated. The gradual
build up in heating power of the boiler can be seen on the front panel.
The HEAT indicator also shows the boiler modulating when it
reaches operating temperature, or if the temperature rise is too quick.
Alarm indication by either ALARM light or the CALL light illuminated
red ashing or steady depending on alarm sequence tripped. If there
is a problem see section 12 - Fault Finding. The HEAT and the CALL
(green) indicators will turn off. The boiler will remain in this tripped
state until it is re-set. To reset an ALARM follow the ‘Alarm Reset’
procedure. Section 13, page 22.
TEMPERATURE CONTROL. The boiler output temperature can
be adjusted from the front panel.(once set, will not need adjustment.)
Min setting for C series is approximately 650C and U series 300C.
Max setting for C series is approximately 800C and U series is 600C.
CLEANING
Use only a damp cloth and mild detergent to clean the boiler outer
casing. Do not use abrasive cleaners. Do not allow water inside
the boiler. Do not immerse in water.
10.0 SERVICING
IT IS ESSENTIAL THAT THE BOILER IS CHECKED ANNUALLY. Checks must include the electrical
connections and inhibitor concentration.
Before any servicing or maintenance is carried out on the system ensure that the electrical supply has been
disconnected rst. Care must also be taken as the water may be scalding hot and at a high pressure.
Check the main electrical power connections are tight. Loose connections can cause a re.
Part Locations and comments (see page 2)
Fuse FS1 is found near the top of the main power PCB assembly.
The temperature switch connected to Conn 3 is situated on the body of the boiler approximately 1/3rd of
the distance up from the bottom between insulation and boiler.
The thermistor assembly plugs into the main power PCB assembly through Conn 4 and is clamped at the top
of the boiler. Care must be taken not to break the ne wires.
The control PCB assembly is mounted on the back of the bottom front panel and plugged into the main
power PCB Conn 2. Great care must be taken when changing this board assembly not to damage any of the
components, especially those adjacent to the mountings.
To change the main power PCB follow ‘Replacing the Main Power PCB’ procedure (see page 20).
Each of the main electrical elements should have a resistance of approximately 19 ohms (29 ohms for 2kW
elements used in 4kW and 11kW boiler) terminal to terminal, (red to red, yellow to yellow, blue to blue and
black to black) and an insulation resistance greater than 2 Meg ohms between terminal and case. If the
elements are open circuit terminal to terminal, or have short circuit insulation resistance terminal to case,
then the boiler must be replaced.
FIGURE 15 : CONTROL PANEL
AMPTEC