Radiant RKR 24, RKR 28, RKR 34, RK 18, RK 25 Instruction Manual

...

Installation, operating, commissioning and maintenance instructions

0694

RKR 24_28_34 - RAD - ING - MAN.INST - 1104A - DIGITECH 2 - REGNO UNITO - EXTRAHEAT

- CBD

Technical specification RADIANT BRUCIATORI S.p.A. Montelabbate (PU) ITALY ENGLISH

Instruction Manual

for model

RKR 24

RKR 28

RKR 34

Wall mounted instantaneous combi boiler

premix condensing boiler

CONTENTS

1. General information

1.1 General warnings page 1

1.2 Product conformity 3

2. Technical characteristics

2.1 Technical data 4

2.2 Dimensions 6

2.3 Internal parts of the boiler 8

2.4 Water circuit 9

2.5 Circulation pump head/flow graph 10

2.6 Printed circuit board – Technical characteristics 11

2.7 Control panel 11

3. Installation

3.1 Reference standard 12

3.2 Boiler room – installation requirements 13

3.3 Unpacking 13

3.4 Installation boiler 14

3.5 Water connections 15

3.6 Central heating circuit 16

3.7 Condensate drain 17

3.8 Gas connection 18

3.9 Electrical connections

3.10 Flue connections 21

4. Commissioning the appliance (authorised personnel)

4.1 General warnings 27

4.2 Filling the system 28

4.3 Filling the condensate trap 29

4.4 Starting up the boiler 30

5. Regulating the appliance (authorised personnel)

5.1 Parameters table 31

5.2 Setting the parameters 32

5.3 Gas Data 38

5.4 Converting the boiler to a different gas type 41

6. Annual Service and Maintenance (authorised personnel)

6.1 General warnings 42

6.2 Boiler inspection 42

6.3 Accessing the boiler 43

6.4 Draining the central heating and domestic hot water system 44

6.5 Maintenance operations 45

6.6 Wiring diagrams 54

6.7 Troubleshooting 58

6.8 Diagnostics 59

6.9 Parts list 60

GENERAL INFORMATION

1. GENERAL INFORMATION

1.1 General warnings

Professionally qualified personnel in accordance with current laws and standards and in line with the

manufacturer’s instructions must install the appliance.

In GB, the installation must be carried out by a Gas Safe Registered Installer. To check for authorised

qualified engineers please contact

Phone Number 0800 408 5500.

It must be carried out in accordance

with the relevant requirements of the:

- Gas Safety Regulations;

- The appropriate Building Regulations either The Building Regulation, The Building Regulations

(Scotland), Building Regulations (Northern Ireland);

- The Water Fittings Regulations or Water Byelaws in Scotland;

- The current I.E.E. Wiring Regulations.

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

The commissioning of the boiler and any subsequent works carried out on the appliance must be

effected by a suitably trained Gas Safe Registered Technician. The BENCHMARK record for Commissioning and Annual Service at the back of this book should be completed.

The appliance must be used solely for the purpose for which it has been designed and manufactured:

central heating and domestic hot water production. Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through noncompliance with current local and national standards and/or the manufacturer’s instructions.

The installation, operation and maintenance manual form an integral and essential part of the product

and must be kept near the appliance always.

This Manufacturer Installation and Maintenance manual must not be removed on completion of the

installation; must be kept in a safe place and made available for future reference. This Manual must be left along with the Benchmark commissioning booklet with the boiler as Regulation 29 of the HSC Gas safety (installation and use) Regulations 1998.

The warnings contained in this chapter have been written for the appliance user, the installer and the

service engineer.

The “operating instructions” chapter of this manual must be read carefully as it provides information on

the operation and the operating limits of the appliance.

This appliance must be used exclusively in an un-vented central heating system.

• After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children in that these items represent a potential hazard and must be disposed of in a responsible manner.

• Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains electricity supply by switching off at the main switch and/or any other isolating device.

• Do not obstruct the air intake or flue exhaust grills.

• Do not obstruct the air intake or flue exhaust terminals.

• In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt any

repairs. Call for professionally qualified technical assistance only.

• Any repairs to the appliance under the manufacturers warranty must be carried out exclusively by the manufacturer’s authorised technicians. Non-compliance with this requirement may compromise the safety of the appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its correct operation, it must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions.

• When the appliance is no longer required for use, any parts that may constitute potential sources of danger must be rendered harmless.

GENERAL INFORMATION

• Only original accessories or optional extras (including electrical parts) must be used with the appliance.

• Should there be a smell of gas present in the room where the appliance is installed, DO NOT attempt to activate any

electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to create a current of air and ventilate the room. Shut-off the main gas supply valve (at the meter), or on the cylinder in the case of bottled gas, and call an authorised service centre.

• Do not attempt to interfere with the appliance in any way.

• As dictated by current legislation, this appliance must be installed exclusively by qualified personnel. Before

starting the boiler for the first time, make sure that it is connected to a water supply and central heating system compatible with its performance characteristics.

• Check the technical data reported on the packing and on the data plate located on the inside of the front casing. Also check that the burner is appropriate for the type of gas to burn.

• Make sure that the pipes and fittings used for the gas service are perfectly tight and that there are no gas leaks.

• Prior to initial start-up, the central heating pipes should be flushed to remove any residues that could compromise the operation of the appliance.

• The appliance can be regarded as being electrically safe when it has been connected to an efficient earth system installed in accordance with the requirements of current safety standards. This fundamental safety requirement must be checked and verified. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an ineffective or non-existent earth system.

• The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the appliance data plate (positioned on the inside of the front casing). In particular, make sure that the cable ratings are adequate for the power absorbed.

• Do not use adapters; multiple sockets or extension leads to connect the appliance to the mains power supply.

• The appliance must be connected to the mains power supply through an appropriate electrical isolator in accordance

with the current wiring regulations.

• When using an electrical appliance, a few fundamental rules must be observed:

• Do not touch the appliance with damp or wet parts of the body or when barefoot

• Do not pull on the electric wires

• Do not leave the appliance exposed to atmospheric elements (rain, sun, etc,) unless these conditions have been

expressly provided for.

• Do not allow the appliance to be used by children or anyone unfamiliar with its operation.

• The user must not replace the power supply cable.

• If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified

electrician.

• When the appliance is no longer required for use, switch off the main power supply, to switch all electrical components off (circulating pump, burner etc.)

GENERAL INFORMATION

1.2 Product conformity

RADIANT BRUCIATORI S.p.A. declares that all its products are manufactured to a high specification and in compliance with the relevant standards.

All RADIANT boilers are CE certified and possess technical and functional characteristics that comply with the following standards:

UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT ≤ 70 kW EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT ≤ 70 kW UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING

BOILERS WITH NOMINAL HEAT INPUT ≤ 70 kW

Gas fired boilers also comply with the following directives: GAS APPLIANCES DIRECTIVE 2009/142/CE LOW VOLTAGE DIRECTIVE 2006/95 CEE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108 CEE BOILER EFFICIENCY DIRECTIVE 92/42 CEE

The materials used such as copper, brass, stainless steel, etc. form a compact, homogeneous, highly functional unit that is easy to install and simple to operate. In its simplicity, the wall-mounted appliance is equipped with all the appropriate accessories required to make it a fully independent boiler capable of satisfying domestic hot water production and central heating needs. All boilers are fully inspected and are accompanied by a quality certificate, signed by the inspector, and a guarantee certificate. This manual must be kept in a safe place and must

accompany the boiler at all times.

RADIANT BRUCIATORI S.p.A. will not be held responsible for any misinterpretation of this manual resulting from the inaccurate translation of same.

RADIANT BRUCIATORI S.p.A. will not be held responsible for the consequences in the case of nonobservance of the instructions contained in this manual or in the case where actions not specifically described herein are undertaken.

Radiant Bruciatori S.p.A. declare that no substances harmful to health are contained in the appliance or used during appliance manufacture and have not used or intend to use any of the following substances in the manufacture of Radiant heating products.

−

Asbestos

−

Mercury

−

CFC's.

TECHNICAL CHARACTERISTCS

2. TECHNICAL CHARACTERISTICS

2.1 Technical data

Models RKR 24 RKR 28 RKR 34

CE Certification n° 0694BN3485 Appliance Type B23p – B33 - C13 - C33 - C43 - C53 - C63 - C83 – C93 Appliance Category II2H3B/P Heat Input max

kW 18 25 34

Heat Input max D.H.W.

kW 23.5 28.5 34

Heat Input min

kW 4 9 10

Heat Output max (50/30°)

19.26 26.68 36.24

Heat Output max

– 80/60°C (Non condensing)

17.69 24.6 33.42

Heat Output min

– 80/60°C (Non condensing)

3.9 8.73 9.73

Full Load Efficiency

(SEDBUK EFFICIENCY)

%,net 98.3 98.4 98.3

Part Load Efficiency

(SEDBUK EFFICIENCY)

%,net 108.1 106.3 107.9

GAS DIRECTIVE 92/42/ECC – Efficiency marking stars 4 Sedbuk band A

Central Heating circuit Central Heating water temperature setting (min-max) °C 30-80 / 25-40 Max. Heating working temperature °C 80 Expansion vessel capacity litres 7 Max. Working pressure (heating) bar 3 Min. Working pressure (heating) bar 0.3

Domestic Hot Water circuit D.H.W. temperature setting (min-max) °C 35-60 Max. Hot water working pressure bar 6 Min. Hot water working pressure bar 0.5 D.H.W. flow rate at ∆T 25K litr/mn 13,3 16 19,2 D.H.W. flow rate at ∆T 30K litr/mn 11,1 13,4 16 D.H.W. flow rate at ∆T 35K litr/mn 9,5 11,5 13,7 D.H.W. flow rate at ∆T 40K litr/mn 8,3 10,1 12 D.H.W. flow rate at ∆T 50K litr/mn 6,7 8,1 9,6

Dimensions (Boiler casing size) Width mm 410 Height mm 730 Depth mm 285 285 310 Weight (net) kg 38 40 42

Hydraulic connections Central Heating Flow connection Ø mm

Central heating Return connection Ø mm

Cold water mains connection Ø mm

D. Hot water connection Ø mm

Gas connection Ø mm

Condensate Drain Ø mm

Flue systems Horizontal-Concentric flue system Ø mm 60/100 Max. Flue length m 6 6 3 Horizontal-Concentric flue system Ø mm 80/125 Max. Flue length m 12 10 8 Twin pipe flue system Ø mm 80/80 Max. Flue length (from terminal to terminal) m 50 Twin pipe flue system Ø mm 60/60 Max. Flue length (from terminal to terminal) m 30 Vertical-Concentric flue system Ø mm 60/100 Max. Flue length m 6 6 3

Vertical-Concentric flue system Ø mm

80/125

Max. Flue length m 12 10 8 Gas Supply

Natural gas G 20 Inlet pressure mbar 20 Gas consumption m3/h 1.91 2.65 3.6 Butane G30 Inlet pressure mbar 30 Gas consumption kg/h 1.42 1.97 2.68 Propane G31 Inlet pressure mbar 37 Gas consumption kg/h 1.4 1.94 2.64

Electrical specifications Power supply V/Hz 230/50 Electrical power consumption W 180 Electrical protection IP X4D

TECHNICAL CHARACTERISTCS

Models

RKR 24 RKR 28 RKR 34

Efficiency 100% (full load 80/60°) % 98.3 98.4 98.3 Efficiency 100% (full load 50/30°) % 107 106.7 106.6 Efficiency 30% (partial load) % 101.1 100.1 100.7 Flue efficiency losses with burner on (50/30°C) (Pn /Pr) % 2,51/2,43 2,20/2,10 2,60/2,40 Flue gas temperature (50/30°C) (Pn) °C 50,8 53 51.7 Flue gas temperature (80/60°C) (Pn) °C 71 65 73.3 Flue Mass (50/30°C) (Pn/Pr) Kg/h 29,95/6,65 42,50/15,30 58,95/17,34 Flue Mass (80/60°C) (Pn/Pr) Kg/h 28,32/6,49 39,32/15,08 54,89/17,15 Air excess (Heat output max/min) (Pn/Pr) λ 1,25/1,3 1,24/1,33 1,27/1,36 NOx content mg/kWh 35 40 32 Condensate production l/h 2 2.2 3 Expansion vessel pre-charge pressure bar 1 Fan electrical power consumption W 75 Pump electrical power consumption W 88 93 Fan head Pa 75 75 120

TECHNICAL CHARACTERISTCS

CWI

HWO

105

110137163

285

131

S R

CWI

HR HWO

65 280 65

730

1525

730

7049 78 80 102 31

410

285

2.2 Dimensions - RKR 24 – RKR 28

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

TECHNICAL CHARACTERISTCS

110137163

310

132

730

CWI

HR HWO

7049 78 80 102 31

310

730

111.5187111.5

48.5 313 48.5

105

RKR 34

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

TECHNICAL CHARACTERISTCS

2.3 Internal parts of the boiler

4 5

27 26

2 3

LEGEND

1. PRIMARY CONDENSING HEAT EXCHANGER

2. PREMIX BURNER UNIT (GAS MANIFOLD + BURNER)

3. CONDENSATE DRAIN PIPE

4. IONISATION ELECTRODE

5. IGNITION ELECTRODE

6. FAN

7. VENTURI

8. IGNITION TRANSFORMER

9. ELECTRONIC GAS VALVE

10. 3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT

11. AUTOMATIC AIR VENT VALVE

12. HEATING SAFETY THERMOSTAT

13. HEATING SENSOR

14. PUMP WITH AIR VENT

15. WATER PRESSURE SWITCH

16. FLUE HOOD

17. SAFETY THERMO FUSE

18. EXPANSION VESSEL

19. D.H.W. SENSOR

20. CONDENSATE TRAP

21. WATER PRESSURE GAUGE

22. AUTOMATIC BY-PASS

23. CONDENSATE DRAIN PIPE

24. SYSTEM DRAIN VALVE

25. ROOM SEAL CHAMBER BACK SIDE

26. 3-WAY VALVE

27. ELECTRONIC FLOWSWITCH

28. DHW EXCHANGER

TECHNICAL CHARACTERISTCS

2.4 Water circuit

LEGEND

PRIMARY CONDENSING HEAT EXCHANGER

PREMIX BURNER UNIT (GAS MANIFOLD+BURNER)

CONDENSATE DRAIN PIPE

IONISATION ELECTRODE

IGNITION ELECTRODE

FAN

VENTURI

IGNITION TRANSFORMER

ELECTRONIC GAS VALVE

10.

3 BAR PRESSURE RELIEF VALVE - HTG CIRCUIT

11.

AUTOMATIC AIR VENT VALVE

12.

HEATING SAFETY THERMOSTAT

13.

HEATING SENSOR

14.

PUMP WITH AIR VENT

15.

WATER PRESSURE GAUGE

16.

FLUE HOOD

17.

SAFETY THERMO FUSE

18.

EXPANSION VESSEL

19.

D.H.W. SENSOR

20.

CONDENSATE TRAP

21.

WATER PRESSURE SWITCH

22.

AUTOMATIC BY-PASS

23.

CONDENSATE DRAIN PIPE

24.

SYSTEM DRAIN VALVE

25.

ROOM SEAL CHAMBER BACK SIDE

26.

FLOW LIMITER

27.

ELECTRONIC FLOWSWITCH

28.

DHW EXCHANGER

29.

3-WAY VALVE

LEGEND HR HEATING RETURN Ø mm

HF HEATING FLOW Ø mm

G GAS Ø mm

CWI COLD WATER INLET

Ø mm 15

HWO HOT WATER OUTLET

Ø mm 15

CD CONDENSATE DRAIN Ø mm

28 29

G CWI HFHR HWO

TECHNICAL CHARACTERISTCS

2.5 Circulation pump head/flow graph

III

Appliance Loss

Pump head at minimum speed

Pump head at second speed

Pump head at maximum speed

III

Flow l/h

Head (kPa)

RKR 24

III

Flow l/h

III

Pump head at maximum speed Pump head at second speed

II I

Pump head at minimum speed Appliance Loss

Head (kPa)

RKR 28

Pump head at minimum speed

Pump head at second speed

Pump head at maximum speed

III

Appliance Loss

Flow l/h

III

Head (kPa)

RKR 34

TECHNICAL CHARACTERISTCS

2.6 DIGITECH 2® printed circuit board – SM30003

Technical characteristics

Adjustments possible by service personnel only

• Standard (30/80°C) / reduced (25-40°C) central h eating temperature

• Water hammer prevention function

• Central Heating timer - (adjustable from 0 to 7,5 minutes)

• Central Heating pump overrun timer

• Domestic Hot Water pump overrun timer

• Minimum Gas pressure setting

• Maximum Heating Load

• Heating output rising time

User settings

• On/Off

• Heating Temperature setting (30-80°C) – (25-40°C)

• D.H.W. temperature setting (35-60°C)

• Summer only mode / Winter only mode / Summer + Winter mode selection

Operation/Functions display

• Lock-Out

• Water deficiency indicator

• Temperature display

 When the boiler is switched off at the switch on the control panel, the word OFF appears on the

display. The D.H.W and central heating frost protection system, nevertheless, remain enabled. If the boiler was previously on, it is switched off and the post-ventilation, pump overrun , circulation pump and three-way valve inactivity protection functions are enabled.

 The remote control, where fitted, remains active and illuminated.

2.7 Control panel

LEGEND

1. ON/OFF BUTTON

HEATING TEMPERATURE CONTROL KNOB

3. D.H.W TEMPERATURE CONTROL KNOB.

4. D.H.W TEMPERATURE BUTTON. KEEP PRESSED FOR 5

SECONDS TO DISPLAY OUTSIDE TEMPERATURE (ONLY IF OPTIONAL OUTDOOR SENSOR IS FITTED)

5. SERVICE BUTTON.

6. SUMMER, WINTER OR SUMMER/WINTER MODE

SELECTION BUTTON.

7. TERMINAL BOARD FOR EXTERNAL WIRING.

8. TEMPERATURE, ERROR CODE AND OPERATING STATUS

DISPLAY

9. TIME CLOCK (optional)

7654321

INSTALLATION INSTRUCTIONS

3. INSTALLATION (authorised personnel)

3.1 Reference standard

In GB, the installation must be carried out by a

Gas Safe

Registered Installer. To check for authorised

qualified engineers please contact

Phone Number 0800 408 5500.

It must be carried out in accordance with

the relevant requirements of the:

- Gas Safety Regulations;

- The appropriate Building Regulations either The Building Regulation, The Building Regulations

(Scotland), Building Regulations (Northern Ireland);

- The Water Fittings Regulations or Water Byelaws in Scotland;

- The current I.E.E. Wiring Regulations.

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

In GB, the following Codes of Practice apply:

BS 5440:Part1 – Flues BS 5440:Part2 – Air Supply BS 5446 Installation of hot water supplies for domestic purposes (1

, 2nd and 3rd family gases) BS 5449 Forced circulation hot water systems BS 6700 Installation of cold water supplies for domestic purposes (1

, 2nd and 3rd family gases) BS 6798 Installation of gas-fired hot water boilers BS 6891 Gas Installation BS 7074 Expansion Vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems BS 7671 IEE wiring regulations.

This appliance meets the requirements of:

- UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS. SPECIFIC REQUIREMENTS FOR CONDENSING

BOILERS WITH NOMINAL HEAT INPUT ≤ 70 kW

- IPX4D rating for electrical appliances.

- EMC DIRECTIVE 89/336 CEE

- LVD DIRECTIVE 73/23 CEE

- BOILER EFFICIENCY DIRECTIVE 92/42 CEE

Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is in the interest of the installer and safety that the law is complied with.

The manufacturers instructions form an integral part of the installation and should be left with the appliance but do not over ride in anyway statutory obligations.

INSTALLATION INSTRUCTIONS

3.2 Boiler room – Installation requirements

Please refer to local and national standards in force in the Country of destination of the product. In particular the manufacturer recommends:

The presence of threaded connections on the gas line, require that the room in which the appliance is

installed is ventilated by means of air intakes.

A compartment used to house the appliance must be specifically designed and constructed for the

purpose. An existing compartment or cupboard may be used providing it is suitably modified. Adequate space for servicing must be provided and it must permit safe installation and termination of the flue. (See 3.4.1 ‘Compartment Ventilation’)

3.3 Unpacking

■

The materials (cardboard) used for packing the appliance are fully recyclable.

■ It is recommended that the packing material is only removed prior to installing the boiler. The

manufacturer will not be held responsible for damage caused by incorrect storage of the product.

■ Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that

these items represent a potential hazard.

A. Place the packed

appliance on the floor (see fig.

1) making sure that the "up” arrow is facing down. Remove the staples and open out the four flaps of the box.

B. Rotate the boiler 90° while manually supporting it from underneath

C. Lift the box and remove the protections. Lift the boiler by grasping the rear part and proceed with the installation.

STORAGE & HANDLING

Please note that prior to installation the Radiant boilers should be stored in the horizontal position with no more than three boilers to a stack; Ensure that the boilers are stored in dry conditions and be aware that the carton is a two man lift;

Fig. 1

INSTALLATION INSTRUCTIONS

3.4 Installing the boiler

■ The appliance must be installed

exclusively on a flat vertical solid wall capable of supporting its weight.

■ The boiler should be fitted within the

building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (the boiler may be fitted inside a cupboard, (see 3.4.1 “Compartment Ventilation”).

■ If the boiler is sited in an unheated

enclosure then it is recommended to leave the power on to give frost protection (frost protection is active even with On/Off switch in Off position).

■ If the boiler is installed in a room

containing a bath or shower reference must be made to the relevant requirements. The appliance controls or any related switch or control should not be within reach while using the bath or shower.

In GB this is the current I.E.E. Wiring regulations and Building Regulations;

In order to allow access to the interior of the boiler for maintenance purposes, it is important that the necessary clearances indicated in figure 1 are respected. To make the installation easier, the boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall.

To install the boiler, proceed as follows (see fig. 2): a. Use a spirit level (of not less than 25

mm long) to mark a horizontal line on the wall where the boiler is to be fitted.

b. Position the top of the template along

the line drawn with the level, respecting the distances indicated. Then mark the centres of the positions of the two wallplugs or anchors. Finally, mark the positions of the water and gas pipes.

c. Remove the template and install the

domestic hot and cold water pipes, the gas supply pipe and the central heating pipes using the fittings supplied with the boiler.

Fix the boiler to the wall using the wall plugs or bracket and connect the pipes.

Compartment Ventilation

Where the appliance is installed in a compartment, no air vents are required.

BS 5440:Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.

MINIMUM DITANCES IN mm

X Y L HBA B

20060 60 410 1000 300

Fig. 1

Fig. 2

INSTALLATION INSTRUCTIONS

3.5 Water connections

In order to safeguard the heat exchanger and circulation

pump, especially in case of boiler replacement, it is recommended that the system is hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators.

Make sure that the domestic water and central heating

pipes are not used to earth the electrical system. The pipes are totally unsuitable for this purpose.

The Isolation Valves provided must be installed

on the heating and D.H.W circuits. This will facilitate all maintenance and service operations where the boiler needs to be drained.

■ To prevent vibration and noise coming from the system, do

not use pipes of reduced diameter, short radius elbows or severe reductions in the cross sections of the water passages.

■ In order to guarantee the reliability of the boiler and prevent

permanent damage in areas with very high water inlet pressure a 2.5 bar pressure reducing valve should be fitted.

■ To facilitate the installation, the boiler is supplied with a

hydraulic connection kit (see fig.2).

Domestic hot water circuit

■ In order to prevent scaling and eventual damage to the D.H.W

heat exchanger, the mains water supply must not have a hardness rating of more than 17.5 °Ck. It is nevert heless advisable to check the properties of the water supply and install the appropriate treatment devices where necessary.

The cold water supply pressure at the inlet to the boiler must be between 0.5 and 6 bar. In areas with higher water inlet pressure a pressure reducing valve must be fitted before the boiler.

The frequency of the heat exchanger coil cleaning depends on the hardness of the mains water supply and the presence of residual solids or impurities, which are often present in the case of a new installation. If the characteristics of the mains water supply are such that require it to be treated, then the appropriate treatment devices must be installed, while in the case of residues, an in-line filter should be sufficient.

All D.H.W. circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.

Guidance G17 to G24 and recommendations R17 to R24 of the Water Regulation Guide.

Central heating circuit

In order to prevent scaling or deposits in the primary heat exchanger, the mains supply water to the heating circuit must be treated according to the requirements of local standards.

This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained.

The outlet connection of the boiler safety valve must be connected to a discharge pipe with a continuous fall from the boiler to outside. It must terminate in a safe position where any water, possibly boiling, can discharge without causing a hazard. The manufacturer will not be held responsible for flooding or damage caused by the operation of the safety valve in the case of system overpressure.

Condensate Drain

The condensate drain flexible pipe supplied with the boiler (conforming to UNI EN 677 standard) must be connected to a proper condensate trap. The condensate discharge into the drainage system is allowed providing a condensate trap (siphon) is installed.

Any condensate discharge pipe work external to the building (or in an unheated part of it) must be insulated to protect against frost. Before switching the boiler On, check the correct condensate discharge.

HFCWIGHWOHR

49 78 70 80 102 31

105

Fig. 2

Fig. 1

Ø 15 mm

Ø 22 mm

CWI

HWO

Ø 22 mm

Ø 15 mm

INSTALLATION INSTRUCTIONS

3.6 Central heating circuit

The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. Refer to the pump performance table for guidelines. System volume -The 7 litre expansion vessel incorporated into the boiler is generally suitable for most sealed heating systems however if the system has a larger volume of water it may be necessary to provide extra capacity for expansion.

The boiler is supplied with the following components built in:Pressure relief valve -complying with BS 6759 and set to operate at 3 bars. The outlet connection of the boiler safety valve must terminate to atmosphere in accordance with current regulations. The manufacturer will not be held responsible for flooding caused by the operation of the safety valve in the case of system overpressure..

Pressure gauge -To indicates the system pressure to be maintained. Expansion vessel – Volume 7 litre. Conforming to BS 7074:1 for GB, By-pass -The boiler incorporates a by-pass, however where all radiators are fitted with thermostatic radiator valves it is

recommended an automatic system by-pass is fitted.

Additional expansion vessel (if required)

Double check valve assy

Temperature/pressure relief valve

Boiler

Automatic air vent

Heating return

System drain tap

Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance

Note: If required, an automatic by-pass is preferred

Radiator

valve

Filling point

DHW outlet

Pressure reducing valve (supplied)

Mains water inlet

Static head of system

Make up vessel

Heating by-pass (if required)

Lockshield valve

Filling the central heating system – figs. 2-3

The system design pressure (cold) should be set to 1.5 bar. This pressure is equivalent to a static head of 15.4 metres of water. Provision should be made to replace water lost from the system during servicing etc. as shown in Figs. 2 and 3. The position for connecting an alternative make-up vessel is indicated in Fig. 1. A double check valve assembly must be used. as shown in Fig. 3. Filling of the system must be carried out in a manner approved by the local Water Undertaking (GB: Guidance G24.2 and Recommendation R24.2 of the Water Regulation Guide). Where allowed the system may be filled via a temporary connection as shown in Fig. 2. After filling, always disconnect the flexible hose of the filling loop. All fittings used in the system must be able to withstand pressures up to 3 bar. Drain taps (to BS 2879) must be used to allow the system to be completely drained.

Double

check valve

assembly

Test cock

Feed cistern to be

located above highest

point in the system

Overflow

Heating

circuit return

Test cock

Double

check valve

assembly

Stop

valve

Mains water

supply

Mains

water

supply

Stop valve

Filling loop

temporarily

Hose

unions

Heating

circuit return

order to prevent scaling or deposits in the primary heat exchanger, the water in the heating circuit must be treated

according to the requirements of standard.

This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained. Frequent topping-up of the system should be avoided and normally indicates a leak within the heating system.

Fig. 1

Fig. 2

Fig. 3

INSTALLATION INSTRUCTIONS

3.7 Condensate drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER. The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run.

CAREFUL ATTENTION IS REQUIRED TO MINIMISE THE RISK OF FREEZING DURING PROLONGED COLD SPELLS.

I. The boiler condensate outlet terminates in a 25 mm flexible plastic pipe for connection to a plastic pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain or suitable soak-away is acceptable.

2. Ensure the discharge of condensate complies with any national or local regulations in force.

BS 6798:2000 & Part H I of the Building Regulations give further guidance.

3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP and take the shortest practicable route to a termination point.

4. Metal pipe work is NOT suitable for use in condensate discharge systems.

5. The pipe should be a minimum of 22 mm diameter and must be supported using suitably spaced clips to prevent sagging.

6. Any pipe fitted externally should not exceed 3 metres. 7 Any condensate discharge pipe work external to the building (or in an unheated part of it e.g. garage) must be insulated to protect against frost. It is also recommended that the pipe diameter is increased to 32mm.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

9. In alI cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped or freezing, as few bends and fittings as possible should be used.

10. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout. Examples are shown of the following methods of termination:- i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) iii) to a drain or gully iv) to a purpose made soak away

450mm min

Holes in the soak-away must

face away from the building

500mm min

External termination to a purpose made soak-away

External termination to a drain or gully

Pipe must terminate above

water level but below surrounding surface

Boiler

Pipe must terminate above

water level but below

surrounding surface

External termination via internal discharge branch e.g. sink waste - downstream

Sink

Termination to an internal soil and vent pipe

Boiler

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