Sime MERIDIAN HE 30 C, MERIDIAN HE 25, MERIDIAN HE 30, BRAVA DGT HE 25, BRAVA DGT HE 30 Installation And Servicing Instructions

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MERIDIAN

HE 30 C

Installation and

servicing instructions

ENSURE THAT THESE INSTRUCTIONS ARE LEFT

FOR THE USER AFTER COMPLETION OF THE

BENCHMARK SECTION

Please read the Important Notice within this guide regarding your boiler warranty

199838

All descriptions and illustrations provided in this manual have been carefully prepared but we reserve the right to make changes and improvements in our products that may affect the accuracy of the information contained in this manual.

This boiler may require 2 or more operatives to move it into its installation site, remove it from its packaging and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lif ting 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: – Grip the boiler at the base – Be physically capable – Use personal protective equipment as appropriate e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light. – Keep back straight – Avoid twisting at the waist – Always grip with the palm of the hand – Keep load as close to the body as possible – Always use assistance

WARNING

Caution should be exercised when performing any work on this appliance. Protective gloves and safety glasses are recommended. – Avoid direct contact with sharp edges. – Avoid contact with any hot surfaces.

NOTICE

Please be aware that due to the wet testing of the appliance, there may some residual water in the hydraulic circuit. – Protect any surfaces, carpets or floorings. – Use a suitable container to catch any water that escape when removing the protective caps from the connections.

SAFE HANDLING

IMPORTANT NOTICE

For the first year all of our appliances are protected by our manufacturer’s guarantee which covers both parts and labour. As you would expect from Sime Ltd, it is our aim to provide our valued customers with the best in after sales and service. To take advantage of any extended warranty offered, all you have to do is to adhere to these 3 simple conditions:

• The installation must be carried out to Manufacturers/Benchmark Standards by a Gas Safe Registered Engineer, and recorded in the installation manual.

• The appliance must be registered with both Sime Ltd and Gas Safe within 30 days of installation.

• The appliance must be serviced annually, by either Sime Ltd or a Gas Safe registered engineer- ensuring that the Benchmark service record in the installation manual is completed.

Failure to comply with the above will result in only the 12 month warranty being offered. In the absence of any proof of purchase, the 12 month warranty period will commence from the date of manufacture of the boiler as shown on the appliance data plate.

The Benchmark Scheme

Sime Ltd is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise safety, efficiency and performance.

Benchmark is managed and promoted by the Heating and Hotwater Industry Council.

For more information visit

www

.centralheating.co.uk

Please refer to commissioning instructions for filling in the checklist at the back of this installation guide.

Note: All Gas Safe registered installers carry a ID Card.

You can check your installer is Gas Safe Registered by calling 0800 408 5577

CONTENTS

1 DESCRIPTION OF THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 6

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 10

3 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 17

4 USE, MAINTENANCE (including BENCHMARK) AND COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 21

5 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 27

6 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 27

7 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 30

8 APPENDIX 1 (GUIDANCE HHIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 35

9 APPENDIX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 47

SIME COMBINATION BOILERS

Installer checklist

Please remember to carry out the following checks after installation. This will achieve complete customer satis-

faction, and avoid unnecessary service calls. A charge will be made for a service visit where the fault is not due to

a manufacturing defect.

– Has a correct by-pass been fitted and adjusted?

– Has the system and boiler been flushed?

– Is the system and boiler full of water, and the correct pressure showing on the pressure gauge?

– Is the Auto Air Vent open?

– Has the pump been rotated manually?

– Is the gas supply working pressure correct?

– Is the boiler wired correctly? (See installation manual).

– Has the customer been fully advised on the correct use of the boiler, system and controls?

– Has the Benchmark Checklist in the use and maintenance section of this manual, been completed ?

IPX4D

Important Information

IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). The manufacturer’s instructions must not be taken as overriding any statutory requirements, and failure to comply with these regulations may lead to prosecution.

No modifications to the appliance should be made unless they are fully approved by the manufacturer.

GAS LEAKS: DO NOT OPERATE ANY ELECTRICAL SWITCH, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPLY AND VENTILATE THE AREA BY OPENING DOORS AND WINDOWS CONTACT THE GAS EMERGENCY SERVICE ON

0800111999.

Meridian HE 30 C: Gas Council number 47-283-46

These appliances comply with the S.E.D.B.U.K. scheme, band “A”

TABLE 2 - Minimum clearances

For servicing ABOVE THE APPLIANCE CASING 300 mm AT THE R.H.S. 15 m m AT THE L.H.S. 15 m m BELOW THE APPLIANCE CASING 200 mm IN FRONT OF THE APPLIANCE 500 mm

TABLE 1 - Connections

R C.H. return 22 mm Compression M C.H. flow 22 mm Compression G Gas connection 15 mm Compression E D.H.W. inlet 15 mm Compression U D.H.W. outlet 15 mm Compression S3 Condensation outlet ø 20 S Safety valve discharge

1.1 INTRODUCTION

MERIDIAN HE 30 C are premixed gas con-

densation thermal modules that employ a microprocessor-based technology to con-

trol and manage all the functions. All modules are compliant with European Directives 2009/142/CE, 2004/108/CE, 2006/95/CE and 92/42/CE. For optimum installation and operation, always fol-

low the instructions provided in this manual. The products manufactured and sold by Sime do not contain any banned materials or substances (ie they comply with ISO9000:2000).

1 DESCRIPTION OF THE BOILER

16 4

18 3

70 60

794

750

60/100

13 9

12 6

450

RE GUMREGUM

Fig. 1

1.2 DIMENSIONS (fig. 1)

MERIDIAN HE 30 C

Heat output

Nominal (80-60°C) kW 28.9

Nominal (50-30°C) kW 31.6

Reduced G20 (80-60°C) kW 5.9

Reduced G20 (50-30°C) kW 6.6

Reduced G31 (80-60°C) kW 7.6

Reduced G31 (50-30°C) kW 8.5

Heat input nominal kW 29.5

Heat input reduced G20/G31 kW 6.2/8.0

Max/min useful yield (80-60°C) % 98.0/95.1

Max/min useful yield (50-30°C) % 107.1/106.4

Useful yield at 30% of the load (40-30°C) %107.0

Termal efficiency (CEE 92/42 directive) 

Losses after shutdown to 50°C (EN 483) W89

Supply voltage V-Hz 230-50

Adsorbed power consumption W115

Electrical protection grade IP X4D

C.H. setting range °C 20/80

Water content boiler l 4.60

Maximum water head bar 3.0

Maximum temperature °C 85

Capacity of the heating expansion vessel l8

Pressure of the heating expansion vessel bar 1.0

D.H.W. setting range °C 10/60

D.H.W. flow rate (EN 625) l/min 13.4

Continuous D.H.W. flow rate ∆t 30°C l/min 14.4

Minimum D.H.W. flow rate l/min 2.2

D.H.W. pressure min/max bar 0.5/6.0

Exhaust fumes temper. at max flow rate (80-60°C)

°C 79

Exhaust fumes temper. at min. flow rate (80-60°C)

°C 67

Exhaust fumes temper. at max flow rate (50-30°C)

°C 51

Exhaust fumes temper. at min. flow rate (50-30°C)

°C 47

Smokes flow min/max kg/h 11/50

2 at max/min flow rate G20 % 9.0/9.0

2 at max/min flow rate G31 % 10.0/10.0

CE certification n° 1312CN5755

Category II2H3P

Typ e B23P-53P/C13-33-43-53-83

NOx emission class 5

Weight when empty kg 33.6

Main burner nozzle

Quantity nozzles n° 2

G20 nozzle diameter diversified ø 2.8/3.8

G31 nozzle diameter diversified ø 2.2/2.9

Consumption at maximum/minimum flow rate

G20 m

/h 3.12/0.66

G31 kg/h 2.29/0.62

Gas supply pressure G20/G31 mbar 20/37

1.3 TECHNICAL FEATURES

1.4 FUNCTIONAL DIAGRAM (fig. 2)

Fig. 2

KEY

1Fan 2 Limit stat 3 Primary exchanger 4 C.H. sensor (SM) 5 Gas valve 6 D.H.W. exchanger 8 Diverter valve

9 Safety thermostat 10 Pump with air release vent 11 D.H.W. flow switch 12 Water inlet filter 14 Pressure relief valve 15 Water pressure switch 16 Automatic bypass 17 Drain vent

18 Expansion vessel 19 Condensate drain trap

21 D.H.W. isolation valve 22 Gas isolation valve 23 C.H. flow isolation valve 24 C.H. return isolation valve 25 D.H.W. sensor (SS)

CONNECTIONS R C.H. return M C.H. flow G Gas connection E D.H.W. inlet U D.H.W. outlet S3 Condensation outlet S Safety valve discharge

bar

Fig. 3

1.5 MAIN COMPONENTS (fig. 3)

KEY

1 Control panel 2 Condensate drain trap 3 C.H. sensor (SM) 4 Safety thermostat 5 Ignition electrode 6 Programming clock 7 Primary exchanger 8 Air release vent

9 Limit stat 10 Exhaust temperature sensor 11 Smoke chamber 12 Expansion vessel 13 Air inlet 14 Ionisation electrode 15 F an 16 Pressure relief valve 17 Air release vent 18 Pump 19 D.H.W. sensor (SS)

NOTE: Analogue pressure gauge

It is important that the boiler is initially filled and started for the first time using the method shown in 2.3.3 section e). This procedure should also be used when refilling after draining a boiler.

The boiler must be installed in a fixed location and only by specialized and qualified person in compliance with all instructions contained in this manual. The installation of this boiler must be in accordance with the relevant requirements of the current Gas Safety (inst allation and use), the local building regulations, and and I.E.E. wiring regulations. Detailled recommendations for air supply are given in BS5440:2. The following notes are for general guidance: it is not necessary to have a purpose provided air vent in the room or compartment in which the appliance is installed.

2.1 ANTI-FREEZE FUNCTION

The boilers are equipped with anti-freeze function which activates the pump and the burner when the temperature of the water contained inside the appliance drops to below value PAR 10. The anti-freeze function can only operate if: – the boiler is correctly connected to the

gas and electricity supply circuits; – the boiler is switched on; – the boiler ignition is not locked out; – the essential components of the boiler

are all in working order.

In these conditions the boiler is protected against frost down to an environmental temperature of -5°C.

ATTENTION: In the case of installation in a place where the temperature drops below 0°C, the connection pipes must be protected.

2.2 FIXING THE WALL MOUNTING BRACKET (fig. 4)

– Mark the position of the two wall mount-

ing bracket fixing holes and the flue/air duct hole on the appropriate wall(s).

–

Drill the two fixing holes using a 10 mm masonry drill and fit the plastic plugs provided.

– Accurately measure the wall thickness,

and note this dimension for later use.

– Secure the wall mounting bracket in

position using the screws provided. Ensure that it is the correct way up, as indicated in fig. 4.

2.3 CONNECTING UP SYSTEM

Before connecting the boiler it is recommended that the system be flushed in accordance to BS 7593, to eliminate any foreign bodies that may be detrimental to the operating efficiency of the appliance. When connecting up the boiler the clearances in fig 1 should be respected. The boiler is supplied with a valve pack part number 5184817A. The boiler can be filled and pressure tested prior to any electrical supply being connected with the use of the analogue pressure gauge.

A safety valve set at 3 bar is fitted to the appliance, the discharge pipe provided should be extended to terminate safely away from the appliance and where a discharge would not cause damage to persons or property but would be detected. The pipe should be a minimum of 15 mm Ø and should be able to withstand boiling water, any should avoid sharp corners or upward pipe runs where water may be retained.

Gas Connection

The gas connection must be made using

seamless steel or copper pipe. Where the piping has to pass through walls, a suitable insulating sleeve must be provided. When sizing gas piping, from the meter to the boiler, take into account both the volume flow rates (consumption) in m3/h and the relative density of the gas in question. The sections of the piping making up the system must be such as to guarantee a supply of gas sufficient to cover the maximum demand, limiting pressure loss between the gas meter and any apparatus being used to not greater than 1.0 mbar for family II gases (natural gas). An adhesive data badge is sited inside the front panel; it contains all the technical data identifying the boiler and the type of gas for which the boiler is arranged.

2.3.1 Connection of condensation water trap

To ensure safe disposal of the condensate produced by the flue gases, reference should be made to BS6798:2009. The boiler incorporates a condensate trap which has a seal of 75 mm, therefore no additional trap is required. The advised method of connection to the condensate trap is by using 20 mm overflow pipe with a socket attached to cover the condensate trap connection. The condensate should ideally be discharged internally into an internal waste pipe(washing machine/sink waste) or a soil pipe to avoid the risk of freezing. External pipe runs should be avoided, but if it is necessary, the pipework should be at least 32mm and protected from the risc of freezing with a waterproof insulation and the length kept to a minimum and not exceeding 3 m. termination should be into an external gully or purpose made soakaway.

2 INSTALLATION

KEY 1 Wall mounting bracket 2 Plastic wall plug (2 Off) 3 Woodscrew (2 Off) 4 Washer (2 Off)

Fig. 4

NOTE: All pipework must have a continuous fall from the boiler and must be resistant to corrosion by condensate, copper or steel is NOT suitable. It should be noted that the connection of a condensate pipe to a drain may be subject to local building control requirements.

2.3.2 Dealing with condensate

See APPENDIX A for guidance on the disposal of condensate.

2.3.3 Requirements for sealed water systems (fig. 5)

The heating system design should be based on the following information: a) The available pump head is given in fig.

14 .

b) The burner starts if the system pres-

sure is sufficient to operate the pressure switch.

c) The appliance is equipped with an inter-

nal by-pass that operates with system heads (H) greater than 3 m. The maximum flow through the by-pass is about 300 l/h. If thermostatic radiator valves are to be installed, at least one radiator should be without a thermostatic valve (usually the bathroom radiator or the radiator in the room containing the

room thermostat).

d) A sealed system must only be filled by a

competent person using a method similar to that shown in fig. 5. The system design should incorporate the connections appropriate to one of these methods.

e) It is most important that the boiler is

not allowed to ignite until it and the heating system is filled. Ensure that the electrical supply to the boiler is turned off. Open the auto air vent, 17 fig 3. Fill the system to approximately 1.5 bar. Use the manual air vent located on the uppermost connection to the primar y heat exchanger (item 8 fig. 3) to release any air retained, and ensure that all the radiators are vented. Top up the system pressure to 1.5 bar. Turn on the power supply to the boiler and put the boiler in the Summer mode. While in the Summer mode, adjust the heating flow temperature to its minimum 20 degrees. Put the boiler into the Winter mode and allow it to ignite. Run the boiler in this mode for approximately 30 minutes, regularly checking that trapped any air is released. and gradually increasing the flow temperature to 60 degrees. When inhibitor is added repeat this procedure with the initial flow temperature at 20 degrees. The flow temperature should then be

set to the desired value.

NOTE: If the domestic water supply is metered, or should a water meter be added at a later time, a small expansion vessel should be included on the Domestic hot water pipework.

2.4 CHARACTERISTICS OF FEEDWATER

– All recirculatory systems will be subject

to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.

– For optimum per formance after instal-

lation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 7593 “Treatment of water in domestic hot water central heating systems”. Sime Ltd recommend only the use of FERNOX products for the flushing and final treatment of the system water. This is particularly important in hard water areas. Artificially sof tened water must not be used to fill the heating system.

METHOD OF FILLING A SEALED SYSTEM

Fig. 5

– It is important to check the inhibitor

concentration after installation, system modification and at every service in accordance with the manufacturer’s instructions (Test kits are available from inhibitor stockists).

FLUES INSTALLATION MUST COMPLY WITH THE CURRENT VERSION OF BS5440.

2.5 INSTALLATION COAXIAL DUCT ø 60/100 - ø 80/125 (fig. 6)

The coaxial suction and discharge pipes are supplied in a special kit (that can be purchased separately) along with assembly

instructions. The diagrams of fig. 6 illustrate some examples of different types of fluing options allowed and the maximum lengths that can be reached.

2.6 INSTALLATION OF SEPARATE DUCTS ø 80 (fig. 7)

The kit with dedicated pipes enables to separate the exhaust fumes pipes from the air suction pipes (fig. 7): –for ø 80 pipes, adaptor code 8093050 is

available upon request.

The maximum overall length, resulting from the sum of all the suction and

discharge pipes, is determined by the load losses of the single connected accessories and should not exceed 15 mm H2O (version 25-30) (ATTENTION: the total length of each pipe should not exceed 50 m, even if the total loss is below the maximum applicable loss.)

See Table 3 for information on the load los- ses of single accessories (fig. 8).

2.6.1 Separate ducts kit (fig. 8)

The diagrams of Figure 8 show a some of examples of the permitted exhausts configurations.

C33

C43

x + y = L (m)

H (m)

C13

L (m)

LIST OF ø 60/100 ACCESSORIES

1 Coaxial duct kit L. 790 code 8096250 2a Extension L. 1000 code 8096150 2b Extension L. 500 code 8096151 3 Vertical extension L. 140 with coupling code 8086950 5 Tile for joint code 8091300 6 Terminal for roof exit L. 1285 code 8091212

(includes 8086950)

Model Length of pipe Length of pipe

ø 60/100 ø 80/125

HV H V

Min Max Min Max

MERIDIAN HE 30 C 5 m 1.3 m 7 m 10 m 1.2 m 13 m

LIST OF ø 80/125 ACCESSORIES

1 Coaxial duct kit L. 785 code 8096253 2a Extension L. 1000 code 8096171 2b Extension L. 500 code 8096170 3 Adapter for ø 80/125 code 8093150 5 Tile for joint code 8091300 6 Terminal for roof exit L. 1285 code 8091212A

(includes 8093150)

H (Horizontal) m

V (Vertical) m

IMPORTANT: – The insertion of each additional 90° bend with a diameter of 60/100 (code 8095850)

reduces the available section by 1.5 meters.

– The insertion of each additional 90° bend with a diameter of 80/125 (code 8095870)

reduces the available section by 2 meters.

– Each additional 45° curve installed a diameter of 60/100 (code 8095550) reduces the

available length by 1.0 metres.

– Each additional 45° curve installed a diameter of 80/125 (code 8095970) reduces the

available length by 1.0 metres.

HORIZONTAL FLUES MUST BE LEVEL

NOTE: Before connecting accessories, it is always advisable to lubricate the internal part of the gaskets with silicon products. Avoid using oils and greases.

Fig. 6

2.7 POSITIONING THE OUTLET TERMINALS (fig. 9)

The outlet terminals for forced-draught appliances may be located in the external perimeter walls of the building. To provide some indications of possible solutions, Table 4 gives the minimum distances to be observed, with reference to the type of building shown in fig. 9.

2.9 ELECTRICAL CONNECTION

The boiler is supplied with an electric cable. Should this require replacement, it must be replaced with one of similar type and dimensions. The electric power supply to the boiler must be 230V - 50Hz single-phase through a 3 amp fused main switch, with at least 3 mm spacing between contacts.

Respect the L and N polarities and the earth connection.

NOTE: SIME declines all responsibility for injury or damage to persons, animals or property, resulting from the failure to provide for proper earthing of the appliance, or incorrect connection of external controls. Any fault or component failure due to incorrect connection of external controls is not covered in the warranty.

12 0

18 3

13 9

18 5

130 (vers. HE 35)

Fig. 7

KEY 1 Adaptor with vent 2 Air intake 3 Exhaust

CA Inlet CS Outlet

C33

Fig. 8

C13

NOTE Before connecting accessories, it is always advisable to lubricate the internal part of the gaskets with silicon products. Avoid using oils and greases.

TABLE 3 MERIDIAN HE 30 C

Load loss - mm H2O

Inlet Exhaust

1 Air/smoke divider, code 8093050 0 0

2 90° bend, code 8077450 0.25 0.30 3 a Extension 80mm L. 1000, code 8077351 0.20 0.20 3 b Extension 80mm L. 500, code 8077350 0.10 0.10

7 45° bend, code 8077451 0.20 0.20

9 Inlet/ exhaust fitting, code 8091401 -- --

10 Articulated tile, code 8091300 -- -11 Vertical roof terminal, code 8091212B * 1.10 0.15 13 Inlet/ exhaust fitting, code 8091401 -- -14 Coaxial Terminal, code 8096253A * 1.10 0.15

* This loss includes the losses with use of item 9 or 13

– If the terminal discharges into a pathway or passageway

check that combustion products will not cause nuisance and that the terminal will not obstr uct the passageway.

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

(78 in) above ground, above a balcony or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed guard.

– Where the terminal is fitted within 850 mm (34 in) of a plas-

tic or painted gutter, or 450 mm (18 in) of paint ed eaves, an aluminium shield at least 1,500 mm (59 in) long must be fitted to the underside of the paint ed surface.

– The air inlet/outlet flue duct MUST NOT be closer than 10

mm (0.4 in) to combustible material.

– In certain weather conditions the terminal may emit a plume

of steam. This is normal but positions where this would cause a nuisance should be avoided.

Terminal position Minimum spacing A Directly below an openable window, air vent

or any other ventilation opening 300 mm 12 in

B Below guttering, drain pipes or soil pipes (*) 75 mm 3 in C/D Below eaves, balconies or carpor t roof 200 mm 8 in E From vertical drain pipes or soil pipes 75 mm 3 in F From internal or external corners 300 mm 12 in G Above adjacent ground, roof or balcony level 300 mm 12 in H From a boundary or surface facing the boiler 600 mm 24 in I From a terminal facing the terminal 1,200 mm 48 in J From an opening in the carport

(eg door, window into dwelling) 1,200 mm 48 in

K Vertically from a t erminal on the same wall 1,500 mm 60 in L Horizont ally from a terminal on the same wall 300 mm 12 in M Horizontally from a vertical terminal to a wall 300 mm 12 in N Horizontally from an openable window or other opening 300 mm 12 in P Above an openable window or other opening 300 mm 12 in Q From an adjacent vertical terminal 600 mm 24 in

(*) For condensing boilers this distance can be reduced to 25 mm without ef fecting boiler per-

formance, but it will be necessary to prot ect the surfaces from the ef fects of condensate

TABLE 4

Fig. 9

2.9.1

Climatic control option

The boiler is designed for connection to an external temperature sensor, supplied on request (code 8094101) in conjunction with remote control (code 8092226), which can automatically regulate the temperature value of the boiler output according to the external temperature. For installation, follow the instruction in the package. Expansion control kit 8092240 will also be required.

2.9.2 External wired controls

The heating function of the boiler can be

controlled by voltage free signal, TA, connected to terminals 5 & 6 af ter removal of the link.

2.9.3 Use with different electronic systems

Some examples are given below of boiler systems combined with dif ferent electronic systems. Where necessary, the parameters to be set in the boiler are given. The electrical connections to the boiler refer to the wording on the diagrams (fig.

11). Zone valve control is activated with every heating request from remote control. Description of the letters indicating the components shown on the system diagrams 1 to 3: M C.H. flow R C.H. return CR Remote control CR 63 SE External temperature sensor TA 1-2 Zone room thermostat VZ 1-2 Zone valve RL 1-2 Zone relay Sl Hydraulic separator P 1-2 Zone pump EXP Expansion card

(code 8092240)

For guidance only, flues should be installed in accordance with BS5440

2 BASIC SYSTEM

MULTI-ZONE SYSTEM WITH VALVE, ROOM THERMOSTAT AND EXTERNAL SENSOR (Code 8094101)

TA 1

VZ1

TA 2

VZ2

1 BASIC SYSTEM

SYSTEM WITH A DIRECT ZONE AND ROOM THERMOSTAT, OR WITH A REMOTE CONTROL (Code 8092219), KIT EXPANSION REMOTE CONTROL (Code 8092240) AND EXTERNAL SENSOR (Code 8094101)

EXP

TA 1

TA 2

RL1

RL2

3 BASIC SYSTEM

MULTI-ZONE SYSTEM WITH PUMP, ROOM THERMOSTATS AND EXTERNAL SENSOR (Code 8094101)

2.10 BOILER ELECTRICAL (fig. 11)

TA (24 VDC)

SE (3.3 VDC)

SS (3.3 VDC)

SM (3.3 VDC)

PA (24 VDC)

TL (3.3 VDC)

TFU

TS (3.3 VDC)

EV 1-2

FL (12 VDC)

SF (3.3 VDC)

EXP (24 VDC)

TRA

Fig. 11

KEY F Fuse (1.6 AT) TRA Ignition transformer PI Pump VFan EA Ignition electrode ER Ionisation electrode EV1-2 Gas valve coil VD Divertor valve OP Programming clock SM C.H. sensor TS Safety thermostat TFU Thermal fuse TL Limit stat FL D.H.W. flow switch SF Exhaust temperature sensor PA Water pressure switch

TA Room thermostat SE External sensor (optional) SS D.H.W- sensor EXP Expansion car d remote control (optional)

NOTE: Connect a voltage free room thermostat TA to terminals 5 & 6 after removal of the link.

CONNECTOR SPARE PART CODES:

CN3 code 6319158 CN4 code 6323856 CN5 code 6316253 CN6 code 6323861 CN7 code 6323860

3 CHARACTERISTICS

3.1 CONTROL PANEL (fig. 12)

1 - DESCRIPTION OF DISPLAY ICONS

SUMMER MODE ICON

WINTER MODE ICON

D.H.W. MODE ICON

HEATING MODE ICON

BURNER LIT ICON

LOCKOUT DUE TO NO IGNITION/FLAME DETECTION

RESET REQUIRED

MAIN DIGITS

Fig. 12

2 - DESCRIPTION OF CONTROLS

OPERATING MODE/RESET

Press this key repeatedly to step from standby to summer to winter. The green LED will flash accompanied by a audible signal, to indicate that the key has been pressed. Press the key for more than two seconds to enter standby. RESET is only available if a re-settable error is signalled.

D.H.W. SET

Press the key to display the D.H.W. temperature value set

HEATING SET

Press the key to display the heating flow temperature value set (value not realtive to the remote control)

DECREASE

Pressing this key decreases the value set

INCREASE

Pressing this key increases the value set

3 - LED GREEN

ON = Indicates the presence of electrical voltage. It switches of momentarily every time the keys are pressed. It can be disabled by setting PAR 3 = 0.

4 - LED RED

OFF = Normal operation ON = Boiler error signalled Flashing when the control panel buttons are pressed inside the PARAMETERS SECTION.

3.2 ACCESS TO INSTALLER'S PARAMETERS

For access to the installer's parameters, press simultaneously the ( and ) keys for 5 seconds. The red LED flashes and the display shows :

The parameters can be scrolled with or . To enter the parameter press or . The value set flashes, the display shows :

Proceed as follows to change the set value: – set the new value using or . – confirm the set value using or .

Press to exit the parameters section. The display is shown automatically after 5 minutes. The parameters section contains the alarms log, info and meters (display only).

3.2.1 Replacing the board or RESETTING parameters

If the electronic board is replaced or reset or the type of gas used is changed, it is necessary to configure PAR 01 and PAR 02 by associating the following values to each type of boiler to be able to restart the boiler:

NOTE: the boiler panel has a label with the values that have to be set for PAR 01 and PAR 02 (fig. 19).

BOILER PAR 2

D.H.W. flow meter 01

With storage tank 03

Heating only 04

D.H.W flow switch 09

D.H.W. flow switch

with D.H.W. sensor 13

PARAMETERS INSTALLER

FAST CONFIGURATION

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING

01 Combustion configuration -- = ND = = “--”

1 ... 20

02 Hydraulic configuration -- = ND = = “--”

1 ... 13

03 Disabling of the green LED 0 = Disabled = = 01

1 = Enabled 04 Correction of external probe values -5 ... 05 °C 1 00 05 Default time for keypad locking -- = Disabled Min. 1 15

1 ... 99

09 Fan rpm Step ignition 00 .... 81

rpm x 100

0,1 from 0,1 to 19,9

1 from 20 to 81

D.H.W. - HEATING

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING 10 Frost protection temperature 0 ... 10 °C 1 03 11 External sensor antifreeze -- = Disabled °C 1 - 2

- 9 ... 05 12 Climatic curve setting 03 ... 40 = 1 20 13 Minimum heating temperature 20 ... PAR 14 °C 1 20 14 Maximum heating temperature PAR 13 ... 80 °C 1 80 15 Maximum heating power 30 ... 99 % 1 99 16 Post-circulation time 0 ... 99 10 sec. 1 03 17 Pump heating activation delay 0 ... 99 10 sec. 1 01 18 Re-ignition delay 0 ... 10 Min. 1 03 19 Flow meter modulation saturation band 0 ... 99 % 1 30 29 Anti-legionella (only D.H.W. tank) O = Disabled = = 0

1 = Enabled

PARAMETERS RE-SET

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING

49 * Reset default parameters -- , 1 = = =

(PAR 01 - PAR 02 equal “---”)

* To reset the circuit board to the default settings, set PAR49 to 1.

PAR1 and PAR2 will need to be set as shown in 3.2.1.

ALARMS (Display)

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING A0 Code of last error = = = = A1 Code of last error - 1 = = = = A2 Code of last error - 2 = = = = A3 Code of last error - 3 = = = = A4 Code of last error - 4 = = = = A5 Code of last error - 5 = = = = A6 Code of last error - 6 = = = = A7 Code of last error - 7 = = = = A8 Code of last error - 8 = = = = A9 Code of last error - 9 = = = =

INFO (Display)

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING i0 External sensor temperature -9 ... 99 °C 1 = i1 C.H. 1 sensor temperature -9 ... 99 °C 1 = i2 C.H. 2 sensor temperature -9 ... 99 °C 1 = i3 Fumes sensor temperature -9 ... 99 °C 1 = i4 Auxiliary sensor AUX temperature -9 ... 99 °C 1 = i5 Set of ef fective heating temperature PAR 13 ... PAR 14 °C 1 = i6 Level ionization flame 00 ... 99 % 1 = i7 Fan speed 00 ... 99 100 rpm 1 = i8 Flow rate D.H.W. flow meter 00 ... 99 l/min 1 =

COUNTERS (Display)

PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT

MEASUREMENT UNIT SETTING c0 Number hours of operation of the burner 00 ... 99 h x 100

0,1 from 0,0 to 9,9

1 from 10 to 99

c1 Number of ignitions of the burner 00 ... 99 x 1000

0,1 from 0,0 to 9,9

1 from 10 to 99 c2 Total number of errors 00 ... 99 x 1 1 00 c3

Number accesses of Installer parameters

00 ... 99 x 1 1 00

Number of accesses of OEM parameters

00 ... 99 x 1 1 00

GAS MODELS PAR 1

METHANE

(G20) 30 C 02

PROPANE

(G31) 30 C 05

3.3 EXTERNAL SENSOR (fig. 13)

If there is an external sensor, the heating settings SET can be taken from the climatic curves according to the external temperature and, limited to with the range values described in point 3.2 (parameters PAR 13 and PAR 14). The climatic curve to be set can be selected from a value of 3 and 40 (at step 1). Increasing the steepness of the curves of fig. 14 will increase the output temperature as the external temperature decreases.

3.5 CARD FUNCTIONING

The electronic card has the following functions:

– Antifreeze protection of the heating cir-

cuits. – Ignition and flame detection system. – Control panel setting for the power and

the gas for boiler functioning. – Anti-jammed for the pump which is fed

for a few seconds (10”) after 48 hours of

inactivity. – Chimney sweep function which can be

activated from the control panel. – Temperature which can be shifted with

the external sensor connected. – Automatic regulation of the ignition

power and maximum heating.

Adjustments are managed automatically

by the electronic card to guarantee maxi-

mum flexibility in use of the system.

3.6 TEMPERATURE

DETECTION SENSOR

Table 4 shows the resistance values of the heating, D.H.W. and fumes sensor.

If the C.H. sensor (SM) and fumes sensor (SF) is faulty or open circuit, the boiler will not function on either heating or D.H.W. If the D.H.W. sensor (SS) is faulty or open circuit, the boiler will function on either heating and D.H.W. (ALL 10).

3.6 ELECTRONIC

IGNITION

Ignition and flame detection is controlled by electrodes on the burner which guarantees reaction in the case of accidental extinction or lack of gas within one second.

3.6.1 Functioning cycle

Burner ignition should occur within 10 seconds of the opening of the gas valve. If after three attempts the ignition is not detected the boiler will lockout (ALL 06):

– Lack of gas

The ignition electrode will discharge for a maximum of 10 seconds. If after three attempts the ignition is not detected the boiler will lockout (ALL 06). This can happen the first time a boiler is switched on, or after long periods of inactivity. It can also be caused by a closed gas cock or a gas valve not operating.

– No ionisation

The boiler will spark for 10 seconds, if after 3 attempts the ionisation is not detected, the boiler will lockout (ALL 06). This could be due to a poor connection or break in the ionisation cable. Check also that the cable is not shorted, badly worn or distorted.

In the case of a sudden loss of voltage, the

burner will immediately switch off. When the voltage is restored, the boiler will automatically start up again.

3.7 HEAD AVAILABLE TO SYSTEM (fig. 14 )

Residual head for the heating system is shown as a function of rate of flow in the graph in fig. 14.

3.8 WATER PRESSURE SWITCH (fig. 15)

The water pressure switch (8) intervenes, blocking burner functioning, if it detects that there is insufficient pressure in the boiler (< 0,6 bar). To restore the boiler operation, increase the system pressure to 1 - 1,2 bar.

TABLE 4 (SM - SS - SF sensors)

Temperature (°C) Resistance (Ω)

20 12.090 30 8.313 40 5.828 50 4.161 60 3.021 70 2.229 80 1.669

Fig. 13

ATTENTION: curves are calculated at an ambient temperature of 20°C. The user can act on the boiler controls to change the environment set for which the bend has been calculated by ±5°C.

600

200 12001000800600400

P OR TATA (l/h)

PREVALENZA RESIDUA (mbar)

500

400

10 0

200

300

MERIDIAN HE 25-30

HE 30 - HE 30 C

HE 25

P OR TATA PREVALENZA (l/h) RESIDUA (mbar)

0512 100 500 200 487 300 468 400 443 500 412 600 377 700 338 800 294 900 246 1030 169

P OR TATA PREVALENZA (l/h) RESIDUA (mbar)

0515 100 485 200 480 300 471 400 462 500 445 600 423 700 391 800 352 900 300 1050 222

HE 25

HE 30 - HE 30 C

Fig. 15

Fig. 14

RESIDUAL HEAD (mbar)

FLOW RATE (l/h)

KEY

1 Condensate drain trap 2 Diverter valve 3 D.H.W. exchanger 4 Gas valve 5 D.H.W. flow switch 6 Pressure relief valve 7 Pump with air release vent 8 Water pressure switch 9 Boiler discharge

10 D.H.W. sensor (SS)

FLOW RATE

(l/h)

FLOW RATE

(l/h)

RESIDUAL HEAD

(mbar)

RESIDUAL HEAD

(mbar)

PLEASE NOTE: During routine servicing and after any maintenance or change of part of the combustion circuit, the following must be checked:

- The integrity of the flue system and the flue seals

- The integrity of the boiler combustion circuit and relevant seals.

- The operational working gas pressure as described in section 4.7.1

- The combustion performance as described in section 4.8.1

4.1 GAS VALVE (fig. 16)

The boiler is supplied as standard with a gas valve, model SIT 848 SIGMA (Fig. 16).

4.2 GAS CONVERSION (fig. 17)

This operation must be performed by authorised personnel using original Sime components.

To convert from natural gas to LPG or vice versa, perform the following operations – Close the gas cock. –Replace the two differential nozzles (1-2)

and relative seal o-rings (3) with those supplied in the transformation kit. NOTE: the difference in the shape of the head of the nozzles, avoid reversal during assembly.

– Reset PAR as shown in 4.2.1. – Apply the nameplate with the new gas

flow layout.

– Calibrate the maximum and minimum

pressures of the gas valve following the instructions provided in paragraph 4.2.2.

4.2.1 New fuel configuration

Access the parameters section by pressing the control panel keys ( and ) at

the same time for 5 seconds. The red LED flashes and the display shows :

Scroll the parameters using or . To enter the fuel configuration paramater PAR 01, use or . The set value f

lashes a MERIDIAN HE 30

C on natural gas will be show as :

For a MERIDIAN HE 30 C boiler to function with LPG, press until 05 appears. Confirm this value using or . Exit the parameters section by pressing .

The table below gives the values to set when the supply gas is changed:

4.2.2 Calibrating the gas valve pressures (See 4.8.1)

This can only be done using a flue gas analyser. If the combustion reading is greater than the acceptable value AND the integrity of the complete flue system and combu-

stion seals have been verified, and the inlet gas pressure has been verified then adjustments to the gas valve can be made as described below. Make only small adjustments (1/8 turn max), and allow time for the combustion analysis to be made before making further adjustments.

Sequence of operations:

Press buttons and at the same time for 5 seconds. Chimney sweep mode, see 4.5.1 (Lo) will appear on the display and the boiler will work at minimum power.

2) Press button to raise the boiler to maximum power (Hi)

3) Determine the CO2 values at max power stated below, if required adjust using the capacity step (5 fig. 16):

4) Press button to bring the boiler to minimum power (Lo).

5) Determine the CO2 values at min power stated below, if required adjust using the OFF-SET adjustment screw (6 fig. 16):

6) Press buttons and several times to verify the pressures; if necessar y, make the appropriate corrections.

7) Press button to exit the function.

4.3 RATIO

Fig. 16

KEY 1 Upstream pressure intake 2 Intermediate pressure intake 3 Air signal inlet (VENT) 4 Downstream pressure intake 5 Capacity step 6 OFF-SET

4 USE, MAINTENANCE (including BENCHMARK) AND COMMISSIONIG

MAX power Boiler CO2 CO2 model (Methane) (Propane) HE 30 C 9,0 ±0,3 10,0 ±0,3

MIN power Boiler CO2 CO2 model (Methane) (Propane) HE 30 C 9,0 ±0,3 10,0 ±0,3

GAS MODELS PAR 1

METHANE

(G20) 30 C 02

PROPANE

(G31) 30 C 05

CO ppm

100 400

0,0011 0,0044

0,0010 0,0040

Fig. 17

4.4 DISASSEMBLING THE SHELL (fig. 19)

To simplify maintenance operations on the boiler, it is also possible to completely remove the shell, as shown in figure 19. Remove the screws securing the control panel and tilt it forward and be able to access the internal components of the boiler.

4.5 MAINTENANCE (fig. 20)

To guarantee the operation and ef ficiency of the appliance and to conform to any extended warranty, it must be serviced regularly, dependant on usage, but at least

4 x

Fig. 19

Codice/Code 8111862 Modello/Model MERIDIAN HE 30 C Matricola/Serial n. 9999999999

PAR 1 = 02 (METANO) / 05 (GPL) PAR 2 = 13

Fig. 20

annually by a qualified Gas Safe Registered engneer.

During maintenance operations, it is important to verify that the condensate trap contains water (this check is particularly important if the generator has not been used for extended periods of time). If necessary, the condensate trap can be filled using the filling point provided (fig. 20).

4.5.1 Chimney sweep function (see also 4.8.1)

To check boiler combustion, press at the same time the installer's key ( e ) for a few seconds. The chimney sweep function will switch on and will continue for 15 minutes. During the 15 minutes functioning of chimney sweep function, pressing the keys ( and ) take the boiler respective at maximum (Hi) and at minimum (Lo) power. From that moment, the boiler will star t working in heating mode at maximum power, with cut off at 80°C and re-ignition at 70°C.

Before activating the chimney sweep function make sure that the radiator valves or zone valves are open.

The test can also be carried out with the boiler working in D.H.W. mode. For this, after activating the chimney sweep function, open one or more hot water taps. Under these conditions, the boiler will function at maximum power with the D.H.W. kept at between 60°C and 50°C. During the test, the hot water taps must remain open. For exit to the chimney sweep function press the key of the control panel.

The chimney sweep function will automatically switch off after 15 minutes from the activation.

4.6 FUNCTIONING ERRORS

When there is a functioning error, an alarm appears on the display and switch on the

red led. Descriptions of the errors with relative alarms and solutions are given below (if a error persists contact a authorised service engineer):

– LOW WATER PRESSURE

ERROR ALARM 02 (fig. 22/a)

If the pressure detected by the water pressure valve is lower than 0.5 bar, the boiler stops and the display shows the alarm “AL 02”. Increase the system pressure to between 1.0 and 1.2 bar (use pressure gauge, fig 22/a) using the external filling loop. The boiler will automatically resume operating.

– C.H. SENSOR ERROR ALARM 05

When C.H. sensor (SM) is open or short circuited, the boiler will not function and the display will show the alarm “AL 05”.

– LOCKOUT ALARM 06 (fig. 22/b)

If the flame control has not detected the presence of the flame after a complete ignition sequence, or for any other reason the card cannot “see” the flame, the boiler will stop and the display will show the alarm “AL 06”. Press the key of the controls to start up the boiler again.

– SAFETY THERMOSTAT ERROR

ALARM 07 (fig. 22/c)

Opening of the safety thermostat will turn off the burner, the display will show

AL07. If the problem persists for more than one minute, the boiler will stop and the red LED will turn on. Press the key of the controls to start up the boiler again.

– FLAME DETECTION ERROR ALARM 08

If a flame is detected when one should not be present, the boiler will stop and the display will show "AL 08"

– D.H.W. SENSOR ERROR ALARM 10

When D.H.W. sensor (SS) is open or short circuited, the boiler function in C.H. and DHW and the display will show alarm “AL 10”. Replace the sensor because the message disappears.

– ACTIVATION OF THE EXHAUST TEMPE-

RATURE SENSOR ERROR “AL 13” (fig. 22/d)

The activation of the exhaust fumes sensor causes the boiler to stop and the display will show AL 13. Press the key of the controls to start up the boiler again.

–

EXHAUST TEMPERATURE SENSOR ERROR “AL 14”

When the exhaust fumes sensor is opened or short-circuited, the boiler stops and the displays shows anomaly AL 14.

– FAN ERROR “AL 15”

If the fan speed is not within the rated speed range , the display will show "AL

15. If the problem persists for more

Fig. 22/b

Fig. 22/c

bar

Fig. 22/a

Fig. 22/d

than two minutes the boiler will stop for thirty minutes and then attempt to resume working.

4.7 COMMISSIONING AND ROUTINE SERVICE

Commissioning and servicing can only be done by a qualified engineer.

4.7.1 Commissioning

PLEASE NOTE: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type defined on the appliance data plate. However it is advisable to check for correct combustion having first checked:

- That the boiler has been installed in

accordance with these instructions.

- The integrity of the flue system and the

flue seals.

- The integrity of the boiler combustion cir-

cuit and all the relevant seals. The following procedure should be done after installation a gas purge and tightness/drop test have been made. Ensure that the auto air vent (12 fig. 3) is opened, turn the electrical supply on. With the boiler on standby fill the system and pressurise to 1.5 bar. Ensure that the pump has been manually rotated. Open the gas cock, press the “ mode key” (fig. 12). Check the operational (working) gas inlet pressure. Set up the boiler to operate at maximum rate as described in 4.5.1 (Chimney sweep]). With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet test point (see fig 16 item 1) is 21 mb +/- 2 mb. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. The boiler will attempt to light. Press “ mode key” (fig. 12). The burner will extinguish. Turn on a DHW tap fully (preferably the bath tap). Set the controls to the required values as shown in the user guide. Complete the Benchmark sheet enclosed in this manual. Explain controls and operation to the user. Leave all documentation with the user.

4.8 ROUTINE SERVICE

To comply with the conditions of any extended warranty offered and to ensure continued safe and efficient operation, the boiler must be serviced at regular intervals, at least once a year. This service must be

recorded in the Benchmark section of this manual. It is the law that a competent person such as a Gas Safe Register registered engineer, must carry out any service work.

4.8.1 Combustion Check (fig. 23)

Competence to carry out the check of combustion performance. PLEASE NOTE: BS 6798: 2009 Specification fro installation and maintenance of gas-fired boilers of rated input not exceeding 70 kw net advises that: * The person carrying out a combustion

measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results;

* The flue gas analyser should be one mee-

ting the requirements of BS7927 or BSEN50379-3 and be calibrated in accordance with the analyser manufacturers requirements, and

* Competence can be demonstrated by

satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS7967, parts 1 to 4.

Conduct a flue gas analysis as detailed in Appendix 2. See 4.5.1 "Chimney sweep" for details how to set the boiler to minimum and maximum outputs..

4.8.2 Burner inspection

– Isolate from mains – Remove case cover – Isolate gas – Drop down control case – Remove ignition and ionisation lead – Disconnect gas pipe from gas valve to

burner mixing arm, – Disconnect air sensing tube – Remove air inlet to fan and disconnect

the fan wiring – Remove the four nuts securing the bur-

ner to the heat exchanger.

– Carefully lif t out the burner. – Check seals and replace if necessary – Replace in reverse order

Test for gas tightness.

4.8.3 Combustion Chamber

Remove any loose debris from the combustion chamber using a soft brush and a vacuum cleaner. Take care not to damage the rear insulation panel.

4.8.4 Condensate Trap

The condensate trap would not normally require removal during service, but can be checked whilst the burner assembly is removed. Carefully pour water into the heat exchanger and check that it flows freely to the drain. Should it require removal, firstly remove the two wire clips securing the condensate drain rubber pipe to the heat exchanger and the condensate trap. Remove the pipe. Remove the 1/2” nut securing the condensate trap to the bracket. Disconnect the drain pipe from the trap. Clean the trap and refit in reverse order.

Fig. 23

*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

www.centralheating.co.uk

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

Customer name: Telephone number:

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Gas Safe register number:

Company name: Telephone number:

Company address:

Commissioning date:

CONTROLS (tick the appropriate boxes)

Time and temperature control to heating

Room thermostat and programmer/timer Programmable room thermostat

Load/weather compensation Optimum start control

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination Boiler

Heating zone valves Fitted Not required

Hot water zone valves Fitted Not required

Thermostatic radiator valves Fitted Not required

Automatic bypass to system Fitted Not required

Boiler interlock Provided

ALL SYSTEMS

’s instructions Yes

What system cleaner was used?

What inhibitor was used? Quantity litres

Yes No

CENTRAL HEATING MODE measure and record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (if applicable) mbar OR Gas inlet pressure mbar

°C

Central heating return temperature °C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes No

Yes No

DOMESTIC HOT WATER MODE Measure and Record:

Gas rate m³/hr OR ft³/hr

Burner operating pressure (at maximum rate) mbar OR Gas inlet pressure at maximum rate mbar

Cold water inlet temperature °C

Hot water has been checked at all outlets Yes Temperature °C

I/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS

Record the following:

At max. rate: CO ppm AND CO/CO

Ratio

At min. rate: (where possible) CO ppm AND CO/CO

Ratio

The heating and hot water system complies with the appropriate Building Regulations Yes

The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes

The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

*All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

www.centralheating.co.uk

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE RECORD

SERVICE 01

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 02

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 03

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 04

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 05

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 06

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 07

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 08

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 09

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 10

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

If an electrical fault occurs on the appliance the preliminary electrical system checks must be carried out first. When any service or replacement of electrical components which has required the breaking and re-making of electrical connections has taken place, the following tests must be repeated: – ear th continuity; – shor t circuit; – polarity; – resistance to ear th.

5.1 EARTH CONTINUITY CHECK

Appliances must be electrically disconnect-

ed, meter set on Ω (ohm) x 1 scale and

adjust zero if necessary. Tests leads from any appliance earth point (e.g. inside control box) see wiring diagrams (section 7) to earth pin on plug.

Resistance should be less than 1 Ω (ohm). If the resistance is greater than 1 Ω (ohm)

check all earth wires for continuity and all contacts are clean and tight. If the resis-

tance to earth is still greater than 1 Ω

(ohm) then this should be investigated futher.

5.2 SHORT CIRCUIT CHECK

Switches turned FULL ON - meter set on Ω

(ohms) x 1 scale. Test leads from L to N on appliance terminal block, if meter reads 0 then there is a short circuit.

Meter set on Ω (ohm) x 100 scale. Repeat

it with leads from L to E. If meter reads less

than infinity (∞) there is a fault.

NOTE: Should it be found that the fuse has failed but no fault is indicated, a detailed continuity check (i.e. by disconnecting and checking each component) is required to trace the faulty component. It is possible that a fault could occur as a result of local burning/arcing but no fault could be found under test. However, a detailed visual inspection should reveal evidence of burning around the fault.

5.3 POLARITY CHECK

Appliance reconnected to mains supply and meter set on 300 V ac scale. Test at appliance terminal block. – Test leads from L to N meter reads

approx.: 240 V ac.

– Test leads from L to E “ ” meter reads

approx. 240 V ac.

–

Test leads from N to E “ ” meter reads from 0 to 15 V ac.

5.4 RESISTANCE TO EARTH CHECK

Appliance must be disconnected from main

supply and meter on Ω (ohm) x 100 scale.

All switches including thermostat on test leads from L to E - if meter reads other than

infinity (∞) there is a fault which should be

isolated. A detailed continuity check is required to trace the faulty component.

IMPORTANT: These series of checks are the first electrical checks to be carried out during a fault finding procedure. On completion of the service/fault finding task which has required the breaking and remaking of electrical connections then the checks 5.1 Earth continuity, 5.3 Polarity and 5.4 Resistance to earth must be repeated.

5 FAULT FINDING

6.1 REMOVAL OF BURNER ASSEMBLY

– Isolate from mains – Remove case cover – Isolate gas – Drop down control case – Remove ignition and ionisation lead – Disconnect gas pipe from gas valve to

burner mixing arm, – Disconnect air sensing tube – Remove air inlet to fan and disconnect

fan wiring – Remove the four nuts securing the bur-

ner to the heat exchanger – Carefully remove the burner assembly – Check seals and replace if necessary – Replace in reverse order – Test for gas tightness

6.2 REMOVAL OF FAN UNIT

– Isolate from mains – Remove case cover – Isolate gas supply – Drop down control cover – Remove the burner as described in 6.1 – Loosen 2 x 8mm bolts from fan and

remove 2 – Remove fan

– Transfer air hose connector and restric-

tor if fitted to now fan – Refit in reverse order – Re commission boiler – Test for gas tightness

6.3 C.H. THERMISTOR

(SM SENSOR)

– Remove case cover – Unclip thermistor from flow pipe – Disconnect cable – Refit in reverse order

6.4 D.H.W. THERMISTOR

(SS SENSOR)

– Remove case cover – Unclip thermistor from flow pipe – Disconnect cable – Refit in reverse order

6.5 SAFETY STAT

– Isolate from mains – Remove case cover – Pull clip forwards slide stat upwards – Remove 2 black wires connected

– Apply heat sink compound to new stat – Replace in reverse order

6.6 EXHAUST TEMPERATURE SENSOR

– Isolate from mains – Remove case cover – Unplug cable from sensor – Unscrew sensor – Refit in reverse order

6.7 IGNITION ELECTRODE

– Turn off power supply – Remove case cover – Disconnect electrode from the PCB – Pull lead through grommet – Remove electrode fixing screw – Carefully remove electrode from bur-

ner

– Replace in reverse order.

6.8 IONISATION ELECTRODE

– Turn off power supply – Remove case cover – Disconnect electrode

6 REPLACEMENT OF PARTS

– Remove electrode fixing screw – Carefully remove electrode from bur-

ner

– Replace in reverse order.

6.9 EXPANSION VESSEL

– Isolate from mains – Remove case cover – Isolate flow and return valves – Drain boiler using fitted drain vent – Disconnect expansion pipe – Remove expansion securing nut – Remove vessel – Check new vessel for correct pressure

1-1.25 bar

– Refit in reverse order

6.10 GAS VALVE (fig. 24)

– Isolate from mains – Remove cover – Isolate gas supply – Disconnect leads from gas valve – Disconnect sensing tube – Remove gas valve – Refit in reverse order ensuring seals are

replaced as required fit in reverse order ensuring seals are replaced as required

– Setting the gas valve procedure for

MERIDIAN HE 30 C:

1. Remove the heating sensor from the flow pipe.

2. Open the downstream test point (4 fig. 24) and connect a digital manometer set on the mmH20 scale. Ensure the meter is zeroed.

3. Simultaneously press the - and + buttons for 5 seconds to enter “chimney sweep”. “Lo” will appear on the display and the boiler runs at minimum power.

4. Press the + button and the boiler will go to maximum power “Hi” will be displayed.

5. Fully open the SHUTTER (5 fig.

24) - turn anti clockwise.

6. With the shutter fully open, adjust the OFF-SET (6 fig. 24) to obtain the first pressure value shown in Table 1 - OFF-SET column, ensure that the value is correct for the gas being used. If these figures are not obtainable, confirm that the working inlet gas pressure is correct.

7. Close the SHUTTER (5 fig. 24) to obtain the second pressure reading indicated in Table 1 – SHUTTER column.

8. Once these adjustments have been obtained, a flue gas analysis must be done. See section 4.2.2.

9. Press the - button to return the boiler to minimum output “Lo” will be displayed.

10. Check the analyzer CO2/Ratio and compare to values reported

in Table 1. Make any final adjustments by small adjustments to the OFF-SET screw.

11. Press the + button and verify that the CO

2/Ratio has remained sta-

ble.

12. Press the Standby key to exit.

13. Refit the heating sensor to the flow pipe.

14. Remove the manometer, close the test point, and check for tightness.

6.11 MAIN HEAT EXCHANGER

– Turn off power supply – Isolate gas supply – Isolate flow and return valves – Drain boiler using drain vent – Remove burner assembly as described

in 6.1 – Remove flue connection – Disconnect flue sensor – Disconnect limit stat –

Remove condensate drain connections

– Disconnect flow and return connections – Remove two fixing brackets – Lif t out heat exchanger – Refit in reverse order – Recommission boiler – Test for gas tightness.

6.12 PUMP HEAD

– Isolate boiler – Remove cover – Isolate flow and return valves – Drain boiler using drain vent – Remove electrical lead from pump – Remove 4 x fixing screws from pump

housing catching any excess water – Pull pump for ward – Refit in reverse order

6.13 DOMESTIC

HEAT EXCHANGER

– Isolate boiler – Remove cover

Fig. 24

KEY 1 Upstream pressure intake 2 Intermediate pressure intake 3 Air signal inlet (VENT) 4 Downstream pressure intake 5 Capacity step 6 OFF-SET

– Isolate flow and return – Turn on D.H.W tap – Close cold water supply isolation valve – Drain boiler using drain vent – Remove 2 screws securing plate heat

exchanger

– Remove plate heat exchanger catching

any excess water

– Ensure that the four O rings are remo-

ved from the technil assembly

– Fit new O rings supplied with new heat

exchanger to the heat exchanger

– Refit in reverse order

6.14 SAFETY VALVE

– Isolate from mains – Remove cover – Isolate flow and return valves – Drain boiler using drain vent – Disconnect pipe from safety valve – Remove safety valve securing clip – Remove safety valve – Refit in reverse order

6.15 DIVERTER VALVE MOTOR HEAD

– Isolate mains – Remove cover – Remove pin from valve head body – Disconnect lead – Remove motor – Refit in reverse order

6.16 AUTO AIR VENT

– Isolate boiler – Remove cover – Isolate flow and return valves – Drain boiler using drain vents – Pull clip forwards and lift auto air vent

upwards

– Refit in reverse order

6.17 DIVERTER CARTRIDGE

– Isolate boiler – Remove cover – Isolate flow and return valves – Drain boiler using drain vent – Remove motor head as 6.15 – Remove pin and withdraw the cartridge.

catching any excess water

– Refit in reverse order ensure cartridge

is locked in position

6.18 WATER PRESSURE SWITCH

– Isolate boiler – Remove cover – Isolate flow and return valves – Drain boiler using drain vent – Remove clip below the switch – Disconnect the wiring – Lif t switch upwards

– Refit in reverse order

6.19 DHW FLOW SWITCH

– Isolate boiler – Remove cover – Isolate the cold water supply and open a

DHW tap

– Remove the two clips securing the pipe

connecting the flow switch assembly to the DHW manifold, and remove the pipe, catching any residual water

– Disconnect the wiring from the flow swit-

– Remove the clip securing the flow switch

assembly to the cold water connection – Remove the flow switch assembly – Refit in reverse order

6.20 CONDENSE TRAP

–

Isolate boiler –

Remove cover –

Remove 2 condense pipes from con-

dense trap –

Remove locking nut holding trap to

bracket –

Refit in reverse order

6.21 FLUE HOOD

–

Isolate boiler –

Remove cover –

Remove air inlet duct –

Remove flue –

Remove condense pipe left hand side

of duct –

Remove 2 screws rear of flue duct –

Remove 2 screws top of boiler case –

Lift out flue duct –

Refit in reverse order –

Checking seals

7 EXPLODED VIEWS

1 6318350 Left hand side frame part 2 6318300 Right hand side frame part 3 6267161 Main exchanger rear brachet 4 6010833 Main exchanger supporting bracket 5 6112330 Bush thermostatic 6 6146728 Limit stat auto reset 80°C 7 6226624 Spring air vent knob 8 6278912 Main exchanger body 9 6277130 Probe NTC D.4X40 10 6010829 Main exchanger fixing bracket 11 6269008 Main exchanger door insulation 12 5188360 Main exchanger door 13 6248870 Combustion chamber O-ring 14 6248871 Glass fibre sealing cord 15 6278359 Premix burner 16 6174823 Gasket for burner flange 17 6278813 Air-gas hose lower side 18 6274370 Air-gas mixer assembly 19 6226470 ORing 52,07 x 2,62 20 6322300 Round nozzle diam. 2,80 MET 20A 6322302 Round nozzle diam. 2,20 LPG 21 6322350 Hexagonal nozzle diam. 3,80 MET 22A 6322352 Hexagonal nozzle diam. 2,90 LPG 22 6267119 Nozzle locking bracket 23 6226403 O-ring 2031 24 6278812 Air-gas hose upper side 25 6226465 O-ring diam. 183,83x2,62 26 6174809 Gasket for ignition electrode 27 6221644 Ignition electrode 28 6221645 Ionisation electrode 29 6174816 Gasket for fan flange 30 6034305 Elbow flange 31 6028703 Gasket for duct flange 32 6261412 Fan 33 6278703 Smoke chamber 34 6248855 P.C. inlet/oulet smokes gasket 35 6010876 Upper protection shield 36 5183726 Rectang. expansion vessel 8 l. 37 6318035 Frame assembly lower side 38 6155420 Time programmer box 39 6197719 Time programmer 40 6155421 Time programmer cover 41 6146112 Pressure gauge 42 6226628 Hydrometer Fixing spring 43 6130707 Expansion vessel connecting pipe

Position

Code

Description

Position

44 6304853 Grey cover 45 6293006 Trap fixing bracket 46 6277205 Water trap 47 6034155 Condensate drainage pipe 48 2051122 Clamp diam. 22,1 49 1010215 Rubber pipe diam. 15x2,5 50 2051120 Clamp diam. 17,3 51 6034165 Condensate drainage rubber pipe 52 6001158 Air intake pipe 40 53 2051200 Hose clamp diam. 50-70 54 6243823 Gas valve type 55 6277441 Pipe connecting gas valve-mixer 56 6227456 Flowing pipe to C.H. system 57 6231360 Temperature sensor 58 6146729 100°C safety stat 60 6227538 Return pipe from C.H. system 61 6226601 Spring for heat exchanger connection 62 6280590 Three way fitting + cap kit 63 6317852 Casing 66 6177505 Ball cock 3/4" x 22 67 6177530 Gas cock 3/4" F x 15 68 6177506 Ball cock 1/2" x 15 69 6142330 Quarter bend 1/2" x 15 70 6304766 Control panel 72 6301485 Main PCB 74 6305050 Control panel cover 80 6265651 Plate heat exchanger 81 6281411 Water rate adjuster 15 l/min 82 6087329 Motor for Honeywell diverting valve 83 6037509 Water pressure switch 84 6226639 Spring clip 85 6149318 Flow water switch 1/2"M.-1/2"M. 86 6119358 Raccord 87 6120559 Nipple 3/4" 88 6226642 Spring clip 89 6226640 Spring clip 90 6119357 Brass cap 91 6226641 Spring clip 92 6040215 Pressure relief valve 3 bar 93 6226472 ORing 17.86x2.62 94 6272331 Circulating pump 95 6013182 Automatic air vent 96 6227134 D.H.W. inlet pipe 97 2030255 Gasket diam. 12,5x18,5x3 98 6226444 O-Ring diam. 13,64 x 2,62

Code

Description

Position

100 6265821 Three-way assembly 101 6265822 Brass junction 102 6231357 D.H.W. temperature sensor

5185139 Conversion kit to LPG 6281576 Water pressure switch + spring 6281534 Gaskets kit 6319695 O-ring kit 5199630 Complete control panel 6323861 6 pole cable connector 6316253 9 pole Stocko connector 6323856 14 pole cable connector 6319158 4 pole cable connector 6323860 5 pole cable connector 6245374 Circulating pump connector 6285003 Ionisation lead L=1000

Products reference: 8111862 Check the correspondence with the boiler data plate.

Code

Description

99 6227036 D.H.W. outlet pipe

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

INDUSTRY GUIDANCE FOR INSTALLERS ON CONDENSATE

DRAINAGE PIPE INSTALLATION

This guidance is endorsed by HHIC members.

1. BACKGROUND

During recent winters the UK has experienced prolonged spells of extremely cold weather down to minus 20

C and below in many areas. This resulted in a significant increase in the number of calls to boiler manufacturers and heating engineers from householders with condensing (high efficiency) boilers where the condensate drainage pipe had frozen and become blocked with ice, causing the boiler to shut down. In the vast majority of cases such problems occur where the condensate drainage pipe is located externally to the building for some part of its length.

British Standards, Building Regulations etc. currently allow condensate drainage pipes to be run either internally or externally, or a combination of these. These documents give guidance on how to install the pipes in order to reduce the possibility of freezing. However this guidance may not be sufficient to prevent freezing in extreme conditions - with widespread and prolonged very low temperatures.

In view of the possibility that UK weather patterns will show more “extremes” in future due to

the effects of global climate change, the following guidance updates previous recommendations on condensate drainage pipe installation. All other technical requirements for condensate drain installation given in British Standard BS 6798:2009, or in boiler manufacturers’ installation instructions should still be followed.

2. REVISED GUIDANCE ON CONDENSATE DRAINAGE PIPE INSTALLATION

Where a new or replacement boiler is being installed, access to an internal “gravity discharge” termination should be one of the main factors considered when determining

potential boiler locations, so that the condensate drainage pipe can be terminated as recommended below. On an existing installation, the guidance below should also be followed if work is carried out to “upgrade” the condensate drain age system to reduce the risk of freezing in extreme conditions.

Internal condensate drainage pipework must be a minimum of 19mm ID (typically 22mm OD) plastic pipe and this should “fall” at least 45 mm per metre away

from the boiler, taking the

shortest practicable route to the termination point.

In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate drainage pipe should be adopted -

8 APPENDIX A (GUIDANCE HHIC)

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

2.1 INTERNAL TERMINATION:

Wherever possible, the condensate drainage pipe should be terminated at a suitable internal foul water discharge point such as (a) an internal soil and vent stack or (b) an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. A suitable permanent connection to the foul waste pipe should be used. Figures 1, 2(a), 2(b) show appropriate connection methods.

The possibility of waste pipes freezing downstream of the connection point should be considered when determining a suitable connection point - e.g. a slightly longer pipe run to an internal soil stack may be preferable to a shorter run connecting into a kitchen waste pipe discharging directly through the wall to an external drain.

Where “gravity discharge” to an internal termination is not physically possible (e.g. the discharge point is above the appliance location, or access is obstructed by a doorway), or where very long internal pipe runs would be required to reach a suitable discharge point, the following measures may be adopted -

2.2 USE OF A CONDENSATE PUMP (TO AN INTERNAL TERMINATION):

Condensate can be removed using a proprietary condensate pump, of a specification recommended by the boiler or pump manufacturer.

The pump outlet should discharge to a suitable internal foul water discharge point, such as (a) an internal soil and vent stack or (b) an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. Figure 3 shows a typical connection method.

suitable permanent connection to the foul waste pipe should be used and the

manufacturer’s detailed installation instructions for the pump should be followed.

2.3 EXTERNAL TERMINATION:

The use of an externally-run condensate drainage pipe, terminating at a suitable foul water discharge point or purpose-designed soakaway, may be also be considered; however if this termination method is chosen then the following measures should be adopted -

The pipe should be run internally as far as possible before going externally and the

pipe diameter should be increased to a minimum of 30mm ID (typically 32mm OD) before it passes through the wall.

The external run should be kept as short as possible, taking the most direct and

“most vertical” route possible to the discharge point, with no horizontal sections in

which condensate might collect.

The external pipe should be insulated using suitable waterproof and weatherproof

insulation (“Class O” pipe insulation is suitable for this purpose) .

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

The use of fittings, elbows etc should be kept to a minimum and any internal “burrs”

on cut pipework should be removed so that the internal pipe section is as smooth as possible.

The customer/householder should be advised that even with the above measures this type of installation could freeze, and that if this were to occur then boiler shutdown could result, requiring remedial action - possibly involving a chargeable engineer call-out.

Where there are likely to be extremes of temperature or wind-chill, the use of a proprietary trace-heating system for external condensate drainage pipework, incorporating an external frost thermostat, should therefore be considered. If such a system is used then the installation instructions of the trace heating manufacturer and any specific recommendations regarding pipe diameter, insulation, etc. should be followed. All other relevant guidance on condensate drainage pipe installation should also be followed.

Other cold weather protection methods approved or endorsed by boiler manufacturers and/or service organisations may be adopted if these are considered suitable by the parties involved.

If an external soil/vent stack is used as the external termination then the connection method shown in Figure 4 should be used, together with the measures on insulation etc. as described above and shown in the diagram.

When a rain water downpipe is used as the termination (NB only permissible if this downpipe passes to a combined foul and rainwater drainage system) an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe itself become flooded or frozen. Figure 5 shows a suitable connection method.

Where the condensate drainage pipe is terminated over an open foul drain or gully, the pipe

should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end. Pipe drainage will be improved if the end is cut at 45

as opposed to a straight cut. The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill. Figure 6 shows a suitable connection method.

Where the condensate drain pipe terminates in a purpose-designed soakaway (see BS 6798:2009 or boiler installation manual for soakaway design requirements) any aboveground section of condensate drainage pipe should be run and insulated as described above. Figure 7 shows a suitable connection method.

3. UNHEATED INTERNAL AREAS:

Internal condensate drainage pipes run in unheated areas such as lofts, basements and garages should be treated as external pipe.

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

NOTES

The Benchmark Commissioning Checklist (located at the back of the boiler installation manual) should be completed as required to record details of the condensate drainage pipe installation.

Where an external condensate drainage pipe is installed, the customer should be made aware of the risks and consequences of its freezing and offered the option to fit trace heating (or other measures approved by the boiler manufacturer or service organisation).

Separate guidance has been published for householders on remedial actions which can be taken if a condensate drainage pipe freezes. This may result in requests for alteration to condensate drainage pipework, in which case the guidance above should be followed.

In some instances (e.g. where an elderly person’s heating needs to be reinstated as an emergency measure) condensate drainage pipes may have been cut in order to bypass any blockage and allow re-ignition of the boiler, with condensate being collected in a suitable container as a temporary solution.

While not unsafe, this is not recommended practice and if such action has been taken then the condensate drainage pipe must be reinstated as soon as possible, using the above guidance to reduce risk of freezing in future.

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 1 – Connection of condensate drainage pipe to internal soil and vent stack

Key

1Boiler 2 Visible air break 375mm trap 4 Visible air break and trap not required if there is a trap with a minimum condensate

seal of 75 mm incorporated into the boiler 5 Soil and vent stack 6 Invert 7 450 mm minimum up to three storeys 8 Minimum internal diameter 19 mm

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 2(a) – Connection of a condensate drainage pipe downstream of a sink, basin, bath or shower waste trap

Key

1Boiler 2 Visible air break 375mm trap 4 Visible air break and trap not required if there is a trap with a minimum condensate

seal of 75 mm incorporated into the boiler. In this case the 100 mm is measured to the

trap in the boiler. 5 Sink, basin, bath or shower 6 Open end of condensate drainage pipe direct into gully 25 mm min below grating but

above water level; end cut at 45 ° 7Sink lip 8 Minimum internal diameter 19 mm 9 Pipe size transition 10 Minimum internal diameter 30 mm 11 Water/weather proof insulation

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 2(b) – Connection of a condensate drainage pipe upstream of a sink, basin, bath or shower waste trap

Key

1Boiler 2 Visible air break at plug-hole 3 75 mm sink, basin, bath or shower waste trap 4 Sink, basin, bath or shower with integral overflow 5 Open end of condensate drainage pipe direct into gully 25 mm min below grating but

above water level; end cut at 45 ° 6 Minimum internal diameter 19 mm 7 Pipe size transition 8 Minimum internal diameter 30 mm 9 Water/weather proof insulation

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 3 – Connection of a condensate pump - typical method (NB manufacturer’s detailed instructions should be followed).

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 4 – Connection of condensate drainage pipe to external soil and vent stack

Key

1 Boiler 7 450 mm minimum up to three storeys 2 Visible air break 8 Minimum internal diameter 19 mm 3 75 mm trap 9 Pipe size transition point 4 Visible air break and trap not required if

there is a trap with a minimum condensate seal of 75 mm incorporated into the boiler.

10 Minimum internal diameter 30 mm

11 Water/weather proof insulation

5 Soil and vent stack 6 Invert

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 5 – External termination to rainwater downpipe (NB only combined foul/rainwater drain)

Key

1 Condensate discharge pipe from boiler 7 Air gap 2 Pipe size transition point

68 mm

PVCu strap-on fitting 3 Water/weather proof insulation 9 Minimum internal diameter 19 mm 4 43 mm 90° male/female bend 10 Minimum internal diameter 30 mm 5 External rain water pipe into foul water 11 End cut at 45 ° 6 External air break

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 6 – External drain, gully or rainwater hopper

Key

1Boiler 2 Visible air break 3 38 mm minimum trap 4 Visible air break and trap not required if there is a trap with a minimum condensate

seal of 38 mm incorporated into the boiler 5 External length of pipe 3 m maximum 6 Open end of condensate drainage pipe direct into gully 25 mm min below grating but

above water level; end cut at 45 ° 7 Minimum internal diameter 19 mm 8 Pipe size transition point 9 Minimum internal diameter 30 mm 10 Water/weather proof insulation

IND GUIDE INST 10-11 HHIC REF T11/0027BRev8

Figure 7 – Example of a purpose-made soakaway

Key

1 Condensate discharge pipe from boiler 2 Ground (this section of the condensate drainage pipe may be run either above or

below ground level); End cut at 45 ° 3 Diameter 100 mm minimum plastic tube 4 Bottom of tube sealed 5 Limestone chippings 6 Two rows of three 12 mm holes at 25 mm centres, 50 mm from bottom of tube and

facing away from house 7 Hole depth 400 mm minimum by 300 mm diameter 8 Minimum internal diameter 19 mm 9 Pipe size transition point 10 Minimum internal diameter 30 mm 11 Water/weather proof insulation

9 APPENDIX 2

FLOWCHART FOR CO AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER

PRIOR TO CO AND COMBUSTION RATIO CHECK

The installation instructions should have been followed, gas type verif ied and gas supply pressure/rate checked as r equired prior to commissioning.

As part of the installation pr ocess, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integri-

ty of the whole flue system to confirm that all components are correctly asembled, f ixed and supported. Check that manufacturer's maximum flue lengths have not

been exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).

The flue gas analyser should be of the correct type, as specified by BS 7967

Prior to its use, the flue gas analyser should have been maint ained and calibrated as specified by the manufactur er. The installer must have the r elevant competence

for use of the analyser.

Check and zero the analyser IN FRESH AIR as per analyser manufacturer's instructions.

NOTE

the air gas ratio valve is factory-set and must not be adjusted DURING

COMMISSIONING unless this action is recommended after discussions

with SIME LTD.

If any such adjustment is recommended and further checking of the boiler

is required the installer/service engineer must be compet ent to carry out

this work and to use the flue gas analyser accordingly.

If the boiler requires conversion to operate with a dif ferent gas family

(e.g. conversion from natural gas to LPG) separate guidance will be provi-

ded by the boiler manufacturer and must be followed.

SET BOILER TO MAXIMUM RATE

Set the boiler to operate at maximum rat e (full load condi-

tion). Allow sufficient time for combustion t o stablilise.

NOTE - Do not insert analyser probe during this period

to avoid possible "flooding" of sensor.

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER

Insert analyser probe int o the air inlet test point and allow readings

to stabilise.

NOTE - The flue must always be installed with flue test point.

This will be located within the first piece connected to the boiler.

Is O2 less than

or equal to 20.6%

and

CO2 less than 0.2%

VERIFY FLUE INTEGRITY

Analyser readings indicate that combustion products and inlet air must be

mixing. Further investigation of the flue is t herefore required.

Check that flue components are assembled, fixed and support ed as per boi-

ler/flue manufacturer's instructions.

Check that flue and flue terminal are no t obstructed.

Is O2 less than

or equal to 20.6%

and

CO2 less than 0.2%

CHECK CO AND COMBUSTION RATIO AT MAXIMUM RATE

With boiler still set at maximum rate, inser t analyser probe into

flue gas samplng point. Allow readings to stablise befor e recording.

Turn off appliance and call SIME

LTD Technical HelplIne f or advice.

the appliance must not be com-

missioned or used, until problems

are identified and resolved.

Is CO less than 350ppm

AND

CO/CO2 ratio less than 0.004

Check all seals around the appliance

burner, internal flue seals, door and

case seals. Rectify where necessary.

SET BOILER TO MINIMUM RATE

In accordance with boiler instructions, set boiler to oper ate at

minimum rate (to minimum load condition). Allow suff icient time for

combustion to stablilise.

NOTE: If manufacturer's instructions do not specify how to set

boiler to minimum rate contact Technical Helpline for advice.

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE

With boiler set at minimum rate, insert analyser probe into flue gas

samplng point. Allow readings to stablise before r ecording.

NOTE - if no flue gas sampling point is present and the correct pro-

cedure is not specified in the manual, contact SIME LTD Technical

Helpline for advice.

Is CO less than

350ppm

AND

CO/CO2 ratio

less than 0.004

Turn off appliance and call SIME LTD

Technical HelplIne for advice.

the appliance must not be commissio-

ned or used until problems are identi-

fied and resolved.

NOTE Check and record CO and combustion ratio at both maximum AND minimum

rate before contacting SIME LTD.

Is CO less than 350ppm

AND

CO/CO

2 ratio

less than 0.004

BOILER IS OPERATING SATISFACTORILY

no further actions required

Ensure test points are capped, boiler case is correctly repleced and all ot her commissioning pro-

cedures are completed.

Complete Benchmark Checklist, recording CO and combustion ratio readings as required.

YES

Cod. 6318136 - 08/2013 - Documentation Dpt.

Sime Ltd

1a Blue Ridge Park Thunderhead Ridge Glasshoughton, Castleford, WF10 4UA

Phone: 0845 9011114 Fax: 0845 9011115

www.sime.co.uk Email: enquiries@sime.co.uk

Sime MERIDIAN HE 30 C, MERIDIAN HE 25, MERIDIAN HE 30, BRAVA DGT HE 25, BRAVA DGT HE 30 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual