heatline Capriz 25s User guide

Download

capiz 25 & capiz 28

capiz 25s

capiz 28s

Condensing Wall Mounted Combination Boiler

Installation, Servicing & User Instructions

atural Gas / LPG

or the boiler name and designation, e.g. CAPRIZ 25S.

HEATLINE™ CAPRIZ 25S / CAPRIZ 28S Condensing System Boilers

British Gas Service Listing

CAPRIZ 25S Condensing System Boiler G.C.No 41-157-10 CAPRIZ 28S Condensing System Boiler G.C.No 41-157-11

capiz 25 & capiz 28

The Heatline

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

He atline

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 CAPRIZ 25S / CAPRIZ 28S boilers with an Installation, Commissioning

come complete

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

Contents

capiz 25 & capiz 28

egaP noitceS

2 ecaferP

3 xoB no sngiS ehT

3 relioB no sngiS ehT

4 snoitalugeR noitallatsnI .1

5 ataD lacinhceT .2

7 scitsiretcarahC relioB .3

7 noitarepO .4

8 noitallatsnI lareneG .5

9 gnitiS ecnailppA .6

01 noitacoL lanimreT eulF .7

21 ofnI eulF lareneG .8

31 snoitcennoC lacirtcelE .9

51 noitallatsnI relioB .01

61 ylppuS saG .11

71 metsyS eht gnilliF .21

71 snoitcnuF lenaP lortnoC .31

81 gninoissimmoC .41

81 stnemtsujdA draobnO .51

91 seciveD ytefaS .61

.71

.81

trahC gnidniF tluaF

gnicivreS enituoR

.91

.02

noisrevnoC epyT saG

Appendices

User Instructions 32

Benchmark Log Book 36- 37

tnemecalpeR tnenopmoC

13 tsiL straP erapS

Preface Warnings

capiz 25 & capiz 28

The Heatline™ gas fired, condensing system 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 the appliance must be re-registered with Heatline™ in orde

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.

to maintain the guarantee.

IMPORTANT NOTE

Speed 2 is the factory default setting

for the Pump.

This setting should be suitable for

most of your applications.

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

Condensate hose

capiz 25 & capiz 28

The Signs on Box

The Signs on Boiler

LOW VOLTAGE ROOM THERMOSTAT – This

The sign of approval the Capriz 25S & Capriz 28S

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.

OTE: Take care as there may be residual voltage within

N some components

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

control box. Note these

(AC or DC)

see section 9.5.

block, which is

as the

should be applied to

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.

Do not crush the packaging as this may damage the appliance.

Store the appliance upright as indicated on the box.

Potentiometer Cover: Removal of the cover, which is found on the back of the control box, gives access to the adjustment potentiometers. N

OTE: Do not make any adjustments without reading the instructions carefully.

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.

1. Installation Regulations

Correctly may invalidate your guarantee and may

.1.

lead a dangerous situation.

Your CORGI registered engineer should carry a

1. 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.

capiz 25 & capiz 28

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

4. On installation the following British Standards

1. must also be considered:

BS 6798 Specification for installation of gas

fired hot water boilers of rated input not exceeding 70kW.

BS 5449 Central heating for Domestic

Premises.

BS 5546 Installation of gas hot water supplies

for domestic purposes.

BS 5440 Flues and Ventilation for gas

appliances of rated input not exceeding 70kW (Part 1 Flues)

BS 5440 Flues and Ventilation for gas

appliances of rated input not exceeding 70kW (Part 2 Air Supply)

BS 6891 Installation of low pressure gas pipe-

work installations up to 28mm (R1!). 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.

2. Technical Data

capiz 25 & capiz 28

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 25S

(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 28S

(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

Capriz 25S

Maximum heating

temperature

ºC 85

PMS

Operating pressure (Bar)

Nominal

(Min)

Expansion Vessel Capacity Litres 7

Expansion Vessel

Pre-charge Pressure

Air Intake Pipe Diameter

Flue Pipe Diameter

Max. Flue Length C12 – C32

Max. Flue Length

C42 – C52

bar 1

mm 100/125 100/125

mm 60/80

(25 kW)

1.5

(0.8)

3.0

(60/100)

7.0

(80/125)

(80/80)

Capriz 28S

(28 kW)

(0.8)

60/80

(60/100)

(80/125)

(80/80)

1.5

3.0

7.0

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

Equivalent Length 450 Bend

Equivalent Length 900 Bend

Net weight

Gross Weight

m 1.0

m 1.5

kg 35

kg 38

1.0

1.5

capiz 25 & capiz 28

10 11 12

A - Heating Flow (22mm) B - Gas Inlet (22mm) C - Cold Water Inlet (15mm) D - Heating Return (22mm)

Key

1 - Condensate Trap

2 - Limit Safety Thermostat 3 - Expansion Vessel (At rear of the boiler) 4 - Burner 5 - Flame Sensor (Ionisation) Electrode 6 - C.H. Sensor (Heating Sensor)

7 - Combustion Chamber 8 - Primary Heat Exchanger 9 - Fan Hood 10 - Fan

Figure 2.1

11 - Air Pressure Switch 12 - Condensing Unit (Turbo heat exchanger) 13 - Overheat Safety Thermostat 14 - Ignition Electrode 15 - Heating Circuit– Pressure Safety Valve 16 - Automatic Air Vent 17 - Water Pressure Switch/Sensor 18 - Pump 19 - Gas Valve 20 - Filter Valve (Below the pump)

3. Boiler Characteristics

excess heat from within the boiler’s heat-exchanger.

capiz 25 & capiz 28

4. Operation

3.1 The CAPRIZ 25S & CAPRIZ 28S are fan flued, wall-mounted condensing type system boilers that supply domestic central heating. Being room sealed the boiler may be installed in any room or internal compartment without the need for purpose made ventilation. However, if the boiler is installed in a compartment it is recommended that the compartment is ventilated for cooling purposes. A functional diagram of the boiler’s 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.

4.1 Using the operating switch the boiler can be switched on.

4.2 CENTRAL HEATING DEMAND: When heating demand is requested and power is on with the timer and thermo stat 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, either the thermostat reaches temperature or the time clock reaches temperature or the time clock reaches the end of its set period, the burner will shut down and the boiler will revert to stand-by, waiting to respond to the next heating demand. The pump will continue to operate for a short period of time to dissipate any

.6 An integral pump located in the boilers main

3 hydraulic circuit circulates water through the primary heat exchanger to either the central heating circuit ,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.

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 for details

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

CENTRAL HEATING HYDRAULIC CIRCUIT

Figure 4.1

capiz 25 & capiz 28

5. General Installation

5.1 Installer Testing & Commissioning Tips

• The installer shall instruct the user in the operation of the boiler, safety devices contained within the boiler and instruction on how to re-pressurise the system if the water pressure falls. The installer should then hand over the instructions 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 Heatline 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

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 fil central heating return valve, the overheat thermostat

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

outlet to get blocked

r is

ter on

• 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.

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

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.

.2 The boiler is designed to operate on fully pumped, pressurised sealed systems operating at a maximum of 3 bar pressure and maximum design flow temperature of 85

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

charged to a pressure of 1 bar and will accommodate a system volume of 125 litres. at an average water temperature of 75°C and maximum 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 5.1

.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.

Cold water supply

Additional expansion vessel (if required)

Figure 5.1

Heating outlet

Flow control valve

Boiler

Flow control valve

Filling device

Flow control valve

Heating return

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

capiz 25 & capiz 28

6. Appliance Siting

.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 50 mm at each side. 600 mm 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 boiler is mounted must be non

6 combustable and sufficient strong 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.

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

To avoid excessive condensation occurring within the boiler flue the boiler should wherever possible, be si ted to ensure the shortest possible flue r un 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 50mm of the

boiler casing without protection.

There must be 50 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.

Figure 7.1

. Note if pluming

capiz 25 & capiz 28

)mm( ecnaraelC

lanimret foor rehtona ro foor eht no erutcurts a morF

Figure 7.1

capiz 25 & capiz 28

Internal Corner External Corner

Double Corners

)margaid eeS( noitpircseD noitacoL

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

300

terminal (See Note 2)

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

P 006 Q 003 llaw tnecajda na ot lanimret eulf lacitrev a morF R From a vertical ue terminal to an adjacent wall which includes an

opening window (See Note 3)

1000

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.

003 )1 etoN eeS( gninepo na woleB A 003 gninepo na evobA B 003 gninepo na ot yllatnoziroH C 57 sepip niard ro sepip lios ,srettug woleB D 002 sevae woleB E 002 foor trop rac ro ynoclab woleB F 051 epip lios ro epip niard lacitrev a morF G

003 level ynoclab ro foor ,dnuorg evobA I

0021 lanimret eht gnicaf lanimret a morF K 0021 gnidliub eht otni trop rac eht ni gninepo na morF L 0051 llaw emas eht no lanimret a morf yllacitreV M 003 llaw emas eht no lanimret a morf yllatnoziroH N

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.

8.2 The standard 700 +/-5 mm flue kit (Figure 8.1) can be routed to the rear, left or right of the appliance by means of a 90° degree bend .This can be purchased with the boiler but there are other various types of flue available if required. The bend is connected to the boiler using the screws provided and sealed with the gasket.

capiz 25 & capiz 28

Figure 8.2

12-C32 C42-C52

60/100 80/125 80/80

24 kW

8 kW

Ø80 Ø80 Ø80

Ø82 Ø82 Ø82

8.6 The air restrictor should not be fitted 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 8.1

.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 1m,the restrictor (air diaphragm)–Figure 8.2 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 APPRO VED FL UE IS TO BE USED WITH HIS PRODUCT.FAILURE TO COMPLY WITH THIS REQUIREMENT WILL INVALIDATE YOUR GUARANTEE AND COULD LEAD TO A DANGEROUS SITUATION.

capiz 25 & capiz 28

.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 9.1

.4 The low voltage room thermostat terminal block is

9 located to behind of left side of the plastic cover

(Figure 9.1)

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 9.2.

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

9.2

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

24V LOW VOLTAGE ROOM THERMOSTAT TERMINAL BLOCK

and gas valve are supplied at 230V AC., all other components and associated circuits are supplied at low

Figure 9.1

voltage.

.8 On connecting the mains electrical supply to the boiler, it is essential to ensure that electrical safety

FITTED BRIDGE

checks for earth continuity, earth resistance, polarity and short circuit are carried out prior to making the final connection. A diagram of the boiler's electrical circuit is

BRIDGE PLUG

given as

Figure 9.3.

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 frost

protection and pump over - run facility. Ensure

that the boilers electrical supply is not interrupted

by any external controls.

Figure 9.2

HALL

EFFECT SENSOR

THERMOSTAT

LIMIT

SAFETY

CENTRAL HEATING

SENSOR

FAN

capiz 25 & capiz 28

GAS CONTROL

VALVE

g g

g/y

AIR PRESSURE

SWITCH

WATER PRESSURE SENSOR

FLAME (IONISATION) ELECTRODE

PUMP

IGNITION

ELECTRODES

r r

w w

24V TIME

CLOCK

(low voltage)

230V ROOM THERMOSTAT CONNECTION

(high voltage)

r r

PRINTED

CIRCUIT

BOARD

OVERHEAT

THERMOSTAT

FUSES (2A)

w w

g/y

g/y CHASSIS

EARTH

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

L E N

230V~50Hz PERMANENT

MAINS SUPPLY

FUSED AT 3A

FUSE RATINGS: F1: 2 A F2: 2 A

Figure 9.3

10. Boiler Installation

capiz 25 & capiz 28

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

Figure 10.1.

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 10.2).

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 line.

(Figure 10.3).

= =

033

Dimension

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

Distance to centre line 169 mm

169

60/100

Figure 10.3

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 10.4).

130 130

CONDENSATE

CONNECTION

CENTRAL HEATING

Figure 10.1

BOILER

Bracket Fixing Slots

Figure 10.2

Figure 10.4

Boiler Mounting Tabs

(NON-CONDENSING)

10.6 Mount the boiler onto the fixing bracket via the

SDV

outlet

(CONDENSING)

boiler mounting slots

0.7 Connect isolation valves assembled to the boiler

1 ensuring the washers are fitted correctly.

151151

0.8 On installing the flue, determine the required

1 length of the o

(Figure 10.6)

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

(Figure 10.4).

capiz 25 & capiz 28

10.9 Measuring from the back of the terminal connection, mark distance 'L' onto the outer air duct.

(Figure 10.5).

L+20 mm

Figure 10.5

Waste

Figure 10.6

10.10

Cut the outer air duct only to the required length

ensuring that the cut is square and free from burrs.

10.11

connection, mark distance 'L' + 20 mm onto the inner flue duct and cut the duct to size, ensuring that the cut is square and free from burrs.

10.12

connect the assembly to the boiler, ensuring that both the air and flue duct joints are fully pushed home into the connecting elbow's collar.

10.13

to the external wall surface using suitable mastic. N trim must be attached to the flue assembly prior to passing the assembly through the wall.

10.14

Data, section 2 in this manual

Measuring from the back of the terminal

Pass the flue assembly through the wall and

With the flue and joints secured fit the flue trim

ote. Where internal access only is available, the flue

For maximum flue lengths refer to the Technical

External

wall face

(Figure 10.5).

10.16

Extract the bottom part of condensate trap, by turning anti-clockwise and fill it with approximately 50 cc water re-connecting it to the boiler.

(Figure10.7).

Figure 10.7

CONDENSATE TRAP

CONDENSATE OUTLET PIPE

10.17

drainage system

Connect the condensate drainage pipe to the

(Figure10.7).

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)

Connect the domestic hot water, cold water inlet,

10.18

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

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.

10.15

Condensing type boilers must be connected to the drainage system. A plastic drain must be fitted to allow discharge of condensate to a drain. Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away. Note if a soak way is used the drain must terminate at least 500 mm from the external wall.

1.2 The internal diameter of the gas supply from the

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).

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

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

capiz 25 & capiz 28

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 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 1.0 bar.

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

(Figure 12.1)

13. Control Panel Functions

bar

Figu

re 13.1

Timer

Function switch

C.Heating temperature control

13.1 C/heating temperature controls: The boiler's integral control unit monitors and adjusts the boiler’s hydraulic circuit water outlet temperature by means of a sensor located on the C/heating flow outlet. The sensor’s electrical resistance is dependant on temperature and determines the current passing through the control potentiometer located on the control panel. The potentiometer control dial allows manual setting of the maximum required temperature (reference value) being between 30º and 85ºC. When the boiler operates the current received is compared to the 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.

System pressure gauge

LED display

bar

Figure 12.1

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.

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.

13.2 Re-set function: Should the boiler lock out at any time, please check the gas supply and ionisation probe position, the boiler may be re-started by switching to standby “O” position (Switch 2 Figure 13.1) waiting 15-30 seconds and switching back to its previous position once the fault has been eliminated.

Boiler Stand-by

Indicator

30 40 50 60 70 80 90

Flashing

Fault on CH

sensor

Outdoor sensor

Flashing

Fault on

DHW sensor

Water

Temperature

Flashing

Fault on

bar

Low System

bar

Pressure Switch

Flashing

Pressure

Flashing

Fault on Air

Flashing

Overheat

Themostat

Flames or Gas

Figure 13.2

Flashing

Failure

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

capiz 25 & capiz 28

14.7 Check the system pressure and top up if necessary.

14.8 Reset the central heating water temperature control

and room thermostat to the desired temperature settings.

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.

14.1 The CAPRIZ 25S & CAPRIZ 28S boilers have been tested and pre-set at the factory and is dispatched with its on board controls set to provide maximum central heating output. Consequently, once all the connections have been made and the boiler has been filled with water to the designed system operating pressure, the boiler may be fired prior to adjusting it’s on board controls set to a mid heating output position.

14.2 Prior to firing, check that the electrical supply to 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 water temperature control to maximum by turning fully clockwise.

Set the external room thermostat to maximum and open the thermostatic radiator valves to maximum.

14.3 Switch the boilers function switch to the heating position.The boiler's control unit will now automatically carry out pre-ignition safety checks before igniting the burner.

14.4 During the 10 second burner ignition attempt visually check that all of the burner blades ignite correctly.

If necessary, adjustments to the ignition rate may be made using potentiometer P4. Turning P4 clockwise increases the ignition rate and anti-clockwise decreases the rate. After successful ignition check the integrity of the boiler's flue for soundness and correct operation.

14.5 In order to maintain the appliance warranty after initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants.

14.6 Restart the boiler and again allow the central 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. Isolate the boiler before carrying out this operation.

15. Onboard Adjustments

15.1 The boiler incorporates 4 potentiometers and a bank of dip switches to allow adjustment to its pre-set parameters. These are situated on the rear of the control panel.(Figure 15.1) The potentiometers can easily be accessed by removing the cover on the rear of control panel (Figure 15.1).However,to reach the dip switches, the control panel must be opened. Factory settings for potentiometers shown below

CAPRIZ 25S CAPRIZ 28S

15.2 Setting the maximum c/heating flow temperature:

The boiler is dispatched with a maximum flow temperature factory set to 85°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.

15.3 255 seconds delay setting: The boiler is capable of 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 15.2) clockwise.

POTENTIOMETER ADJUSTMENT COVER

P7 P5 P2 P4

line

Figure 15.2Figure 15.1

line

POTENTIOMETERS 4 OFF

capiz 25 & capiz 28

6 5 4 3 2 1

15.4 Setting the Heating output: The CAPRIZ 25S & CAPRIZ 28S boilers are factory set to give maximum c/heating output. The heat output for heating is pre-set on potentiometer P2. (Figure 15.3).This can be adjusted to suit the system as required.

15.5 Gas valve ignition capacity. The graduated opening of the gas valve for ignition rate is governed by the 1st potentiometer P4 control, which is factory set to 4 o’clock. 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.

15.6 The boilers integral pump is factory set to 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. (

Figure 15.4)

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

Important

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

POTENTIOMETERS

POTENTIOMETER S 4 OFF

DIP SWITCHES

Figure 15.3

H (m)

0.0 0.5 1 .0 1.5 2.0 2.5 3.0 3.5

QH Chart

Figure 15.4

16. Safety Devices

16.1 An hydraulically operated primary pressure sensor monitors water pressure or water shortage in the primary hydraulic circuit and will switch the boiler off if the pressure is below 0.3bar and will switch the boiler off if the pressure falls below 0.8bar. However it is recommended the pressure is set at 1.5 bar.

16.2 The temperature of the water flowing from the 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. Refer to section 13.2

16.3 An air pressure switch situated in the boiler's fan 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.

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

1 2 3 4 5 6 7 8

DIP

8 DIP SWITCHES IN THE OFF POSITION

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

Factory Settings (NG)

Capriz 25S Capriz 28S

Dipswitch 1 OFF OFF

Dipswitch 2

Dipswitch 3

Dipswitch 4

Dipswitch 5

Dipswitch 6

Dipswitch 7

Dipswitch 8

OFF OFF

OFF ON

* Dipswitch 7 must be ON position for LPG (Propane).

17. Fault Finding Chart

capiz 25 & capiz 28

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

capiz 25 & capiz 28

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

FAULT FINDING CHART 5

Does burner ame

modulate ?

Yes

Normal operation

capiz 25 & capiz 28

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 18.2)

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 18.1.

INNER CASING PANEL

Figure 18.2

VIEWING WINDOW

SECURING SCREWS

Release the side panels by removing the screws on

the upper and lower sides

(Figure 18.3).

Remove the

panels by swinging them out and lifting them up.

Figure 18.3

SECURING SCREWS (4 OFF)

8.6 Remove the combustion chamber cover by

removing four screws on sides.

SECURING SCREWS (6 OFF)

(Figure 18.4)

SIDE PANELS

Figure 18.1

Figure 18.4

COMBUSTION CHAMBER

VIEWING WINDOW

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 18.5)

bend.

HALL

EFFECT

SENSOR

ELECTRICAL CONNECTIONS

FAN

PRESSURE SWITCH CONNECTION TUBE

Figure 18.5

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.

(Figure 18.6 &18.7)

SPARK GAP 4mm

BURNER

SENSING TUBE

GROMMET

Figure 18.6

EARTH LEAD

SECURING SCREW

capiz 25 & capiz 28

Figure 18.8

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

Figure 18.7

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.

Disconnect the cold water inlet connection to the

boiler.

Clean and inspect the filter, replace if necessary. Re-fit the filter and reinstate the cold water inlet

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.

capiz 25 & capiz 28

9.4 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 19.1)

Unclip the sensor from the pipe.

Disconnect the leads from the sensor.

PRIMARY HEAT EXCHANGER OUTLET PIPE

CENTRAL HEATING SENSOR

ELECTRICAL CONNECTIONS

Figure 19.1

Fit replacement sensor.

Fit the leads and replacement the sensor.

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 18.

capiz 25 & capiz 28

19.5 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.

9.6 Air pressure switch

The air pressure switch is located on the top of

the expansion vessel

(Figure 19.2).

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)

9.7 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 Section 18.8 retaining all washers/gaskets for use on re-assembly.

Remove the manifold as shown in

Figure 18.8.

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.

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.

Technical

9.3Figure 1

AIR PRESSURE SWITCH

ELECTRICAL CONNECTIONS

SENSING TUBES (2 OFF)

Figure 19.2

9.8 Printed circuit board (PCB)

Turn off and isolate the electrical supply.

Remove the interface cover by lifting the two

latches.

(Figure 19.4- 19.5)

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.

Figure 19.4

CONTROLS CIRCUIT BOARD COVER

RETAINING CLIPS

CONTROLS FASCIA

RETAINING CLIPS

Figure 19.5

capiz 25 & capiz 28

Pull off the motor, remove the cover and disconnect

the electrical leads from cable box Figure 19.8.

Figure 19.8

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.

9.9

Replacing the pump body:

Remove the motor as described above.

PRINTED

CIRCUIT

BOARD

SCREW

9.9

ump

Follow 19.9a or 9b depending on type of failure.

9.9

Replacing motor:

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

OFF

Figure 19.6

Remove the screws shown in

COVER

Figure 19.7.

Figure 19.7

PUMP HEAD

Remove the pressure gauge connection

as detailed in (

Remove the expansion vessel pipe by removing the

19.10).

clip on the pump body.

Disconnect the electrical leads of low pressure

sensor.

Remove the return hydroblock.

Disconnect the pumps outlet fitting.

(Figure 19.9)

UNION NUT

CLIP

UNION NUT

EXPANSION VESSEL PIPE

PRESSURE GAUGE CONNECTION

PUMP BODY

Figure 19.9

SECURING SCREW

CLIP

PUMP BODY

SECURING SCREWS (4 OFF)

capiz 25 & capiz 28

Remove the fixing screws from the pump and

hydraulic block at the bottom of the boiler

( Figure 19.10 ).

SECURING SCREW

SECURING SCREWS

Figure 19.10

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.

9.10 Low water pressure sensor

Drain the boiler’s hydraulic circuit as detailed in

19.2).

(

LOW WATER PRESSURE SENSOR

Figure 19.11

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.

SECURING SCREWS (6 OFF)

VIEWING

COMBUSTION CHAMBER COVER

Figure 19.12

WINDOW

9.11 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.

9.12 Gas valve

Ensure that gas supply to boiler is turned off.

Disconnect the electrical connections to gas valve

modulating coil.

capiz 25 & capiz 28

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 19.13).

ELECTRICAL PLUG

SCREW

Figure 19.13

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 19.14).

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.

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:

aximum and Minimum setting

19.13

Connect a suitable pressure gauge to the pressure outlet on the gas valve

mbar

Figure 19.15

(Figure 19.15).

Figure 19.16

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

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.

igure 19.16)

Adjust inner screw to give correct min burner

pressure whilst holding 10 mm nut on maximum

GAS ISOLATION VALVE

SUPPLY PIPE CONNECTION

SECURING SCREWS

Figure 19.14

adjuster. Clockwise to increase,

Anti-clockwise to decrease.

Figu

re 19.17

(Figure 19.17)

Re-connect the lead of gas valve coil.

19.15

Safety Thermostats

capiz 25 & capiz 28

After adjustment refit plastic cap on gas valve

adjuster and remove gauge and leak test pressure

test point.

19.14

xpansion vessel

Drain the boiler’s hydraulic circuit as detailed in

19.2)

(

Disconnect the pipe coupling on expansion vessel

(Figure 19.18).

SECURING NUT

FLEXIBLE PIPE CONNECTION

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

Locate the overheat safety thermostats at the front left handside of the boiler and on the right handside of the primary heat exchanger

(Figures 19.20 & 19.21)

Disconnect the electrical connections from

the thermostat.

LIMIT SAFETY

THERMOSTAT

Figure 19.20

ELECTRICAL CONNECTIONS

PIPE CLIP

Figure 19.18

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

Remove the side panels as described in section 18

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

(Figure19.19)

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 1 bar (15 psi)

Figure 19.19

Figure 19.21

PRIMARY HEAT EXCHANGER

OVERHEAT SAFETY THERMOSTAT

Unclip the thermostat from the pipe.

Fit the replacement thermostat in reverse order of removal.

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

20. Gas Type Conversion

capiz 25 & capiz 28

19.16 Pressure relief valve ( Figure 19.22)

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.

PRESSURE SAFETY RELIEF VALVE

UNSCREW TO REMOVE

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 section 18.8 ( shown Figure 18.8)

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.

DISCHARGE PIPE

Dipswitch 1 OFF OFF

Dipswitch 2

Dipswitch 3

Dipswitch 4

Dipswitch 5

Dipswitch 6

Dipswitch 7

Dipswitch 8

R.H. HYDRAULIC BLOCK

Factory Settings (NG)

Capriz 25S C apr iz 28S

OFF OFF

OFF ON

Figure 19.22

Factory Settings (LPG)

Capriz 25S C apr iz 28S

OFF OFF

ON ON

OFF ON

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

APPENDICES

SPARE PARTS LIST

PART No. DESCRIPTION ORDER CASE

1 2 3 4 5 6 7 8

11 ELECTRONIC CONTROL BOARD 3003202166 12

31 41

51 16 17 18 19

52 26

HYDROBLOCK – PUMP PART 3003200232

-28 kW NG)DLOFINAMHTIW(RENRUB

DRACECAFRETNI

OVERHEAT SAFETY THERMOSTAT 3003200379

IGNITION ELECTRODE - RIGHT 3003202200

IGNITION ELECTRODE - LEFT 3003202201

FLAME SENSE ELECTRODE 3003202102

L CAPRIZ 25SENAPTNORF L CAPRIZ 28SENAPTNORF

SSENRAHGNIRIW

SYSTEM BY PASS PIPE

3003202154 3003200421LENAPLORTNOC9

3003200183

3003200176 3003200177

3003202321 3003200937

8300023003HCTIWSERUSSERPWOL 9100023003EVLAVYTEFAS 6331023003PMUP 8200023003LESSEVNOISNAPXE 9140023003EVLAVSAG 3512023003-24 kW NG)DLOFINAMHTIW(RENRUB

4800023003REVOCBCP01

2510023003ROSNESHC 3760904003EGUAGERUSSERPRETAW

5612023003NAF 2300023003HCTIWSERUSSERPRIA

5771023003PARTETASNEDNOC 6840023003REGNAHCXEOBRUT

capiz 25 & capiz 28

25S & 28S

User Instructions

capiz 25 & capiz 28

Condensing

Wall Mounted

System Boiler

www.he a t l i ne.co . u k

atural Gas / LPG

HEATLINE™ CAPRIZ 25S / CAPRIZ 28S Condensing System Boilers

British Gas Service Listing

CAPRIZ 25S Condensing System Boiler G.C.No 41-157-10 CAPRIZ 28S Condensing System Boiler G.C.No 41-157-11

MPORTANT INFORMATION

capiz 25 & capiz 28

The Heatline

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

He atline

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 25S / CAPRIZ 28S boilers with an Installation, Commissioning

come complete

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 25S.

The CAPRIZ 25S / CAPRIZ 28S is a high efficiency gas fired system 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.

ENERAL DESCRIPTION OF BOILER

The CAPRIZ 25S & CAPRIZ 28S are system boilers for central heating appliances. 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 CAPRIZ 25S / CAPRIZ 28S can be set to operate central heating.

CENTRAL HEATING MODE :

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.

capiz 25 & capiz 28

CCESS TO THE BOILER CONTROLS

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

(Figure 1)

bar

Timer

Function switch

C.Heating temperature control

OILER CONTROLS

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

System pressure gauge

LED display

(Figure 2)

is as follows:

bar

Figure 2

1. (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.

2. 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.)

Figure 1

capiz 25 & capiz 28

4. 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

On installation your installer will have filled the boiler 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 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 2 bar.

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.

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,

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

SYSTEM PRESSURE

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

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

capiz 25 & capiz 28

3005114697

capiz 25 & capiz 28

Nottingham Road,

Tel: 01773 596 099

Fax: 01773 828 123

Email: sales@heatline.co.uk

Heatline

Belper,

Derbyshire,

DE56 1JT

heatline Capriz 25s User guide

Specifications and Main Features

Frequently Asked Questions

User Manual