RED-RING Hotbox L318 User guide

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Redring Hotbox Boiler
Models L318 and LP330
User and Installer Instructions
Please keep these instructions safe, should you move house,
please hand them over to the next occupier.
COMPLIANT TO : BS EN 60335-2, BS EN 55014-2 and BS EN 50081-1

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Redring Hotbox Boiler
THE HALOGEN BOILER, L318, LP330
HALOGEN POWERED WALLMOUNTED BOILER
USER&INSTALLERS INSTRUCTIONS
PLEASE KEEPTHESE INSTRUCTIONS SAFE. SHOULD YOU MOVE HOUSE, PLEASE
HAND THEM OVER TO THE NEXT OCCUPIER.
1. Introduction
The Halogen Boiler is a wall-mounted appliance, suitable for installation onto small sealed heatingsystems.
It incorporates all the components for sealed systemrequirements, these include, pressure gauge, pressure
relief valve, expansion vessel, circulatingpump and manual reset overheat thermostat. A manual air vent is
also located on the appliance. There are two controls on the appliance, one adjusts the water flow
temperature, and the other is an on/off switch. A 2 mlongelectrical flex with integral plugenables the
appliance to be connected into a standard 13A ringmain socket or via the 24 hour plugin timer supplied.
2. Technical Specification
Performance Data
L318 LP330
Electrical Input kW 6 x 0.300 10 x 0.300
Heat Output to Water kW 1.71 2.85
Heat Output Convection kW 0.09 0.15
General Specification
L318 LP330
Product Catalogue Number 29-394601 29-394602
Halogen Bulb Heat Source 6 x 300W 10 x 300W
ElectricitySupply 220 - 240V ~ 50 Hz
220 - 240V ~ 50 Hz
External Fuse (supplied plug) 10A 13A
Water Connections Flow 22 mm Copper 22 mm Copper
Water Connections Return 22 mm Copper 22 mm Copper
Expansion Vessel Charge 0.5 bar 0.5 bar
Minimumoperatingflow temp. 20°C 20°C
Maximumoperatingflow temp. 70°C 70°C

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Overall Dimensions & MinimumClearances
Clearances Operational Maintenance
Side mm 5 5
Top mm 200 200
Bottom mm 200 200
Front mm 5 500
3. Installation Requirements
Statutory Requirements
The installation should also be in accordance with the relevant recommendations in the current editions of
the followingBritish Standards:
BS 7074: Pt 1 Expansion vessels and ancillaryequipment for sealed water systems
BS 5449 Forced circulation hot water systems for domestic premises
BS 7671 Requirements for Electrical Installations. IEE WiringRegulations.
BS 4814 Expansion Vessels usingan internal diaphragm for sealed hot water systems.
BS 6798 Installation of gas fired boilers of rated input not exceeding70 kW Net.
BS 6759: Pt 1 Safetyvalves
BS 1362 General purpose fuse links for domestic & similar purposes. (Primarilyfor use in
plugs).
BS 5376 Code of Practice for selection & installation of gas space heating
Boiler Location
The boiler is not suitable for external installation. The position selected must be within the buildingunless
protected bya suitable enclosure. There must be adequate space for installation, servicingand operation of
the boiler as well as adequate air circulation.

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If the boiler is to be placed in acupboard this cupboard should not be used as astoragecupboard. Ventilation
should be provided as detailed below.
Ventilation
This boiler does not require a purpose provided air ventilation in the room, however it does require roomair
to circulate through the boiler to ensure the convection heat output performance is maintained.
If the boiler is installed in an enclosure or small cupboard, there must be an equivalent ventilation free area
in the enclosure or small cupboard to that of the boiler.
Upper Ventilation Free Area These should be the same or larger than in the
appliance case mm2
Lower Ventilation Free Area As above
Electrical Supply
This appliance must be earthed
The appliance is supplied with a 2 melectrical flex with integral fused plug, which requires a standard 220 -
240V ~ 50Hzsupplyvia a normal ringmain socket. If required, the plugconnection can be made via the 24
hour plugin timer supplied.
All fuses must be ASTA approved to BS 1362
In the event of an electrical fault after installation of the boiler, preliminaryelectrical systemchecks must be
carried out. i.e. earth continuity, short circuit, polarityand resistance to earth.
Central Heating Systems
This boiler is designed specificallyfor use in small, pressurised, sealed systeminstallations. The installation
must complywith BS 6798.
SafetyValve – The safetyvalve, which is pre-set at a maximumof 3 bar is an integral part of the boiler and
cannot be adjusted. Its relief outlet must be piped to a suitable outside position.
Pressure Gauge
This indicates the systemfill pressure. It will show a higher pressure when the systemis hot.
Circulating Pump
The circulatingpump is located inside the boiler case. Its performance is suitable for all systems to which
the boiler should be connected.
Expansion Vessel
The expansion vessel, which is located inside the boiler case, has a capacityof 2.0 L, with a pre-charge of
0.5 bar.
The maximumheatingsystemwater content usingthis integral expansion vessel is 24.0 L. This is with a
cold fill of 0.5 bar.
Should the systemvolume be in excess of that specified, a second expansion vessel must be connected to the
heatingsystem. BS 5449 gives further guidance for expansion vessel sizing.
Vessel Charge and Initial SystemFill Pressure Bar 0.5 1.0 1.5
For Expansion Vessel Capacity
(Multiplythe systemVolume by) 0.0833 0.109 0.156
Total systemwater capacityusingthe integral
2.0 L expansion vessel Litres 25.0 18.4 12.8

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Example: 30L systemtotal capacityrequires an expansion vessel capacityof
30 x 0.0833 = 2.5 litres with a 0.5 bar vessel charge and systemcold fill pressure.
Filling Point
The heatingsystemmust be provided with a suitable fillingmechanismto both complete the initial fill and
top up the systemif necessary. The fillingdevice must complywith Water Supply(water fittings)
Regulations and the local Water AuthorityRegulations. Refer to BS 5376: for guidance.
Typical System Diagrams
Thermostatic radiator valves should NOT be used with this boiler.
The boiler is designed for small sealed heatingsystems usuallyoperatingwithin a single room.
4. Installing The Appliance
Unpacking The Appliance
Unpackthe appliance and checkthe contents with the list below.
1 Boiler
4 Screws
4 Rawlplugs
1Installation & ServicingInstructions includingGuarantee
1 Plugin 24 hour timer

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Location
Before installingthe boiler checkthat the chosen location is suitable, ensuringadequate clearance is
available for both installation and servicing. The appliance must be mounted on a flat vertical wall.
Prepare the Appliance
Remove the front panel byunscrewingthe two screws at the bottomof the case. Rotatingthe case forwards
at the bottom10 mm and liftingit off in an upward direction.
Preparing the Wall
Usingthe diagrams earlier in these instructions, or the appliance as a template, markfour positions on the
wall were the fixingscrews will fit. Ensure the appropriate clearances for the boiler have been established.
The wall should be drilled with a 4 mm masonrydrill after ensuringthere are no electric cables within the
hidden fabric of the building.
Insert the rawl plugs followed bythe two upper screws. These should be inserted to within 2 mm of the wall.
Marka suitable position for the pressure relief discharge pipe ensuringa suitable position outside. Drill
through the wall with a 16 mm minimumdiameter masonrydrill to accept a 15 mm copper pipe. This is for
the pressure relief discharge.
Mounting the Boiler
Locate the boiler onto the two screws. Fit the two lower screws and tighten all 4 screws to secure the
appliance in position.
Water Connections
Refer to Section 3 for detailed information.
The boiler flow and return service valves should be connected directlyto the heatingsystem. The flow is on
the right hand side, the return beingon the left hand side. Each is marked accordingly.
A suitable method of fillingthe systemshould be fitted to the system. The method used for fillingthe system
must complywith the local Water AuthorityRegulations. A drain cockshould be fitted to the lowest point of
the system. The pressure relief outlet should be connected to a suitable outside position.
Electrical Connections
The appliance is supplied with a 2 mlength of 3-cone cable with a normal plugpre-wired. This can be
plugged directlyinto a suitable 220 - 240V ~ 50 Hz, ringmain 13 A wall socket.
If required, the plugin timer supplied can be added to control the appliance on / off periods.
5. Commissioning & Testing
The front cover to the boiler should now be replaced.
Fill and flush the systemwith all the valves open. Refill the systemand checkfor soundness. Vent the
system, includingeach radiator and the boiler. At this point the heatingsystemshould have been thoroughly
flushed with cold water, filled and vented to a pressure of 0.5 bar cold and be free fromleaks.
Note: With the appliance switched on and the thermostat set at the lowest (off) position the pump will
circulate water around the systembut the halogen bulbs are prevented fromoperating.
Plugin the boiler and switch on the electrical supply. Switch the appliance switch on and turn the control
knob to high. The pump should start to circulate water around the systemand the Halogen bulbs will start to
heat the water. A thermostat within the boiler will control the temperature of the water as set on the control
knob.

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Allow the heatingsystemto reach operating temperature and then examine for water leaks.
Turn off the boiler and drain whilst still hot.
Refill and vent the heatingsystemensuringall air is cleared fromthe systemand the cold fill pressure is set
at the design pressure.
The pressure gauge should be at 0.5 bar.
Set the indicator on the pressure gauge to co-inside with this initial cold fill pressure.
Allow the appliance to operate to its maximumtemperature to ensure correct operation of the boiler controls.
Checkthe maximumpressure of the systemwhen at this maximumtemperature and ensure no water has
been expelled fromthe pressure relief outlet.
Hand the instructions to the user for retention and instruct in the efficient and safe operation of the boiler.
Advise the user of the precautions necessaryto prevent damage to the heatingsystemand buildingin the
event of the systemremaininginoperative duringfrost conditions.
6. Operation and User notes
Duringnormal operation of the boiler and its heatingsystemthere should onlybe a need to switch the boiler
on and off as required. The 24 hour plugin timer provided can be used to provide this function.
The operation pressure will rise and fall in line with temperature increase and decrease of the heatingsystem
water temperature. This is normal operation. However should the pressure fall below that set on the pressure
gauge (0.5 bar) this is an indication there is either a leakin the heatingsystemor the expansion vessel is too
small for the heatingsystemvolume. You should consult your Service Engineer in order to correct the fault.
To shut off the boiler for short periods turn the thermostat switch to the off position. This will leave the
pump circulatingwater around the heatingsystem.
To shut off the boiler for longer periods turn the boiler switch to the off position, this will switch the pump
and the heatingbulbs off, allowingthe heatingsystemto cool to ambient temperature.
To shut off the boiler for extended periods whilst the house maybe unoccupied when there is a possibilityof
frost turn the boiler switch to the off position and electricallyisolate the boiler. Drain the heatingsystem
down. If a suitable anti freeze has been introduced into the heatingsystemit maynot be necessaryto drain
down.
WARNING:- Do not switch on the appliance if there is a possibilitythat the water in the heater is frozen.
Your installer will advise you about drainingthe system
7. Routine Servicing and Replacement of Parts
As this is an electrical boiler there is no need for regular preventative maintenance, however at periodic
intervals each of the bulbs should be checked for operation.
Before commencinganyservice operation, ISOLATE the mains electrical supplyto the boiler byswitching
off at the mains plugand removingthe plugfromthe socket. Remove the boiler front cover byfirst
unscrewingthe two screws at the base of the boiler and rotatingand liftingthe cover off the boiler.
After completinganyservice operation, refit the boiler cover and re commission the boiler as detailed in
Section 5.
Should the supplycord become damaged it must be replaced bya special cord assemblyavailable fromthe
manufacturer or its service agent.

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Replacing a bulb
• Remove the lid fromthe bulb box, remove the faultybulb and replace with a new bulb. Do not touch the
bulb with bare fingers, as this will reduce the life of the bulb. Use clean tissue paper or similar to hold
the bulb.
• Checkthat the bulb is seated correctlyon the contacts.
• Replace the top of the bulb box, locatingit onto the pins provided.
Replacing a bulb temperature limit thermostat
• The bulb temperature limit thermostat can onlybe replaced as a complete lamp holder unit as follows.
• Disconnect the power supplyfromthe lamp holder at one side of the holder and the limit thermostat and
withdraw the lamp holder fromthe lamp box.
• Replace with a new lamp holder assembly, locatingit onto the pins provided.
• Ensure the wires are connected correctly.
Replacing the control thermostat
• Pull off the electrical connections fromthe thermostat body, notingthe termination positions on the
body.
• Pull off the control knob fromthe spindle.
• Remove the two fixingscrews and lower the thermostat.
• Withdraw the thermostat phial fromthe pocket located on the side of the boiler flow pipe.
• Withdraw the thermostat and capillaryfromthe boiler.
• Replace in reverse order takingcare to route the capillaryawayfromanyelectrical connections and that
the electrical connections to the thermostat bodyare arranged as the original.
Replacing the overheat thermostat
• Pull off the electrical connectors fromthe thermostat body.
• Remove the locknut securingthe thermostat bodyto the lower casingpanel and lift the thermostat from
its mountingposition.
• Remove the phial fromthe pocket on the side of the boiler flow pipe and withdraw the thermostat and
capillaryfromthe boiler.
• Replace in reverse order takingcare to route the capillaryawayfromanyelectrical connections.
Replacing the circulating pump
• Isolate the pump usingthe valves at each side of the pump or the appliance isolation valves on the flow
and return connections to the boiler.
• Disconnect the plugand socket connection in the pump electrical supply.
• Remove the pump fromthe pipe work.
• Refit a replacement pump in reverse order ensuringit is pumpingin the correct direction and the
electrical wiringis correct.
• Open the isolation valves, ensure the systemcold fill pressure is correct, there are no water leaksand the
systemis correctlyvented of all air.

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Replacing the expansion vessel
• Isolate the boiler usingthe appliance isolation valves on the flow and return connections to the boiler.
• Remove the expansion vessel fromthe pipe work.
• Refit a replacement expansion vessel in reverse order usinga recognised method of sealingthe threaded
joint.
• Open the isolation valves, ensure the systemcold fill pressure is correct, there are no water leaksand the
systemis correctlyvented of all air.
Replacing the pressure reliefvalve
• Isolate the boiler usingthe appliance isolation valves on the flow and return connections to the boiler.
• Disconnect the pressure gauge tappingfromthe top of the relief valve.
• Release the discharge pipe fromthe valve.
• Remove the pressure relief valve fromthe pipe work.
• Refit a replacement pressure relief valve in reverse order usinga recognised method of sealingthe
threaded joint.
• Open the isolation valves, ensure the systemcold fill pressure is correct, there are no water leaksand the
systemis correctlyvented of all air.
Replacing the pressure gauge
• Isolate the boiler usingthe appliance isolation valves on the flow and return connections to the boiler.
• Remove the pressure gauge fromthe pipe workas described above.
• Depress the locatingtabs on the gauge bodyand push the bodythrough the mountingbracket.
• Refit a replacement pressure gauge in reverse order ensuringthe seal at the pressure relief valve is
sound.
• Open the isolation valves, ensure the systemcold fill pressure is correct, there are no water leaksand the
systemis correctlyvented of all air.
8. Fault Diagnosis
If a fault develops, or is suspected, call your Service Engineer as soon as possible
Go through the followingchecklist before you make contact
• Is the electricity supplyon?
• Are the lamps lit?
• Has the limit thermostat tripped?
• Are the boiler isolation valves open?
• Are the pump isolation valves open?
• Is the boiler switch on (givinga red “Power ON” light)?
• Is the heatingsystemwater pressure correct?
• Is the boiler temperature control set correctly?
• Is the time clock(if fitted) callingfor central heating?
• Is the roomthermostat (if fitted) set high enough?
• Are the radiator valves open?

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Fault Finding Chart
If the radiators do not get hot or do not reach the boiler flow operating temperature follow the guide below to
establish the possible cause.