heatline capriz 25, capriz 28 User guide

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Page 1

capriz 25

capriz 28

Condensing Wall Mounted Combination Boiler

Installation, Servicing & User Instructions

Page 2

atural Gas / LPG

HeatlineTM Capriz 25 / Capriz 28 Condensing Combination Boilers

British Gas Service Listing

Capriz 25 Condensing Combination Boiler G.C. No 47 - 157 - 12 Capriz 28 Condensing Combination Boiler G.C. No 47 - 157 - 13

The Heatline

range of heating boilers is manufactured from hight quality materials, enabling reliability and optimum performance.

Heatline

is committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings.

Type test for purpose of EEC Regulations certified by:

Notified Body IMQ

1BP2727 CE Directive 90/396/EEC

1BP2728DR CE Directive 92/42/EEC

CE Directive 73/23/EEC CE Directive 89/396 EEC (modified from 93/68)

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.

‘Benchmark’ Log Book

As part of the industry - wide initiative the CAPRIZ25 / CAPRIZ 28boilers come complete with an Installation,Commissioning and Service Record Log Book. Please read the Log book carefully and in accordance with current regulations 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 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. Capriz 25.

Page 3

Contents

egaP no i t c eS

2 eca f e rP

3 xoB n o s n giS e h T

3 r e l i oB no s n g i S ehT

4 sno i talu g e R n oi tal latsnI .1

5 ataD lac inhceT . 2

7 sc i t s i ret carahC re l i oB . 3

7 no i t a r e pO . 4

8 no i t a l l a t sn I l a r eneG . 5

01 g nitiS ec n ailpp A .6

01 no i t acoL l an imr eT eu l F . 7

. 71

. 81

. 91

. 02

Appendices

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gn i c i v r eS en i t uoR

no i s r evnoC epyT saG

21 o f n I eu l F l a r eneG . 8

31 sno i t c ennoC l ac i r t ce l E . 9

51 no i tal latsnI rel ioB .01

61 y l ppuS s aG . 1 1

71 metsyS eht gni l l iF .21

71 sno i t cnuF l enaP l o r t noC . 31

81 gninoi ssimm oC .41

81 stnemtsujdA draobnO .51

91 s e c i v eD y t e f aS . 6 1

t ne m eca l peR t nenop m oC

33 t s iL st raP erapS

User Instructions 34

Benchmark Log Book 38- 39

Page 4

Preface Warnings

The Heatline™ gas fired, condensing combination boiler meets the requirements of all appropriate 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) Electromagnetic Compatibility Directive 89/396 EEC

(modified from 93/68)

Heatline™ 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.

anual 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

Heatline™ accepts no responsibility for the unsatisfactory performance of the appliance or flue arising from the failure to comply with the installation and user instructions. Incorrect installation could invalidate your guarantee and may lead to prosecution.

If the boiler is sold to another customer, all documents must be transferred from existing customer to the new one and th Heatline™ in order

The boiler must be installed in accordance with these instructions and all the regulations currently in force. Read these instructions carefully before installing or using the appliance.

SHOULD YOU SMELL GAS: Turn the gas valve off at the Gas Meter or Gas Cylinder, ventilate the room by opening windows and doors (EXTINGUISH ANY NAKED FLAMES, DO NOT OPERATE ANY ELECTRICAL SWITCHES) and call Transco on 0800 111 999 or if you use LPG call your gas supplier.

e appliance must be re-registered with

to maintain the guarantee.

Speed 2 is the factory default setting

This setting should be suitable for

IMPORTANT NOTE

for the Pump.

most of your applications.

NOTE: Cables on the cap ; 1- Ionisation cable 2 - Earth cable 3 -

Condensate hose

Page 5

The Signs on B

The sign of approval the Capriz 25 & Capriz 28 boilers have been certified by IMQ Italy.

This is a fragile piece of equipment: Do not drop.

Avoid getting the box 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.

OTE: Take care as there may be residual voltage within

N some components

The Signs on Boiler

LOW VOLTAGE ROOM THERMOSTAT – This picture shows the terminal located at the left corner on the rear of the drop down terminals are not intended to drive the thermostat but simply connect across the switch that opens and closes thermostat operates. NOTE – This is a voltage free connection and no power these terminals. For mains powered thermostats

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.

Potentiometer Cover: Removal of the cover, which is found on the back of the control box, gives access to the adjustment potentiometers. N make any adjustments without reading the instructions carefully.

control box. Note these

(AC or DC)

see section 9.5.

block, which is

as the

should be applied to

OTE: Do not

1 2

Handling

This appliance is heavy, truck if possible and obtain assistance if required.

To remove the appliance :

1. Carefully slit or remove the scaling tape being careful not to scratch the appliance door.

2. fully open the carton lid and remove any instructions & components.

3. Read the instructions carefully before installation of the appliance.

4. Roll the carton onto its open face.

5. Lift the carton free of the inner packaging.

6. Remove the mounting bracket and valve package.

7. Stand the boiler on its base within the styrene block and remove the top packaging piece.

8. If you wish to remove the stryene base lie the appliance on its back to do so.

Page 6

1. Installation Regulations

Correctly may invalidate your guarantee and may

.1.

lead a dangerous situation.

Your CORGI registered engineer should carry a

1.2. CORGI 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 CORGI on 0800 915

0480.

3. This appliance must be installed in accordance

1. with the Gas Safety (Installation 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.

4. On installation the following British Standards

1. must also be considered:

For further information or advice (UK) contact HeatlineTM: Service please call: 0870 609 2091 Spares please call: 0870 777 8402 Technical assistance please call

Or by E mail on our Web Site at www.heatline.co.uk

: 0870 777 8318

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 (R1¼). Reference should also be made to British Gas Guidance Notes for Installation of Domestic Gas Fired Boilers.

5. Due to the manufacturer’s continuous

1. 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.

6. To ensure reliability and continued performance

1. 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.

Page 7

2. Technical Data

Heat Input (max)

Heat Output (max)

Heat Input (min)

Heat Output (min)

Useful efficiency at

100% load

Useful efficiency at 30%

Burner injector

Burner Pressure

(Natural Gas)

Burner Pressure

(Propane)

load

mm.

mbar

Capriz 25 (25 kW)

25.7

24.7

10.2

102.4

1.20 NG

0.75 LPG

Max 12.5

Min 2.5

Max 28.5 /36.5

Min 6 / 7.8

Capriz 28 (28 kW)

28.5

27.6

10.2

96.8

103.3

1.15 NG

0.75 LPG

Max 14

Min 2.3

Max 28.2 /36.2

Min 4.5 / 6

Maximum heating

temperature

Max. domestic hot water

temperature

ºC 85

ºC 64

PMS

Operating pressure (Bar)

Nominal

(Min)

Domestic water supply

pressure (Bar)

PMS

(Min) 8 (0.25) 8 (0.25)

Expansion Vessel Capacity Litres 7

Expansion Vessel

Pre-charge Pressure

Domestic Water Supply Output

at 30º C

∆ T

Air Intake Pipe Diameter

bar 1

Lt/min 11

mm 100/125 100/125

Capriz 25 (25 kW)

1.5

(0.8)

Capriz 28 (28 kW)

1.5

(0.8)

13.12

Power Supply

Max. power

consumption

Level of Protection

Case Dimensions

220~240V-50Hz

Input

Watt

220

IPX 4 D

330d x 405w x 720h

220~240V-50Hz

220

IPX 4 D

330d x 430w x 720h

Flue Pipe Diameter

Max. Flue Length C12 – C32

Max. Flue Length

C42 – C52

Equivalent Length 450 Bend

Equivalent Length 900 Bend

Net weight

Gross Weight

mm 60/80

3.0

(60/100)

7.0

(80/125)

(80/80)

m 1.0

m 1.5

kg 37

kg 40

60/80

3.0

(60/100)

7.0

(80/125)

(80/80)

1.0

1.5

Page 8

Figure 1

13 14 15

DCBA

A - Heating Flow (22mm) B - D.H.W. Outlet (15mm) C - Gas Inlet (22mm) D -Cold Water Inlet (15mm) E - Heating Return (22mm)

Key

1 - D.H.W. Sensor 2 - Diverter Valve Motor

(Three Way Valve Motor) 3 - Diverter Valve (Three Way Valve) 4 - Condensate Trap 5 - Limit Safety Thermostat 6 - Expansion Vessel (At rear of the boiler) 7 - Burner 8 - Flame Sensor (Ionisation) Electrode 9 - C.H. Sensor (Heating Sensor)

10 - Combustion Chamber 11 - Primary Heat Exchanger 12 - Fan Hood 13 - Fan

14 - Air Pressure Switch 15 - Condensing Unit (Turbo heat exchanger) 16 - Overheat Safety Thermostat 17 - Ignition Electrode 18 - Heating Circuit– Pressure Safety Valve 19 - Secondary Heat Exchanger (Plate H.E.) 20 - Automatic Air Vent 21 - Water Pressure Switch/Sensor 22 - Pump 23 - Gas Valve 24 - D.H.W. Flow Sensor 25 - Filter Valve (Below the pump)

Page 9

3. Boiler Characteristics

The Capriz 25 / 28 is a fan flued, wall- mounted

3 condensing type combination boiler that supplies both

central heating and mains fed domestic hot water.Being room sealed the boiler may be installed in any room or internal compartment without the need for purpose made combustion 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 as figure 1. A functional diagram of the boiler’s principal components is given as

VENTILATION section in user manual

Range rated from 25kW and 28kW the Capriz 25/ Capriz 28 heat output can be focused to match the designed heating systems adjustments.

.3 An electronic control unit, consisting of a PCB,

3 which includes ignition module, provides direct burner ignition and flame supervision along with continuous modulation of the burner’s gas supply.

.4 An interface unit, which includes boiler adjustment

3 potentiometers and fault display provides easy service ability to the boiler.

.5 Heat transfer to the boiler’s primary hydraulic

3 circuit is obtained via a primary, gas to water heat exchanger contained within a hermetically sealed combustion chamber. A 230 volt, duel speed fan expels the products of combustion from the combustion chamber to outside air via an associated flue system. The fan is activated at the beginning of each ignition cycle and its operation monitored by means of negative and positive sensing points connected to an air pressure switch.

.6 A secondary heat exchanger allows the

3 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 64°C.

.7 An integral pump located in the boilers main

3 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 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.

.8 Room temperature can be controlled by the use of an

3 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

.9 The boiler boiler’s control panel incorporates an LED display, which indicates the state of operation and fault defect codes.

Note: Domestic hot water demand draws preference

4. Operation

Using the operating switch the boiler can be set to

operate either on domestic hot water only or domestic hot water and heating.

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 figure 21.

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 dire the heating system. Schematic diagrams showing the flow within the boiler’s central heating hydraulic circuit figure 2a and D.H.W. hydraulic circuit figure 2b are given.

Figure 2a

CENTRAL HEATING HYDRAULIC CIRCUIT

ctly to

Page 10

5. General Installation

4.3 DOMESTIC HOT WATER MODE:

On opening a hot water outlet 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 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.

Figure 2b

DOMESTIC HOT WATER HYDRAULIC CIRCUIT

.4 DOMESTIC HOT WATER AND CENTRAL HEATING

ODE:

When heating demand is requested, power is on and the thermostats are calling for heat, 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, e.g. the thermostat reaches temperature, 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 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 boiler’s dipswitches are set. See section 15.4 for details.

during the heating period

.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 with the Benchmark Logbook that has been completed.

• The user should be instructed to keep the

instructions in a safe place for servicing and future reference.

• It is important to keep the boiler clear of dust during

the installation. In particular, do not allow debris to enter the top of the boiler where the flue connection is made. This may cause the fan 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 wate retained within the boiler when packed. Please ensure that you spin the pump rotor manually before firing the boiler.

• It is important that the boiler must be used in

conjunction with a Hydroline approved flue and all flue connections are correctly sealed.

• Remember to flush out the system, both cold and

hot, in order to remove the debris from the system. 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 systems.

his boilers central heating output has been set to a

• T

id range position. However you may choose to

djust this using potentiometer P2 to meet the

equirement of the system.

• Remember to release the small cap on top of the

auto air purge device on the pump, 1 turn, before filling. This will ensure that air is removed as the system fills.

o not use the pressure relief valve as a means of

• D

flushing the system, please use the valve below the pump. Discharging water from the pressure relief valve may allow water to seep after you have left the job, causing the boiler to lose pressure and debris to collect on the seating.

• 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 an outlet

• it is likely that the cold water inlet valve filter has

become blocked, whilst blockage of the filter on central heating return valve, the overheat thermostat

outlet to get blocked

r is

Page 11

will cause the heater to lock out at as the water flow is reduced.

• If you are able to obtain hot water but not heating it is also advisable to check that the room thermostat and any external time clock that may be fitted 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 figure 21

• When commissioning the boiler check the inlet pressure is at 20mbar and burner pressure against the Technical data, section 2.

• Note an anti-cycle delay time can be set up to a maximum of 255 seconds by adjusting potentio

meter 2 as described in section 15.5

If you experience any problems please refer to the

•

installation and commissioning guidelines within the boiler instruction manual. If necessary, please contact Heatline

Service Enquiries, in the UK, for further

advice and assistance on 0870 777 8318

OTE – FOR INSTALLERS:

EMEMBER IT IS A REQUIREMENT TO COMPLETE

HE BENCHMARK CODE OF PRACTICE LOGBOOK

EFORE LEAVING THE INSTALLATION.

.7 On installation it is important to ensure that the heat

5 exchanger is not a natural collecting point for air and where possible, the system pipe work should have a gradient to ensure any excess air is carried naturally to other purpose made, air release points.

5.8 In high water volume systems or under floor heating systems where prolonged operation of the boiler is expected at temperatures below 60°C, a by-pass must be installed on the boiler outlet in order to prevent condensation forming inside the combustion chamber. Failure to comply with this requirement will invalidate the manufacturer’s guarantee.

5.9 The pressure relief discharge must be directed away from any electrical equipment or where it could cause a hazardous situation.

5.10 To enable adequate drainage of the system drain cocks compliant with BS2879 must be fitted at the lowest points in the system pipe-work.

5.11 To obtain the best hot water performance from your boiler it is suggested that the cold water supply to the boiler is the first draw off from the incoming mains supply. Note that the boiler will not operate unless there is a minimum pressure of 0.25bar with a flow rate

.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 85

.3 The boiler’s integral expansion vessel is pre-

5 charged to a pressure of 0.5bar and will accommodate a system volume of 125 litres. at an average water temperature of 75°C and ma ximum system pressure of 3 bar. If the system volume is more than 125 litres. an additional expansion vessel must be fitted to suit the size of the system. A typical installation of an additional pressure vessel is shown in figure 3

.4 The heating circuit should be designed and

5 balanced to give a 20

C temperature rise across the

boiler flow and return.

.5 When fitting a new boiler to an existing system the

5 system must be thoroughly flushed in accordance with the recommendations of BS7593 prior to installation.

.6 It is recommended that the system should be

5 protected by an anticorrosion inhibitor. Failure to comply with this requirement may invalidate your guarantee.

of 2.5l/min. Where inlet pressures exceed 8bar, a pressure regulator must be fitted to the cold water supply.

5.12 Where cold water mains are fitted with a water meter, check valve(s) or loose jumper stopcock, a domestic hot water mini-expansion vessel may need to be fitted.

5.13 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. Failure to comply may invalidate your guarantee. The local water undertaking will advise on water hardness.

5.14 To obtain the best hot water performance from your boiler it is suggested that supplies to outlets are run in 15mm copper, as short as possible and where practical, be insulated to reduce heat loss.

.15 The boiler incorporates a frost protection

5 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.

Page 12

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. Appliance Sitin

.1 If the boiler is to be installed in any room or

6 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 requirements of British Standard 7267 (confirm) (I.E.E. Wiring Regulations) and Building Regulations.

If the boiler is installed in a compartment there

6 must be purpose made ventilation for cooling purposes

.3 The boiler is not suitable for external installation

6 unless protected by a purpose made building such as a boiler house.

.4 The following clearances are recommended for

6 installation purposes; 200mm above, 300mm below and 50mm at each side. 600mm is required at the front but this may be provided by opening a cupboard door.

.5 The boiler must be sited at least 1m away from

6 flammable materials and heat sensitive walls must be protected by an appropriate insulating material.

.6 The wall on which the boiler is mounted must be

6 sufficiently strong enough to support the weight of the boiler.

.7 A condensate drain pipe must be fitted to allow

6 discharge of condensate to a drain or soak way. Where possible condensate should be discharged into the household internal drainage system. If this is not practical, discharge can be made into an external drain. If neither of the above options are possible then condensate must be discharged into a purpose designed soak way.

To avoid excessive condensation occurring

within the boiler flue the boiler should wherever possible, be possible flue run is utilised.

.8 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 20 mm 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 noncombustible sleeve or fire stop which has a

minimum clearance of 25 mm from the flue pipe. 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.

.9 When the boiler is intended for use with LPG it must

6 not be installed in a room or internal space below ground level.

7. Flue Terminal Location

.1 The flue terminal must be sited with minimum

7 clearances as specified in becomes problematic or causes a nuisance a plume management kit is available from your stockist.

.2 Current regulations and standards require a terminal

7 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.

.3 Where the flue terminates within 1m of a plastic or

7 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.

sited to ensure the shortest

Figure 4

. Note if pluming

It is recommended that any external condensate pipe is insulated and increased to 32mm diameter in order to prevent the condensate from freezing.

Page 13

s e v a e w o l e B E

Figure 4

Internal Corner External Corner

H From an internal or external corner or to a boundary alongside the

Double Corners

300

terminal (See Note 2)

J From a surface or a boundary facing the terminal (See Note 2) 600

P 006lanimre t foor rehtona ro foor eht no erutcur ts a m orF Q 003 l law tneca jda na ot lanimret eul f lac i t rev a m orF R From a vertical ue terminal to an adjacent wall which includes an

1000

opening window (See Note 3)

Notes: 1. An opening here means an opening element, such as an openable window, or a

xed opening such as a air vent. However, in addition, the outlet should not be nearer than 150mm to an opening into the building fabric formed for the purpose of accommodating a built in element, such as a window frame.

2. Boundary as dened in the Building Regulations (England & Wales) or the Building Standards (Scotland) Regulations.

3. Where the wall adjacent to a vertical ue terminal includes an opening window, the clearance between the terminal and any part of the opening window must

not be less than 1000 mm.

) mm ( e c n a r a e l C ) ma r g a i d e e S ( n o i t p i r c s e D no i t acoL

003 ) 1 e t oN e eS ( gn i nepo na wo l eB A 003 gn i nepo na e vobA B 003 gn i nepo na o t y l l a t noz i r oH C 57 sepip niard ro sepip l ios , sret tug woleB D 002 002 foor t rop rac ro ynoc lab wo le B F 051 epip l ios ro epip niard lac i t rev a m orF G

003 l eve l y noc l ab r o f oo r , dnuo r g evobA I

0021 l an imr e t eh t gnica f l an imr e t a mo rF K 0021 gnidl iub eht otni t rop rac eht ni gninepo na m orF L 0051 l law e m as eht no lanimret a m or f yl lac i t reV M 003 l law e m as eht no lanimret a mor f yl latnoz i ro H N

Page 14

7.4 The flue should not be sited where the condensate plume may give rise to a nuisance factor under certain weather conditions.

OTE: If you have difficulty siting the flue in an

ppropriate location your supplier will be happy to

upply an “anti-plume management kit”, which

ischarges the flue products at a higher level.

8. General Flue Info

The boiler utilises a concentric flue arrangement

8 which consists of a 60mm-diameter inner flue and 100mm-diameter outer air inlet duct.

.2.

Various types of flues can be purchased with the

8 boiler but the standard 700+/-5mm flue kit (figure 5) is supplied with the boiler, which can be routed to the rear, left or right of the appliance by means of a 90° bend. The bend is connected to the boiler using the screws provided and sealed with the gasket.

Figure 6

12-C32 C42-C52

60/100 80/125 80/80

24 kW

8 kW

Ø80 Ø80 Ø80

Ø80 Ø82 Ø82

8.6 The air diaphragm should be removed if the length of the flue pipe installation is below:

12-C32 C42-C52

60/100 80/125 80/80

24 kW

8 kW

>1 m >2 m

Figure 5

.3. The 60/100 mm flue pipes may be extended up to a

8 maximum of 2.5 m using additional spare components available from your supplier. This length can be increased to 7 m using the 80/125 mm flue kit.

.4. A vertical 60/100 mm flue kit is also available from

8 your supplier up to a maximum length of 3m. The terminal is suitable for a flat or pitched roof. This length can be increased to 7 m using the 80/125mm flue kit.

.5. If horizontal and vertical flue lengths are less than

8 1 m, the restrictor (air diaphragm) – figure 6 must be fitted on the combination boiler.

Please find the information sheet for the installation of restrictor given with documentation group. The diameter of air diaphragm changes according to the installation types.

8.7. The connection of vertical flue system is similar to the Horizontal flue connection. The flue is connected to the boiler via connection screws whilst the sections are held together with the clamps provided.

.8. To avoid condensate dripping from the terminal the

8 flue should be installed with an upward gradient (from the boiler) of 3

built in.

.9. The installation types for room sealed versions are

. Note that some new flue may have the

C12-C32-C42-C52

.10. The boiler can be used with separate ducts such as

8 80/80 to fit required type of installations.

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 HIS PRODUCT.FAILURE TO COMPLY WITH THIS REQUIREMENT WILL INVALIDATE YOUR GUARANTEE AND COULD LEAD TO A DANGEROUS SITUATION.

Page 15

.3 Other than for a bathroom installation the point of

FOR CONDENSING BOILERS IT IS RECOMMENDED THAT AN ANTI PLUME KIT IS FITTED IF THE TERMINAL IS LESS THAN 2.5 m FROM A BOUNDARY. IN ADDITION THERE IS 45

ELBOW AVAILABLE TO

DEFLECT THE PLUME AWAY FROM WINDOWS ETC.

9. Electrical Connections

.1 The boiler is supplied factory wired complete with

1.5 m of mains fly lead. All electrical connections to the mains supply must be made in full accordance with the current I.E.E. regulations.

.2 The boiler must be connected to an effective earth

9 system. Using the cable supplied the boiler may be connected via a 3 amp fused three pin plug to an unswitched shuttered socket outlet. However if the boiler is installed in a room containing a bath or shower regulations dictate that disconnection must be incorporated in the fixed wiring with a switch provided for disconnection from the mains supply having a contact separation of at least 3 mm on all poles and fused at 3 amp.

9 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.

Warning: On no account must any external voltage be a

pplied to any of the terminals on the heating control

onnection plug. Figure 7

.4 The low voltage room thermostat terminal block is

located to behind of left side of the plastic cover

(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 please refer to

figure 8.

9.5 Mains powered thermostats must be connected directly to the mains circuit board as indicated in

Cut the existing link and connect the wires into the

Figure

thermostat circuit.

.6 Ensure that the polarity of the mains connection is correct as reversed polarity may cause the appliance to malfunction.

.7 While the boiler's main pcb, pump, three-way valve and gas valve are supplied at 230V AC., all other

24V LOW VOLTAGE ROOM THERMOSTAT TERMINAL BLOCK

components and associated circuits are supplied at low voltage.

Figure 7

.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

FITTED BRIDGE

BRIDGE PLUG

and short circuit are carried out prior to making the final connection. A diagram of the boiler's electrical circuit is given as

figure 9.

9.9 Fuse Ratings

Circuit Board F1 – 2 amp fast blow F2 – 2 amp fast blow

PRINTED CIRCUIT BOARD

Important Note

Connection to the mains electrical supply must be maintained at all times in order to provide domestic hot water, frost protection and pump over-run facility. Ensure that the boilers electrical supply is not interrupted by any external controls.

Figure 8

Page 16

HALL

EFFECT SENSOR

THERMOSTAT

WATER FLOW SENSOR

LIMIT

SAFETY

DOMESTIC

HOT WATER

SENSOR

CENTRAL HEATING

SENSOR

THERMOSTAT CONNECTION

(high voltage)

FAN

230V ROOM

GAS CONTROL

w w

VALV E

g/y

THREE WAY

VALV E

AIR PRESSURE

SWITCH

WATER PRESSURE SENSOR

FLAME (IONISATION) ELECTRODE

OVERHEAT

THERMOSTAT

FUSES (2A)

PUMP

IGNITION

ELECTRODES

g/y CHASSIS

EARTH

g/y

24V TIME

CLOCK

(low voltage)

PRINTED

CIRCUIT

BOARD

w w

g/y

24V ROOM THERMOSTAT CONNECTION

(low voltage)

br BROWN b BLUE g/y GREEN/YELLOW

5 4 3 2 1

USER

INTERFACE

g GREY gn GREEN bk BLACK m MAUVE r RED w WHITE

KEY

LEN

230V~50Hz PERMANENT

MAINS SUPPLY

FUSED AT 3A

FUSE RATINGS: F1: 2 A F2: 2 A

Figure 9

Page 17

10. Boiler Installation

10.1 Prior to installing the boiler check the contents of the carton: Appliance, Valves (Fixing Jig Optional), Wall Hanging Bracket, Mounting Template Service, Installation and User Manual, Guarantee Card and Benchmark Log Book. The boiler dimensions are given in Figure 10.

0.2 Ensure that the boiler is suitable for the gas supply by checking the data plate, which is situated on the inside of the control panel door, and that the system and chosen boiler position is in accordance to Sections 5, 6 and 7 of these instructions.

0.3 Position the supplied template on the wall,

1 ensuring it is level both vertically and horizontally

(figure 11

). Mark the boiler fixing jig (if required), 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 vertical

figure 12)

line. (

= =

033

Dimension

Capriz 25 Capriz 28 A 405 430 B 169 C 60/100

Distance to centre line 169 mm

169

60/100

Figure 12

10.4 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).

0.5 Using a 8·5mm drill bit, drill the holes for fixing jig

1 (optional) and hanging bracket. Locate and secure the supplied wall mounting bracket in position (

figure 13

130 130

CONDENSATE

CONNECTION

CENTRAL HEATING

DOMESTIC WATER

Figure 10.

BOILER

Bracket Fixing Slots

Figure 11.

Figure 13

Boiler Mounting Tabs

(NON-CONDENSING)

0.6 Mount the boiler onto the fixing bracket via the

SDV

outlet

(CONDENSING)

boiler mounting slots, (

0.7 Connect isolation valves assembled to the boiler

figure 13

ensuring the washers are fitted correctly.

8686

151151

0.8 On installing the flue, determine the required

1 length of the o

figure 15

(

uter air duct by measuring the distance 'L'

) from the face of the external wall to the back of boiler's elbow connecting collar. The measurement for the i

nner flue duct will be 'L' + 20mm

Page 18

0.9 On installing the flue, determine the required

1 length of the o distance 'L' (

uter air duct by measuring the

Figure 14

) from the face of the external wall to the back of boiler's elbow connecting collar. The measurement for the i

lue duct will be 'L' + 20mm

0.1

0 Measuring from the back of the terminal

nner

connection, mark distance 'L' onto the outer air duct. (

L+20 mm

figure 14

)

‘

soak away. Note if a soak way is used the drain must terminate at least 500mm from the external wall.

0.17 Extract the bottom part of condensate trap, by

1 turning anti-clockwise and fill it with approximately 50 cc water re-connecting it to the boiler.

(Figure 16).

Figure 16

Figure 14

Waste

0.11 Cuttheouter air duct only to the required length

ure 1

‘

External

wall face

ensuring that the cut is square and free from burrs.

0.12 Measuring from the back of the terminal

1 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.

0.13 Pass the flue assembly through the wall and

1 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.

CONDENSATE TRAP

CONDENSATE OUTLET PIPE

0.18 Connect the condensate drainage pipe to the

1 drainage system.

(Figure 16)

Note due to the acidic nature of the condensate the drainage system must be made of non-corrosive material such as plastic tubing. More detailed information on condensate discharge is provided in BS 6798 (Specification for installation of gas fired hot water boilers of rated input not exceeding 70kW)

0.19 Connect the domestic hot water, cold water inlet,

1 heating system flow & return and pressure relief valve pipework to the boiler fittings, ensuring that the pipework has been correctly flushed before final connection. The electrical connections to the boiler must be in accordance to Section 9 of these instructions.

NOTE: Place the filling loop in a visible accessible p

osition and instruct the user how to pressurise the

ystem if there is a fall in pressure.

11. Gas Supply

0.14 With the flue and joints secured fit the flue trim

1 to the external wall surface using suitable mastic.

ote. Where internal access only is available, the flue

N trim must be attached to the flue assembly prior to

1.1 The gas supply pipe must be capable of supplying

1 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.

passing the assembly through the wall.

1.2 The internal diameter of the gas supply from the

0.15 For maximum flue lengths refer to the Technical

1 Data, section 2 in this manual

0.16 Condensing type boilers must be connected to

1 the drainage system. A plastic drain must be fitted to allow discharge of condensate to a drain.

1 meter to the boiler's gas inlet connection must not be less than 22mm.

1.3 The meter governor must be capable of delivering a

nominal pressure of 20mbar (for natural gas).

Condensate should, if possible, be discharged into the

1.4 On final connection of the gas supply to the boiler,

internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed

1 the complete gas installation including the gas meter, must be tested for tightness and purged.

Page 19

12. Filling the System

2.1 The boiler must not be operated without water.

2.2 On completion of the boiler installation and ensuring that all water connections are correctly made the boiler may be filled with water via the filling loop (not supplied with the boiler). Ensure that two manual feed valves and boiler isolation valves are open.

2.3 Release the cover cap of the boiler's automatic air vent situated on top of the pump.

2.4 The manual feed valves must be closed and the

filling loop disconnected once the pressure gauge, sited on the boiler’s control panel, indicates a system pressure between 1.0 and 1.5 bar.

2.5 Check that all the water connections throughout

the system are sound and bleed each of the heating system’s radiators in turn. As air is vented the system pressure may need topping back up to 1.0bar.

2.6 Air must be vented from the boiler's pump by

unscrewing the pump’s integral vent plug and allowing water to bleed for a few seconds. Take care not to allow water to splash onto any electrical components.

Release the cover cap (behind the pump) when

the filling complete

2.7 When the system is bled of any air it must be re-

1 filled until the pressure shown on the display gauge indicates a system pressure of 1.5 bar.

(Figure 17)

Figure 17

13. Control Panel Functions

Timer

D.H.W. temperature control

Function switch

3.1 Central heating and D.H.W. temperature controls:

1 The boiler's integral control unit monitors and adjusts both the boiler’s hydraulic circuit and D.H.W. water outlet temperatures by means of sensors located on the Central/heating and D.H.W. flow outlets. The sensors electrical resistance, which is dependant on temperature, determines the current passing through the control potentiometers located on the control panel. The respective potentiometer control dial allows manual setting of the maximum required temperature (reference value) being between 30º and 85ºC for C/heating and 35º and 64ºC for D.H.W. When the boiler operates in heating or D.H.W. manually set reference value. The difference of the two values operates the modulation of the gas valve adjusting the useful heat output generated and stabilising the temperature to within ±1ºC.

3.2 Re-set function: Should the boiler lock out at

1 any time, please check the gas supply and ionisation probe position, the boiler may be re-started by switching to standby “O” position ( waiting 15-30 seconds and switching back to its previous position once the fault has been eliminated.

3.3 Function switch: The three position switch

1 allows the boilers operation to be set to 'Stand-by’ (centre position), ‘Heating + D.H.W.’ (left hand position) or ‘D.H.W. only’ (right hand position)

Boiler Stand-by

Indicator

mode, the current received is compared to the

456-

Water

Temperature

bar

Figure 18

C.Heating temperature control System pressure gauge LED display

Switch 3 figure 18

)

2.8 If the pressure shown on the gauge exceeds 1.5

bar discharge the excess pressure from the system via a radiator valve or pipe connection. Do not use the safety discharge valve as the valve seat may become contaminated with debris and fail to re-seal.

30 40 50 60 70 80 90

bar

Flashing

Fault on CH

sensor

Flashing

Fault on

DHW sensor

Flashing Fault on

Outdoor sensor

bar

Pressure Switch

Flashing

Low System

Pressure

Flashing

Fault on Air

Flashing

Overheat

Themostat

Flashing

Flames or Gas

Failure

Page 20

Important Note.

7 6 5 4 3 2 1

In order to maintain the appliance’s warranty and so as to comply with the Domestic Heating Compliance Guide; when the boiler is to be installed to an existing central heating system, the system must be properly cleansed using a proprietary cleanser before the boiler is connected to the system. On all installations, after connecting the boiler to the system and initially filling with water, a proprietary inhibitor must be added to the system water to prevent corrosion.

14. Commissioning

4.6 In order to maintain the appliance warranty after

1 initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants.

4.7 Restart the boiler and again allow the central

1 heating system to reach maximum operating temperature. Check that all the water connections throughout the system are sound and bleed each of the heating systems radiators and purpose made air release points in turn.

4.8 Check the system pressure and top up if necessary.

4.9 Reset the central heating & domestic hot water temperature controls and room thermostat to the desired temperature settings.

4.1

The Capriz 25 & 28 boilers have been tested

pre-set at the factory and is dispatched with its

and on board

controls set to provide a maximum central heating and D.H.W. output. Consequently, once all the connections been filled with water

have been made and the boiler has

to the desingned system operating pressure, the boiler may be fired prior to adjusting it’s on board parameters to match the heating systems requirements.

4.2 Prior to firing, check that the electrical supply to

1 the boiler is 'On' (The green boiler ‘Stand by’ indicator will light) and the gas service cock is in the open position.

Set the boiler's central heating and domestic hot water temperature controls to maximum by turning them fully clockwise.

Set the external room thermostat (if fitted) to maximum and open the thermostatic radiator valves to maximum.

4.3 Switch the boilers function switch to the central

1 heating and domestic hot water position. The boiler's control unit will now automatically carry out preignition safety checks before igniting the burner.

4.4 During the 10 second burner ignition attempt

visually check that a

of the burner blades ignite correctly. If necessary, adjustments to the ignition rate may be made using potentiometer P4. Turning P4

lockwise increases the ignition rate and anti-

c clockwise decreases the rate. After successful ignition check the integrity of the boiler's flue for tightness and correct operation.

4.5 Check the boiler for correct domestic hot water

1 operation by opening and closing the household domestic hot water draw off taps.

Important Notice

• Failure to thoroughly power flush the heating system with the boiler disconnected or to add an anti corrosion inhibitor to the system water will invalidate the boiler's warranty.

• The condensate trap must be filled with water and plastic discharge pipe connected to drain before operating the boiler.

15. Onboard Adjustments

5.1 The boiler incorporates 4 potentiometers and a

1 bank of dip switches to allow adjustment to its pre-set parameters. These are situated on the rear of the control panel.

The potentiometers can easily be accessed by removing the cover on the rear of control panel However,to reach the dip switches, the control panel must be opened.

5.2 Setting the maximum c/heating flow temperature:

(Figure 20).

The boiler is dispatched with a maximum flow temperature factory set to 90°C. Where a lower maximum temperature is required such as in the case of under-floor heating, the factory setting can be altered between a maximum of 50°C and a minimum of 30ºC, by fitting dip switch '6' into ON position.

POTENTIOMETER ADJUSTMENT COVER

(Figure 19).

POTENTIOMETERS 4 OFF

Figure 20Figure 19

Page 21

6 5 4 3 2 1

15.3 Setting the boiler's integral pump: The boiler's integral pump is factory set to operate in both central heating and D.H.W. mode. Where an external pump is incorporated into the system design the integral pump may be disconnected in central heating mode by fitting dip switch '5' into the ON position.

5.4 Setting the 45 seconds delay: The boiler is factory

1 set to exclude the delay of 45 seconds before reignition between the closing of a hot water tap and CH start-up. This delay can be set to 45 seconds by setting dip switch ‘3’ (

Important

Gas Type Jumper, Dip Switch 1, Dip Switch 4 and Dip Switch 5 are factory set and must not be adjusted.

POTENTIOMETERS

1 2 3 4 5 6 7 8

Figure 22

) into the OFF position.

DIP SWITCHES

POTENTIOMETERS 4 OFF

DIP

Figure 21

DIP SWITCH ON POSITION

DIP SWITCH

OFF POSITION

ON DIP

1 2 3 4 5 6 7 8

ON DIP

1 2 3 4 5 6 7 8

8 DIP SWITCHES IN THE OFF POSITION

Figure 22

5.5 255 seconds delay setting: The boiler is capable of

1 up to 255 seconds ignition delay (anti cycling time) before re-ignition following burner shut down on the primary hydraulic water reaching its set temperature. This delay can be increased up to a maximum of 255 seconds by turning potentiometer P5 (

Figure 22

)

clockwise.

5.6 Pump working mode setting: The boiler is factory set to operate the pump for a period of 45sec before and after a heating cycle. This delay can be cancelled by setting dipswitch ‘2’ (

Figure 22

) to the ON position. However, this is not recommended as the boiler overheat thermostat may trip out, causing lock-out of the boiler.

15.7 Setting the Heating output: The B24 boiler is factory set to give mid range central heating output. The maximum and minimum heat output for heating and domestic hot water may be adjusted, if required, using potentiometers P2 (

Figure 22).

15.8 Gas valve ignition capacity. The graduated opening of the gas valve for ignition rate is governed by potentiometer P4 control, which is factory set. To assist in setting the boiler's modulating gas rate parameters the ignition rate of the valve can be forced from minimum to maximum rate by setting the potentiometer clockwise.

15.9 Dip switch 8 is factory set to OFF for 25 kW and set to ON for 28 kW.

5.10 The boilers integral pump is factory set to

1 speed 2 setting to give a 1000 l/hr flow on a nominal over 4 m head. The pump may be adjusted to a lower speed to match the designed central heating system

(

requirements.

H (m)

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5

16. Safety Devices

Figure 23)

QH Chart

Figure 23

6.1 A hydraulically operated primary pressure sensor

1 monitors water pressure or water shortage in the primary hydraulic circuit and will switch the boiler off if the pressure is below 0.3bar. The boiler will not operate until the circuit has been re-pressurised.

6.2 The temperature of the water flowing from the

1 primary heat exchanger is monitored by an overheat thermostat located on the outlet pipe. If the water temperature gets too hot the switch opens, cutting off the electrical supply to the gas valve and causing the boiler to ‘Lock-out’. Once activated the boiler has to be manually re-set by switching the control knob off (for 15 seconds) and on again.

6.3 An air pressure switch situated in the boiler's fan

1 compartment monitors the boiler's flue operation. If a partial obstruction within the flue occurs the fan will continue operating but the boiler's burner will shut down until the blockage is cleared.

6.4 The boiler's control unit has in-built frost protection

1 device that fires the boiler's burner when the temperature of primary hydraulic water falls below 6°C. The device works irrespective of any room thermostat

setting and will protect the complete heating system. On reaching a water temperature of 15°C the boiler reverts back to normal operation.

16.5 If there is a fault on DHW sensor, system continues operation by controlling DHW outlet temperature by flow sensor and CH sensor, which limits the temperature up to 65ºC during DHW operation. If such failure occurs and displays on LED screen, please contact service department.

Page 22

17. Fault Finding Chart

FAULT FINDING CHART 1

S T A

Mains LED ON ? R T

Is 240 Vac present at

pin X15 on PCB ?

Create demand

Yes

Bar LED Flashing ?

Fan running at full

speed?

Yes

Is pump running ?

Check pump wiring

connections & voltage

Yes

Does Pressure Gauge

show >1 bar ?

Yes

If boiler temperature

Does pump run now ?

> 6 ºC frost

rotection activated

Check low water pressure

switch cables &

connections clean or

replace as required

Repressurise system

Go to Chart 3

Go to Chart 2

Yes

Go to Chart 2

Replace PCB

Check fuses F1 & F2

on PCB replace as

required

FAULT FINDING CHART 2

T A R

LED ON?

Is Central Heating

LED ashing ?

Is overheat LED

ashing ?

Is the pump running

Yes

Replace user interface PCB ?

Check or replace Central

Heating NTC.

10-12 kohms @ 20 ºC

Check overheat

thermostats

Go to Chart 3

Check wiring /

connections mains

voltage @ pin X12

pin X16 & X17

Yes

Replace pump

Replace PCB

Page 23

FAULT FINDING CHART 3

S T A R T

Does Fan operate ?

Yes

Is the air pressure

switch activated ?

Check fan / tubes /

ue assembly and

case seals

Yes

Go to Chart 4

Replace Fan

Yes

Is 240 Vac present at

Yes

Fan ?

Does appliance

perform a pre-

purge of fan &

Are any LED faults

pump ?

indicated ?

FAULT FINDING CHART 4

Yes

Does sparking

commence ?

Check wiring and

condition of HT leads?

Does the burner ignite & remain on ?

Does the boiler attempt to light 3 times in 1 minute

intervals

Yes

go to lock out ?

Yes

Does boiler

Check the air

pressure switch

Does burner ignite ?

Yes

operation

Yes

Reset by turning to

standby for 15 secs

Yes

Go to Chart 5

Replace PCB

Go to Chart 2

Does the boiler

Is ame present

before lock out?

Check gas valve /

gas supply and

Check ignition and ionisation probes for correct position &

Replace PCB

Yes

light ?

damage

Check related sensors & replace

pressures & probe

Go to

Chart 5

Check burner /

injectors gas

Go to

Chart 5

Go to

Chart 5

Replace PCB

Page 24

FAULT FINDING CHART 5

Does burner ame

modulate ?

Yes

Normal operation

Release the hermetic chamber cover by removing two screws on both sides and by lifting them to release from their retaining hooks

RETAINING LUGS

. ( Figure 26)

Chwck wiring from PCB to modulation

Yes

Replace gas valve

coil on gas valve

Replace PCB

18. Routine Servicing

SERVICE PROCEDURE

1. Remove the outer case as outlined in section“Replacing Components”

2. Visually check all joints for gas/water tightness.

3. Visually inspect the flue system.

4. Check the condition of the seals around the combustion chamber.

5. Check condition of electrodes and their location. Conduct a flue gas analysis of CO/CO2 ratio to confirm the combustion

gas ratio is less that 0.004. If not check the combustion chamber and flue system for signs of leakage,damage or blockage. Remove any obstruction and clean as necessary. If clear check burner pressures, injectors or gas valve settings. Adjust and clean as necessary.

18.1 To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced regularly. The servicing must be carried out by a competent person in accordance with

the Gas Safety (Installation and Use) Regulations. The frequency of servicing will depend upon the particular installation conditions and usage, but in all cases the boiler must be serviced at least once a year.

8.2 Following servicing of the boiler the relevant

1 sections of the 'Benchmark' Installation, Commissioning and Servicing Log Book must be completed.

8.3 Prior to servicing a check of the flue operation

1 and terminal guard (if fitted) along with a preliminary check of the boilers operation must be undertaken.

8.4 Ensure the boiler is cold and that both the

1 electrical and gas supplies to the boiler are isolated before commencing service of the boiler.

8.5 Remove the boiler casing as follows:

Open the front panel by removing two screws at

the bottom of the boiler,

Figure 25.

INNER CASING PANEL

Figure 26

VIEWING WINDOW

SECURING SCREWS

Release the side panels by removing the screws on

the upper and lower sides (

Figure 27

). Remove the

panels by swinging them out and lifting them up.

Figure 27

SECURING SCREWS (4 OFF)

8.6 Remove the combustion chamber cover by

removing four screws on sides.

SECURING SCREWS (6 OFF)

(Figure 28)

SIDE PANELS

Figure 25

Figure 28

COMBUSTION CHAMBER

VIEWING WINDOW

Page 25

18.7 Disconnect the electrical leads and air pressure switch connection tube from the fan, remove the fan screws and withdraw fan from fan hood with its 56º

(Figure 29)

bend.

HALL

EFFECT

SENSOR

ELECTRICAL CONNECTIONS

PRESSURE SWITCH CONNECTION TUBE

Figure 31

SECURING SCREW

Figure 29

FAN

PRESSURE SWITCH CONNECTION TUBE

FAN HOOD

18.8 Remove the burner assembly from the combustion chamber as follows:

Pull off the ignition and flame electrode leads

from the PCB and remove the wires with grommet from the combustion chamber base.

SPARK GAP 4mm

BURNER

SENSING TUBE

GROMMET

(Figure 30)

Figure 30

EARTH LEAD

SECURING SCREW

LEFT HAND SIDE OF BURNER

Remove the burner-retaining screws at the sides

RIGHT HAND SIDE OF BURNER

and remove the burner.

8.9 Visually check for debris/damage and clean/replace

1 as necessary the following items:

⇒ Heat exchanger ⇒ Burner ⇒ Fan/compartment ⇒ Electrodes ⇒ Insulation/gaskets

Note. All washers/gaskets must be retained for use on

re-assembly, replace if damaged.

8.10 To clean the condensate trap, which is located at

1 the back left hand corner of the appliance, remove the plastic hose from the outlet and insert a suitable allen key into the outlet and remove the sump by turning anticlockwise. Clean the sump using a dilute solution of bleach. Apply a little silicone grease to the O ring and replace the sump so that the O ring is just engaged. Do not over tighten.

Important.

Clean the heat exchanger using a soft brush or

vacuum cleaner. D

o not use any tool likely to

damage painted finish of heat exchanger.

Clean the burner by washing in soapy water.

Allow to dry thoroughly before re-fitting.

Do not use wire or a sharp instrument to clean

the burner injectors.

Ensure the ignition electrode gap is set to 4 mm.

FLAME AND IGNITION ELECTRODE LEADS

8.11 The boiler is fitted with a cold water inlet filter

1 which must be inspected on each service. To access the filter:

Close the isolating valve on the boiler's cold water

domestic inlet by turning the valve head fully clockwise.

Page 26

Open one or more hot water taps to drain the

domestic hot water circuit.

Disconnect the cold water inlet connection to the

boiler.

Clean and inspect the filter, replace if necessary

as described in (

Re-fit the filter and reinstate the cold water inlet

18.20).

connection to the boiler, fit new gasket as required.

Fully open the isolating valve on boiler's cold

water inlet and check for leaks.

8.12 On completing the service reassemble the boiler

1 components in reverse order of removal, ensuring that all component joints and gaskets are sound. Any damaged seal or gasket must be replaced.

8.13 Reinstate the boiler's electrical and gas supplies

1 and check for gas soundness and correct boiler operation.

CAUTION!

While there are no substances harmful to health contained within this appliance, some component parts of the boiler (insulation pads, gaskets and rope seals) are manufactured from man made fibres. When damaged or broken these fibres may cause a temporary irritation. High dust levels may irritate eyes and upper respiratory system. It is important therefore, that sensible precautions are applied when exchanging components.

19. Component Replacement

9.1 Ensure that both the electrical and gas supplies

1 to the boiler are isolated before replacing any component part.

9.2 To prevent the need to drain the entire heating

1 system when replacing the boiler's integral pump, expansion vessel, safety relief valve and pressure sensor,

the boiler’s hydraulic circuit may be isolated from the central heating circuit by closing the boilers isolation valves. Opening the discharge valve will then drain the boiler’s hydraulic circuit. Note clean the valve seat to ensure it seals before re-filling the boiler.

9.3 For replacement of the following components it will be necessary to remove the boiler casing panels as described in Section 17.

9.4 Domestic hot water sensor

The domestic hot water sensor is located on the left

side of the hydraulic block’s hot water side.

32)

(Figure

Carefully disconnect the leads from the sensor.

Figure 32

ELECTRICAL CONNECTIONS

DOMESTIC HOT WATER SENSOR

Remove the sensor using a 13mm spanner.

Fit the replacement sensor ensuring the washer is

correctly fitted. Re-fit the leads to the replacement sensor

9.5 Central heating sensor

The c/heating sensor is located on left side of the

combustion chamber on the outlet of the primary heat exchanger.

(Figure 33)

Unclip the sensor from the pipe.

Disconnect the leads from the sensor.

PRIMARY HEAT EXCHANGER OUTLET PIPE

CENTRAL HEATING SENSOR

ELECTRICAL CONNECTIONS

Figure 33

Fit replacement sensor.

Fit the leads and replacement the sensor.

Page 27

5Figur

19.6 Fan Unit

Disconnect the electrical leads from the fan.

To remove the fan, disconnect the 90º bend from

the top of the boiler

Disconnect the electrical leads and air pressure

switch connection tube from the fan, remove the fan screws and withdraw fan from fan hood with its 56º bend.

(Section 18.7)

Fit the replacement fan unit in reverse order and

reconnect the electrical leads and sensing tube.

WARNING! Ensure that the earth lead is re-connected.

9.7 Air pressure switch

The air pressure switch is located on the top of

the expansion vessel. (

Figure 34)

Remove the sensing tube and electrical

connections from the air pressure switch, noting which tube is connected to which port.

Remove the air pressure switch by pulling

forward off its bracket.

Fit the replacement switch in reverse order of

removal.

BRACKET

SECURING SCREWS (2 OFF)

9.8 Burner

Note. The replacement burner is supplied as component parts and requires assembly on site.

Remove the burner assembly from the combustion

chamber as detailed in S

ection 18.7 retaining all

washers/gaskets for use on re-assembly.

Remove the manifold as shown in

Figure 31.

Fit the manifold with new burner injectors and

tighten, ensuring that the injector size, marked on each injector is the same as stated in the ‘

ata’ section for the type of gas being used.

Technical

INJECTOR

BURNER INJECTOR BAR

Replace the burner bar and re-fit the burner blades

(replace any damaged seals as necessary) and reassemble the boiler in reverse order.

Check gas soundness and boiler operation.

e 3

AIR PRESSURE SWITCH

ELECTRICAL CONNECTIONS

SENSING TUBES (2 OFF)

Figure 34

9.9 Printed circuit board (PCB)

Turn off and isolate the electrical supply.

Remove the interface cover by lifting the two

latches.

(Figure 36- 37)

Remove the electrical connections to the PCB by

pulling carefully, noting the locations of all the terminals.

Release the screws securing the PCB to the control

panel and lift out the PCB.

Fit the replacement PCB in reverse order to

removal, ensuring that the PCB electrical connections are fully pushed home.

Check and re-set as necessary the potentiometers

and dip switches to the same value as the old PCB.

Page 28

RETAINING CLIPS

Figure 36

CONTROLS FASCIA

RETAINING CLIPS

CONTROLS CIRCUIT BOARD COVER

Figure 37

PRINTED

CIRCUIT

BOARD

9.10 Pump

SCREW

OFF

Figure 38

Follow 18.10a or b depending on type of failure.

9.10a Replacing motor:

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

Remove the screws shown in

COVER

Figure 39

PUMP HEAD

Pull off the motor, remove the cover and disconnect

the electrical leads from cable box Figure 40.

Fit the replacement motor in reverse order ensuring

correct polarity of the electrical connections.

Re-open the isolating valves on the flow and return

connections, refill, vent and re-pressurise the system and check for leakage.

9.10b Replacing the pump body:

Remove the motor as described above.

Figure 40

Remove the secondary water-to-water heat

Remove the expansion vessel pipe by removing the

exchanger as detailed in (1

9.12).

clip on the pump body.

Remove the pressure gauge connection

as detailed in (

19.11).

Disconnect the electrical leads of low pressure

sensor.

Disconnect the pumps outlet fitting.

(Figure 41)

UNION NUT

CLIP

UNION NUT

ELECTRICAL CONNECTION

EXPANSION VESSEL PIPE

PRESSURE GAUGE CONNECTION

PUMP BODY

Figure 41

SECURING SCREW

CLIP

PUMP BODY

SECURING SCREWS (4 OFF)

Page 29

Remove the fixing screws from the pump and

hydraulic block at the bottom of the boiler

(Figure 42)

SECURING SCREW

SECURING SCREWS

Figure 42

Remove the pump assembly.

Remove the pump body from the hydraulic

assembly by releasing the clip.

Fit the replacement body in reverse order

ensuring that the pump washers are sound and fitted correctly and the polarity of the electrical connections are correct.

Open the isolating valves on the low and return

connections, refill, vent and re-pressurise the system ensuring all joints are sound.

9.11 Low water pressure sensor

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

9.12 Secondary Heat Exchanger

Drain the boiler’s hydraulic circuit as detailed in

19.2)

(

Remove the two screws which connect the heat

exchanger to hydraulic circuit.

(Figure 44)

SECURING SCREWS

Figure 44

Remove the exchanger from the gap on the left hand

side.

Figure 45

LOW WATER PRESSURE SENSOR

Figure 43

ELECTRICAL CONNECTIONS

Remove the pressure sensor by turning it in an

anticlockwise direction.

Fit the replacement sensor in reverse order of

removal ensuring all washers are fitted. Replace damaged washers as necessary.

Open the isolating valves on the flow and return

connections, refill, vent and re-pressurise the system ensuring all joints are sound.

THREE WAY VALVE MOTOR

Fit the new heat exchanger checking that the plate

numbers are the same and reassemble the boiler in reverse order ensuring all washers are fitted or replaced as required.

Open the isolating valves on the flow and return

connections, refill, vent and re-pressurise the system ensuring all joints are sound.

Page 30

SECURING SCREWS (6 OFF)

VIEWING

COMBUSTION CHAMBER COVER

Figure 46

WINDOW

9.13 Primary Heat Exchanger

Drain the boiler’s hydraulic circuit as detailed in

19.2)

(

Remove the pipe clips on the pipes of heat

exchanger.

Release the union connections on the connection

pipes, retaining the washers for re-assembly.

Remove the CH temperature sensor on the return

pipe.

Remove the pump-heat exchanger and heat

exchanger-three way valve connection pipes.

Remove the combustion chamber cover.

Remove the heat exchanger by pulling forward.

Fit the new heat exchanger and reassemble the

boiler in reverse order ensuring all the washers are fitted, or replaced as required.

Open the isolating valves on flow and return

connections, refill, vent and re-pressurise system ensuring the all joints are sound.

9.14 Gas valve

Ensure that gas supply to boiler is turned off.

Disconnect the electrical connections to gas valve

modulating coil.

Release the connection from gas valve and

manifold inlet, retaining the washers for use on reassembly (

GAS VALVE AND MANIFOLD INLET CONNECTIONS

SENSING TUBE

MODULATING COIL

ELECTRICAL AND EARTH CONNECTIONS

Figure 47

ELECTRICAL PLUG

SCREW

Figure 47

Release the main gas connection between the gas

valve supply tube and gas inlet valve, retaining the washer for use on reassembly.

Remove the gas valve's two securing screws and

washers from the underside of the boiler.

(Figure 48)

Rotate the gas pipe and withdraw gas valve

assembly.

Refit in reverse order to removal, the polarity of the

wires to the modulating coil is not important, replace any damaged washers as required.

Check gas soundness and correct boiler operation.

GAS ISOLATION VALVE

SUPPLY PIPE CONNECTION

SECURING SCREWS

Figure 48

Page 31

Following replacement the maximum and minimum settings for natural gas must be checked to Technical data, section 2.

Check the gas valve settings and re-calibrated by the following method if required:

After adjustment refit plastic cap on gas valve

adjuster and remove gauge and leak test pressure

test point.

9.16 Expansion vessel

9.15 Maximum and Minimum setting

Connect a suitable pressure gauge to the pressure outlet on the gas valve. (Figure 49)

mbar

Figure 49

Remove plastic cover from gas valve adjuster

Create domestic hot water demand by operating a hot water faucet.

Adjust 10 mm brass nut to gain correct maximum

burner pressure ensuring the inner screw is held

Figure 50

Drain the boiler’s hydraulic circuit as detailed in

19.2)

(

Disconnect the pipe coupling on expansion vessel

Figure 52

(

FLEXIBLE PIPE CONNECTION

SECURING NUT

Figure 52

Release and remove the nut securing the expansion vessel to the boiler.

in place with the use of a cross head screw driver

clockwise to increase, anti-clockwise to decrease.

(Refer to Technical Data for pressure settings)

Remove one lead from the modulating gas valve

coil.

(Figure 50)

Adjust inner screw to give correct min burner

pressure whilst holding 10 mm nut on maximum

adjuster. Clockwise to increase,

Anti-clockwise to decrease.

Figure 51

Remove the side panels as described in section 18.4.

Lift the vessel out of boiler from the gap over the chasis (

Figure 53

) and fit the replacement vessel to the boiler in reverse order to removal, ensuring that sealing washer is fitted to pipe connection before tightening, replace the washer if necessary.

Using a pressure gauge, ensure that expansion vessel charge pressure is 0·5bar (7·5psi)

Figure 53

Open the isolating valves on the flow and return connections, refill, vent and pressurise the boiler ensuring all joints are sound.

Re-connect the lead of gas valve coil.

Page 32

19.17 Safety Thermostats

Remove the front panel, combustion chamber cover and right side panel.

Locate the overheat safety thermostats at the front left handside of the boiler andontheright handside of the primary heat exchanger

(Figures 54a& b)

Disconnect the electrical connections from

the thermostat.

LIMIT SAFETY

THERMOSTAT

PRESSURE SAFETY RELIEF VALVE

UNSCREW TO REMOVE

ELECTRICAL CONNECTIONS

PIPE CLIP

PRIMARY HEAT EXCHANGER

OVERHEAT SAFETY THERMOSTAT

Unclip the thermostat from the pipe.

Figure 54a

Figure 54b

DISCHARGE PIPE

R.H. HYDRAULIC BLOCK

Figure 55

9.19 Hydroblock

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

Remove the secondary heat exchanger as described in (

19.12)

Remove the pump assembly as described in

19.10)

(

Remove the section of the hydroblock from the pump by releasing the clip.

Release the exchanger outlet pipe nut and rotate the pipe for easy removal of the left section of the hydroblock as described in section (

19.13)

Disconnect the three way valve motor, electrical connection and remove the motor by releasing the clip as described in section (

19.22)

Fit the replacement thermostat in reverse order of removal.

9.18 Pressure relief valve (Figure 55).

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

Disconnect the discharge pipe on the outlet of the safety valve.

Remove the safety valve from the hydraulic block and retain the o-ring for use on reassembly, replace as necessary.

Fit the replacement safety valve in reverse order to removal and refill, vent and pressurise boiler ensuring all joints are sound.

Release the nut connecting the CH outlet connection to the hydroblock. (Figure 56).

Figure 56

ELECTRICAL CONNECTIONS

DOMESTIC HOT WATER SENSOR

Page 33

Disconnect the DHW sensor as described in (19.4).

9.21 Flow sensor

Remove the screw securing the left part of the hydroblock to the combination boiler

Figure 57).

(

Figure 57

Fit the replacement hydroblock parts in reverse order to removal ensuring all seals are correctly located and replaced if necessary.

Open the isolating valves on the flow and return connections, refill, vent and pressurise boiler ensuring all joints are sound.

Remove the flow sensor using a pair of pliers.

FLOW SENSOR

ELECTRICAL CONNECTION

Figure 59

UNCLIP TO REMOVE

Fit a replacement sensor in reverse order to removal.

9.22 Three way valve motor

Figure 58

9.20 Filter.

Switch off the electrical supply to the boiler.

Close the domestic cold water supply valve below the boiler (Second valve on the right)

Open a hot water faucet and drain the domestic hot water system.

Disconnect the valve connection from the boiler

Either pop out the filter with a screw driver or disconnect the filter housing from the bottom of the hydroblock using a 24mm spanner.

Ensure that the electric supply to the boiler is switched OFF.

Remove the electrical connection to the motor.

Remove the clips connecting the valve to hydroblock. Fit the replacement valve in reverse order ensuring the valve is fitted properly.

ELECTRICAL CONNECTION

Figure 60

CLIP

THREE WAY VALVE MOTOR

Pop out the filter and clean or replace as necessary.

Reassemble the components in reverse order. Open the valve and check for leaks.

Page 34

20. Gas Type Conversion

Warning

Gas conversion must be carried out by a competent person as defined in the Gas Safety and Use Regulations.

If gas type conversion is required (from NG to LPG

etc.), follow the steps below:

The burner must be removed as 18.8 (shown Figure

31.)

Fit the injector bar and tighten, ensuring that the injector size, marked on each injector is the same as stated in the relevant section of the ‘Technical

foData’ r the type of gas that will be used.

Fit the burner (replace if necessary) and reassemble the boiler.

Check for gas soundness.

Dip switch 7 must be ON position for LPG and, OFF for NG.

Check the minimum and maximum burner pressures.

Check the gas circuit for soundness and the correct operation of the boiler.

Important.

Attach the labels supplied as follows:

Replace the adhesive “User Instruction” label. Stick the LPG label in a prominent position within the boiler. Stick the foil label over the existing gas type on the

plate of the boiler.

data

Page 35

APPENDICES

SPARE PARTS LIST

PART No. DESCRIPTION ORDER CASE

1 HYDROBLOCK – THREE WAY VALVE PART 3003200017 2 HYDROBLOCK – PUMP PART 3003201529

8300023003HC T I WSERUSSERPWOL3 9100023003E V L A VY T EF A S4 6331023003PMU P5 8200023003LESSEVNO I SNAPXE6

9140023003E V L A VS AG7 8 9

11 12

16 17 18 19

26 27 28

-28 kW NG)DLO F I NAMHT I W ( R ENRUB

ELECTRONIC CONTROL BOARD 3003202166 31 41 51

02 12 22 32 42 52

SECONDARY HEAT EXCHANGER 24 kW SECONDARY HEAT EXCHANGER 30 kW

DRACECAFRE TN I

OVERHEAT SAFETY THERMOSTAT 3002185050

IGNITION ELECTRODE - RIGHT 3003202200

IGNITION ELECTRODE - LEFT 3003202201

FLAME SENSE ELECTRODE 3003202102

L CAPRIZ 25ENA PT NO R F L CAPRIZ 28ENA PT NO R F

S S E N R A HG N I R I W

3003202154 3003202178L E NA PL O R T NO C

3003200026 3003200025 3003200183

3003200176 3003200177

3003202174

3512023003-24 kW NG)DLO F I NAMHT I W ( R ENRUB

4800023003R E V O CB C P

2510023003ROSNESHC 3760904003E G U A GE R U S S E R PR E T AW

5612023003NAF 2300023003H C T I WSE R U S S E R PR I A

5771023003PARTE T A SNEDNOC 6840023003R E G N A H C X EO B R U T

Page 36

25 & 28

Condensing

Wall Mounted

Combination Boiler

User Instructions

www.heatline.co.uk

Page 37

atural Gas / LPG

HeatlineTM Capriz 25 / Capriz 28 Condensing Combination Boilers

British Gas Service Listing

Capriz 25 Condensing Combination Boiler G.C. No 47 - 157 - 12 Capriz 28 Condensing Combination Boiler G.C. No 47 - 157 - 13

MPORTANT INFORMATION

The Heatline

range of heating boilers is manufactured from hight quality materials, enabling reliability and optimum performance.

Heatline

is committed to the continual development of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings.

Type test for purpose of EEC Regulations certified by:

Notified Body IMQ 5

1BP2727 CE Directive 90/396/EEC 1BP2728DR CE Directive 92/42/EEC

CE Directive 73/23/EEC CE Directive 89/396 EEC

(modified from 93/68)

‘Benchmark’ Log Book

As part of the industry - wide initiative the CAPRIZ 25 / CAPRIZ 28 boilers come complete with an Installation,Commissioning and Service Record Log Book. Please read the Log book carefully and in accordance with current regulations 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 must be left with the end user and the relevant sections completed on each subsequent Service visit.

The CAPRIZ 25 / CAPRIZ 28 is a high efficiency gas fired combination boiler and represents the highest level of technology found in today’s gas boiler market.

In order to maintain peak efficiency and performance your boiler must be serviced annually. This should be undertaken by a competent CORGI registered engineer. Failure to undertake this service work may invalidate your warranty.

All CORGI Registered Installers carry a CORGI ID card and have a registration number, which should be recorded and entered on your Benchmark log book. You can check your Installer registration by contacting CORGI on 0800 915 0480.

The boiler’s ‘

Log Book’ must be completed at each

Service visit.

AS SAFETY (INSTALLATION AND USE) REGULATIONS

It is a legal requirement that all gas appliances must be installed and serviced by a competent person in accordance with the regulations. Failure to install or service gas appliances correctly could lead to prosecution. It is in your interest and that of safety to ensure compliance with the law. For electrical safety the boiler must be earthed and protected by a 3

use.

ote. In the event of a fault the appliance should not be

-amp

used until fault has been rectified by a competent person.

ENTILATION

On installation the boiler must be installed with minimum

clearances

of 50mm each side, 200mm above, 300mm below with 600 mm access to the front. If an opening door is to be fitted across the front of the boiler allow 5 mm clearance to the front panel. Should the boiler be installed in a closed compartment it is recommended that there are minimum air vents of 30 square cm at both high and low levels.

Page 38

ENERAL DESCRIPTION OF BOILER

G The CAPRIZ 25 / CAPRIZ 28 is a combined domestic hot water and central heating appliance. The internal control unit electronically provides direct burner ignition and combustion supervision along with continuous modulation of the burner’s gas supply. By means of a manual switch the boiler can be set to operate in one of two operating modes, domestic hot water only or domestic hot water and central heating.

OMESTIC HOT WATER MODE:

D When hot water demand is requested the boiler will fire automatically. An integral pump is then energised and hot water from the boilers primary circuit is circulated through the secondary heat exchanger, allowing the instantaneous transferral of heat to the incoming cold water. The secondary heat exchanger is protected against an internal build up of lime scale by limiting the hot water temperature at the tap to a maximum of 64°C. Hot water will continue to flow through the tap until no longer required. When the demand for hot water ceases the integral pump may continue to run for a short while to dissipate any excess heat within the boiler.

OMESTIC HOT WATER AND CENTRAL HEATING

ODE:

M When heating demand is requested the boiler will fire automatically. An integral pump is then energised and hot water from the boilers primary circuit is circulated

around the heating systems pipe-work and radiators. The heat output from the boiler is automatically adjusted by the boiler’s internal control unit to match the heating demand. As the water temperature of the heating system increases the gas input to the burner decreases, conserving energy and increasing efficiency. When the demand for heating no longer exists, either the room thermostat is satisfied or the heating period has ended, the burner will shut down and the boiler will

revert to stand-by, waiting to respond to the next heating demand. The integral pump may continue to run after shut down for a short while to dissipate any excess heat within the boiler.

Figure 1

CCESS TO THE BOILER CONTROLS

The boiler controls are sited at the bottom of the boiler’s front case.

123-

(figure 1)

bar

Timer D.H.W. temperature control Function switch

456-

bar

C.Heating temperature control System pressure gauge LED display

Figure 2

Please Note. When domestic hot water is called for during the heating mode, the boiler will automatically revert to domestic hot water mode until the demand for hot water ceases. NOTE: Depending on the boiler set up there may be a delay of 45secs before the boiler re-fires.

OILER CONTROLS

The function and operation of the main controls located on the control panel fascia

(figure 2)

is as follows:

. Function switch. This is the boilers main operating

switch. In the

position the boiler is in stand-by

mode and power supply is ON. For the boiler to

operate the switch must be in the

position.

When switched to the

position the boiler will operate only to supply domestic hot water. (Summer use) For the boiler to operate to give both central heating and domestic hot water the

switch must be in the

. Central Heating temperature control. The position

of this control dial will determine the temperature of the water delivered to the radiators. The water temperature can be set from a minimum of 30º C (anticlockwise stop position) to a maximum of 85º C (clockwise stop position.)

position (Winter use)

Page 39

3. D.H.W. temperature control The position of this control dial will determine the temperature of the domestic hot water delivered to the taps or shower unit. The water temperature can be set from a minimum of 35º C (anticlockwise stop position) to a maximum of 64º C (clockwise stop position.)

. Boiler On The boiler ‘Stand by’ indicator (green)

lights when power is supplied to the PCB.

. Water Temperature The temperature of the

water leaving the boiler is given by the red light indicators situated alongside the burner 'Stand by' indicator light.

. Fault Indicator The control unit has an in-built

fault diagnostic function. When a fault occurs, the type of fault is indicated by the appropriately 'flashing' red light indicator. A listing of the display lights and meanings can be found in Section 13 of the Installation and Servicing Instructions.

. Boiler Lockout When the first red light indicator

from right (flame or gas fault) or the second from right (overheat fault) lights, the boiler will need to re-set. To re-set the boiler the function switch

must be switched to the

position and after 30 seconds back to its previous (summer or winter) position.

. Pressure gauge The pointer on the gauge

indicates the pressure within the boiler and central heating system and should, when the water is cold, read between 1 and 2bar.

If the pressure gauge falls below 1bar the system and boiler must be re-pressurised via the filling loop. The filling loop should be located below the boiler.

Note. A Service Engineer must be contacted if a boiler fault continues to occur.

but not necessarily the full system. Ensure that vulnerable sections of the circuit are adequately lagged.

SYSTEM PRESSURE

On installation your installer will have filled the boiler

and system to its effective working pressure. The boiler's pressure gauge should be regularly checked to ensure that this pressure is maintained between 1 and 2 bar. If there is a significant or frequent drop in pressure then your installer should be consulted.

PERATING THE BOILER

On installation your installer will have filled the boiler

and system to its effective working pressure. The boiler's pressure sensor should be regularly checked on the LED to ensure that this pressure is maintained between 1 and 2 bar. If there is a significant loss in pressure the boiler will lock out. The system may be re-charged by opening the filling loop to charge the system back up to 1.5 bar as indicated on the LED panel. DO NOT OVERCHARGE THE BOILER PRESSURE BEYOND 2 BAR AS THE BOILER WILL NOT OPERATE. The filling loop, a flexible hose with two valves, should be located below the boiler on the right to either one of the outer pipes, see

DO NOT CLOSE ANY OF THE FOUR VALVES

10.

connecting the second pipe

Figure

DIRECTLY CONNECTING TO THE BOILER. If the boiler frequently loses pressure then your installer should be consulted.

CLEANING The boiler casing may be cleaned with a damp cloth followed by a dry cloth to polish. D

o not use abrasive or

solvent cleaners.

FURTHER ADVICE For further information or advice (UK) contact HeatlineTM:

Service please call: 0870 609 2091 Spares please call: 0870 777 8402 Technical assistance please call

: 0870 777 8318

Or by E mail on our Web Site at www.heatline.co.uk

FROST PROTECTION

The boiler has a built in frost protection device that protects the boiler from freezing. If the boiler is to be left and there is a risk of frost, ensure that the gas and electrical supplies are left connected. The frost protection device will light the boiler when the

temperature of the boiler water falls below 6 the temperature reaches 15

C, the boiler will shut

C. When

down.

ote: This device works irrespective of any room

N thermostat setting and will protect the boiler,

Page 40