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
17962.1155.11307 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.
2
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
3
GENERAL
Ta b l e 1 --- B o i l e r D a t a
mini HE C24mini HE C28mini HE C32
Gas supply type & connectionII
Inlet / Outlet connection --- Domestic Hot Water15 mm copper
Flow & return connection --- Central Heating22 mm copper
Flue terminal diametermm (in.)100 (4)
AverageFlueTemp. ---MassFlowRateDeg C | g/s9018.89021.19021.5
Max working pressure (sealed system)bar (lb/in2)3.0 (43.5)
Max DHW water inlet pressurebar (lb/in2)10.0 (145.0)
Min DHW water inlet pressurebar (lb/in2)0.3 (4.4)
Electrical supply230 Vac 50 Hz
Max power consumptionW140150150
External fuse rating3A
Internal fuse ratingF1-- -F2 3.15 AF
Water content --- CHlitre (gal.)2.1 (0.46)2.2 (0.48)2.2 (0.48)
*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 C24mini HE C28mini HE C32
Burner pressure (Hot)G20
Input based on nett CVkW (btu/h)25.0 (85 295)29.0 (98 942)33.3 (113 620)
Input based on gross CVkW (btu/h)27.7 (94 516)32.2 (109 871)37.0 (126 244)
Domestic hot water specific ratel/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
3
Btu/ft
) nett.
G31
G31
G31
G31
3
(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
3
/H --- divide the gross heat input (Btu/h) by the
3
)
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
3
)
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.
II
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)
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)
30.7 (104 602)
1.6 (0.6)
7.7 (3.1)
12.1 (41 284)
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)
32.2 (109 866)
34.4 (117 374)
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)
32.2 (109 866)
34.4 (117 374)
34.4 (117 374)
0.95 (121.0)
2.7 (1.1)
7.3 (2.9)
15.0 (51 180)
15.0 (51 180)
15.6 (53 227)
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.
4
mini HE --- Installation & Servicing
GENERAL
mini HE
Boiler sizeG.C. appliance No.PI No.
(Benchmark No.)
mini HE C2447---348 ---3887BQ81
mini HE C2847---348 ---3987BQ81
mini HE C3247---348 ---4187BQ81
Destination countries: GB, IE
CONTENTS
Air supply9
Benchmark Commissioning Checklist62
Boiler clearances6
Boiler exploded view14
Electrical connections25
Electrical supply10
Fault finding51
Flow wiring diagram27
Flue fitting16
Gas conversion33
Gas safety regulations7
Gas supply8
Installation15
Mandatory requirements7
Replacement of components38
Safe handling7
Servicing34
Short list of parts59
Thermostatic radiator valves12
Water connections23
Water treatment9
Wiring diagrams26
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
BoilerPage
Make and model5
Appliance serial no. on data badge14
SEDBUK No. %4
Controls
Time and temperature control to heating28/29
Time and temperature control to hot water28/29
Heating zone valvesN/A
TRV’s12
Auto bypass12
Boiler interlock12
For all boilers
Flushing to BS.75939
Inhibitor9
Central heating mode
Heat inputto be calculated
BoilerPage
Burner operating pressuremeasure and record
Central heating flow temp.measure and record
Central heating return temp.measure and record
For combination boilers only
Scale reducer12
Hot water mode
Heat inputto be calculated
Max. operating burner pressuremeasure and record
Max. operating water pressuremeasure and record
Cold water inlet tempmeasure and record
Hot water outlet temp.measure and record
Water flow rate at max. settingmeasure and record
For condensing boilers only
Condensate drain24
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
5
GENERAL
1BOILER WATER CONNECTION
400
31
257
16
803
50
35
700
Wall
mounting
Plate
Condensate
drain
connection
area
Pipe sizeO.D. mm
CH flow22
CH return22
Gas inlet22
DHW cold inlet15
DHW hot outlet15
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
2BOILER 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.
6
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 5440:1Flues (for gas appliances of rated input not
exceeding 70 kW).
BS 5440:2Ventilation (for gas appliances of rated input
not exceeding 70 kW).
BS. 5449Forced circulation hot water systems.
BS. 5546Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)
BS 6700Design, installation testing and maintenance of
services supplying hot water for domestic use.
BS. 6798Installation of gas fired hot water boilers of
rated input not exceeding 70 kW.
BS. 6891Low pressure installation pipes.
Health & Safety Document No. 635.
7
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 .
8
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 eaves25 mm ( 1”) ***
4 Below balconies or a car port roof25 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 terminal1200 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”) ***
25 mm ( 1”) ***
300 mm (12”)
600 mm (24”)
1200 mm (48”)
1500 mm (60”)
300 mm (12”)
300 mm (12”)
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.
9
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:
3ELECTRICAL 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.
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
4SEALED 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’.
2
).
2
2
)formini HE C32.
2
) and temperature of 110 ûC. Extra
)formini HE C24 and mini HE C28.
10
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 valveAdditional 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).
2
) is reached.
Hose unions
2
). 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 setting3.0
Vessel pre ---charge pressure
(bar)
System volume (litres)V o lume of expansion vessel
75---------
1000.30.81.4
1251.82.53.2
1503.44.25.0
1755.06.07.0
2006.57.68.7
2258.19.310.6
2509.611.112.4
27511.212.814.3
30012.814.516.1
Multiply this factor by
system volume and deduct
6 litres to obtain size of
additional vessel for other
system volumes.
0.50.71.0
0.7
in addition to 6 litre unit
fitted to boiler
0.0630.0690.074
Ta b l e 6 mi n i H E C 3 2
System charge pressure
0.50.71.0
(bar)
Safety valve setting3.0
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
1250.81.62.3
1502.53.44.1
1754.05.16.0
2005.66.87.8
2257.28.69.7
2508.810.311.5
27510.312.013.4
30011.913.715.2
Multiply this factor by
0.0630.0690.074
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
6
5
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.
4
3
2
1
0
0200400600800100012001400
Flow rate l/hour
mini HE --- Installation & Servicing
11
GENERAL
5BOILER 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.
6DOMESTIC 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
TRV
TRV
A
D
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
B
Balancing valve
12
mini HE --- Installation & Servicing
GENERAL
7BOILERWATERCIRCUITDIAGRAM
35
34
23
21
20
19
18
36
37
15
16
13
26
14
12
10
6
11
17
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
24
25
22
27
1
33
28
29
30
31
8
9
5
2
32
7
34
7 Cent ral heating flow cock
8B 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
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
21
20
19
18
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
17
16
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
9UNPACKING
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
A
B
E
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
D
C
F
ITurret--- 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)
O
N
M
G
L
H
I
K
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
J
INSTALLATION
10PACKAGING
To unpack the boiler refer to the instructions on carton end
flap.
mini HE --- Installation & Servicing
15
INSTALLATION
11FITTING 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
MinimumMaximum
C o --- a x i a l 6 0 --- 1 0 00.3 (11.8”)2.7 (8’ 10”)
C o --- a x i a l 8 0 --- 1 2 50.5 (19.7”)8.5 (27’ 10”)
Ta b l e 8 mi n i H E C 3 2
MinimumMaximum
C o --- a x i a l 6 0 --- 1 0 00.3 (11.8”)1.8 (5’ 11”)
C o --- a x i a l 8 0 --- 1 2 50.5 (19.7”)6.0 (19’ 8”)
Cuttheflueductatthesameleveloftheairductedge.
Cut this end
Groove
Horizontal Concentric
Air duct
Rear OutletWall thickness + 125 mm
Rear outlet+Stand --- off Wall thickness + 160 mm
Side Outlet --- RHWall thickness + Gap +62 mm
Side Outlet --- LHWall 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
Restrictor
16
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,andminiHE C28.
Flue exhaust ”a”
32
30
28
26
24
22
20
18
16
14
12
10
8
6
Restrictor
4
50 mm
2
0
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”
32
30
28
26
24
22
20
18
16
14
12
10
8
6
Restrictor
4
50 mm
2
0
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.
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:
b
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
14WALL 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)
a
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
15DRILLING 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.
18
mini HE --- Installation & Servicing
INSTALLATION
16CUTTING 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
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.
6D e --- b u r r t h e c u t e d g e s.
1
2
Measure from
this
RING
mini HE --- Installation & Servicing
19
INSTALLATION
18FITTING 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.
19ROOF 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.
I
H
G
F
E
DA
C
B
20
mini HE --- Installation & Servicing
INSTALLATION
p
20FLUE 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.