Mamiya C32, C28, C24 User Manual

Download

installation and servicing

mini HE

Your Ideal installation and servicing guide

For details of document amendments, refer to page 3

Model

Serial No.

C24,C28,C32

For users guide see reverse of book

When replacing any part of this appliance, use only spare parts that you can be assured conform to safety and performance specification that we requir e. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers

17962.1155.1 1307 68A4 GB

*1796211551*

For the v ery latest copy of literature for specificatio n pu rposes plea se visit o u r w ebsite www .idealbo iler s.com wher e yo u will be able to download the relevant informatio n in pdf format.

mini HE --- Installation & Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from book reference.................17962.1155.1 4206

F Page 10 -- Sentinel company name & address amended

Caradon Ideal Limited reserve the right to vary specification without notice

mini HE --- Installation & Servicing

GENERAL

Ta b l e 1 --- B o i l e r D a t a

mini HE C24 mini HE C28 mini HE C32

Gas supply type & connection II

Inlet / Outlet connection --- Domestic Hot Water 15 mm copper

Flow & return connection --- Central Heating 22 mm copper

Flue terminal diameter mm (in.) 100 (4)

AverageFlueTemp. ---MassFlowRate Deg C | g/s 90 18.8 90 21.1 90 21.5

Max working pressure (sealed system) bar (lb/in2) 3.0 (43.5)

Max DHW water inlet pressure bar (lb/in2) 10.0 (145.0)

Min DHW water inlet pressure bar (lb/in2) 0.3 (4.4)

Electrical supply 230 Vac 50 Hz

Max power consumption W 140 150 150

External fuse rating 3A

Internal fuse rating F1-- -F2 3.15 AF

Water content --- CH litre (gal.) 2.1 (0.46) 2.2 (0.48) 2.2 (0.48)

Water content --- DHW litre (gal.) 0.2 (0.044)

Dry weight kg (lb.) 42.5 (93.7) 44.5 (98.1) 44.5 (98.1)

Size: Height / Width / Depth mm (in.) 803 (31 5/8”) / 400 (15 3/4”) / 345 (13 9/16”)

Lift weight kg (lb.) 37.5 (82.7) 39.5 (87.1) 39.5 (87.1)

Ta b l e 2 --- P e r f o r m a n c e D a t a --- C e n t r a l H e a t i n g

mini HE C24 mini HE C28 mini HE C32

Max Min Max Min Max Min

Burner pressure (Hot) G20

Input based on nett CV kW (btu/h) 25.0 (85 295) 11.0 (37 530) 29.0 (98 942) 13.0 (44 353) 33.3 (113 620) 15.7 (53 568)

Input based on gross CV kW (btu/h) 27.7 (94 516) 12.2 (41 628) 32.2 (109 871) 14.4 (49 135) 37.0 (126 244) 17.4 (59 368)

Output Non Condensing G20

Output Condensing G20

Gas consumption (Hot) G20

Seasonal efficiency* G20

NOx classification Class 2

mbar

G31

(in.w.g.)

kW (btu/h) 24.6 (83 973)

G31

kW (btu/h) 26.6 (90 754)

G31

l/s (ft3/h)

G31

l/s

(SEDBUK)

G31

10.8 (4.3)

35.5 (14.2)

23.7 (80 894)

26.6 (90 754)

0.72 (91.5)

0.30

Band B 87.7 Band B 87.0

1.5 (0.6)

7.7 (3.1)

10.2 (34 936)

11.1 (37 871)

10.8 (36 997)

0.31 (39.5)

0.13

*The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by a notified body.

Ta b l e 3 --- P e r f o r m a n c e D a t a --- D o m e s t i c Ho t W a t e r

mini HE C24 mini HE C28 mini HE C32

Burner pressure (Hot) G20

Input based on nett CV kW (btu/h) 25.0 (85 295) 29.0 (98 942) 33.3 (113 620)

Input based on gross CV kW (btu/h) 27.7 (94 516) 32.2 (109 871) 37.0 (126 244)

Output Non Condensing G20

Output Condensing G20

Gas consumption (Hot) G20

Flow 35 ûCtemp.rise l/m (gpm) 10.0 (2.2) 11.7 (2.6) 13.1 (2.9)

Domestic hot water specific rate l/m (gpm) 11.9 (2.6) 13.9 (3.1) 14.6 (3.3)

Note: the gas consumption is calculated using a calorific value of 38.7 MJ/m

Btu/ft

) nett.

G31

(1038 Btu/ft3) gross or 34.9 MJ/m3(935

To obtain the gas consumption at different calorific value: -- -

a. FOR L/S --- divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m

b. FOR FT

/H --- divide the gross heat input (Btu/h) by the

)

gross C.V. of the gas (Btu/ft

mbar (in.w.g.)

kW (btu/h) 24.6 (83 973)

kW (btu/h) 26.6 (90 754)

l/s (ft3/h) l/s

)

10.8 (4.3)

35.5 (14.2)

23.7 (80 894)

26.6 (90 754)

0.72 (91.5)

0.30

Key to Symbols:

IE = Ireland, GB = United Kingdom (Countries of destination) PMS = Maximum operating pressure of water C

12C32C52

connection via concentric ducts to a horizontal or vertical terminal or twin flue system.

2H3P

H or 3rd family gas group 3P

G20 20mbar, G31 37mbar, 22 mm copper

2H3P

10.0 (4.0)

36.0 (14.4)

28.3 (96 488)

27.4 (93 599)

30.7 (104 602)

0.83 (105.5)

0.34

Band B 87.6 Band B 87.1

28.3 (96 488)

27.4 (93 599)

30.7 (104 602)

1.6 (0.6)

7.7 (3.1)

12.1 (41 284)

13.2 (44 965)

12.9 (44 016)

0.37 (47.0)

Maximum

10.0 (4.0)

36.0 (14.4)

0.83 (105.5)

0.34

0.14

13.0 (5.2)

36.0 (14.4)

32.2 (109 866)

34.4 (117 374)

0.95 (121.0)

0.39

Band B 86.8 Band B 88.8

13.0 (5.2)

36.0 (14.4)

32.2 (109 866)

34.4 (117 374)

0.95 (121.0)

2.7 (1.1)

7.3 (2.9)

15.0 (51 180)

15.6 (53 227)

0.45 (57.2)

0.18

0.39

= a room sealed appliance designed for

= appliance designed for use on 2nd family gas group

CAUTION. To avoid the possibility of injury during the installation, serv i cing or cleani ng

of this appliance care should be taken handling edges of sheet steel components.

mini HE --- Installation & Servicing

GENERAL

mini HE

Boiler size G.C. appliance No. PI No.

(Benchmark No.)

mini HE C24 47---348 ---38 87BQ81 mini HE C28 47---348 ---39 87BQ81 mini HE C32 47---348 ---41 87BQ81

Destination countries: GB, IE

CONTENTS

Air supply 9

Benchmark Commissioning Checklist 62

Boiler clearances 6

Boiler exploded view 14

Electrical connections 25

Electrical supply 10

Fault finding 51

Flow wiring diagram 27

Flue fitting 16

Gas conversion 33

Gas safety regulations 7

Gas supply 8

Installation 15

Mandatory requirements 7

Replacement of components 38

Safe handling 7

Servicing 34

Short list of parts 59

Thermostatic radiator valves 12

Water connections 23

Water treatment 9

Wiring diagrams 26

For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions. Self -- -certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page

Make and model 5 Appliance serial no. on data badge 14 SEDBUK No. % 4

Controls

Time and temperature control to heating 28/29 Time and temperature control to hot water 28/29 Heating zone valves N/A TRV’s 12 Auto bypass 12 Boiler interlock 12

For all boilers

Flushing to BS.7593 9 Inhibitor 9

Central heating mode

Heat input to be calculated

Boiler Page

Burner operating pressure measure and record Central heating flow temp. measure and record Central heating return temp. measure and record

For combination boilers only

Scale reducer 12 Hot water mode Heat input to be calculated Max. operating burner pressure measure and record Max. operating water pressure measure and record Cold water inlet temp measure and record Hot water outlet temp. measure and record Water flow rate at max. setting measure and record

For condensing boilers only

Condensate drain 24 For all boilers: complete, sign & hand over to customer For assistance see Technical Helpline on the back page

NOTE TO THE INSTALLER: COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

mini HE --- Installation & Servicing

GENERAL

1 BOILER WATER CONNECTION

400

257

803

700

Wall

mounting

Plate

Condensate

drain

connection

area

Pipe size O.D. mm

CH flow 22

CH return 22

Gas inlet 22

DHW cold inlet 15

DHW hot outlet 15

83 (3 1/4”)

52 (2”)

65 (2 9/16”)

CH flow

DHW hot outlet

65 (2 9/16”)

64 (2 1/2”)

Gas inlet

CH return

DHW cold inlet

2 BOILER CLEARANCES

All dimensions in mm (in.)

The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions.

200 (7 7/8”)

25 (1”) 50 (2”)

Side and Rear Flue

a. Providedthattheflueholeiscutaccurately,e.g.withacore

drill, the flue can be installed from inside the building where wall thickness does not exceed 600 mm (24”).

Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside.

installation from inside ONLY

b. If a core boring tool is to be used inside the building the

spaceinwhichtheboileristobeinstalledmustbeatleast wide enough to accommodate the tool.

273 (10 3/4”) 127 (5”)

190 (7 1/2”)

200 (7 7/8”)

Bottom clearance

The bottom clearance, after installation, can be reduced to 20mm. However, 200mm must be available for servicing.

Front clearance

The minimum front clearance when built into a cupboard is 50mm (2”) from the cupboard door. However 450mm (17 3/4”) overall clearance is still required, with the cupboard door open, to allow for servicing.

95 (3 3/4”)

mini HE --- Installation & Servicing

GENERAL

INTRODUCTION

mini HE C24, mini HE C28 and mini HE C32 are wall

mounted, low water content, balanced flue, condensing combination gas boilers.

Central heating (CH) output and domestic hot water (DHW) output are both fully modulating:

-- - between 10.2 (34 936) and 24.6* (83 973) kW (btu/h) for

model mini HE C24;

-- - between 12.1 (41 284) and 28.3* (96 488) kW (btu/h) for

model mini HE C28.

--- between 15.0 (51 180) and 32.2* (109 866) kW (btu/h) for

model mini HE C32.

* outputs for G31 (propane) are slightly different. See section Boiler Data at page 4 for detailed figures.

Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation.

Theboilersaresuitableforconnectiontofullypumped, pressurised sealed water systems ONLY.

AsystembypassisnotrequiredwhenTRV’sarefittedtoall radiators (see Frame 5). The boiler incorporates an automatic bypass.

A circulating pump, pressure gauge, safety valve and heating expansion vessel are provided.

The CH flow temperature is controlled by a temperature probe. In DHW mode the boiler modulates to sustain a nominal adjustable water flow temperature of 55 ûC.

The boiler casing is of white painted mild steel with a drop --- down controls access door.

The boiler temperature control is located behind the control panel door.

The main heat exchanger is made of copper.

The condensing heat exchanger (recuperator) and the DHW heat exchanger are stainless steel.

The system pipework must include drain cocks in appropriate places. Pipework may be taken downwards.

For upwards pipework installation an additional frame (optional) must be used (see frame 25).

OPTIONAL EXTRA KITS

Programmer Kit fits neatly within the casing. Separate fitting instructions are included with the kit. Note. If using an alternative programmer read Frame 33 first.

Horizontal Concentric Extension Ducts

Up to 2,7 m (8’ 10”) for mini HE C24, mini HE C28 models.

Upto1,8m(5’11”)formini HE C32 model.

Other available kits are listed in frame 9.

SAFE HANDLING

This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:

F Grip the boiler at the base. F Be physically capable. F Use PPE as appropriate, e.g. gloves, safety footwear.

mini HE --- Installation & Servicing

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.

F Keep back straight. F Avoid twisting at the waist. F Avoid upper body/top heavy bending. F Always grip with the palm of the hand. F Use designated hand holds. F Keep load as dose to the body as possible. F Always use assistance if required.

DHW OPERATION

With no call for CH the boiler fires only when DHW is drawn off. When there is a call for CH, the heating system is supplied at the selected temperature until DHW is drawn off. The output is then directed by the diverter valve to heat the secondary heat exchanger and supply a maximum draw ---off of:

mini HE C24 10.0 (2.2) l/min (gpm) at 35 degree rise.

mini HE C28 11.7 (2.6) l/min (gpm) at 35 degree rise.

mini HE C32 13.1 (2.9) l/min (gpm) at 35 degree rise.

The nominal DHW temperature is 55 ûC, but water drawn off when the boiler has been on for central heating may be hotter than this, for a short period of time.

GAS SAFETY

Current Gas Safety (Installation and Use) Regulations or rules in force

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force. In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the:

F Gas Safety (Installation and Use) Regulations F The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

F The Water Fittings Regulations or Water byelaws in

Scotland.

F The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE , the installation must be carried out by a Competent Person and installed in accordance with the current edition of I.S.813 ”Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

Detailed recommendations are contained in the following British Standard Codes of Practice:

BS 5440:1 Flues (for gas appliances of rated input not

exceeding 70 kW).

BS 5440:2 Ventilation (for gas appliances of rated input

not exceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for

domestic purposes (2nd Family Gases)

BS 6700 Design, installation testing and maintenance of

services supplying hot water for domestic use.

BS. 6798 Installation of gas fired hot water boilers of

rated input not exceeding 70 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635.

GENERAL

The Electricity at Work Regulations, 1989.

The manufacturers notes must NOT be taken, in any way, as overriding statutory obligations.

IMPORTANT These appliances are CE certificated for safety and performance. It is, therefore,importantthatnoexternal controldevices,e.g.fluedampers,economisersetc.,are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Ltd. in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Caradon Ideal Ltd. could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels, which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of the boiler in its manufacture.

LOCATION OF BOILER AND FLUE OUTLET

The boiler must be installed on a flat and vertical wall, capable of adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary, unless required by the local authority.

The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7, 1998.

Bathroom Installations

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower.

For Ireland reference should be made to the current ETCI rules for electrical installations and I.S.813:2002

Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

Note. It is not permissible to install a mains socket in a bathroom.

Where installation will be in an unusual location, special procedures may be necessary and BS 6798 gives detailed guidance on this aspect.

Compartment Installations

A compartment used to enclose the boiler should be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided that it is modified for the purpose.

In both cases details of essential features of cupboard / compartment design, including air cupboard installation, are to conform to the following:

F BS 6798 (No cupboard ventilation is required - -- see “Air

supply” for details)

F The position selected for installation MUST allow

adequate space for servicing in front of the boiler .

F For the minimum clearances required for safety and

subsequent service, see the wall mounting template and frame 2. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier. Natural gas boilers must be installed on a gas supply with a governed meter. A gas meter can only be connected by the local gas supplier or by a registered CORGI engineer.

Propane gas boilers MUST be installed with pipes, cylinders and pressure regulators fitted in accordance with BS.5482.1. Bulk tank installations MUST comply with the Home Office code of practice for storage of liquefied petroleum gas at fixed installations. The complete installation MUST be tested for gas tightness and purged as described in the above code.

The boiler is adjusted at the factory for use with the relevant supply gas. A working gas pressure equal to that stated in Table 1 MUST be available at the boiler inlet.

Where applicable, the appliance can be converted for G 2 0 --- N a t u r a l G a s o r G3 1 --- P r o p a n e Ga s b y u s in g t h e appropriate conversion kit.

IMPORTANT Installation pipes MUST be fitted in accordance with BS. 6891. In IE refer to I.S. 813.2002. Pipework from the meter to the boiler MUST be of an adequatesize,i.e.notlessthan22mmO.D.copperor3/4” BSP iron.

FLUE INSTALLATION REQUIREMENTS

Thefluemustbeinstalledinaccordancewiththe recommendations of BS. 5440--- 1 2000. In IE refer to I.S. 813.2002.

The following notes are intended for general guidance.

1 The boiler MUST be installed so that the terminal is

exposed to external air.

2 It is important that the position of the terminal allows the

free passage of air across it at all times.

3 Minimum acceptable spacing from the terminal to

obstructions and ventilation openings are specified in Tab l e 4.

4 Where the lowest part of the terminal is fitted less than 2m

(6’6”) above a balcony, above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard. Ensure that the guard is fitted centrally.

5 Where the terminal is fitted within 850mm (34”) of a plastic

or painted gutter or 450mm (18”) of painted eaves then an aluminium shield at least 750mm (30”) long should be fitted to the underside of the gutter or painted surface fitted centrally above the flue.

6 The air inlet/products outlet duct and the terminal of the

boiler MUST NOT be closer than 25mm (1”) to combustible material. Detailed recommendations on the protection of combustible material are given in BS. 5440---1:2000. In IE refer to I.S. 813.2002.

Table 4 --- Balanced flue terminal position

Terminal position

1 Directly below, above or along side

of an openable window, air vent or other ventilation opening

2 Below guttering, drain pipes or soil

pipes

3 Below eaves 25 mm ( 1”) ***

4 Below balconies or a car port roof 25 mm ( 1”) ***

Minimum spacing

300 mm (12”)

25 mm ( 1”) ***

mini HE --- Installation & Servicing

GENERAL

5 From vertical drain pipes or soil

pipes*

6 Fr om an internal or external corner

or to a boundary along side the terminal

7 Above adjacent ground, roof or

balcony level

8 From a surface or a boundary

facing the terminal.

9 From a terminal facing a terminal 1200 mm (48”)

10 From an opening in a car port (e.g.

door or window) into dwelling

11 Vertically from a terminal on the

same wall

12 Horizontally from a terminal on the

wall

* If the terminal is within 150mm of any vertical soil or drain pipe, an aluminium shield at least 400mm (15 3/4”) long should be fitted equi--- distant from the terminal and close to the pipe.

*** Only 1 spacing down to 25mm is allowable per installation.

Vertical Terminals

13 Above the roof pitch with roof

slope of all angles.

Above flat roof

14 From single wall face

From corner wall faces

Twin Flue Applications

15 Centre distance between air inlet

and flue outlet ducts

** Where the twin flue ducts are positioned at or near the above minimum centres the wall sealing gaskets should be trimmed to allow them to fit flat to the wall. This should be done for both inside and outside wall gaskets

Terminals guards are available from boiler suppliers --- ask for Tower Flue Guard, Model K6. In case of difficulty seek advice from:

Grasslin UK Ltd.,To wer house, Vale Rise, Tonbridge, Kent TN9 1TB T el. +44 (0) 1732 359 888 Fax No. +44 (0) 1732 354 455 www.tfc---group.co.uk

IMPORTANT It is absolutely ESSENTIAL to ensure, in practice, that products of combustion discharging from the terminal cannot re --- enter the building or any other adjacent building through ventilators, windows, doors other sources of natural air infiltration, or forced ventilation / air conditioning.

If this should occur the appliance MUST be turned OFF, labelled as “unsafe” until corrective action taken.

25 mm ( 1”) ***

300 mm (12”)

600 mm (24”)

1200 mm (48”)

1500 mm (60”)

300 mm (12”)

600 mm (24”)

1000 mm (40”)

120mm (5”) **

AIR SUPPLY

It is NOT necessary to have a purpose---provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS6798, Clause 12, BS 5440:2 and in IE I.S. 813:2002 may be disregarded.

mini HE --- Installation & Servicing

WATER CIRCULATION SYSTEM

The boilers are designed for connection to pressurised, fully pumped, sealed water central heating systems ONLY. The domestic hot water (DHW) calorifier is incorporated within the combi boiler and only requires connection to the mains water supply.

Additional Pumps.

The boiler is supplied with an integral circulating pump. If the boiler is to be used in conjunction with any additional circulating pumps, please contact the Technic al Helpline for advice on application.

IMPORTANT

A minimum length of 1m of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping.

Ensure that the mains water supply pressure is adequate to provide the required DHW flow rate. Refer to Table 1 on page 4.

The central heating system should be in accordance with BS. 6798 and, in addition, for smallbore and microbore systems BS. 5449.

The domestic hot water system should be in accordance with BS. 5546 and BS. 6700.

Copper tubing to BS 2871:1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water.

Any soldered joints on potable water pipework MUST NOT be made with solder containing lead.

Ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss and any possible freezing - -- particularly where pipes run through roof spaces or ventilated underfloor spaces.

Draining taps should be at least 1/2” BSP nominal size and be in accordance with BS 2879.

WATER TREATMENT

Central Heating

Antifreeze fluid, corrosion and scale inhibitor fluids suitable for use with boilers having copper heat exchangers may be used in the central heating system.

IMPORTANT

The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited INVALID.

Caradon I deal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water T r eatment in Central Heating Systems.

Caradon Ideal Limited recommend the use of Fernox, GE Betz Sentinel or Salamander water treatment products, which must be used in accordance with the manufacturers instructions.

Notes.

1. It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers’ instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS 7593:2006 details the steps necessary to clean a domestic heating system.

3. In hard water areas, treatment to prevent lime scale may be necessary --- however, the use of artificially softened water is NOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

GENERAL

Domestic Hot Water

In hard water areas where mains water can exceed 200ppm Total Hardness (as defined by BS 7593:2006 Table 2) a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company. The use of artificially softened water, however, is NOT permitted.

Caradon Ideal Limited recommend the use of Fernox Qantomat, Sentinel Combiguard and Calmag CalPhos I scale reducing devices, which must be used in accordance with the manufacturers’ instructions.

For further information contact:

3 ELECTRICAL SUPPLY

Warning. This appliance must be efficiently earthed.

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply. For Ireland reference should be made to the current ETCI rules for electrical installations.

Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ +44 (0) 1799 550811

Salamander (Eng) Ltd Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BY

+44 (0) 121 378 0952

The point of connection to the mains should be readily accessible and adjacent to the boiler , except for bathroom installations where the point of connection to the mains MUST be situated outside of the bathroom.

Note. Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

Calmag Ltd. Unit 4---6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN +44 (0) 1535 210320

Sentinel Performance Solutions The Heath Business & Technical Park Runcorn Cheshire WA7 4QX +44 (0) 800 389 4670

4 SEALED SYSTEM REQUIREMENTS

Central Heating

Note. mini HE boilers are suitable for fully pumped pressurised sealed systems only.

REQUIREMENTS

1 General

The installation must comply with the requirements of BS. 6798 and BS. 5449.

2 Flow Temperature

The installation should be designed to work with flow temperatures of up to 90 ûC.

3 Working Pressure

All components of the system must be suitable for a working pressureof3bar(45lb/in care should be taken in making all connections so that the risk of leakage is minimised.

The following components are incorporated within the appliance:

a. Circulating pump.

b. Safety valve; with a non ---adjustable pre--- set lift pressure of 3bar(45lb/in

c. Pressure gauge; covering a range of 0 --- 4 bar.

d1. 6 litre expansion vessel; with an initial charge pressure of

0.7 bar (10.5 lb/in

d2. 7 litre expansion vessel; with an initial charge pressure of

1.0bar(15lb/in

For further details refer to BS.5449:1 and the British Gas Corporation publication ’Specifications for Domestic Central Heating and Hot Water’.

)formini HE C32.

) and temperature of 110 ûC. Extra

)formini HE C24 and mini HE C28.

4 Filling the system

Fill the system through a temporary hose connection from a draw---off tap supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling.

When installing the filling connection provided with the boiler an additional WRAS approved valve must be fitted to the mains water supply upstream of the double check valve to fully comply the Water Regulations

Stop valve Additional stop valve

CH return

Temporary hose (disconnect after filling)

System filling and make ---up

Proceed with the following:

F Thoroughly flush out the whole of the system with cold

water before fitting the boiler.

F Fill and vent the system until the pressure gauge registers

1.5bar(22lb/in

F Release water from the system until a pressure of 1 bar

(15 lb/in

To av oid getting debris on the valve seat, do not use the safety valve to do this.

F Light the boiler and heat the system to the maximum

working temperature. Examine for leaks.

F Turn off the boiler and drain the system while still hot. F Refill and vent the system. F Re --- pressurise the system to the desired charge pressure

(see Table 5).

) is reached.

Hose unions

). Examine for leaks.

Mains Water Supply

Double check valve assembly Note direction of f low

mini HE --- Installation & Servicing

GENERAL

Table 5 mini HE C24, mini HE C28

System charge pressure (bar)

Safety valve setting 3.0

Vessel pre ---charge pressure (bar)

System volume (litres) V o lume of expansion vessel

75 --- --- ---

100 0.3 0.8 1.4

125 1.8 2.5 3.2

150 3.4 4.2 5.0

175 5.0 6.0 7.0

200 6.5 7.6 8.7

225 8.1 9.3 10.6

250 9.6 11.1 12.4

275 11.2 12.8 14.3

300 12.8 14.5 16.1

Multiply this factor by system volume and deduct 6 litres to obtain size of additional vessel for other system volumes.

0.5 0.7 1.0

0.7

in addition to 6 litre unit

fitted to boiler

0.063 0.069 0.074

Ta b l e 6 mi n i H E C 3 2

System charge pressure

0.5 0.7 1.0

(bar)

Safety valve setting 3.0

Vessel pre ---charge pressure

0.7

(bar)

System volume (litres) Volume of expansion vessel

in addition to 7 litre unit

fitted to boiler

75 --- --- ---

100 --- --- 0.4

125 0.8 1.6 2.3

150 2.5 3.4 4.1

175 4.0 5.1 6.0

200 5.6 6.8 7.8

225 7.2 8.6 9.7

250 8.8 10.3 11.5

275 10.3 12.0 13.4

300 11.9 13.7 15.2

Multiply this factor by

0.063 0.069 0.074 system volume and deduct 7 litres to obtain size of additional vessel for other system volumes.

5 Size of expansion vessel

For the system water expansion to be contained by the 6 litre expansion vessel fitted to the following models:

mini HE C24, mini HE C28

the cold system volume must not exceed:

96 litres when pressurised to 0.5 bar (cold)

88 litres when pressurised to 0.7 bar (cold)

81 litres when pressurised to 1.0 bar (cold)

If the pressure exceeds 2.65 bar when the boiler is up to temperature with all radiators in use then an additional expansion vessel MUST be installed on the return pipework.

For expansion volumes see Table 5.

6 Hydraulic Loss Remaining pump capacity

mH2O

For the system water expansion to be contained by the 7 litre expansion vessel fitted to the following model:

mini HE C32

the cold system volume must not exceed:

111 litres when pressurised to 0.5 bar (cold)

101 litres when pressurised to 0.7 bar (cold)

95 litres when pressurised to 1.0 bar (cold)

If the pressure exceeds 2.65 bar when the boiler is up to temperature with all radiators in use then an additional expansion vessel MUST be installed on the return pipework.

For expansion volumes see Table 6.

Guidance on vessel sizing is given in BS 7074:1 and BS 5449

For IE refer to the current edition of I.S. 813.

7 Draining the system

Draining taps MUST be located in accessible positions to permit the draining of the whole central heating system, including the central heating side of the boiler. The taps should be at least 1/2” BSP nominal size and be in accordance with BS 2879.

0 200 400 600 800 1000 1200 1400

Flow rate l/hour

mini HE --- Installation & Servicing

GENERAL

5 BOILER CONTROL INTERLOCKS

Thermostatic radiator valves.

Caradon Ideal Ltd. support the recommendations made by

leading manufacturers of domestic heating controls that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS5449. Such an arrangement will provide for a more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods, saving electrical energy.

It is therefore strongly recommended that, when thermostatic radiator valves are used, the space heating temperature control over a living/dining area or a hallway, having a heat requirement of at least 10% of the boiler output, is achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves as stated in BS5449.

6 DOMESTIC HOT WATER

REQUIREMENTS

1 The domestic hot water service must be in accordance

with BS 5546 and BS 6700.

2 For the minimum and maximum working pressures of the

mini HE C24, mini HE C28 and mini HE C32 domestic hot water circuit refer to Table 1, page 4.

3 The cold water supply pipe should be flushed before

fitting the boiler.

4 The boilers are suitable for connection to most types of

washing machine and dishwashing appliances.

For further information refer to “Good Practise Guide 143” a publication of the energy efficiency office, available from the building research establishment Garston Watford WD2 7JR tel: +44 (0) 1923 664258

The boiler is fitted with an automatic internal bypass. No further system bypass is required.

Typical installation

TRV

5 When connecting to suitable showers,i.e.thosedesigned

for modulating domestic hot water, ensure that:

a. The cold inlet to the boiler is fitted with an approved

anti---vacuum or syphon non --- return valve.

b. Hot and cold supplies are of equal pressure.

6 Hard water areas

In areas where the water is ’hard’ it is recommended that a proprietary scale---reducing device is fitted into the boiler cold supply, within the requirements of the local water company.

Room T/stat

Balancing valve

mini HE --- Installation & Servicing

GENERAL

7BOILERWATERCIRCUITDIAGRAM

1 Domestic hot water (DHW) heat exchanger 2 Domestic hot water (DHW) flow switch 3 Domestic hot water (DHW) outlet pipe 4 Domestic cold water inlet cock 5 Three--- way diverter valve 6 Main circuit drainage cock

7 Cent ral heating flow cock 8 B y --- p a s s v a l v e 9 Central heating (CH) return cock 10 3 bar pressure relief valve 11 Gas cock 12 Expansion vessel 13 Gas valve inlet pressure tap 14 Modulating gas valve 15 Burner pressure tap 16 Flame detection electrode 17 Ignition electrodes 18 Burner 19 Combustion chamber 20 Primary heat exchanger 21 Fan 22 Air pressure switch 23 Venturi device 24 Flue outlet pipe 25 Air intake pipe 26 Automatic air vent 27 Overheat thermostat 28 Pump 29 Pump vent plug 30 CH temperature probe 31 CH flow switch 32 DHW temperature probe 33 CH circuit temperature/pressure gauge 34 Recuperator 35 Flue temperature probe 36 Condensate trap 37 Condensate drain pipe

mini HE --- Installation & Servicing

8 B O I L E R A S S E M B LY ---

Exploded View

INSTALLATION

9 10 11

14 15

1 Air pressure switch 2 Recuperator 3Condensatetrap 4 Overheat thermostat 5Condensingtomainheat

exchanger connection pipe 6 Primary heat exchanger 7 Inner case cover 8 Flame detection electrode 9 Ignition electrodes 10 Heat exchanger return pipe 11 Auto air vent 12 Main circuit drainage cock 13 Pump

14 DHW flow switch 15 DHW temperature probe 16 Right hand panel 17 Boiler front panel 18 Appliance data badge (inside) 19 Left hand panel 20 CH circuit pressure gauge 21 Model identification & instructions 22 Control panel door 23 Electronic control pcb 24 CH temperature probe 25 CH flow switch 26 Heat exchanger flow pipe 27 Return manifold

28 3 way diverter valve

29 DHW heat exchanger

30 Bypass pipe

31 3 bar pressure relief valve

32 Gas valve

33 Gas valve outlet pipe

34 Injector manifold

35 Burner

36 Flue hood

37 Fan

38 Expansion vessel

39 Venturi

40 Flue temperature probe

mini HE --- Installation & Servicing

INSTALLATION

9 UNPACKING

The boiler is supplied fully assembled in one pack A, together with a standard flue assembly for lengths up to 960 mm (37” 3/4), rear or side flue outlet, in pack B.

Unpack and check the contents.

Pack A contents

ATheboiler.

B Hardware pack C Wall mounting plate

D Wall mounting template

E User’s, Installation & Servicing instructions.

F Filling loop assembly

Hardware pack contents

F 22 mm CH connection pipe --- 2 off. F 22 mm Gas supply connection pipe --- 1 off. F 15 mm DHW cold inlet connection pipe --- 1 off. F 15 mm DHW hot outlet connection pipe --- 1 off. F 1/2” connection nut --- 2 off. F 1/2” sealing washer --- 3 off. F 3/4” sealing washer --- 6 off. F 3/4” Gas supply isolating valve --- 1 off. F 3/4” CH circuit isolating valve --- 2 off. F 1/2” DHW cold inlet isolating valve --- 1 off.

Pack B contents

G Air intake pipe ø 100 mm (4”), flue pipe ø 60 mm (2” 3/8)

with terminal grille assembly

H Centring spring

I Turret--- air pipe gasket J Fluepipegasket K Boiler--- turret gasket L Flue turret M Self tapping screws 4,8x13 --- 4 off N Wall finishing gasket --- internal (plastic) O Wall finishing gasket --- external (rubber)

Optional extras, if ordered, are available in separate boxes.

F Electronic programmer kits --- 24 hrs & 7 day F Extension duct kit pack D (ø 60/100) F Flue support kits ø 80, 100, 125 F Vertical outlet flue kit with elbow (ø 60/100) F 90û Elbow kit (ø 60/100) F 45û Elbow kit (ø 60/100) F Roof flue kit (ø 80/125) F Universal weather collar (for roof flue kit) F Flat roof weather collar (for roof flue kit) F Extension duct kit (ø 80/125) F 90û Elbow kit (ø 80/125) F 45û Elbow kit (ø 80/125) F Condense drain vertical (ø 80/125) F Twin pipe kit (ø 80) with air and flue terminals F Extension duct kit (ø 80) F 90û Elbow kit (ø 80) male---female F 45û Elbow kit (ø 80) male---female F Vertical condense drain (ø 80) F Horizontal condense drain (ø 80) F Condense trap F Stand---off bracket F Natural gas to LPG conversion kit F LPG to natural gas conversion kit F Condensate pump kit F High level flue outlet kit (mini HE C24, mini HE C28 only) F Pre---piping frame

INSTALLATION

10 PACKAGING

To unpack the boiler refer to the instructions on carton end flap.

mini HE --- Installation & Servicing

INSTALLATION

11 FITTING THE FLUE SYSTEM

The minimum and maximum equivalent length for c o --- a x i a l p i p e s ø 6 0 --- 1 0 0 a n d ø 8 0 --- 1 2 5 m m a r e g i v e n i n Table 7 for mini HE C24 and mini HE C28 and in Table 8 for mini HE C32 .

The minimum and maximum equivalent length for ø 80 mm twin pipe systems are given in Table 9 for mini HE C24 and mini HE C28 and in Table 10 for mini HE C32.

For roof flue systems having a flue length greater than 3m and all twin pipe systems, a condensate drain kit must be fitted at the lowest point in the system. See the list of optional extras (frame 9) for available drain kits.

Refer to the assembly instructions contained within the

INSTALLATION

chosen flue kit packaging for the correct assembly and installation.

The horizontal sections of flue pipes must have a slope not less than 1.5 deg. (25 mm per metre) towards the boiler.

In the flue kit of pack B the flue pipe is angled within the air duct therefore the air duct must be horizontally installed.

If one or more extensions need to be used they must be adequately supported so that there is no sag in the flue pipe and a minimum fall of 1.5 deg. (25 mm per metre) over the whole length towards the boiler is ensured.

Table 7 mini HE C24, mini HE C28

Minimum Maximum

C o --- a x i a l 6 0 --- 1 0 0 0.3 (11.8”) 2.7 (8’ 10”)

C o --- a x i a l 8 0 --- 1 2 5 0.5 (19.7”) 8.5 (27’ 10”)

Ta b l e 8 mi n i H E C 3 2

Minimum Maximum

C o --- a x i a l 6 0 --- 1 0 0 0.3 (11.8”) 1.8 (5’ 11”)

C o --- a x i a l 8 0 --- 1 2 5 0.5 (19.7”) 6.0 (19’ 8”)

Cuttheflueductatthesameleveloftheairductedge.

Cut this end

Groove

Horizontal Concentric

Air duct

Rear Outlet Wall thickness + 125 mm

Rear outlet+Stand --- off Wall thickness + 160 mm

Side Outlet --- RH Wall thickness + Gap +62 mm

Side Outlet --- LH Wall thickness + Gap +208 mm

Twin pipe flue kits

For calculation of total flue length, the distance MUST be measured from the centreline of the flue duct/air duct connection to the end of the flue outlet grille/air inlet duct.

For each additional 45û M&F and 90û M&F flue bend used, themaximumpermissiblelengthoffluesystemmustbe reduced by 0,9m or 1,65m respectively.

The restrictor to be used and the lengths of allowable equivalent flue outlet / air inlet ducts are indicated in Table 9 for mini HE C24, mini HE C28,inTable10formini HE C32 and in the following graph.

The restrictor size is marked on its body.

N.B.: The air intake and the flue outlet must not terminate on opposite sides of the building.

Air intake adapter

Restrictor

Gasket

Co---axial Flue kits.

Horizontal. For calculation of total flue length, the distance MUST be measured from the centreline of the concentric elbow to the end of the terminal.

Vertical outlet For calculation of total flue length, the distance MUST be measured from the centreline of the outlet connector at the boiler top panel to the end of the terminal grille.

For each additional 45û and 90û flue bend used, the maximum permissible length of flue system must be reduced by1mor1,5mrespectively.

Cutting lengths of flue and air ducts

Measure the wall thickness and, when using a side outlet, the gapbetweentheinnerwallandtheboilersidecasing. Use the following chart to calculate the cutting length of air duct.

Mark the air duct making reference on the groove.

Table 9mini HE C24, mini HE C28

Equivalent pipe length (air duct + flue duct)

Between 1 (39“) and 15 m (49’ 2”) ø50mm

More than 15 m (49’ 2”) up to 30 m (98’ 5”) ø55mm

Table 10mini HE C32

Equivalent pipe length (air duct + flue duct)

Between 1 (39“) and 24 m (78’ 9”) ø50mm

Restrictor

mini HE --- Installation & Servicing

INSTALLATION

For the correct use of the restrictors with twin pipes refer to the following diagram for the models mini HE C24,andmini HE C28.

Flue exhaust ”a”

Restrictor

50 mm

0 2 4 6 8 101214161820222426283032

Restrictor

55 mm

Allowed values

Air intake ”b”

Refer to the following diagram for the model mini HE C32.

Flue exhaust ”a”

Restrictor

50 mm

0 2 4 6 8 101214161820222426283032

Allowed values

Air intake ”b”

Cutting lengths of flue and air ducts

Measure the wall thickness and, when using a side outlet, the gap between the inner wall and the boiler side casing. Use the following chart to calculate the cutting lengths of both flue and air ducts.

Marktheairductandflueduct making reference on the groove.

Groove

Twi n P ipe

Air duct

Rear Outlet Wall thickness + 130 mm

Rear outlet+Stand --- off Wall thickness + 165 mm

Side Outlet --- RH Wall thickness + Gap + 187 mm

Side Outlet --- LH Wall thickness + Gap + 93 mm

Flue Duct

Rear Outlet Wall thickness + 130 mm

Rear outlet+Stand --- off Wall thickness + 165 mm

Side Outlet --- RH Wall thickness + Gap +67 mm

Side Outlet --- LH Wall thickness + Gap + 213 mm

INSTALLATION

12 REAR FLUE ASSEMBLY

Legend

1 Wall finishing gasket - -- external (rubber) 2 Self tapping screw 4,2x13 3 Flue turret 4 Boiler---turret gasket 5 Fluepipegasket 6 Turret --- air pipe gasket 7 Centring spring 8 Air/flue pipe with terminal grille assembly 9 Wall finishing gasket --- internal (plastic)

mini HE --- Installation & Servicing

INSTALLATION

13 WALL MOUNTING TEMPLATE

(rear flue)

IMPORTANT

Detailed installation steps are given directly on the wall mounting template

1 Tape the template into the selected position. 2 Ensure squareness by hanging a plumbline. 3 Mark onto the wall the following:

a. the wall mounting plate screw positions

b. the position of the flue duct.

(Mark the centre of the hole as well as the circumference) 4 Remove the template from the wall

INSTALLATION

14 WALL MOUNTING TEMPLATE

(side flue)

IMPORTANT

Detailed installation steps are given directly on the wall mounting template

1 Tape the template into the selected position.

2 Ensure squareness by hanging a plumbline.

3 Mark onto the wall the following:

a. the wall mounting plate screw position

b. Extend the centre line as shown.

Mark the flue duct centre from the corner (see diagram

and template)

Extended centre

Spirit level

Note. mark the centre of the hole as well as the circumference. If extension duct kit pack D has to be used, the pipes must have the correct slope as detailed in frame 11.

4 Remove the template from the wall

15 DRILLING THE WALL

Rear flue shown

IMPORTANT

Ensure that, during the cutting operation, masonry falling outside the building does not cause damage or personal injury.

1 Cut the flue hole (preferably with a 5” core boring tool),

ensuringthattheholeissquaretothewall. 2 Drill the fixing holes with an 8mm (5/16”) masonry drill.

Fit suitable wall plugs (not provided).

Note. If the teminal is to be sited within 25---40 mm of a corner or vertical pipe (refer to Table 4) then the hole MUST be acc urately cut and the rubber weather seal trimmed.

5” diameter flue hole

Section through wall

Note: Check all of the hole positions before drilling.

mini HE --- Installation & Servicing

INSTALLATION

16 CUTTING THE FLUE

Notes.

A If using the extension ducts go to Frame 17.

B If stand---off frame is used it is essential this is taken into

consideration when marking the flue (see Frame 11).

1 Measure and note the wall thickness. 2 Fo r side flues measure and note the gap between the

casing and wall. 3 From the table in Frame 11, determine the flue length

required. Mark and cut both outer and inner tube.

Ensure the support spring clip is in position to facilitate

cutting. 4 Toensurethetubeiscutsquare,markthefluealltheway

around.

17 FITTING THE EXTENSION KITS

Measure from

this

RING

INSTALLATION

1 Fittheinnerflueextensionductontotheinnerflueduct.

2 Fit the outer flue extension duct onto the outer air duct.

3 Repeat steps 1 and 2 if a second flue extension is

required.

4 Measure and mark the flue length required onto the flue,

measuring from the ring near the terminal. (Refer to Frame

11 for the detail of flue length calculation).

5 To ensure a square cut, mark the flue all the way around.

6 D e --- b u r r t h e c u t e d g e s.

Measure from

this

RING

mini HE --- Installation & Servicing

INSTALLATION

18 FITTING THE OPTIONAL ROOF FLUE

KIT (Flat or Pitched)

Note.

A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit.

This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

Connection to the top of the boiler is made using a separately supplied vertical connector.

WEATHER PROOFING

INSTALLATION

Where the flue passes through the roof line an adequate seal must be made. This is achieved by using either:

--- Flat roof weather collar

-- - Universal weather collar.

ACCESSORIES

Flue Duct Extension Kits are available for flue lengths extending beyond 1m. These packs contain 1m extension ducts and may be cut to the desired length.

19 ROOF FLUE KIT

CONTENTS/OPTIONS

A Flue assembly with terminal B Flue seal collar C3,5X13screw D Pitched roof tile/flat roof tile weather collar E Vertical connector (80/125) F Retention screws G Roof flue extension duct kit (80/125) H90û elbow kit (80/125) I45û elbow kit (80/125)

If the offset vertical option is used an elbow Kit is required. For a full accessories list refer to Frame 9, Optional Extras.

mini HE --- Installation & Servicing

INSTALLATION

20 FLUE TERMINAL POSITION

The terminal should be positioned so that products of combustion can safely disperse at all times.

Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided.

Minimum dimensions are shown below.

610 mm

min.

610 mm

min.

21 FLUE ARRANGEMENT

80/125

Part No. Description

n/a Maximum Flue Length

(m)

201 548 Flue ext. 80/125 7 7 5

201 547 Terminal Vertical Roof

80/125

158 431 WeatherCollarPitched

Roof

158 432 Weather Collar Flat

Roof

201 550 90û Elbow kit (80/125) 4 4 4 201 551 45û Elbow kit (80/125) 4 4 4

202 708 Vertical Connector 1 1 1

Note.

The equivalent flue length resistance of the 90û elbow kit (80/125) is 1.5 m and the 45û elbow kit (80/125) is 1.0 m.

Quantity

C24 C28 C32

8.5 8.5 6

1 1 1

Terminal Position Minimum Dimension

Directly below an opening,

airbrick,windows,etc.

Below plastic / painted

gutters

Painted surface 300 mm

Below eaves or balcony 500 mm

300 mm

INSTALLATION

mini HE --- Installation & Servicing

INSTALLATION

22 ASSEMBLING THE ROOF FLUE KIT

Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied. (Refer to No. 6 below)

Ensure the cut pipe ends are free from any burrs.

1 Ensure the flue seal collar B is located onto the flue

assembly A. 2 Position the roof flashing plate D (supplied separately)

overtheholecutintheroofandinsertflueassemblyA

from the roof end. 3 Push fit the vertical connector E (supplied separately) into

INSTALLATION

the boiler flue connection and retain with the screws F

(supplied with the vertical connector kit). ENSURING THE

GASKETS IN THE BOILER FLUE OUTLET ARE

CORRECTLY FITTED.

4 “Push” fit extension duct J (if required (supplied

separately)) and the roof flue kit assembly A into the

connector E. 5 If the last extension duct requires cutting, measure the

distance (outer ducts) between the duct and the terminal

and add 100 mm to this dimension. This gives the length

of the last extension duct.

NOTE. Check thepositionoftheinnerflueductrelativetothe outer duct on the assembled extension duct(s) and ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal.

6 Slide down and position the flue seal collar B over the roof

plateDandsecureitwiththethreescrewsCtotheflue

assembly A. 7 Finally ensure the roof flashing plate D is correctly sealed

to the roof. 8 Flue over 3 meters long.

For flues over 3 m long a conensate drain and trap must

be fitted. The trap must be connected to a suitable waste

pipe. See frame 9 for available trap kit.

Ø 60

Ø 100

MAX LENGTH:

C 2 4 --- 8 . 5 m C 2 8 --- 8 . 5 m

C 3 2 --- 6 m

min 16

max 41

mini HE --- Installation & Servicing

23 FITTING THE WALL

MOUNTING PLATE

Refer to frame 25 for service connections.

Fit the wall mounting plate

Directly to the wall

F Offer up wall mounting plate. F Screw through the fixing holes using 3 off no. 14x2”

screws (not provided).

F Check alignment with spirit level. F Tighten screws.

INSTALLATION

24 MOUNTING THE BOILER

Lift the boiler onto the wall mounting plate locating the bar at the rear of the back panel assembly into the bracket.

As added protection, the boiler should be lifted with the lower polystyrene packaging in place.

Lower the boiler into position.

Remove the lower packaging. Remove the front and side panels (refer to frame 30) and strip off the protective coating. The panels may be placed to one side and re---fitted when the installation is complete.

Note. Before fitting the flue system, fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A. Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

Fit the flue system referring to the instructions contained with the kit.

Make good the internal wall surface using the seal provided.

25 CONNECTIONS

Fit the service valves, washers and tail pipes as shown.

INSTALLATION

Central Heating flow

Domestic hot water outlet

Connect to the tail pipes by proprietory fittings.

The pipework may be directed down or through the rear wall as required.

The pipework may be directed upwards by using the optional stand off bracket kit. See illustration for upward pipework routing

Gas inlet

Domestic cold water inlet

Central Heating return

mini HE --- Installation & Servicing

INSTALLATION

26 CONNECTING THE FLUE TO THE

BOILER

Note. Beforefittingtheflueturretfillthecondensatetrapor

siphon trap within the boiler by pouring a cupful of water into the flue outlet. Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

1 Insert the flue assembly through the prepared hole in the

wall (ensuring the 145mm minimum dimension is

maintained). 2 Fit the inner (plastic) and outer (rubber) wall gaskets to the

flue terminal pipe. 3 Locate the gasket and flue turret on the top of the boiler.

CHECK THAT THE FLUE SEAL LOCATED IN THE TOP

INSTALLATION

OF THE RECUPERATOR IS SECURE AND GIVING AN

EFFECTIVE SEAL.

4 Locate the flue into the turret and push to ensure full

engagement. 5 Secure the flue turret on top of the boiler using the four

screws provided. 6 Fluesover1meterlong.

Fix the flue support bracket to the wall, using the two wall

plugs and wood screws provided.

27 SAFETY VAL VE DRAIN

The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage to electrical components and wiring.

145

Pressure relief valve

28 CONDENSATE DRAIN

Refer also to the British Gas document: “Guidance Notes for the installation of Domestic Gas Condensing Boilers” (1989).

The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building.

The boiler includes a trap that prevents combustion products entering the drain. However an additional trap with a seal of at least 75 mm and an air break between the traps is required if the condensate drain pipe is connected to sanitary pipework.

Condensate drain

Additional trap

The length of the condensate pipe should be kept at minimum and must be arranged so that obstruction (e.g.

Discharge pipe

through freezing) of external drainage pipework does not give rise to spillage within the dwelling.

If a part of the drainpipe runs externally this part should be kept as short as possible and protected to reduce the risk of freezing.

IMPORTANT

If excessive external pipework cannot be avoided an additional condensate removal pump (available as an option) and insulation are recommended to prevent possible freezing.

The drain outlet on the boiler is a 25 mm o.d. plastic pipe. This size must not be reduced below 21.5 mm o.d. (standard overflow pipe) in any part of its length.

All pipework and fittings in the condensate drain system must be made of plastic. No other materials may be used.

To avoid condensate being trapped:

--- the drainpipe should be run with a fall of at least 2.5û (45

mm/m) away from the boiler;

--- the number of bends and joints should be kept at minimum;

--- the drainpipe should be adequately fixed to pevent pipe sagging.

mini HE --- Installation & Servicing

INSTALLATION

29 ELECTRICAL CONNECTIONS

Warning. This appliance MUST be efficiently earthed

A mains supply of 230 V ~ 50 Hz is required.

Mains wiring should be 3 core PVC insulated flexible cord NOT LES S than 0.75 mm Table 16. (0.5mm not electrical reasons.)

Mains wiring external to the boiler MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations.

(24 x 0.2mm) and to BS. 6500,

flex is not acceptable --- for mechanical,

30 ELECTRICAL CONNECTIONS

Incoming mains wiring detail

To gain access to the power supply and external controls terminal blocks:

1 Remove the screws A and the front panel of the case.

For Ireland reference should be made to the current ETCI rules for electrical installations.

The supply connection is intended to be made via a double pole switch having a 3 mm (1/8”) contact separation in both poles, serving only the boiler and system controls. A 3 pin UNSWITCHED socket may, alternatively, be used.

The external fuse rating should be 3A.

For external controls wiring see frame 33. Note: the switch contacts of any external programmer, room or frost thermostat must be volt free. Connecting a switched live feed to external controls terminal block may be dangerous and will result in serious damage to the boiler.

4 Remove the side panels or move the lower part of the side

panels and pull the control panel forward.

When completely pulled out, the panel can rotate 45û downwards to facilitate the operations on the internal parts.

5 Loosen the screws D and remove the service panel.

INSTALLATION

2 Remove the screws B. 3 Loosen the screws C.

Volt free contacts Thermostat link Remove when wiring external thermostats.

Refer to frame 33

Note: Ensure that the lengths of the current conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor.

Mains

Power supply terminal block

External co ntrols terminal block

mini HE --- Installation & Servicing

INSTALLATION

31 PICTORIAL WIRING

mini HE C24, mini HE C28, mini HE C32

Wiring diagram for boiler equiped with electronic control p.c.b. typ e: Bertelli & Partners DIMS11 ---SA03/16740

Electric supply

terminal block

INSTALLATION

gnye

3.15AF 3.15AF

External controls

terminal block

123

bubnbk

bubu

Three way

diverter valve

bnbubk

K3 K4

COM

Ignition

electrodes

Flame detection

electrode

Condensate

trap

X11

Pump Fan

gnye

bk bk

gnyebu

gnye

wh wh

Primary circuit

flow switch

Air pressure

switch

gywhburdbububk

LD1LD2LD3

bn = brown bu = blue bk = black wh = white rd = red gy = grey gn = green ye = yellow vt = violet og = orange gnye = green/yellow

D.h.w. flow

switch

C.h. temperature

probe NTC

1 2 3 4 7 8 95 10 11 12 13 14

17 18

LD1LD2LD3

Modulating

gas valve

SB1

Safety

thermostat

19 20 21 22 23

24 25 26 27

LD4

temperature

SB1

t t

Flue

rdwh

D.h.w. temperature

probe NTC

15 16

2829303132333435363738

Electronic control p.c.b. Pin position ref. numbering

LD4

Electronic control P.C.B.

rd bk

Time switch

mini HE --- Installation & Servicing

32 FUNCTIONAL FLOW DIAGRAM

mini HE C24, mini HE C28, mini HE C32

INSTALLATION

Gas Valve (on---off operators)

Fan

Air pressure switch

CH flow switch

DHW flow switch

INSTALLATION

bkbk bu

33342829

Electronic

control pcb

Gas Valve (modulation coil)

Three way div. valvebn

DHW temp.rd probe NTC

Safety thermostat

Flue temperature probe NTC

151639

Condensate trap

Ignition electrodes

Detection electrode

Pump

CH temp. probe NTC

mini HE --- Installation & Servicing

INSTALLATION

33 EXTERNAL ELECTRICAL CONTROLS

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations.

For Ireland reference should be made to the current ETCI rules for electrical installations.

The external fuse rating should be 3A.

Route the electrical supply flexible cord and the external control flexible cord as illustrated. Lock the flexible cords in place with the clamps provided.

INSTALLATION

230V supply

ELECTRICAL CONNECTIONS FOR A COMBI BOILER

Optional Programmer Kits

Optional digital programmer kits are available with their relevant instructions.

Both 24hr and 7day kits are available.

thermostat should be wired into the system. To maintain frost protection with the programmer selector switches set to OFF, all the controls MUST be left in the running position.

The frost thermostat should be sited in a cold place but where it can sense heat from the system.

Wiring should be as shown, with minimal disturbance to other wiring.

External Programmers

On the combi boilers, this should be of the single channel type (as this boiler does not incorporate a pre --- heat facility for the instantaneous hot water service).

Programmers with room thermostat --- see diagram B.

Note. lf the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework.

Earths are not shown for clarity but must never be omitted.

Optional frost’stat

Room thermostat

Power supply terminal block

External co ntrols

terminal block

Note: the switch contacts of any external programmer, room or frost thermostat must be volt free. Connecting a switched live feed to external controls terminal block may be dangerous and will result in serious damage to the boiler.

Room Thermostat

This should be wired as shown in diagrams A.

Frost protection

Central heating systems fitted wholly inside the house do not normally require frost protection as the house acts as a ‘storage heater’ and can normally be left at least 24 hours without frost damage.

This appliance is provided with a built in anti --- freeze system that operates the boiler when the temperature is below 5 ûC. Therefore, when the boiler is not lit and used in cold weather, with consequent risk of freezing do not isolate the boiler

from the electricity supply or close the gas inlet cock.

However, if parts of the pipework run outside the house or if theboilerwillbeleftoffformorethanadayorsothenafrost

External programmer

Optional frost’stat

N.B. These diagrams are schematic only and do not show external terminal strips etc.

Room thermostat

Power supply terminal block

External co ntrols terminal block

mini HE --- Installation & Servicing

34 INITIAL LIGHTING

INSTALLATION

AB CD E F

Legend

A Appiance On lamps B Domestic hot water temperature control C Main switch and radiator temperature control D Boiler reset button E Lock --- out signal lamp F Programmer (optional) G System pressure and temperature gauge

Central Heating flow

Domestic hot water outlet

Gas inlet

Domestic cold water inlet

INSTALLATION

Central Heating return

IMPORTANT Before lighting the boiler you should note especially that:

1 Check that all the drain cocks are closed and any valves

in the flow and return are open.

2 Check that the system has been filled and pressurised

and that the boiler is not air locked. 3 Remove boiler front panel. 4 Ensure the dust cap on the automatic air vent is open at

least one full turn and leave this permanently open 5 Ensure that the pump is free to rotate

i Remove the vent plug

ii Using a screwdriver, rotate the shaft several times

iii Replace the vent plug

Note. Some slight water leakage will occur

6 Remove the screw in the burner pressure test point

indicated on the following picture and connect a gas

pressure gauge via a flexible tube.

Be sure to select the correct pressure test point. Refer to

Tables for pressures.

mini HE --- Installation & Servicing

7 Check that the gas service cock is ON. 8 Switch the electricity supply ON and check that all

external controls are calling for heat.

9 Set the main switch C to ’ON’. Following a pre--- purge

period the gas control solenoid valve should open and the spark commence, continuing until the burner is established.

10 Check that the burner lights smoothly. If this does not

occur within 20 seconds, turn the main switch to ’O’ position, wait for 5 seconds then try again by pressing the reset button ’D’. If the burner still does not light, refer to the ’Fault Finding’ section.

11 Test for gas tightness around ALL boiler gas components,

using leak detection fluid.

12 Operate the boiler for 10 minutes to stabilise the burner

temperature.

13 Check that the burner pressures are correct. The boiler is

factory pre ---set and should not need adjustment.

However if adjustment is required refer to frame 35. 14 Set the boiler main switch to ’O’. 15 Remove the pressure gauge and tube. Replace the

sealing screw in the pressure test point. Ensure a gas

tight seal is made. 16 Refit the boiler front panel using the screws previously

removed. 17 Switch the boiler on again.

INSTALLATION

35 TO ADJUST PRESSURES

Nomenclature of the parts on the gas valve

H Modulation operator’s electric connectors

I Minimum gas pressure adjustment

J Maximum gas pressure adjustment

K On --- off operators electric connector

L On---off operators

M Gas valve inlet pressure test point

N Burner pressure test point

INSTALLATION

(burner pressure).

By rotating clockwise the pressure increases.

10 Turntheboileroffandre---connectthewiretothe

modulating operator.

11 Start the boiler and check again the maximum gas

pressure setting. 12 Turn the boiler off and disconnect the gauge and close the

gas valve outlet pressure test point N

Important: after the gas pressure checks and any adjustment operations, all of the test points must be sealed and replace the adjustment protection cap.

Ignition rate adjustment

1 Turnontheboiler.

2 Check that the boiler lights up uniformly and adjust the

ignition gas pressure, if necessary.

To adjust the ignition gas pressure:

3 Open the gas valve outlet pressure test point N and

connect the gauge.

4 Rotate the radiator temperature control C as indicated in

the next figure and ensure that the room thermostat, if

fitted, is set to “heat demand”. 5 Run the boiler in c.h. mode (do not open any d.h.w. tap)

1 Remove the front panel of the case.

2 Open the gas valve inlet pressure test point M at the valve

input, connect a suitable pressure gauge and check the gas pressure of the supply network.

3 Remove the gauge and close the pressure test point M.

4 Open the burner pressure test point N and connect the

gauge.

5 Remove the protection cap from the mechanical pressure

adjustment components (I and J)

6 Start the boiler at its maximum power .

Operate the boiler in DHW mode or ensure that the boiler is not range rated if the test is carried out in CH mode.

Maximum valve setting

7 If necessary, rotate the maximum gas pressure

adjustment J using a spanner until you obtain the required pressure as indicated on Table 1 at page 4 (burner pressure). By rotating clockwise the pressure increases.

Minimum valve setting

8 Turn the boiler off and disconnect one of the two

connectors H.

9 Start the boiler and if necessary, rotate the minimum gas

pressure adjustment I using a spanner until you obtain the required pressure as indicated on Table 1 at page 4

CA DEB

6 Press and hold the reset button D for about 10 seconds

until the lock --- out signal light E blinks.

7 The lamps A should give the indication of the next figure;

ifnotthenpresstheresetbuttonDuntilyouobtainit.

Where:

8 Press and hold the reset button D for about 5 seconds

until the lock --- out signal light E is switched off.

The boiler runs in c.h. mode and the lights A give the follow indication:

Where: Flashing lamp, alone

9 Rotate the DHW temperature control B on a position

corresponding to an adequate ignition pressure. By

rotating clockwise the pressure increases.

Suggested ignition pressures:

Natural gas G20 - -- 6 (2,4) mbar (in w.g.) Propane G31 --- 13 (5,3) mbar (in w.g.)

10 Make a note of the position of the DHW temperature

control B. 11 Turn the boiler off and on positioning the main switch C as

indicated in the next figure.

Lamp ON

Lamp OFF

or simultaneously with an other lamp.

Lamp OFF

mini HE --- Installation & Servicing

INSTALLATION

CA DEB

12 Press and hold the reset button D for about 10 seconds

until the lock --- out signal lamp E blinks.

13 Press the reset button D repeatedly (4 times) until the

lamps A give the follow indication:

36 ANTI CYCLING SETTING

It is possible to set the minimum delay time that must pass between two ignitions of the burner in c.h. function mode.

1 Turn the boiler on positioning the main switch C as follow:

Where:

14 Turn the DHW temperature control B to the minimum (fully

counterclockwise) and then on the position noted on step

10. By turning the control B the lock ---out signal lamp E

blinks quickly (2 per second) indicating that the setting

has changed and must be memorized. 15 To memorize the setting press and hold the reset button D

for about 5 seconds until the lamps A briefly blink

simultaneously. 16 To reset the boiler to the normal operation turn it off and

on by the main switch C checking the ignition pressure

and that the burner lights up uniformly. The boiler

automatically resets to its normal operation after 10

minutes if the above reset operation is not performed.

The lamps A will flash a number of times corresponding to the setting.

4 To change the setting turn the DHW temperature control B

to a position corresponding to the desired delay. By

turning the control B, the lock --- out signal lamp E blinks

quickly (2 per second) indicating that the setting has

changed and must be memorized.

Lamp ON

Lamp OFF

INSTALLATION

CA DEB

2 Press and hold the boiler reset button D for about 10

seconds until the lock---out signal lamp E blinks

3 The lamps A should give the indication as in next figure

(reignition frequency). If not, press the reset button D repeatedly to obtain it.

Where:

At this time it is possible to determine the current setting by keeping the reset button D pressed for more than 5 seconds.

Lamp ON

Lamp OFF

37 COMMISSIONING AND TESTING

The benchmark Logbook or equivalent self certification should be completed and signed to demonstrate compliance with Building Regulations.

A. Electrical Installation

Checks to ensure electrical safety should be carried out by a competent person.

ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter .

11/2

5 To memorize the setting press and hold the reset button D

for about 5 seconds until the lamps A briefly blink

simultaneously.

6 To reset the boiler to the normal operation turn it off and

on by the main switch C. The boiler automatically resets to

its normal operation after 10 minutes if the above reset

operation is not performed.

The factory setting anti cycling time is 3 minutes.

B. Gas Installation

1 The whole of the gas installation, including the meter,

should be inspected and tested for tightness and purged

in accordance with the recommendations of BS. 6891. In

IE refer to I.S. 813:2002. 2 Purge air from the gas installation by loosening the gas

cock union and purge until gas odour is detected. 3 Retighten the union and test for gas tightness.

WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.

51/2

81/2

Delay (minutes) Setting No.

mini HE --- Installation & Servicing

INSTALLATION

38 GENERAL CHECKS

Make the following checks for correct operation:

1Hotwater.

a. Fully open all DHW taps in turn and ensure that water flows freely from them.

b. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate.

c. Ensure that DHW temperature of approximately 35 ûCrise is obtained at the tap. This corresponds to a flow rate of about

litres/min (gpm)

10.1 (2.2) mini HE C24

INSTALLATION

11.7 (2.6) mini HE C28

13.1 (2.9) mini HE C32

d. Tur n o ff t h e DH W t ap.

2 Central heating (all models)

Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.

3Gasrate---G20

Check the boiler gas rate when the boiler is at full output.

The gas rate checked at the gas meter, with no other appliance in use will normally be:

litres/min (ft

44.2 (1.56) mini HE C24

51.2 (1.81) mini HE C28

58.8 (2.08) mini HE C32

/min) models

models

If this check is not possible, ensure that the burner pressure is:

mbar (in. w.g.)

10.8 (4.3) mini HE C24

10.0 (4.0) mini HE C28

13.0 (5.2) mini HE C32

4 Water circulation system

Note. Fernox Superfloc flushing solution should be used during the flushing procedure.

models

a. With the system HOT examine all water connections for

tightness.

b. With the system still HOT , turn off the gas, water and electricity supplies to the boiler and drain down, to complete the flushing process.

c. Refill the system, adding inhibitor (see ’Water Treatment’), if required.

Vent as necessary to clear all air and, again, check for water tightness. After venting, repressurise as required.

d. Balance the system. It is suggested that, initially, all radiator handwheel valves (or TRVs if fitted) be set fully open, that all lockshield valves be set a half --- turn open.

Make minor adjustments to each radiator to achieve the same differential on all.

5Fluesystem

Check the integrity of the flue outlet and air inlet system to the boiler ensuring no leaks are evident from piping joints or flue/air sampling points.

Finally, set the system controls to the users requirements.

If an optional programmer kit is fitted refer to the instructions supplied.

mini HE --- Installation & Servicing

INSTALLATION

39 GAS CONVERSION

1 Check that the gas cock fitted under the boiler is turned

off and the appliance is switched off at the mains isolating

spur. 2 Remove the front panel of the case.

3 Takeoffthelidofthesealedchamber. 4 Take the front panel of the combustion chamber off and

remove the burner as explained in frame 43. 5 Carry out the conversion for the type of gas, replacing the

burner injectors correctly as explained in frame 51.

6 Re--- assemble the burner, the front panel of the

combustion chamber and the lid of the sealed chamber. 7 Switch on the appliance at the mains isolating spur.

8 Turn the boiler OFF positioning the main switch C as in

figure below.

CA DEB

9 Disconnect the CH temperature probe (24 on page 14). 10 Press and hold the reset button D for about 10 seconds

until the lock --- out signal lamp E blinks.

11 Connect the CH temperature probe (24 on page 14). 12 Press the reset button D repeatedly (4 times) until the

lamps A give the follow indication:

Where:

At this time it is possible to determine the current setting by keeping the reset button D pressed for more than 5 seconds. The lamps A will flash a number of times corresponding to the setting of the DHW temperature control B (see next figure).

Lamp ON

Lamp OFF

Gas type

Setting No.

NATURAL

GAS

Gas supply

Natural gas 1 125 mA

L.P.G. 4 165 mA

13 To change the setting turn the DHW temperature control B

to a position corresponding to the gas used as shown in thefigureabove. By turning the control B, the lock --- out signal lamp E blinks quickly (2 per second) indicating that the setting has changed and must be memorized.

14 To memorize the setting keep pressed the reset button D

for about 5 seconds until the lamps A briefly blinks

simultaneously. 15 Open the gas cock. 16 To reset the boiler to the normal operation turn it ON by

the main switch C on the desired operation and checking

the ignition pressure and that the burner lights up

uniformly. The boiler automatically resets to its normal

operation after 10 minutes if the above reset operation is

not performed.

The factory setting is Natural gas.

17 Calibrate the gas valve according to the instructions given

in this manual. 18 Set the correct gas pressure for central heating output

required. 19 Stick the self---adhesive label (included with the

conversion kit, indicating the type of gas, and the gas

pressures to which the appliance has been set) over the

existing label on the bottom of the control panel and

replace the adjustment protection cap. 20 Replace the front panels of the case. 21 Check the correct operation of the boiler.

Position of knob B

Approx. Max current through the modulator device

L.P.G.

INSTALLATION

40 HANDING OVER

After completing the installation and commissioning of the system, the installer should hand over to the householder by the following actions:

1 Hand the User’s Instructions to the householder and

explain his or her responsibilities under the Gas Safety (Installation and Use) Regulations 1994 and amendments 1996 or rules in force.

2 Draw attention to the Lighting Instruction label affixed to

the inside of the lower front door.

3 Explain and demonstrate the lighting and shutting down

procedures.

4 The operation of the boiler and the use and adjustment of

ALL system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption.

5 Advise the user of the precautions necessary to prevent

damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

mini HE --- Installation & Servicing

6 If a programmer is fitted, draw attention to the

Programmer Instructions and hand them to the

householder.

7 After installation and commissioning please complete the

Commissioning Checklist before handover to the customer. For IE, it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002.

8 Stress the importance of regular servicing by a CORGI

registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR. In IE, servicing work must be carried out by a competent person.

Emphasise to the user that the boiler may stop working if the system pressure is lowered by draining radiators to decorate behind them. In particular, explain to the user how the domestic hot water temperature varies with flow rate. This is especially important when water is drawn off while the boiler is already running for central heating.

SERVICING

41 SERVICING SCHEDULE

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary.

The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.

It is the law that any service work must be carried out by a registered CORGI installer . In IE, servicing work must be carried out by a competent person.

SERVICING

1 Turn the heating controls to maximum so that the boiler

lights and remains running. Check that no other gas appliances in the house are in use or likely to be used.

2 When the boiler has settled down check the gas rate at

the meter (if the meter is of the pointer type you should time only complete revolutions of the pointer). Check the gas rate against the figures given in Table 2 for CH operation.

3 For a combination boiler, fully open a hot water tap. When

the boiler has settled down check the gas rate, as in step 2,checkingthemeasuredrateagainstthefiguresgivenin Table 3 for HW operation.

4 Run the boiler and check the percentage of CO and CO2

in the flue gasses at the sampling point indicated in the following drawing.

Air intake Sampling points

Exhaust gas Sampling points

Note. If your meter reads CO in parts per million the figure must be divided by 10,000 to convert it to a percentage.

5 IftheratioofCO/CO

measured in steps 3 and 4 are close to nominal then no further action need be taken. If not, proceed to step 6.

6 Cl ean the main burner. 7 Clean the heat exchanger. 8 Chec k the injectors for blockage or damage. 9 Check that the flue terminal is unobstructed. 10 Check and clean the condensate trap and drain (see

frame 73).

The servicing procedures are covered more fully in Frames 42 to 47 and MUST be carried out in sequence.

WARNING.

ALWAYS turn off the gas supply at the gas service cock, and switch off and disconnect the electricity supply to the appliancebeforeservicing.

Switching the boiler on/off switch ‘off’ does not fully isolate the boiler.

ALWAYS test for gas tightness and carry out functional checks on reassembly.

IMPORTANT. When work is complete the boiler inner front sealing panel MUST be correctly refitted, making a good seal.

DO NOT OPERATE THE BOILER IF THE SEALlNG PANEL IS NOT FITTED.

Complete the service section in the Benchmark Commissioning Checklist.

is less than ,004 and the gas rates

mini HE --- Installation & Servicing

SERVICING

42 REMOVAL OF OUTER AND INNER

CASING

1 Turn off the gas supply at the gas service cock and

disconnect the electricity supply.

2 Remove the screws A and lift off the boiler front panel.

3 Loosen the screws B. 4 Bring the base of the panels away from the boiler and lift

them, freeing them from the top hooks.

5 Remove the screws C and remove the boiler inner casing.

SERVICING

mini HE --- Installation & Servicing

SERVICING

43 BURNER REMOVAL AND CLEANING

1 Disconnect the electrical supply. 2 Remove outer and inner casing (refer to frame 42). 3 Undo the screws A and remove the fan holder bracket B

and the combustion chamber panel C.

4 Remove the screws D and the plate E.

SERVICING

6 Undo the four screws F placed at the right and left sides of

the burner and extract it.

7 Brush off any deposits that may have collected on the

burner, ensuring that the flame ports are unobstructed. Note: brushes with metallic bristles MUST NOT be used.

8 Inspect the spark and detection electrodes. Ensure they

are clean and in good condition; replace if necessary.

9 Check the spark electrodes gap is correct.

4 mm (5/32”)

5 Disconnect the electrodes leads.

44 BURNER PRESSURE CHECK

After any servicing, reference should be made to:

--- Table 2 and Table 3 (or the data plate) which quote details

of the burner pressures.

45 CLEANING THE HEAT EXCHANGER

1 Open the combustion chamber as explained in steps 1 to

3 of frame 43.

10 mm (3/8”)

Ignition

Female

10 Check that the spark and detection electrodes leads are in

good condition and renew as necessary.

If the burner pressures are incorrect ensure the inlet pressure, with the appliance running, is correct (refer Table 1).

If the burner pressures require adjustment refer to frame 35 “To adjust pressures”.

If the appliance still does not operate correctly refer to the appropriate fault finding chart.

2 Place a plastic sheet or similar beneath the heat

exchanger and remove all visible loose deposits from the heat exchanger fins, using a suitable brush.

Detection

Burner blade

Male

4 6 R E --- A S S E M B LY

Re --- assemble the boiler in the following order: 3 Refit the burner. 4 Reconnect the electrodes to the electronic p.c.b.. See

frame 43 for correct connectors.

5 Refit the combustion chamber panel and the fan holder

bracket and plate E.

6 Refittheinnercasecover.

IMPORTANT. Ensure the boiler sealing panel is correctly fitted and that a good seal is made.

7 Refittheboilersideandfrontpanels.

8 Turn on the gas supply at the gas service cock.

9 Reconnect the electrical supply.

mini HE --- Installation & Servicing

SERVICING

47 FAN AND VENTURI REMOVAL AND

CLEANING

1 Disconnect the electrical supply.

2 Remove outer and inner casing.

3 Disc onnect the connectors A and the earth connection B.

4 Disc onnect the pipe which connects the venturi device to

the air pressure switch.

5 Unscrew the screw C and remove the fan holder bracket

7 Chec k that the impeller runs freely. Clean with a soft brush

or renew as necessary. Refer to frame 58 for replacement.

Note: Always take care when handling the fan, in order to preserve the balance of the impeller.

8 Check the venturi E for cleaness.

SERVICING

9 Re---assemble in reverse order.

To correctly connect the venturi device to the air pressure switch, refer to the following illustration.

--- +

6 Remove the fan by sliding it towards left (see the arrow).

mini HE --- Installation & Servicing

SERVICING

REPLACEMENT OF COMPONENTS

48 GENERAL

When replacing any component:

1 Isolate the electricity supply at the switched spur.

N.B. Turning the boiler “ON/OFF” switch does not isolate the live supply to the boiler.

2 Turn off the gas supply.

SERVICING

IMPORTANT. When work is complete the inner case cover must be correctly fitted, ensuring that a good seal is made.

49 SPARK AND DETECTION

ELECTRODE REPLACEMENT

1 Disconnect the electrical supply. 2 Remove outer and inner casing (refer to frame 42). 3 Open the combustion chamber and disconnect the

electrodes leads. 4 Remove the burner. Refer to frame 43. 5 Undo the screws that hold the electrodes and remove. 6 Fit new electrodes as necessary following the sequence

illustrated.

Ignition 1

Ignition 2

Detection 3

THE BOILER MUST NOT BE OPERATED IF THE INNER CASE COVER IS NOT FITTED.

If the CH and/or the DHW circuits have been emptied:

3 Open the hydraulic circuit cocks, refill / re ---pressurise

pipeworks and vent the system.

4 Test fire the boiler

5 Disconnect the filling loop.

7 Check the spark gap.

4 mm (5/32”)

10 mm (3/8”)

Ignition

Female

8 Re---assemble in reverse order. 9 Check the ignition and operation of the burner.

Detection

Burner blade

Male

50 BURNER REPLACEMENT

1 Remove the burner as explained in frame 43 2 Remove the spark and detection electrodes.

Refer to frame 49.

51 BURNER INJECTORS

REPLACEMENT

1 Remove the burner. Refer to frame 43.

2 Unscrew the injectors from the gas manifold.

3 Check that the new injectors are of the correct size and fit

it using new gaskets.

4 Re---assemble in reverse order.

5 Check the operation of the boiler.

3 Fit the electrodes on the new burner and check the spark

gap.

4 Re---assemble in reverse order.

5 Check the operation of the boiler.

Injectors

Burner

Gas manifold

mini HE --- Installation & Servicing38

SERVICING

52 OVERHEAT THERMOSTAT

REPLACEMENT

1 Remove outer and inner casing (refer to frame 42). 2 Remove the screws A and the plate B.

53 FLUE TEMPERATURE PROBE

REPLACEMENT

1 Remove outer and inner casing (refer to frame 42). 2 Disconnectthewiresfromthefluetemperatureprobe. 3 Unscrew the steel temperature probe adaptor A (complete

with the temperature probe) from the recuperator. 4 Ensure the probe is positioned as shown with the metal

sheath end level with the brass fixing nut B.

3 Disconnec t the wiring C .

4 Remove the spring D which holds the overheat thermostat

on the pipe of the primary heat exchanger and remove it.

5 Re---assemble in reverse order.

6 Apply an adequate quantity of heat conducting

compound between the pipe and the thermostat.

6 Fit the new probe/adaptor assembly into the recuperator

and re --- assemble in reverse order.

SERVICING

5 Ensure that on the probe, the length C that enters the

recuperator is 18 mm.

54 TEMPERATURE PROBE

REPLACEMENT

1 Disconnect the electrical supply. 2 Remove the front and right hand side casing panels (refer

to frame 42).

Removal of CH temperature probe

3 ToremovetheCHtemperatureprobecloseoffthe

isolating cocks of the CH circuit at the bottom of the boiler. 4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

Removal of DHW temperature probe

3 To remove the DHW temperature probe close off the

isolating cock of the DHW circuit at the bottom of the

boiler. 4 Empty the DHW circuit.

Replacement

5 Disconnect the leads from the probe to be replaced and

unscrew it .

6 Screw in the new probe, using a new gasket, reconnect

and re --- assemble in reverse order.

CH temperature

probe

DHW temperature

probe

Drainage cock

mini HE --- Installation & Servicing 39

SERVICING

55 GAS V ALVE REPLACEMENT

Check

1 Disconnect the electrical supply.

2 Remove the front casing panel.

3 Disconnect the connector A and check the electrical

resistance of the coil referring to the following diagram

SERVICING

O n --- o f f o p e r a t o r approx. 4 180 Ω*

* at ambient temperature.

4 If the resistance of the coil is different from the value

stated by ±10% or greater, replace the unit as described

below.

Replacement

5 Turn off the gas supply at the gas service cock and

disconnect the electricity supply.

6 Remove the front casing panel (refer to frame 42).

7 Disc onnect the connectors A and B.

8 Disconnect the earth wiring from the gas valve. 9 Unscrew the connectors C and remove the pipe D 10 Unscrew the inlet connector . 11 Unscrew the screws E and remove the valve. 12 Fit the new gas valve in reverse order ensuring new

gaskets are fitted and check for gas tightness.

13 Check the operation of the boiler.

C D

56 WATER TEMPERATURE ---PRESSURE

GAUGE R EPLACEMENT

1 Disconnect the electrical supply.

2 Remove the front and right hand side casing panels (refer

to frame 42).

3 Release system pressure by opening the main circuit

drainage cock A

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

4 Remove the fork B and the probe holder spring C.

5 Pull out the control panel (see frame 30).

6 Squeeze the tabs D to release the temperature---pressure

gaugeEandremoveit.

7 Re---assemble in reverse order.

57 EXPANSION VESSEL REPLACEMENT

If the CH expansion vessel is faulty, there are 2 options:

A If it has a punctured diaphragm, but is otherwise leak free,

thanitcanbeleftinplaceandanewvesseladdedtothe

return side of the system, external to the boiler, provided it

is of adequate capacity and pre --- charge pressure.

B If there is at least 400 mm (16”) clearance above the

boiler, the expansion vessel can be changed without

removing the boiler (rear exit flues will have to be

disturbed).

For option B, proceed as follows:

1 Disconnect the electrical supply.

2 Gain access to the controls area by removing the boiler

front panel (refer to frame 42).

3 Close off the isolating cocks of the CH circuit at the

bottom of the boiler.

4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul the valve.

5 Completely unscrew the connection A, the locknut B and

remove the expansion vessel from the top of the boiler.

6 Re---assemble in reverse order.

C B

mini HE --- Installation & Servicing40

SERVICING

58 FAN REPLACEMENT

1 Disconnect the electrical supply. 2 Remove outer and inner casing. 3 Disc onnect the connectors A and the earth connection B. 4 Disc onnect the pipe which connects the venturi device to

the air pressure switch. 5 Unscrew the screw C and remove the fan holder bracket

6 Remove the fan by sliding it towards left (see the arrow). 7 Re---assemble in reverse order.

Note: Always take care when handling the fan, in order to preserve the balance of the impeller.

To correctly connect the venturi device to the air pressure switch, refer to the following illustration.

--- +

SERVICING

59 VENTURI REPLACEMENT

1 Removethefan(seeframe58). 2 Remove and replace the venturi device A by unscrewing

the screw B. 3 Re---assemble in reverse order.

60 AIR PRESSURE SWITCH

REPLACEMENT

Two different types of air pressure switch may be used in the boiler. Refer tho the following drawings in accordance with the type of air pressure switch used.

1 Disconnect the electrical supply.

2 Remove outer and inner casing as explained in frame 42.

3 Disc onnect the pressure sensing pipe from the air

pressure switch.

4 Disconnect the electrical harness from the air pressure

switch.

COM

”L” connection

N.C.

N.O.

”H” connection

(not used)

5 Undo the two screws which hold the air pressure switch to

the chassis and remove it.

6 Replace the switch.

7 Re---assemble in reverse order.

To correctly connect the venturi device to the air pressure switch, refer to the illustration of frame 58 and to the following illustrations in accordance with the type of pressure switch used.

”H” connection

(not used)

”L” connection

mini HE --- Installation & Servicing 41

SERVICING

61 PUMP REPLACEMENT COMPLETE

1 Disconnect the electrical supply. 2 Remove the front and right hand side casing panels (refer

to frame 42). 3 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

4 Disconnect the connector A. 5 Loosen the connector B.

SERVICING

6 RemovetheforkCandthepipeD.

C DAB

7 Remove the fork E and the connection of the capillary

pipe of the pressure gauge.

8 Remove the locking plate F.

9 Completely loosen the connection G.

10 Unscrew the two screws H that hold the pump on the

frame

11 Remove the pump towards the front of the boiler

Re --- assemble in reverse order.

When reassembling the pump, check the correct location of the O ---ring gasket in the inlet port of the pump that seals the connection between the pump and the brass group .

IGF

If the motor only needs replacing, disconnect the connector A, unscrew the 4 screws I and remove the pump motor forwards.

mini HE --- Installation & Servicing42

SERVICING

62 ELECTRONIC CONTROL/IGNITION

PCB REPLACEMENT

1 Disconnect the electrical supply.

2 Gain access to the controls area by removing the boiler

front panel and pulling the control panel (refer to frame

30).

3 Remove the screws A and remove the service panel

4 To gain access to the electronic control/ignition p.c.b.

remove the screws B and remove the control panel lid.

Control panel lid

Service panel

5 Remove all the wiring connected to the electronic

control/ignition p.c.b.

To disconnect the connectors indicated, delicately flex the

hook present on one side of each socket.

SERVICING

8 Unscrew the four screws that hold the electronic

control/ignition p.c.b. on to the control panel.

9 Remove it by lifting its rear edge and freeing it from any of

the wiring.

10 Re ---assemble in reverse order.

Important

When re---assembling the electronic control/ignition p.c.b.:

11 Fit the p.c.b. into the control panel by first inserting the

front lower edge under the control knob shafts. Lower the rear edge and ensure that no wiring is trapped beneath.

12 Insert the spindles in the control panel knobs until the

notch C reaches the potentiometer edge. It is not necessary to force them in the knob.

13 While tightening the screws that fix the electronic

control/ignition p.c.b. on the control panel, keep the p.c.b. towards the control panel fascia making sure of the contact between the boiler reset button D and the tab E. Replace the wiring connections ensuring correct engagement in the sockets

6 To disconnect the connectors indicated in the next figure,

delicately press the hook present on one side of each

socket.

7 Remove the spindles of the CH and DHW temperature

adjustment knobs by delicately pulling them with pliers in

the direction shown by the arrows.

Attention

After installing the electronic control/ignition p.c.b.:

14 Make sure the CH (

adjustment knobs can move freely for the complete range. If not, remove the spindle again as described at step 7, turn the knob half a turn and re ---insert the spindle.

15 Operate the boiler and close the gas inlet cock so that the

boiler goes into the safety lock ---out state. Verify the correct operation of the boiler reset button by pressing and releasing it.

16 Open the gas inlet cock and check the boiler operates

correctly.

The replacement PCB is supplied pre---set for Natural Gas and an anti cycling time of 3 minutes. If the installation requires adjustment of these settings refer to frames 35 and 36 for the procedures

)andDHW( ) temperature

mini HE --- Installation & Servicing 43

SERVICING

If required, to check the PCB is set correctly for this boiler type the following procedure should be followed.

Boiler mode setting

17 Remove the front panel of the case. 18 Position the control knob C as in the figure below and

disconnect the C.h. temperature probe.

SERVICING

CA DEB

19 Press and hold the reset button D for about 10 seconds

until the lock --- out signal lamp E blinks. 20 Connect the c.h.temperature probe. 21 Press the reset button D repeatedly (twice) until the lamps

A give the indication as follows (boiler mode).

Where:

At this time it is possible to determine the current setting by keeping the reset button D pressed for more than 5 seconds. If the lamps A flash once go to step 24; if not proceed as follows:

Lamp ON

Lamp OFF

22 Turn the knob B clockwise and then to minimum position.

By turning the knob B, the lock--- out signal lamp E blinks quickly (2 per second) indicating that the setting has changed and must be memorized.

23 To memorize the setting press and hold the reset button D

for about 5 seconds until all the three lamps A briefly blink simultaneously.

24 Press the reset button D (once) until the lamps A give the

indication as follow:

Where:

At this time it is possible to determine the current setting by keeping the reset button D pressed for more than 5 seconds. If the lamps A flash once go to step 27; if not proceed as follows:

25 Turn the knob B clockwise and then to minimum position.

By turning the knob B, the lock--- out signal lamp E blinks quickly (2 per second) indicating that the setting has changed and must be memorized.

26 To memorize the setting press and hold the reset button D

for about 5 seconds until all the three lamps A briefly blink simultaneously.

27 To reset the boiler to the normal operation turn it off and

on by the main switch and radiator temperature control C. The boiler automatically resets to its normal operation after 10 minutes if the above reset operation is not performed.

Lamp ON

Lamp OFF

mini HE --- Installation & Servicing44

SERVICING

63 CH FLOW SWITCH REPLACEMENT

1 Disconnect the electrical supply.

2 Remove the front casing panel.

3RemovetheforkA.

4 Open the box B and disconnect the switch.

64 CH FLOW SWITCH MEMBRANE

REPLACEMENT

1 Disconnect the electrical supply. 2 Remove front casing panel (refer to frame 42). 3 Close off the isolating cocks of the CH circuit at the

bottom of the boiler. 4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

5 Remove the CH circuit flow switch (see frame 63). 6 Unscrew the four screws A, open the hydraulic operator

and remove the membrane B. 7 Re---assemble in reverse order.

When assembling the membrane, ensure to place the

5 Re---assemble in reverse order.

Refer to the following illustration for the correct wiring connectors on the switch

N.O.

do not use

Looking through the switch box B it is possible to verify the position of the spindle C

Boiler OFF Pump operating

concave side of the membrane towards the actuator plate C and locate the reference hole in the membrane over the pressure transfer nipple D.

SERVICING

mini HE --- Installation & Servicing 45

65 DHWFLOWSWITCHREPLACEMENT

1 Disconnect the electrical supply. 2 Remove the front panel of the case (refer to frame 42). 3 Disconnect the connector A and remove the switch B by

delicately levering it upwards with a screwdriver. 4 Replace the switch and re --- assemble in reverse order

SERVICING

66 DHW FILTER AND FLOW LIMITER

REPLACEMENT

1 Disconnect the electrical supply. 2 Remove the front panel of the case and empty the DHW

circuit. 3 Remove the flow switch A (see frame 65). 4 Unscrew the body C and extract the flow switch group. 5 To remove the filter B from the flow switch group separate

it from the threaded ring by levering it. 6 Re---assemble in reverse order.

A --- f l o w sw i t c h

C --- body

O --- r i n g

Spring

Magnetic ring

Float

Flow limiter

Threaded ring

B --- f i l t e r

Flow limiter

The mini HE C24 model is factory fitted with a 10 litre/min. flow limiter.

The mini HE C28 model is factory fitted with a 12 litre/min. flow limiter.

The mini HE C32 model is factory fitted with a 14 litre/min. flow limiter.

Ta b l e 1 1

Nominal flow rate (litres/min)

10 Yellow

12 Brown

14 Pink

To install the threaded ring with the flow limiter:

1 Disconnect the electrical supply.

2 Remove the front panel of the case and empty the DHW

circuit.

3 Remove the flow switch A (see frame 65).

4 Remove the flow switch group (see frame 66 above)

5 Unscrew the threaded ring and remove it from the body C.

6 Extract the flow limiter.

7 Fit the correct colour coded limiter (see Table 11 above)

and screw the threaded ring tight into the body C.

8 Re---assemble in reverse order.

Colour

mini HE --- Installation & Servicing46

SERVICING

67 PRIMARY HEAT EXCHANGER

REPLACEMENT

1 Disconnect the electrical supply.

2 Remove outer and inner casing as explained in frame 42.

3 Close off the isolating cocks of the CH circuit at the

bottom of the boiler.

4 Release system pressure by opening the main circuit

drainage cock. Do not release CH pressure using the

pressure relief valve. It may cause debris within the

system to foul the valve.

5 Remove the combustion chamber panel A by unscrewing

the screws B and removing the fan holder bracket C.

6 Remove the screws D and the plate E.

7 Loosen the connection F and slightly move the pipe G

upwards.

8 Remove the clip H and the safety thermostat I. It is not

necessary to disconnect it from the wiring.

9 Completely unscrew the connection J and move the pipe

K downwards freeing it from the heat exchanger

connection.

10 Remove the clip L.

11 Move the pipe M upwards freeing it from the connection

and rotate towards right.

12 Remove the heat exchanger by sliding it forwards.

Fit the clip H with the arrow pointing upwards as illustrated in the drawing.

Do not force the connection F when tighting it.

SERVICING

K L E

13 Re ---assemble in reverse order.

68 RECUPERATOR REPLACEMENT

1 Disconnect the electrical supply.

2 Remove outer and inner casing as explained in frame 42.

3 Close off the isolating cocks of the CH circuit at the

bottom of the boiler.

4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

5 Remove the fan A (see frame 58) and the air pressure

switch B (see frame 60).

6 Remove the flue temperature probe

7 Completely loosen the connection D and slightly move the

pipe E upwards. 8 RemovetheclipFandmovethepipeGdownwards

freeing it from the connection, then turn it towards right. 9 Using pliers, remove the spring H moving it downwards

and disconnect the rubber pipe I.

10 Remove the bracket J by unscrewing the screws that hold

it on the frame.

11 Rotate the recuperator K as indicated by the arrow and

remove it towards the front of the boiler.

12 RemovetheclipLandthepipeE.

13 Reassemble the recuperator carrying out the removal

operations in reverse order.

After reassembling ensure that the fan---exchanger and exchanger---elbow gaskets are correctly mounted and ensure a good sealing.

C (see frame 53)

C B

mini HE --- Installation & Servicing 47

69 DIVERTER VALVE ACTUATOR

REPLACEMENT

1 Disconnect the electrical supply. 2 Remove front casing panel (refer to frame 42).. 3 Disconnect the connectors A. 4 Remove the fixing spring B and remove the actuator C.

Re --- assemble in reverse order.

When reassembling the actuator, refer to the wiring diagram in frame 31 for the correct wiring connection.

SERVICING

70 DIVERTER VALVE INTERNAL PARTS

REPLACEMENT

1 Disconnect the electrical supply.

2 Remove front and left hand casing panels (refer to frame

42).

3 Close the isolating cocks of the CH circuit and DHW

supply at the bottom of the boiler.

4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

5 Release the pressure of the DHW circuit by opening a hot

tap.

6 Removethedivertervalveactuator(seeframe69).

7 Remove the fork D and remove the primary circuit flow

switch E.

8 Disconnect both CH and DHW temperature probes F.

9 Unscrew the connector G, disconnect the CH flow and

DHW outlet isolator valves.

SERVICING

B AC

(rear view) 13 Refer to the following exploded view to remove the

internal parts of the three way diverter valve.

F F

10 Remove the DHW heat exchanger (see frame 71).

11 Remove the fork H and move away the pipe I.

12 Unscrew the screw J and remove the diverter (flow)

group.

14 Re ---assemble in reverse order.

mini HE --- Installation & Servicing48

SERVICING

71 DHW HEAT EXCHANGER

REPLACEMENT

1 Disconnect the electrical supply. 2 Remove outer casing (refer to frame 42). 3 Close the isolating cocks of the CH circuit and DHW

supply at the bottom of the boiler. 4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

5 Release the pressure of the DHW circuit by opening a hot

tap. 6 Removethedivertervalveactuator(seeframe69). 7 Completely unscrew the two Allen key screws A which

hold the exchanger to the brass groups.

8 Move the exchanger towards the rear of the boiler and

extract it.

9 Re---assemble in the reverse order.

Attention. When reassembling the exchanger be sure to put the off center location/securing pin indicated towards theleftsideoftheboiler.

SERVICING

72 CH DRAIN COCK REPLACEMENT

1 Disconnect the electrical supply 2 Remove front and right hand casing panels

(refer to frame 42). 3 Close off the isolating cocks of the CH circuit at the

bottom of the boiler. 4 Release system pressure by opening the main circuit

drainage cock.

Do not release CH pressure using the pressure relief

valve. It may cause debris within the system to foul

the valve.

5 Remove the CH drain cock A from the return body. 6 Re---assemble in reverse order.

mini HE --- Installation & Servicing 49

SERVICING

73 CONDENSATE TRAP REPLACEMENT

1 Disconnect the electrical supply 2 Remove front and right hand casing panels

(refer to frame 42). 3 Disconnect the trap from the draining pipe.

To clean the condensate trap and drain

4 Unsc rew the bottom cover and remove the inner fitting

and ball. 5 Check and clean all parts thoroughly. 6 Check and clean the discharge pipe from the boiler to the

SERVICING

drain.

To replace the condensate trap

7 Using pliers, remove the spring A moving it upwards. 8 Remove the nut B and lower the trap. 9 Disconnec t the wirings from the trap.

74 PROGRAMMER REPLACEMENT

(if fitted)

1 Disconnect the electrical supply. 2 Gain access to the electronic control/ignition p.c.b. (steps

1 to 4 of frame 62).

3 Disconnect the wiring at the programmer.

10 Reassemble carrying out the removal operations in

reverse order.

4 Squeeze the hooks that hold the programmer on the

control panel fascia and withdraw the faulty programmer.

5 Re---assemble in reverse order.

When reassembling the new programmer, refer to the wiring diagram in frame 31 for the correct wiring connection.

6 Replace the panels and check the operation of the new

programmer.

mini HE --- Installation & Servicing50

FAULT FINDING

75 ELECTRONIC CONTROL/IGNITION

P.C.B. OPTICAL INFORMATION

The electronic control/ignition p.c.b. is provided with three lamps (L.E.D. indicators) A, that give optical information during the normal operation of the boiler or for service and fault fiinding purpose.

Normal operation

The green lamp on the left is directly visible on the control panel fascia and it gives information during the normal operation of the boiler. The other two lamps are normally switched off.

The following table gives the relationship between the visible lamp indication and its meaning.

Boiler in stand--- by condition. (function control in position).

Anti---freeze system active.

A short pulse every 4 seconds

Boiler ON condition (function control in or position)

1secondON1secondOFF

The following table gives a summary of the relationship between each of the possible lamp combinations and their meaning.

Normally operating boiler

C.h. operation

D.h.w. operation

Frost protect operation

D.h.w. operation Excessive temperature on primary circuit

Faulty c.h. temperature probe NTC

Faulty d.h.w temperature probe NTC

Faulty flue temperature probe NTC

Faulty primary circuit (no water or absence of flow)

Faulty air pressure switch

Lack of burner ignition (no ignition signal from the full seqence ignition device)

FAULT FINDING

76 DIVERTER VALVE ACTUATOR

SPINDLE POSITION

To remove the diverter valve actuator refer to frame 69.

The following illustrations indicate the relationship between the electric command coming from the main control p.c.b. and the position of the brass spindle when the boiler operates in either DHW mode or CH mode.

In both figures the relationship between the position of the actuator and the resistance of the motor windings (the motor must be disconnected from the wiring) is also given.

Overheat thermostat lock out

Flue temperature probe NTC lock out

Lack of power supply or fauly electronic control p.c.b. *

Faulty Electronic control/ignition p.c.b.. *

Lamp

OFF

* These conditions are normal only for a short time when the power supply is applied to the boiler.

If permanent they indicate a faulty p.c.b.

Spindle

visible

Lamp

CH mode DHW mode

Flashing lamp, alone

or simultaneously

with an other lamp.

Open circuit

Spindle fully

retracted

Flashing lamp,

alternate with

another lamp.

9,4 Kohm

mini HE --- Installation & Servicing

bkbnbu

9,4 Kohm

bkbnbu

bn = brown

230 V

bu = blue bk = black

230 V

Open circuit

FAULT FINDING

77 FAULT FINDING

WARNING

Care must be taken when conducting fault finding tests to guard against the risk of electric shock.

230 Vac is the nominal UK supply voltage. This may vary between 253 Vac and 196 Vac.

When checking continuity ensure power is off to the appliance.

Ensure the room thermostat (if fitted) and programmer are calling for heat

Also that all services are on and the selector switch is set to heating*

FAULT FINDING

Are only the two

green leds on fr ont

fascia flashing

together or

alternately?

yes

Are only the two green

leds on front fascia

flashing alternatively?

yes

With the boiler in heating

mode, what is the maximum burner

pressure with boiler and

system cool ?

(pressure values are

giveninTable2page4

Continued

from page 56.

yes yes

Does the heating

flow pipe become

warm quickly?

yes

no no

Wait 60 se conds

Is the gas inlet

pressure > 17 mbar?

yes

Adjust the burner pressure. refer to

frame 35. Ca n the max

burner pressure* be

achieved?

Is it a system boiler?

yes

Is there a DHW tap

open?

yes

DHW

tap

START

Isthereatleastoneof

the led flashing?

yes

Continued on page

54 of fault finding.

Rectifygassupplyfault

Is there at least 15V dc

at the connections on

modulator coil?

yes

Adjust max ’stop’ on Gas Valvetoachievethemax

burner pressure*

Disconnect DHW

flow sensor wiring.

Does the heating

flow pipe now

become warm?

With a fast pulse showing on LED 1 the boiler will continue to operate with a reduced performance in some fault conditions.

Before commencing fault finding please check the following:

Are all wiring connections OK ? Are the function selector settings correct (Refer to frame 35, 36 and 39)

Pay attention that if the boiler locks out five times in an hour, it is not sufficient to press the reset button to re - --start the boiler but it is necessary to disconnect the boiler from the main

supply and, after reconnect it, to press the reset button.

no no

yes

Is there 230V between

Live and Earth at the

mains connection in

the control box?

yes

Is there continuity

across the fuses on

yes

Is there 230V at the

Live connection to PCB

yes

Replace faulty PCB

Is modulator harness

continuity O.K?

yes

Replace faulty PCB

Is there 230V between Blue and Brown at

t h e 3 --- w a y

valve

connection?

yes

Remove the motor

assembly, with 230V at

the connections is the

spindle visible? Refer

to frame 76.

the PCB?

pin 4?

Is the continuity

o f t h e 3 --- w a y valve harness

O.K?

yes

Replace faulty PCB

Rectify external

Replace faulty fuses and check for wiring

Repair or replace

nonononono

Replace faulty

motor assembly

wiring fault

fault

wiring fault

faulty wiring

Repair or

replace

faulty

wiring

Continued on page

53 of fault finding.

Replace the DHW flow

detector sensor body. Does the heating flow

become warm?

yes

Faulty sensor now

replaced

yes

Replace faulty valve

body assembly

nono

Dismantle the DHW

detector valve. Refer to

frame 66 and clean.

W h e n r e --- a sse m b l e d

with DHW taps closed,

does the heating flow

pipe become warm?

yes

* see Table 2 at page 4 for the correct value

Replace the faulty

DHW detector

valve

mini HE --- Installation & Servicing

Continued from page

52 of fault finding

FAULT FINDING

With the boiler and

heating circuit warm

does the burner

pressure reduce if the

heating temperature setting is reduced to

minimum?

yes

When a DHW tap is

opened and the DHW

temperature is set to

maximum, does the

water become hot?

yes

Is there between 0V dc

and 16V dc at the

connections on the

modulating coil?

(0=min, 16=max)

yes

Is the burner pressure

within min and max

value* with the boiler

running?

yes

Repair faulty gas

valve

no no

Is the boiler mode

setting correct?

(Refer to frame 62)

yes

Is the red LED

illuminated on DHW

flow sensor?

yes

Is there 230V

ac between

Blue and

Black at the

3 --- w a y v a l ve

connection?

yes

no no

Is the continuity of the

modulator harness

O.K?

yes

Adjust burner pressure.

Refer to frame 35.

Repair faulty PCB

Follow the instruction “Boiler mode setting”

(Refer to frame 62)

no no no

Is the

continuity of

t h e 3 --- w a y

valve

harness

O.K?

yes

Is there 5V dc between

Red and Blue on

connecting harness?

yes

Repair or

replace

faulty

wiring

Is the harness

continuity O.K?

yes

Repair faulty PCB

Repair or replace

faulty wiring

Repair or

replace

faulty

wiring

FAULT FINDING

Continued on page

58 of fault finding

Remove the

motor

assembly, with

230V at the

connections is

the spindle fully

retracted? Refer

to frame 76.

yes

Replace

faulty valve

body

assembly

Repair faulty

PCB

Replace

faulty motor

assembly

Replace the

sensor. Is

red LED

illuminated?

yes

Faul ty

sensor

now

replaced

no no

Dismantle the DHW detector

valve and clean.

Refer to frame 66.

Reassemble.

Does the DHW

water become

hot?

yes

* see Table 2 at page 4 for the correct value

Repair or

faulty DHW

detector

replace

valve

mini HE --- Installation & Servicing

Continued from page 52 of fault

finding. Is there at

least one of the

LEDs flashing?

FAULT FINDING

Is LED 1 flashing with

FAULT FINDING

Is the heating circuit pressurised to at least 1 bar and full y vented

Remove the pump

nut. Does the pump

rotate freely when

When the pump

runs does the

spindle of the water

flow detector extend to operate the micro switch?

Refer to frame 63.

Is there continuity

between C and NO

contacts on micro

switch when the

switch is operated?

LED 2 on ?

yes

of air?

yes

turned)

yes

Are LED2 and LED 3

flashing?

yes

Check resistance of

CH temperature probe. Is it between 12 kΩ and 1.5 kΩ ?

yes

Repair or replace

faulty wiring

Re---pressurise

system and vent

Replace faulty pump

Replace faulty

diaphragm and clean

housing of debris, if any.

refer to frame 64.

Replace faulty micro

switch

no no

Are LED2 flashing

and LED 3 on?

yes

no no

Replace faulty

thermistor

Check resistance of

DHW temperature probe. Is it between 12 kΩ and 1.5 kΩ ?

yes

Repair or replace

faulty wiring

Continued on page

55 of fault finding

Replace faulty

thermistor

yes

Is the continuity of

the micro switch

harness O.K?

yes

Replace faulty PCB

Repair or replace

faulty wiring

mini HE --- Installation & Servicing

FAULT FINDING

Continued from page 54

of fault finding

Is there a burner

pressure during

ignition period?

yes

Are LED 1 and LED 3

flashing with LED 2

on, plus lockout LED

on the fascia on?

Is there > 17 mbar at

thegasvalveinlet?

Press reset button. Is

yes

there 230V across the

Brown and Blue gas

valve connection

during ignition?

Is there between 0V dc

and 16V dc at the

connections on the

(0=min, 16=max)

Is the burner pressure

within min and max

value* with the boiler

yes

modulating coil?

yes

running?

yes

Repair faulty gas

valve

nono

Rectify gas supply

fault.

no no no

Is there

230V at

Brown and

Blue at

gas valve

harness

connector

on PCB?

yes

Repair or

replace

faulty wiring

Adjust burner pressure.

Refer to frame 35.

Is fuse

continuity

O.K . on

yes

Replace faulty PCB

Continued on

page 57 of

fault finding

PCB?

Is the continuity of the

modulator harness

O.K?

yes

Repair faulty PCB

Replace

fuses

Repair or replace

faulty wiring

FAULT FINDING

Is there ignition at the

burner?

yes

Continued on page 56 of

fault finding

no no no no

Is a spark

visible at the

burner during

ignition?

yes

Is the ignition burner

pressure correct? Refer

to frame 35.

yes

Ensure the ignition electrode position and spark gaps are correct.

Are the ignition

leads

disconnected

or damaged

and sparking

to earth?

yes

Replace

faulty

electrode

assy. Make

connection.

Adjust ignition burner

pressure

Rectify or replace. Refer to frame 49.

Are the ignition leads correctly

connected to

PCB?

yes

Replace

faulty PCB

* see Table 2 at page 4 for the correct value

Rectify

faulty

connection

mini HE --- Installation & Servicing

Continued from page 55

of fault finding

FAULT FINDING

Is the burner light on?

yes

Does the burner

remain alight more

than 10 seconds?

yes

Can the minimum burner

pressure be achieved ?

(Pressure values are given

in Table 2 on page 4)

yes

Isthecondensefreely

discharged through the

condensate trap and

pipework?

yes

Replace faulty PCB

Is the position of the

detection electrode correct, and electrode undamaged? Refer to

frame 49.

yes

Is the resistance of the

detection electrode

assembly < 5Ω from tip to

connector ?

yes

Is the polarity of

the mains correct?

Adjust the burner minimum

pressure refer to frame 35

Check the condensate trap and discharge pipework for

cleanliness

Rectify electrode

position or replace

faulty electrode.

yes

Replace faulty detection

lead assy.

Rectify wiring fault

Connect lead correctlyIs the lead connected ?

Is the burner pressure

within min and max

value* with the boiler

running?

yes

Replace faulty PCB

Adjust burner pressure.

Refer to frame 35.

Refer back to page 52 of fault finding to continue.

* see Table 2 at page 4 for the correct value

mini HE --- Installation & Servicing

Continued from page 55 of fault

finding

FAULT FINDING

Is LED 1 and LED 2

flashing and LED 3

on?

yes

Wait for 1 minute. Is

the fan still running?

yes

Is LED 1 and LED 2

on and LED 3

flashing?

yes

Allow the boiler to

cool. Is the

resistance of the flue

temperature probe

< 600 Ω ?

yes

Replace the probe

and press the reset

button

no no

Is there 230V at

the fan

connections?

yes

Replace faulty fan.

Is LED 1 on and LED 2 flashing?

yes

Remove the flue

temperature probe.

Is the resistance of

the probe > 30 KΩ ?

yes

Replace the probe

and press the reset

button

no no

Is the harness in

short circuit?

yes

Replace faulty wiring

Is there continuity

betweenNCandCatthe

Air Pressure Switch?

yes

Is there continuity of the

Air Pressure Switch

harness?

yes

no no

Is LED 1 on and

LED 2 and LED 3

flashing?

yes

Has the main

overheat thermostat

operated? (Check

continuity)

yes

Allow boiler to cool

and press re ---set

Is the continuity of

thefluetemperature

probe harness OK?

yes

Replace faulty PCB

Check the

recuperator

Replace faulty Air

Pressure Switch.

Repair or replace

faulty wiring.

Is LED 1, LED 2

and LED 3 on?

Is there continuity of

overheat thermostat

wiring at PCB

connection?

Replace faulty gas

Replace faulty wiring

yes

valve

yes

Replace faulty

Repair or replace

damaged wiring

PCB

FAULT FINDING

Is there continuity

across C and NO on

the Air Pressure

Switch?

yes

Is the Air Pressure

Switch harness continuity O.K?

yes

Is the burner on?

yes

Repair or replace

faulty flame

detection signal

connection harness.

Refer to frame 49.

Are the sensing

pipes undamaged

and connected?

Istheflueclearand

venturi O.K?

Replace faulty Air

Pressure Switch

Repair or replace

faulty wiring.

Replace faulty PCB

yes

mini HE --- Installation & Servicing

Replace faulty PCB

Replace sensing

pipes.

Clear flue

Repair or replace

venturi

Continued from

page 53

Is there a temperature rise

of 35 ûCacrosstheDHW

circuit at:

10.0 L/min 24 kW model

11.7 L/min 28 kW model

13.1 L/min 32 kW model

FAULT FINDING

no no no

Is there max burner

pressure* when the

boiler first lights?

yes

Is there > 17 mbar

gas pressure at the

gas inlet?

yes

Rectify gas supply

fault.

FAULT FINDING

yes

With the DHW hot

does the burner

pressure modulate if

the DHW temperature

setting is reduced to

minimum?

yes

Adjust the max setting

on the gas valve. Refer

to frame 35. Check that

max burner pressure*

can be achieved.

nono

Is the maximum water

flow correct

10.0 L/min 24 kW model

12.0 L/min 28 kW model

14.0 L/min 32 kW model

no no no

Is there between 0V dc and

16V dc at the connections

on the modulating coil?

(0=min, 16=max)

yes

Is the burner pressure within

min and max value* with

the boiler running?

yes

Is the cold water supply

adequate? refer to frame

6 and Table 1 at page 4.

Check the DHW inlet

filter. Remove debris

and clean or replace

Adjust burner pressure.

Refer to frame 35.

yes

filter.

Is the continuity of the

modulator harness O.K?

yes

Rectify water supply

fault.

Repair or replace

faulty wiring.

Boiler Operating

Correctly

Replace faulty gas

valve.

Replace faulty PCB

* see Table 2 at page 4 for the correct value

mini HE --- Installation & Servicing

The following are parts commonly required as replacements, due to damage or expendability. The failure or absence is likely to affect the safety and/or performance of this appliance.

The list is extracted from the British Gas List of Parts which contains all available spare parts.

The full list is held by British Gas, Caradon Plumbing Ltd. distributors and merchants.

When ordering spares please quote:

1 Boiler model (see Data Plate) 2 Appliance G.C. number (see Data Plate) 3Description 4 Quantity 5ProductNo.

Key No.

1 173 ---148 Burner (mod. mini HE C24) 1 075427

2 H 0 7 --- 3 3 7 Main heat exchanger + ’O’ rings (mod. mini HE C24) 1 173991

3 H 0 7 --- 1 1 2 Recuperator 1 173993

4 169 ---069 Injectors for natural gas (mod. mini HE C24) 12 075692

5 H 2 1 --- 0 4 8 Fan (mod. mini HE C24) 1 173983

6 H 4 4 --- 1 6 2 Gas valve + gaskets 1 174465

7 169 ---127 Air pressure switch (mod. mini HE C24, mini HE C32) 1 173236

8 E 8 3 --- 0 1 3 Safety valve 1 172494

9 H 4 4 --- 1 6 9 Electronic regulation p.c.b. 1 174469

10 E 00 --- 6 8 4 Primary circuit flow switch 1 075419

11 E 83 --- 0 8 2 DHW flow switch 1 174462

12 E 00 --- 6 8 8 Main. flow switch membrane 1 075421

13 E 83 --- 1 0 1 Overheat thermostat 1 172512

14 E 57 --- 0 4 8 DHW heat exchanger + ’O’ rings (mod. mini HE C24) 1 075460

15 H 2 0 --- 9 8 6 Automatic air purger valve 1 173813

16 H 0 7 --- 8 4 0 Pump + ’O’ rings 1 174004

17 E 83 --- 1 4 5 Temperature--- pressure gauge 1 172551

18 H 3 2 --- 5 9 8 Flue temperature probe 1 174478

19 E 83 --- 0 8 6 Three way diverter valve (electric actuator) 1 172505

20 H 2 1 --- 0 6 0 Sealed chamber gaskets kit 1 173986

21 H 3 2 --- 5 5 0 Magnetic flow switch and filter 1 174461

22 E 83 --- 1 2 7 Ignition electrode --- left 1 172533

23 E 83 --- 1 2 6 Ignition electrode --- right 1 172532

24 E 83 --- 1 2 2 Detection electrode 1 172531

25 E 69 --- 2 4 3 Window (glass + rubber frame) 1 170977

26 169--- 141 1/2” flat gasket 3 075514

27 169--- 033 3/4” flat gasket 4 075415

28 H 4 4 --- 1 7 0 Fuse 3,15 AF 2 174470

29 164--- 026 Temperature probe (main or DHW circuit) 1 172496

30 H 2 1 --- 0 5 2 Side case panel 2 173987

G.C. No Description No. Off/

Boiler

173--- 149 Burner (mod. mini HE C28, mini HE C32) 1 075535

H 0 7 --- 5 4 2 Main heat exchanger + ’O’ rings (mod. mini HE C28) 1 173992

H 4 5 --- 1 5 3 Main heat exchanger + ’O’ rings (mod. mini HE C32) 1 174481

Injectors for natural gas (mod. mini HE C28, mini HE C32) 14

E 0 1 --- 1 5 6 Injectors for LPG (mod. mini HE C24) 12 173982

Injectors for LPG (mod. mini HE C28) 14

H 4 5 --- 1 7 8 Injectors for LPG (mod. mini HE C32) 14 174483

H 2 1 --- 0 4 9 Fan (mod. mini HE C28, mini HE C32) 1 173984

H 0 8 --- 6 0 5 Air pressure switch (mod. mini HE C28) 1 173136

E 5 7 --- 0 4 9 DHW heat exchanger + ’O’ rings (mod. mini HE C28, mini HE C32) 1 075540

Product No.

mini HE --- Installation & Servicing

31 H 0 7 --- 8 5 8 Control panel door 1 173988

32 H 0 7 --- 8 8 2 Front case panel 1 173989

22 24

1410

1612

25 26 27

28 29

mini HE --- Installation & Servicing

INSTALLER

NOTIFICATION

GUIDELINES

IT IS A REQUIREMENT OF CORGI MEMBERSHIP

TO REGISTER EVERY GAS APPLIANCE

Install and commission

this appliance to

manufacturers’ instructions

Complete the

Benchmark Checklist

In addition a change to Building Regulations (England and

Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Competent Person’s

SELF CERTIFICATION SCHEME

If you notify via CORGI Scheme, CORGI will then notify the Building Control (LABC) who relevant Local

Authority Building Control (LABC)

scheme on members behalf

Scheme members only:

Call CORGI on 0870 88 88 777 or

log onto:

www.corgi--- notify.com

within 10 days

You must ensure that the

notification number issued by

CORGI is written onto the

Benchmark Checklist

Choose Buildings

Regulations

notification route

BUILDING CONTROL

Contact your relevant Local

Authority Building Control (LABC)

who will arrange an inspection or

contact a government approved

inspector

LABC will record the data and will

issue a certificate of compliance

CORGIwillrecordthedataandwill

send a certificate of compliance to

the property

mini HE --- Installation & Servicing

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

BOILER SERIAL No. NOTIFICATION No.

To comply with the Building Regulations, each section must have a tick in o ne or other o f the boxesCONTROLS

TIME & TEMPERATURE CONTROL TO HEATING

TIME & TEMPERATURE CONTROL TO HOT WATER

HEATING ZONE VALVES

HOT WATER ZONE VALVES

THERMOSTATIC RADIATOR VALVES

AUTOMATIC BYPASS TO SYSTEM

ROOM T/STAT & PROGRAMMER/TIMER

CYLINDER T/STAT & PROGRAMMER/TIMER

FITTED

FITTED NOT REQUIRED

FITTED

FITTED NOT REQUIRED

PROGRAMMABLE ROOMSTAT

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS ?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE

BURNER OPERATING PRESSURE (IF APPLICABLE)

CENTRAL HEATING FLOW TEMPERATURE

CENTRAL HEATING RETURN TEMPERATURE

FOR COMBINATION BOILERS ONLY

COMBI BOILER

NOT REQUIRED

m3/hr ft/hr

N/A mbar

°C

HAS A WATER SCALE REDUCER BEEN FITTED?

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

YES NO

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)

COLD WATER INLET TEMPERATURE

HOT WATER OUTLET TEMPERATURE

WATER FLOW RATE lts/min

m3/hr ft/hr

N/A mbar

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS?

YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM CO MPLIES WITHPARTS4&7OFTHEBUILDINGREGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND CO MMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2RATIO READING? CO/CO2RATIOYESN/A

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN D E MONSTRATED TO THE CUSTOMER

°C

THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

COMMISSIONING ENG’S NAME

PRINT CORGI ID No.

SIGN DATE

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls

SERVICE 1

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SERVICE 2

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SIGNATURE

SERVICE 7

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

SIGNATURE

SERVICE 8

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

ENGINEER N AME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

Technical Training

The Ideal Boilers T echnical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers engineers and system specifiers.

For details of courses please ring: 01482 498 432.......

commissioning & servicing of central heating systems

thecodeofpracticefortheinstallation

Ideal boilers

P.O. Box 103, National Ave, Kingston upon Hull HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137

Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

Ideal Installer/Technical Helpline: 01482 498 663

www.idealboilers.com

Tel. 01482 492251 Fax. 01482 448858. Registration No. London 322 137. Ideal Boilers, P.O. Box 103, Na tional Ave, Kingston Upon Hull, HU5 4JN.

notice. performanceof its products. The rightis therefore reserved to vary specification without Caradon Ideal limited pursues a policy of continuing improvement in the design and

www.idealboilers.com

01482 498660

Ideal Consumer Helpline:

This is not a fault with the appliance but is relevant to the varying temperature of the incoming cold mains water supply.

the flow rate will need to be reduced at the outlet taps to achieve the same temperatures achieved in the warmer summer months. As the ambient temperature of the cold main varies during the summer and winter months it is likely in the colder winter months that supply domestic hot water at the stated flow rates, (as shown in the boiler installation instructions), to achieve a 35ûC temperature rise. The nature of all combination boilers is to heat up water directly from the incoming mains water supply directly through the boiler to

heating

F Check the radiator temperature control (C) is set at the winter setting for central

thermostat by turning fully up --- If this does not respond contact your installer

F Check the room thermostat is set at the required temperature --- T est the room

at an “on” period --- If it still does not operate contact your installer

F If fitted with an external programmer check that the central heating channel is set

is set to “auto” - -- If it still does not operate contact your installer

F Check that integral programmer is set to an “on” period and the function switch

correctly.

F Check that the air pressure switch test caps, on top of the boiler, are fitted

then this is not a boiler fault --- Contact the gas supplier

F Check gas supply (try another gas appliance cooker/fire etc) If no gas supply

does not fire contact the installer

F Is the lockout signal lamp (E) alight --- Press boiler reset button (D) --- If boiler still installer unable to do so or if the pressure continues to drop after filling then contact your off the tap on the filling loop and press the reset button (D) to reset the boiler. If

If not re---pressurise via the filling loop to 1 bar (if unsure contact your installer), turn

F Check pressure gauge on boiler shows a minimum of 1 bar. flashing every 4 seconds. If not this is not a boiler fault --- contact the installer

F Is there power to the boiler i.e. is the left hand side green LED (A) alight and

for central heating Operating for hot water but will not operate

attemptatignition Fan & pump run continuosly but there is no

water and then goes to ignition lockout will not fire for either central heating or hot Boiler goes through ignition sequence but

or hot water Boiler is not working for central heating

Problem Solution

Troubleshooting --- Typical Non Product Faults

we reserve the right to levy a charge for the visit, or for any pre---arranged visit where access is not gained by the engineer. external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance Note. In line with our current warranty policy we would ask that you check through the following guide to identify any problems

PointsforBoilerUser

problem recurs, consult your service engineer. Ifthesesimplechecksfailtosolvetheproblem,orthe

look for stop valves not fully open. of 3.5 litres per minute (or 1 pint in 10 seconds or less). If not, Check that cold water flows out of the taps at a minimum rate

Heating but no hot water

both calling for heat. Check that the programmer and room thermostat (if fitted) are

Hotwaterbutnoheating

boiler reset button D to restart the ignition sequence. Check the lock --- out signal lamp E. If it is illuminated press the

0,5 bar. Check that the system water pressure gauge G reads at least

that all switches are on. Check that gas and electricity are available at the boiler and

No heating or hot water

FAULTS

CORGI registered installer. The appliance should be serviced at least once a year by a

MAINTENANCE

Do not use abrasive cleaning materials.

mild detergent. To remove stubborn marks and stains use a damp cloth and

For normal cleaning simply dust with a dry cloth.

CLEANING

Do not search for gas leaks with a naked flame.

gas supplier without delay. Should a gas leak or fault be suspected contact your local

seconds. position. The appliance operation light A will flash every 4 To turn the boiler off set the function selector C to the O

For short periods

TO SHUT DOWN THE BOILER

resulting gas savings. performance consistent for a longer period of time with Consequently, the DHW heat exchanger will keep its

periodic descaling. treatment device. With such a device you should avoid In these cases, however, it is advisable to install a small water

annoying incidences of scale deposits and clogging. shown in the following illustration (about 50 ûC) minimises may be particularly great, not exceeding the position as Moreover, where the amount of limescale present in the water

be f ully exploited. with cold water. In this way, the automatic control facilities will commensurate with the demand, minimising the need to mix It is advisable to adjust the DHW temperature to a level

Adjustment

extinguishing of the burner when running. set to the minimum, it is normal to see a cycle of lighting and Where the demand is at a low level or with the temperature

the limits of maximum and minimum output. keep the temperature of DHW delivered constant, between automatically controls the flow of gas to the burner in order to The adjustment system integrated within the boiler

from that of the CH circuit. Adjustment of the DHW temperature is completely separate

ESCAPE OF GAS

competent person should be sought. assistance of a CORGI registered installer or in IE a the end of the pipe. If this fails to remedy the problem the waterovertheexposedpipeancleaninganyblockagefrom attempt may be made to free the obstruction by pouring hot If freezing is suspected and the pipe run is accessible an

freezing, can cause automatic shutdown of the boiler. Blockage of the condensate drain, caused by debris or Thecondensatedrainmustnotbemodifiedorblocked.

imum (55 ûC)

CONDENSATE DRAIN

from the electricity supply or close the gas inlet cock.

with consequent risk of freezing do not isolate the boiler Therefore, when the boiler is not lit and used in cold weather, that operates the boiler when the temperature is below 5 ûC This appliance is provided with a built in anti --- freeze system

FROST PROTECTION

3 If necessary, empty the water circuits.

circuits fitted under the boiler.

2 Shut off the gas supply cock and the valves for the water

1 Switch the electricity supply off.

When you do not expect to use the boiler for a long period:

For long periods

Minimum (35 ûC) Ma

temperature control knob B. (within the power limits of the appliance) by turning the from a minimum of about 35°C to a maximum of about 55°C ThetemperatureoftheDHWleavingtheboilercanbevaried

CONTROL OF DHW TEMPERATURE

Minimum (38 ûC) Maximum (85 ûC)

settings: Approx CH flow temperatures for the boiler thermostat

turning the knob C. minimum of about 38°C to a maximum of about 85°Cby The output temperature of CH water is adjustable from a

CONTROL OF CH TEMPERATURE

THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE

the regular servicing of all central heating systems to ensure safety and efficiency. installation and commissioning of central heating systems in the UK and to encourage aims of the programme. Benchmark has been introduced to improve the standards of Caradon Ideal Limited is a member of the Benchmark initiative and fully supports the

Commissioning Checklist. You can check your installer by calling CORGI direct on 01256 372300. All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in the Benchmark

consult a CORGI registered installer. Reference should be made to the Installation Instructions or above then a fault is indicated. If the lights sequence observed on the boiler is not included

another lamp. alternate with

Flashing lamp,

with an other lamp.

or simultaneously

Flashing lamp, alone

Frost protect operation

DHW operation

CH operation

Normally operating boiler

OFF

Lamp

meaning during normal operaion of the boiler between each of the possible light combinations and their The following table gives a summary of the relationship

DIAGNOSTIC LIGHTS

The front clearance can be reduced to 50mm (2”). The bottom clearance can be reduced to 20mm (3/4”). use, providing the encasing parts are removeable for servicing: After installation the following clearances are allowable during theboilercasemustbeallowedforservicing. at left, 50 mm (2“) at right and 450 mm (17 3/4“) at the front of Clearances of 200 mm (7 7/8“) above and below, 25 mm (1“)

MINIMUM CLEARANCES

competent person. corrected by a CORGI registered installer or in IE a then it MUST NOT BE USED until the fault has been

F If it is known or suspected that a fault exist on the boiler

tampered with. components on this appliance be used incorrectly or

F Under no circumstances should any of the sealed

compartment MUST NOT be used for storage purposes.

F If the boiler is installed in a compartment then the

correctly fitted and forming an adequate seal.

F This appliance must not be operated without the casing

IMPORTANT NOTES

(operating boiler). The appliance operation light A will flash every 2 seconds main switch as in the following illustration.

3 If the boiler is to be used for CH and DHW position the

(stand---by condition). The appliance operation light A will flash every 4 seconds

2 Switch the electricity supply on.

are open.

1 Check that the valves located in the lower part of the boiler

TO LIGHT THE BOILER

G System pressure and temperature gauge F Programmer (optional) E Lock --- out signal lamp D Boiler reset button C Main switch and radiator temperature control B Domestic hot water temperature control A Appliance operation lights

BC D EF

installation. The means of isolation must be accessible to the user after plug and socket serving only the boiler and system controls. having a 3 mm (1/8”) contact separation in both poles, or a isolation of the electrical supply, such as a double pole switch, Connection must be made in a way that allows complete

Supply 230 V 50 Hz. The fusing should be 3 A.

Theappliancemustbeefficientlyearthed.

ELECTRICITY SUPPLY

followed, for safe and economical operation of the boiler. It is essential that the instructions in this booklet are strictly

competent person, in accordance with the above regulations. must be installed by a CORGI registered installer or in IE a In your own interest, and that of safety,it is the law that this boiler

Regulationsorrulesinforce Current Gas Safety (Installation & Use)

SAFETY

automatic spark ignition and fan assisted combustion. water content combination gas boilers featuring full sequence

mini HE are wall mounted, room sealed, condensing, low

INTRODUCTION

Destination countries: GB, IE

mini HE C32 G.C. appliance No. 47 ---348 ---41 mini HE C28 G.C. appliance No. 47 ---348 ---39 mini HE C24 G.C. appliance No. 47 ---348 ---38

BOILER CONTROLS

mini HE

reconditioned or copy parts that have not been clearly authorised by Ideal Boilers assured conform to safety and performance specification that we require. Do not use When replacing any part of this appliance, use only spare parts that you can be

reverse of book For installation and servicing guide see

C24,C28,C32

You r Ide a l u se r s guid e

mini HE

Mamiya C32, C28, C24 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual