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User manual and Installation instructions

1. Particular attention should be paid to pipes pas sing through ventilated spaces in roofs and under floors By pass The appliance includes an automatic by pass valve which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system due to the closing of thermostatic valves or cock type valves within the system The by pass is calibrated to assure a minimum flow of 500 600 Its hr through the main heat ex changer If you are installing a system that includes thermo static radiator valves TRV and or small bore 8 10 mm it may be necessary to fit an external by pass to facilitate correct operation of the boiler The fitting of an external bypass helps to prevent and limit system noise Air release points These must be fitted at all high points where air will natural collect and must be sited to facilitate com plete filling of the system Expansion vessel The appliance has an integral sealed expansion vessel to accommodate the increase of water vol ume when the system is heated Refer to Tab 4 1 on page 18 for its technical data If the heating circuit has an unusually high water content calculate the total expansion and add an additional sealed expansion vessel with adequate capacity Mains water feed central heating There must be no direct connection to the mains water supply even through a non return valve without the approval of the Local Wate
2. Voltage V CO content 9 0 9 8 range min max At nominal heat input of 33 5 kw W E CO content 96 range min max At minimum heat input of 11 0 kW AE Frequency Hz Power consumption W Protection degree External fuse rating Internal fuse rating Other flue gas figures Flue design At nominal heat input non condensing Flue pipe diameter O content 26 5 2 Coaxial mm 60 100 i e CO content ppm 120 Twin split pipes mm 80 z Exhaust temperature C 80 Roof 80 125 mm Nominal heat flow rate kW 33 5 Pr A E Other specifications IS Exhaust temperature E 80 Height mm 58 Width INSTALLATION mm Smoke production E kg h Depth mm Weight dry kg Water volume in the boiler I kg up to 1 bar E Values refer to tests with a 1 m chimney working at the nominal heat input 17 Z O H 5 EN x e z Technical information EEJ Hydraulic specifications 1000 1200 1400 I h Fig 4 3 model M110 24SM 1000 1200 1400 l h Fig 4 4 model M110 32SM The hydraulic specifications in Fig 4 3 and Fig 4 4 representthe pressure available head for the central heating system as a function of the flow rate The load loss due to the boiler has already been subtracted 18 Operation of integral By pass valve The boiler is fitted with an automatic by pass valve 44 on page 12 which protects the primary heat exchanger Theinte
3. Wall hung fan flue room sealed high efficiency gas boiler User manual and Installation instructions GARDA PLUS HE Models M110 24SM E M110 32SM E recommended A GARDA PLUS HE are condensing high efficiency sealed chamber fan flue gas boilers They are fully electronically controlled and have electronic ignition The materials they are made of and the control systems they are equipped with give you safety a high level of comfort and energy savings to allow you to get the greatest benefit out of Congratulations on your choice independent heating GARDA PLUS HE allow a higher efficiency by reducing the flue gas temperature such that the water vapour formed during the combustion is condensed out This allows a gain of useful heat that otherwise would be lost Remember that 1 The manual must be read thoroughly so that you will be able to use the boiler in a safe and sen sible way must be carefully kept It may be necess ary for reference in the future First lighting up must be carried out by competent and responsible engineer 1 The manufacturer disclaim all liability for any translations of the present manual from which incorrect in terpretation may occur cannot be held responsible for non ob servance of instructions contained in this manual or for the consequences of any pro cedure not specifically described Using the boiler Y Before lighting the boiler you ar
4. and remove the gas pipe J Fig 8 6 7 Leave the air box with the air hose clamped to the water pipe 8 Remove the nuts K Fig 8 5 and the burner fan group D a 36 Maintenance Fig 8 6 right side of the fan 9 Disconnect the connector of the fan L by pres sing the plastic hook M placed on the rear side of the connector Fig 8 7 Fig 8 7 rear view of the fan If you notice dirt on the coil of the condensing heat exchanger 19 on page 12 brush out it with a bristle paintbrush and remove the dust with a hoover Reassemble the parts carrying out the removal operations in reverse order Checking the pressurisation in the expansion vessel Empty the central heating system as described in section 8 4 of this chapter and check that the pres sure in the expansion vessel is not less than 1 bar See also section 4 6 page 18 of this manual If the pressure is lower take steps to correct the pressure level Cleaning the burner The burner 38 on page 12 does not need special maintenance but it is sufficient to dust it with a bristle paintbrush To reach the burner do the operations described in the section 8 6 of this manual EX Checking the flue Have the integrity of the flue outlet pipe 47 on page 13 air intake pipe 48 on page 13 checked periodically at least once a year For all the above maintenance operations it is ad visable to call an approved Service E
5. data expressed in the present documentation at any time and without prior notice The present documentation is an informative support and it cannot be considered as a contract to wards third parties Boiler installation and commissioning tips The installation must be carried out by a qualified person who will be responsible for observing the current Regulations Installing the boiler 1 Do not forget to remove the transit caps and plugs from the boiler connections these are fitted to every boiler Y Keep the boiler clear of dust during in stallation and in particular do not allow any dust or debris to enter the top of the boiler where the flue connection is made It is rec ommended that you put a dust sheet over the top of the boiler until you are ready to make the flue connection Because every boiler is fired and tested live at the factory a small amount of water re mains within the boiler It is possible for this water to initially cause the pump to seize Itis therefore recommended that the pump rotor be manually turned to free its rotation before turning the boiler on J Remember to release the auto air purge before filling the boiler See the instructions to identify the location of this device This boiler allows to control the flow tem perature of the central heating system at very low levels In case of underfloor heating system a tem perature limiting device e g asafety thermo stat is re
6. however an additional trap with a seal of atleast 75 mm and an air break between thetraps is required Fig 5 2 The length of the condensate pipe should be kept at minimum To avoid condensate being trapped thedrainpipe should be run with a fall of atleast 2 5 45 mm m away from the boiler the number of bends and joints should be kept at minimum General requirements the drainpipe should be adequately fixed to prevent pipe sagging If a part of the drainpipe runs externally this part should be keptas short as possible and protected to reduce the risk of freezing Condensate drain Fig 5 2 EEN water circulation c h Detailed recommendations are given in BS 6798 and BS 5449 the following notes are given for general guidance For Ireland IE refer to 1 5 813 2002 Pipework The return temperature must not be lower of 30 C Copper tubing to BS EN 1057 is recommended for water pipes Jointing should be either with capil lary soldered or with compression fittings Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps The appliance has a built in automatic air release valve it should be ensured as far as possible that the appliance heat exchanger is not a natural col lecting point for air Except where providing useful heat pipes should be insulated to prevent heat loss and to avoid freezing
7. 5 Fig 1 3 on page 2 which controls the c h operation J LULULULI hor TIMER D Ww wu Wu wu wu wu NU l H 2004 LA F E D C B Fig 2 13 Display and control panel Mode selector switch Reset button Enter button Increase setting button Decrease setting button On off button Day selection buttons Day display Time display ON OFF display c 7 T10nmocoouc Instructions for use Setting the current time and weekday Note with a new unit or when the reset button B has been pressed the first day indicator H on the left and the time display are flashing Set the mode selector switch A to the position and press the buttons D or E until the current time appears in the display I Press the day selection button corresponding to the current day considering that button 1 Monday button 2 Tuesday and so on The clock starts by moving the switch A to the AUTO position Setting example shown in Fig 2 14 Current time 16 30 day Thursday AUTO TIMER O 0 0 0 Os Os O Fig 2 14 Setting the switching time and day or days 20 memory locations are available corresponding to 10 on off sequences Set the mode selector switch A to the C1 position The symbols shown in Fig 2 15 appears in the display ON Fig 2 15 Press the buttons D or E to set the desired ON time Press the buttons G to set the desired day or days of ope
8. 6 blinks The lamps should give the indication as in Fig 7 9 coefficient K setting If not press the reset button repeatedly to obtain it Where Lamp OFF TOD mo Fig 7 9 5 To change the setting turn the knob 9 on a posi tion corresponding to the desired coefficient K By turning the knob 9 the lock out signal lamp 6 blinks quickly 2 per seconds indicat ing that the setting has changed and must be memorised 9 A Coeff K Setting No Fig 7 10 6 To memorize the setting keep pressed the reset button 7 for about 5 seconds until the lights 10 briefly blinks simultaneously To reset the boiler to the normal operation turn it OFF and ON by the function selector knob 8 33 O E 3 x e z O E 3 x e z Commissioning In any case the boiler automatically resets to its normal operation after 10 minutes After setting the coefficient K position the knob 8 as shown in Fig 7 11 in order to obtain the c h flow temperature accordingly with the chart of Fig 7 7 Fig 7 11 However the setting pointof the c h flow tempera ture can be manually increased or decreased within a range of 15 C by turning the knob 8 The effect of the knob 8 for a coefficient K set to 1 5 80 70 60 50 40 30 20 20 15 10 5 0 5 10 15 20 25 External temperature C Fig 7 12 Checking the ignition device With the burner on high
9. Conformity to indicate com pliance to 1 S 813 2002 This appliance must be installed by a compet ent person in accordance with the Gas Safety installation amp Use Regulations EX Related documents The installation of this appliance must be in ac cordance with the relevant requirements of the current Gas Safety Installation amp Use Regula tions the Local Building Regulations the current E E Wiring Regulations the Regulations and by laws of the local water undertaking and in Scotland in accordance with the Building Stan dards Scotland Regulation Health and safety document n 635 Electricity at work regs It should also be in accordance with the British Standard Codes of Practice In Ireland IE The installation must be carried out by a Competent Person and installed in accord ance with the current edition of 1 S 813 2002 Do mestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installations EEN Location of appliance The appliance may be installed in any room or in ternal space although particular attention is drawn to the requirements of the current I E E Wir ing Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the combined appliance in a room containing a bath or shower For Ireland IE reference should be made to t
10. Each elbow used in addition to the standard flanged elbow reduces the overall acceptable length of the flue system as follows 45 reduce length by 0 5 m 90 reduce length by 1 m Min 0 3 m Max 10m 60 100 90 1 T Twin pipe kits y 80 mm Fig 6 6 Various twin split pipes kits and optional acces sories elbows are available to assist in the ter mination of the flue where the boiler is installed in a location remote to an outside wall These kits allow for separation of the air supply pipe from the pipe that discharges the exhaust gasses Consequently it is possible to extend the flue system to a greater distance than that pro vided by the standard horizontal co axial flue If either an additional 45 or 90 accessory elbow is used then the maximum permissible length of either pipe must be reduced by 0 90 m or 1 65 m respectively Referring to Fig 6 6 the minimum length required for pipes a and b is 0 3 m E Fig 6 5 25 Z O E 3 E E lt Installation Maximum equivalent length a b of 40 metres can be achieved utilising extensions Fig 6 6 Vertical roof kit Fig 6 7 Co axial 80 125 mm This kit allows vertical termination of the flue pipe through the roof The kit is 1 2 min length Exten Fia 6 8 sion pieces Co axial are also available which al Ip lows the flue system to be extended to a total 4 Remove
11. Where possible terminal position which could cause a nuisance should be avoided 19 Z O E 5 E E lt z H 5 EN x e z General requirements The minimum acceptable spacing from the ter minalto obstructions and ventilation openings are specified in Fig 5 1 Terminal position mm A Directly below a window or other opening 300 B Below gutters soil pipes or drain pipes 75 C Beloweaves nde 200 D Below balconies s esses 600 E Below car port roof NO F From vertical drain pipes and soil pipes 150 G From internal corners suu 450 H From external corners 300 I Above ground or balcony level 300 J From a surface facing a terminal 600 K From a terminal facing a terminal 1 200 L From an opening in the car port e g door window into dwelling NO M Vertically from a terminal in the same wall 1 500 N Horizontally from a terminal in the same wall 300 O Above the roof pitch with roof slope less than or equal to 30 oo 350 Above the roof pitch with roof slope more than 30 600 P Fromwallface nn 600 Q From above or to side of an opening 300 Wherever practicable to do so the flue should be ex tended beyond the perimeter of the balcony Qonsideration should be given to adding protection against condensate to the adjacent structure EZ Gas supply The
12. ae 9 Route the electrical supply flexible cord and the external control flexible cord as illustrated in Fig 6 14 Lock the flexible cords in place with the flexible cord clamps E o a AN To the fused spur isolation switch mb O O terminal block External controls To the external control device Oele SUS QC iw Fig 6 14 6 10 External frost protection 10 Connect the frost thermostat between ter minals 1 and 2 as shown in Fig 6 15 or Fig 6 16 Do not connect live wires to terminals to which the frost thermostat must be con nected 28 Room thermostat 230V rating Frost Thermostat 230V rating e g E p S e zZz 3 2 mb Power supply O terminal block D External controls terminal block 0o Fig 6 15 E e 3 2 1 O External controls e terminal block Fig 6 16 Z S Room thermostat with anticipating resistor 230V rating Frost thermostat 230V rating Om 4G OK Power supply terminal block o EXI External temperature probe optional Location Installation The external
13. d h w system 35 8 9 Checking the flue 37 8 4 Emptying the c h system 35 8 10 Drain pipe inspection 37 Bd 8 5 Combustion analysis check 36 8 11 Visual inspection of appliance 38 8 6 Cleaning the condensing 8 12 Gas pressures and soundness 37 5 heat exchanger and burner 36 8 13 Water inhibitor concentration 37 z Abbreviations used in the manual C h Central heating D h w Domestic hot water D c w Domestic cold water Appliance description KEN Overview Fig 1 1 1 2 3 Case front panel Control panel Control panel cover EEN Control panel NO A A C h circuit temperature and pressure gauge Time switch c h control Lock out signal lamp Lockout reset button 8 Function selector and c h temp control knob 9 D h w temperature control knob 10 Appliance operation lights KEM isolation valves 16 15 14 13 12 11 Fig 1 2 bottom view of the boiler 11 Condensate drain pipe 12 C h return valve 13 D c w inlet valve 14 Gas inlet valve 15 D h w outlet pipe 16 C h flow valve KEM Technical data For detailed technical data see section 4 3 or 4 4 of this manual KEEN operation lights Three lights 10 in Fig 1 3 give detailed indication regarding the operation of the boiler The following table gives the relationship between each of the possible light combinations and their meaning during the normal ope
14. seconds Fig 7 4 31 O E 3 E E Z Z O E 3 E E Z Commissioning The boiler will now go through an ignition se quence and the burner will light If after four ignition attempts about four minutes the boiler fails to light the boiler will go to lockout and the lock out signal lamp 6 will appear To reset the boiler press and release the boiler re set button 7 For the first lighting up and following maintenance procedures for the gas supply it may be necess ary to repeat the resetting operation several times so as to remove the air present in the pipework After five consecutive resetting attempts the reset button is inhibited To restore its function it is necessary to switch the boiler off and on from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance Checking the gas supply pressure This boiler has been tested to the highest qual ity control standards The maximum and minimum gas pressures are already set during this quality control process and the appliance does not need any particular adjustment However if there is variation to the gas supply pressure it is possible that a harmonic noise could resonate through the boiler during oper ation In these circumstances it maybe necess ary to reset the gas valve in accordance with the section 11 Gas Valve of the Service Manual It should be noted that a flue gas analyser is r
15. temperature probe must be installed on an external wall of the building avoiding the possibility of direct exposure to the sun s rays places subject to humidity or mould the proximity of fans ventilation openings or flue terminals Connection For the electrical connection to the boiler use elec tric wires which conform to the current regulations with flexible cord each core having a cross sec tion area not less than 0 50 mm The connection wiring of the external tempera ture probe is part of a safety extra low voltage circuit therefore it has to be routed through a duct separated from the mains voltage wirings The maximum allowable length of the wiring is 20 m For details concerning the connection of the probe to the boiler refer to the instructions given with the external temperature probe kit 29 O E 3 x e 7 Commissioning WARNING The commissioning of this boiler and system must only be undertaken by a professionally qualified person in accordance with the re quirements of the Gas Safety Installation and Use Regulations and be approved by C O R G I Ensure that the Benchmark Log Book is satis factorily completed during the commissioning process The Log Book is located at the end of this manual This manual should be handed to Fig 7 1 the User following completion of the installa tion and commissioning process Failure to Ms comply with these requiremen
16. the appropriate manufac turer whose function it is to dissolve any foreign matter which may be in the system INHIBITION Primary Heating Circuit On the final refilling of the heating system it is im portant to ensure the system water is treated with a Suitable scale and corrosion inhibitor in accord ance with the manufacturers instructions Condensate pipe and traps The full length of the condensate pipe should be check for leaks The boiler has a built in condensate trap pro vided with a ball valve that prevents the escape of combustion products when the trap is empty It is however recommended that any other trap in the drain system is correctly filled with water before to run the boiler Lighting the boiler Some products incorporate an anti cycling time delay It is normal when first switching the boiler on for the boiler to operate on heating for a few sec onds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The ignition delay cycle does not prevent normal operation of the boiler to pro vide d h w If external controls are fitted e g Timeclock room thermostat ensure they call for heat 1 Turn on the electricity supply to the boiler switching on the fused spur isolation switch The appliance operation light 10 will flash every 4 seconds 2 Turn the function selector 8 as in Fig 7 4 The appliance operation light 10 will flash every 2
17. the side panels or move the lower part Z O 3 E E 72 Z overall maximum permissible length of 10 m of the side panels as indicated in Fig 6 9 and Optional 45 and 90 elbows can be used to offset pull the control panel the flue route When completely pulled out the panel can ro Each additional elbow reduces the overall accept tate 45 downwards to facilitate the operations able length of the flue system as follows on the internal parts 45 reduce length by 0 5 m 90 reduce length by 1 m Gl la Fig 6 9 ae max 10m 45 0 5m 5 Loosen the screws L and remove the service O panel Fig 6 10 Y CON Electrical connections Fig 6 7 Connection to the electricity supply 1 Remove the front panel of the case see the section 8 2 in this manual 2 Remove the screws and J Fig 6 8 3 Loosen the screws K 26 Installation Fig 6 10 For the electrical connection to the boiler use elec tric wires which conform to the current regulations with flexible cord each core having a cross sec tion area not less than 0 75 mm 6 Connect the electrical supply flexible cord coming from the fused spur isolation switch to the power supply terminal block of the boiler Fig 6 11 keeping the same connections for the live brown wire and the neutral blue wire External 3 A fuse or fused plug with same current rating is recommended Do not connect live wires
18. to terminals to which the room thermostat must be con nected 7 Connect the earth wire yellow green Connection of a room thermostat The room thermostat must be connected to the terminal block situated next to the control panel Any external controls and connection lines must be rated at 230 V but under no circum stances should external live voltage be con nected to the room thermostat link on the boiler Do not connect live wires to terminals to which the room thermostat must be connected When connecting any type of external control the link M in Fig 6 11 must be removed To fused spur L isolation switch Power supply terminal block i O O Or OD SQ Oz D External controls O terminal block OY O 8 Connect the room thermostat between ter minals 1 and 3 as shown in Fig 6 12 or Fig 6 13 Room thermostat 230V rating L N Sd 2 Power supply 3 2 1 2 terminal block SAS E NM External controls O 2 terminal block Fig 6 12 27 Z O E 3 E E lt z E 3 EN x e Installation Room thermostat with delay resistor 230V rating Power supply L9 ur terminal block SEO E 3 2 OLS D Fig 6 13
19. 0 Commissioning Fig 7 3 5 Gradually open stopcock at the filling point connection to the c h system until water is heard to flow do not open fully 6 Close the condensing heat exchanger air purger valve 17 Fig 7 2 when water begins to flow out 7 Open each radiator air vent starting at the lowest point of the system and close it only when clear water free of bubbles flows out 8 Purge the air from the pump by unscrewing the pump plug 28 Fig 7 3 release the pump shaft by turning in the direction indicated by the arrow on the information plate 9 Replace the pump plug 10 Continue filling the system The actual reading should ideally be 1 3 bar and not less than 0 3 bar 11 Close all air release valves on the c h system 12 Inspect the boiler and the system for water soundness and remedy any leaks discovered 13 Cold flush the system to remove any loose par ticles and any system debris before starting the boiler for the first time The flushing procedure must be in line with BS7593 2006 Treatment of Water in d h w c h Systems When the installation and second filling are completed turn on the c h system and run it until the temperature has reached the boiler operating temperature The system must then be immediately flushed through This procedure must be repeated twice more During this operation we highly recommend the use of a c h flushing detergent in the quan tities as specified by
20. Gas meter is connected to the service pipe by the local gas region or a local gas region contrac tor If the gas supply for the boiler serves other appliances ensure that an adequate supply is 20 available both to the boiler and the other appliance when they are in use at the same time Pipework must be of adequate size Pipes of a smaller size than the boiler inlet connection should not be used Installation pipes should be fitted in accordance with BS 6891 and the complete installation should be tested for soundness For Ireland IE refer to 1 5 813 2002 BEM air supply The room in which the boiler is installed does not require a purpose provided air vent EGM ventilation If installed in a cupboard or compartment it is not necessary to provide additional ventilation for cooling for this particular product However con sideration must be given to clearance require ments for maintenance see section 6 2 and under no circumstances must stored articles be al lowed to come into contact with the boiler or flue pipe Condensate drain Ensure that the condensate discharge complies with the national or local regulations in force The condensate pipe must be fitted in accordance with Building Regulations Drainpipe material should be resistant to acid as the condensate is slightly acid with a pH less than 6 5 The boiler includes atrap 32 on page 12 that pre vents the combustion products entering the drain
21. IE refer to 1 5 813 2002 The boiler is supplied for connection to a 230 V 50 Hz supply The supply must be fused at 3A The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance by the use of a fused double pole isola tor having a contact separation of at least 3 mm between poles or alternatively by the use of a 3A fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363 The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except were the appliance is installed in a bathroom this must then be sited outside the bathroom 6 Installation EM Warnings The use of gas appliances is subject to statutory control it is essential to observe the current regulations and laws in force see also chapter 5 The appliance must discharge combustion products directly outside or into a suitable ex haust duct designed for this purpose Combustion products must be discharged using original flue kits only since they are inte gral parts of the boiler The safety relief valve and the condensate drain must be connected to a suitable drain or discharge in a safe manner The electrical wiring must conform with current Regulations in particular the boiler must be earthed using the cor rect bonding clamp a fused spur isolation switch with a gap of atleast3 mm between the contacts mus
22. NATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE 17962 1251 2 0407 44A5 UK Biasi UK Ltd Newman Park Western Way Wednesbury WS10 7BJ Sales Tel No 0121 506 1340 Sales Fax No 0121 506 1360 Service Tel No 0121 506 1350 Service Fax No 0121 506 1370 www biasi co uk
23. OMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m3 hr ff hr BURNER OPERATING PRESSURE IF APPLICABLE N A mbar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE mS hr f hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE N A mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS ves FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO2 RATIO READING NA YES CO CO RATIO THE OPERA
24. TION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT___________________ CORG ID No SIGN DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIG
25. ampling points Fig 8 1 Side panels 3 Loosen the screws C Bring the bottom of the panels away from the boiler and lift them free ing them from the top hooks Fig 8 2 Fig 8 2 EEN Emptying the d h w system 1 Turn off the d c w inlet isolating valve 13 in Fig 8 3 and turn on the hot water taps and any drain cocks Z47U Closed position EEN Emptying the c h system 1 Close the c h isolating valves 12 and 16 in Fig 8 3 2 Open the central heating drain cock 26 in Fig 8 4 35 MAINTENANCE Maintenance 3 A small quantity of water will remain in the d h w heat exchanger after draining If the boiler is being drained to prevent freezing the d h w heat exchanger must be removed and inverted to drain fully or an antifreeze solution added Fig 8 4 EEEN Combustion analysis check If it is necessary to carry outa combustion analysis remove the plugs indicated in Fig 8 1 Reference figures are given in the sections 4 3 or 4 4 of this manual LLI O z lt z Lu E z lt EX Cleaning the condensing heat exchanger and burner To remove the burner fan group D Fig 8 5 1 Take off the front and side panels of the case 2 Remove the sealed chamber lid 3 Disconnect the connectors of the ignition elec trodes E and detection electrode F Fig 8 5 4 Disconnect the rubber pipe G Fig 8 6 Unscrew the gas connector H Fig 8 5 6 Remove the fixing fork
26. c water installation must be in accord ance with the relevant recommendations of BS 5546 Copper tubing to BS EN 1057 is recom mended for water carrying pipework and must be use for pipework carrying potable water For Ireland IE refer to 1 5 813 2002 Ear Water treatment Central heating circuit Where a new boiler is fitted to a new system with either plastic or copper pipes it is important the system is fully flushed on completion to ensure flux residues swarfs oils and other installation de bris is removed 22 Where a new boiler is fitted to an existing system it is important the debris from the existing system is fully removed in order to ensure the efficiency of the new appliance is maintained Details on flushing procedure are given in the sec tion 7 4 of this manual Domestic hot water circuit scale protection In areas where the water is hard i e more than 200 ppm total hardness as defined by BS 7593 2006 Table 2 it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company EM Electrical supply Warning this appliance must be earthed External wiring to the appliance must be carried out by a competent person and be in accordance with the current I E E Regulations and any local regulations which apply Reference should be made to the current ETCI rules for electrical installations For Ireland
27. commended to stop the boiler in case that the water temperature exceeds the design temperature J You are strongly advised to flush out the system both cold and hot in order to remove system and installation debris Y It is also sensible to initially fire and com mission the boiler before connecting any ex ternal controls such as aroom thermostat By this method if you have a subsequent prob lem following the addition of an external con trol you can eliminate the boiler from your fault analysis Y If the boiler is fitted with a digital pro grammer when setting the times for auto matic operation remember that for every ON time there must be an OFF time to fol low and that on every occasion you enter a time you must also indicate which days that you want the boiler to follow the timed set tings J Some products incorporate an anti cycl ing time delay It is normal when first switch ing the boiler on for the boiler to operate on heating for a few seconds then switch off After 3 4 minutes has elapsed the boiler will then re ignite and operate perfectly normally The ignition delay cycle does not prevent normal operation of the boiler to provide d h w V If you are in any doubts as to the installa tion or operation of the boiler please read the instruction manuals thoroughly and then if necessary contact Biasi UK for advice and assistance Please remember that if you are in any doubt about the insta
28. d The day display H gives a flashing indication ofthe active day or group of days Instructions for use Press the button or the buttons G corresponding to the day or days for which it is intended to apply the modification The corresponding day display stops flashing and a new switching time can be set or deleted The time setting can be modified now by pressing button D or E and the operation can be switched on or off by pressing the button F To delete a time set press the button D or E untilthe symbols shown in Fig 2 15 appears in the time display The new settings are memorised by moving the switch A to a different position Manual operation The operation of the time switch can be forced on or off constantly or for a timed period To force constantly on or off the timer operation set the mode selector switch A to the TIMER posi tion The symbols shown in Fig 2 18 appears on the display O O 0 0 Os Os O Fig 2 18 The operation can be switched permanently on or off by pressing the button F and leaving the switch A in the TIMER position To force a timed delay on or off operation set the mode selector switch A in the TIMER position Set the time delay by pressing the button D or E and the operation can be forced on or off by pres sing the button F The time delay can be set within the following ranges 1 to 23 hours with steps of 1 hour 1 to 27 days with steps of 1 day The time delay s
29. demonstrate the function of time and temperature controls if fitted Explain how to turn off the appliance for both short and long periods and advise on the precautions necessary to prevent damage should the appliance be inoperative when freezing condi tions may occur Fill in the details required on the Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee reg istration Finally advise the User that for continued safe and efficient operation the appliance must be ser viced by a competent person at least once a year 8 Maintenance EX Warnings The procedures detailed in this chapter must be carried out only by a professionally qualified person Thus you are advised to contact an Authorised Service Agent For Ireland IE the servicing work must be carried out by a competent Person For efficient and continuous operation of the boiler you are advised to have at least once a year maintenance and cleaning done by an Approved Service engineer Isolate the appliance from the electricity supply by turning off the fused spur isolation switch adjacent to the appliance and turn off the gas cock before carrying out any pro cedures whatsoever for cleaning mainten ance opening or dismantling boiler panels EEM Dismantling the external panels Front panel 1 Loosen the three screws A Fig 8 1 2 Lift and remove the panel B Air Flue exhaust S
30. e quired for this procedure Checking the inlet pressure 1 32 Remove the front panel of the case see sec tion 8 2 and lower the control panel see sec tion 6 9 Loosen the internal screw onthe Inlet Pressure Test Point 41 Fig 7 5 of the Gas Valve and connect a pressure gauge using a suitable hose Fig 7 5 10 9 8 Open the gas inlet valve 14 on page 2 Turn on the electricity supply to the boiler switching on the fused spur isolation switch The appliance operation light 10 will flash every 4 seconds Set the function knob 8 as illustrated in Fig 7 6 7 6 Fig 7 6 6 7 Open at least one hot water tap fully Read the inlet pressure value and ensure that itis within the limits given in the table Gas sup ply pressures sections 4 3 and 4 4 of this man ual Ifit does not comply with the required pressure check the gas supply line and governor for faults and or correct adjustment Switch off the boiler close the gas inlet valve and close the water tap Disconnect the pressure gauge and close the Inlet Pressure Test Point 41 Fig 7 5 Important after the checks all of the test points must be sealed Commissioning Maximum output in c h mode The maximum useful output in c h mode of model can be varied and on model M110 32SM is fac tory set to 24 kW To change the maximum useful output value in c h mode refer to the electronic control ignition pcb sectio
31. e ad vised to have a professionally qualified per son check that the installation of the gas supply is gas tight isofthe correct gauge for the flow to the boiler is fitted with all the safety and control de vices required by the current Regulations Ensure that the installer has connected the pressure relief valve outlet to a drain pipe The manu facturers are not responsible for damage caused by opening of the pressure relief valve and consequent escape of water if not connected correctly to the drain the installer has connected the conden sate outlet to a suitable drain pipe 1 On detecting the smell of gas don t operate any electrical switches the telephone or any device that may produce sparks open the windows and doors at once to create a draught of air which will purge the area shut off the gas cocks get the assistance of a qualified person 1 Do not touch the appliance with parts of the body that are wet or damp and or bare feet 1 Do not block or modify the condensate outlet and pipework Y In case of structural work or mainten ance near the exhaust duct and or fume ex haust devices or their attachments turn off the appliance On completion of the work have a professionally qualified person check their efficiency 1 Repairs under guarantee must be car ried out only by an approved engineer using genuine spare parts Thus do no more than s
32. ed x vi LTN vi AYSN vi TS Sis x DN Flame detection error S O O x Other faults O Ox Lamp OFF Lamp ON Lack of power supply or faulty electronic control p c b Meaning of symbols Flashing lamp alone or simultaneously with an other lamp Flashing lamp alternate with another lamp 2 Instructions for use FAM Warnings Biasi UK Ltd support the Benchmark initiat ive The Benchmark Log Book is located at the back of this manual and should be com pleted by the Installing Commissioning En gineer and handed over to the User for fu ture reference by other visiting Engineers Also included is the Service Interval Record card that should be completed by the Ser vice Engineer following the annual service maintenance of the boiler and system All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your Benchmark Log Book You can check your installer is registered by calling CORGI di rect on 01256 372300 In order to guarantee safety and correct oper ation it is essential that all the tests are carried out by a competent and responsible service engineer before lighting up the boiler The tests are described in the installation in structions in section 7 commissioning Ensure that the c h circuit is regularly filled with water even if the boiler is only used for d h w supply checking t
33. er The latter option in particular not only cleans out the system but also has an anti corrosive effect by promoting formation of a protective skin on metal surfaces and neutralising gases present in the water We recommend the use of a suitable universal inhibitory to protect the c h system from cor rosion FEN Installing the bracket Precautions Before mounting the bracket check that the di mensions for fitting the exhaust fume duct are complied with refer to the leaflet included with the flue kit packed separately Utilise the paper template supplied with the boiler to determine the fixing position for the bracket and boiler Securely mount the bracket to the wall using appropriate fixings suitable for the type of wall construction and capable of supporting the 23 z ie E 3 E E e Installation total wet load Refer to the weight given in the technical data tables specific for each model ZE Overall dimensions C A gt cum Ae80 Vd Z O E 3 E E lt Electric connection area 257 Cold water C h Gas inlet return A B and C c o i 2 o e Condensate flow drain connection D h w area outlet A air intake flue outlet pipe co axial B flue outlet pipe y 80 mm twin kit C air intake pipe 80 mm twin kit Fig 6 2 all dimensions in mm 24 DEB Joints pezen bd Gas c h retu
34. er has to be done very fre quently have the system checked for leaks If water comes out of the pressure relief valve Check on the temperature and pressure gauge 4 on page 2 that the pressure in the central heating circuit is not close to 3 bars In this case tempera ture rise in the circuit can cause the pressure relief valve to open So that this does not happen and to decrease the pressure to a normal value it is advisable to vent some of the water in the appliance through the bleed valves present in the radiators If in time a reduction in domestic hot water supply is observed The likely causes may be impurities caught in the domestic hot water flow switch filter or limescale deposited in the domestic hot water heat ex changer It is advisable to have the appliance cleaned out by an Authorised Service Centre En gineer If water should occasionally leak from the boiler shut off the valves positioned under the boiler Fig 2 12 on page 7 and call an Authorised Ser vice Centre Engineer In this case or in case of problems other than those mentioned here switch off the boiler as described in section 2 6 on page 7 and call a competent and responsible service engineer 11 Z O E 3 E E Z 4 Technical information KEN overview 30 29 Fig 4 1 11 Condensate drain pipe 12 C h return valve 13 Domestic cold water inlet valve 12 14 Gas inlet valve 15 D h w outlet pipe 16 C h
35. etting is activated by moving the switch A to the AUTO position The ON OFF display J flashes indicating that the current state of operation has been forced To delete the timed delay setting set the mode se lector switch A in the TIMER position press the button D or E until the symbols shown in Fig 2 18 appears in the display and then set the mode se lector switch A to the AUTO position Setting example shown in Fig 2 19 forced ON state for 4 hours Resetting To completely reset the timer press the reset but ton with a pointed object pencil CAUTION pushing the reset button will complete ly erase the settings as well as all the data includ ing the current time and day 3 Useful advice EX central heating For reasonably economical service install a room thermostat Never shut off the radiator in the area where the room thermostat is installed If a radiator or a convector does not heat up check that no air is present in it and that its valve is open Ifthe ambient temperature is too high do not alter the radiator valves Reduce the central heating temperature instead by means of the room ther mostat and the function selector 8 in Fig 3 1 Fig 3 1 EEN Frost protection This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 C Therefore when the boiler is not lit and used in cold weather with consequent risk of fre
36. ezing do not switch off the boiler at the fused spur isola tion switch or close the gas inlet cock EEN Periodic maintenance For efficient and continuous operation of the boiler it is advisable to arrange maintenance and cleaning by an Authorised Service Centre En gineer at least once a year During the service the most important compo nents of the boiler will be inspected and cleaned This service can be part of a maintenance con tract In particular you are advised to have the following checks carried out domestic hot water heat exchanger condensing heat exchanger burner exhaust fume duct and flue pressurisation of the expansion tank 10 filling up of the central heating circuit bleeding of air from the central heating system general check of the appliance s operation EEJ External cleaning Before carrying out any cleaning disconnect the appliance from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance To clean the external panels use a cloth soaked in soapy water Do not use solvents abrasive powd ers or sponges Do not carry out cleaning of the appliance and or its parts with readily flammable substances for example petrol alcohols naphtha etc EEN Operational faults If the lock out signal lamp 6 in Fig 3 2 comes on this indicates that the safety lock out has stopped the boiler To re start the boi
37. flame close the gas cock After four ignition attempts within about four min utes the lock out signal lamp 6 Fig 1 3 on page 2 must appear To reset the boiler press and release the boiler reset button 7 Fig 1 3 on page 2 Checking the flue system The flue system should be visually checked for soundness Check all clamps gaskets and fixing are secure and tight 34 Ensure thatthe flue terminal is sited correctly in ac cordance with the flue fitting instructions and Fig 5 1 on page 20 of this manual To carry out a combustion check refer to the in structions given in the section 8 5 of this manual Reference figures are given in the sections 4 3 or 4 4 of this manual Flue gas figures Checking the condensate drain pipe Check the soundness and integrity of the conden sate drain pipe Verify the cleanness and correct filling of the con densate traps Instructing the user Hand over this combined User amp Installation man ual and the Service manual to the end user and ex plain how to use the unit in both c h and d h w modes Take the User step by step through the lighting in structions Show the User how to switch off the appliance quickly and indicate the position of the electric supply isolator Explain the proper use and adjustment of all sys tem controls this will ensure the greatest possible fuel economy Explain the function and use of the function selec tor Explain and
38. flow valve 17 Condensing heat exchanger air purger valve 18 C h temperature probe NTC 19 Condensing heat exchanger 20 Safety thermostat 21 Flame detecting electrode 22 Transformer 23 Air hose 24 C h pressure relief valve 25 Automatic air purger valve 26 Main circuit drain valve 27 Pump 28 Pump vent plug 29 Gas valve 30 D h w temperature probe NTC 31 Primary circuit flow switch 32 Condensate trap 33 D h w heat exchanger 34 Three way diverter valve 35 Fan 36 Spark generator 37 Ignition electrodes 38 Burner 39 Flue temperature probe NTC 40 D h w flow switch 41 Gas valve inlet pressure test point 42 Gas valve outlet pressure test point 43 C h expansion tank 44 By pass valve 45 Domestic water circuit filter 46 D h w flow limiter 47 Flue outlet pipe 48 Air intake pipe 49 Flue exhaust sampling point 50 Air sampling point Technical information EEN Main diagram INSTALLATION Fig 4 2 Technical information ZEN Technical data Domestic hot water mod M110 24SM Maximum temperature Minimum temperature Maximum pressure Nominal Minimum pressure IE Flow rate Minimum minimum l min 30 rise D l min 35 rise D l min 40 rise D l min Maximum kW 24 4 BTU h 83 248 Gas supply pressure G20 Minimum kw 5 8 Norm BTU h 19 788 Maximum condensing kW 26 3 BTU h 89 730 Mini
39. gral automatic by pass will ensure a mini mum flow through the primary heat exchanger of the boiler in the eventthatthe flow around the cen tral heating circuit is restricted due to closure of thermostatic or system control valves EN Expansion vessel Note this boiler is designed for operation only in a sealed central heating system The height difference between the pressure relief valve and the highest point in the system may be 7m at most For greater differences increase the pre load pressure in the expansion vessel 43 on page 12 and the system when cold by 0 1 bar for each additional 1m Capacity Pre load pressure Maximum volume of water in the system Tab 4 1 Where conditions are Average maximum temperature of the system is 80 C Initial temperature when filling up the system is 10 C For systems with volumes greater than 1541 an additional expansion vessel must be provided 5 General requirements Biasi UK Ltd support the Benchmark initiative The Benchmark Log Book is located at the back of this manual and should be completed by the Installing Commissioning Engineer and handed over to the User for future reference by other visiting Engineers Also included is the Service Interval Record card that should be completed by the Service Engineer following the annual service maintenance of the boiler and system For Ireland IE it is necessary to complete a Declaration of
40. hat the pressure indicated on the temperature and pressure gauge 4 is not lower than that shown in Fig 2 2 If the pressure reading on the pressure gauge is below that shown in Fig 2 2 then the system will require topping up A filling loop is normally provided by the installer for this purpose If you are in any doubt regarding this pro cedure you are advised to contact your In staller or an Approved Engineer This appliance is provided with a built in anti freeze system that operates the boiler when the temperature is below 5 C Therefore when the boiler is not lit or used in cold weather with consequent risk of freezing do not switch off the boiler at the fused spur isolation switch or close the gas inlet cock When you do not expect to use the boiler for a long period and the boiler is not to be used for frost protection then follow the instructions given in section 2 6 on page 7 PEN Refilling procedure 1 Isolate the boiler from the electrical supply at the fused spur Reconnect the filling loop as demonstrated in Fig 2 1 Control valve Double check valve Temporary connection Supply pipe cold water inlet C h return pipe Fig 2 1 2 Open the valves of the filling loop and watch the gauge until it reaches normal filling pres sure as shown in Fig 2 2 Control valve Normal filling pressure Fig 2 2 3 Close the valves and remove the filling loop If you experience any diffic
41. he current edition of 1 S 813 2002 and the current ETCI rules for electrical installations Where a room sealed appliance is installed in a room containing a bath or shower any electri cal switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower The location must permit the provision of an ad equate flue and termination For unusual locations special procedures may be necessary and BS 6798 gives detailed guidance on this aspect A compartment used to enclose the appliance must be designed specifically for this purpose This appliance is not suitable for external installa tion EEN Five system The provision for satisfactory flue termination must be made as described in BS 5440 part 1 For Ireland IE refer to 1 5 813 2002 The appliance must be installed so that the flue ter minal is exposed to external air It must not be installed so that the terminal dis charges into an other room or space as an out house or lean to lt is important that the position of the terminal allows a free passage of air across at all times The terminal should be located with due regard for the damage or discoloration that might occur to building products in the vicinity In cold and or humid weather water vapour may condense on leaving the flue terminal the effect of such pluming must be considered Pluming may easily occur at the terminal
42. irements 19 optional asana aan 2 5 1 Related documents 19 ARD m 5 2 Location of appliance 19 7 Commissioning 5 8 Flue system 19 7 1 Electrical installation 5 4 Gas supply 4152994299495 5999493 20 7 2 Gas supply installation 5 5 Airsupply 0 e 00 eee 20 7 3 Filling the d h w system 5 6 Ventilation oooooooo 20 7 4 Initial filling of the system 5 7 Condensate drain 20 7 5 Condensate pipe and traps 5 8 Water circulation C h 21 7 6 Lighting the boiler 5 9 Domestic water 22 7 7 Checking the gas supply pressure 5 10 Water treatment 22 7 8 Maximum output in c h mode i 7 9 External temperature probe settin 5 11 Electrical supply 22 eotional P Ma E an 3 ds 6 Installation 23 7 10 Checking the ignition device 34 6 1 Warnings ane aA d adr eoa dads 23 7 11 Checking the flue system 34 6 2 Precautions for installation 23 7 12 Checking the condensate drain pipe 34 6 3 Installing the bracket 23 7 13lnstructing the user 34 8 Maintenance 35 8 7 Checking the pressurisation 8 1 Warnings ssi coats ret arke 35 in the expansion vessel 37 RT 8 2 Dismantling the external panels 35 8 8 Cleaning the burner 37 E 8 3 Emptying the
43. izontal flue kit Fig 6 5A the flue pipe is angled within the air duct therefore the air duct must be horizontally installed If one or more extensions have to be used they must be adequately supported so that there is no sag in the flue pipe and a minimum fall of 1 5 deg 25 mm per metre over the whole length towards the boiler is ensured CEN Choice of flue The following flue kits are available for connecting to the boiler Standard horizontal flue kit Fig 6 5A Co axial 60 100mm nominal length 1m This kit is normally supplied with the boiler and can be fitted to allow discharge to the rear or either side of the boiler via the flanged boiler adapter elbow Minimum length required is 0 3 m Maxi mum equivalent length of 10 metres can be achieved utilising extensions This flue system can only be used to discharge horizontally itis not de signed to enable termination in the vertical plane Vertical kit with 90 elbow Fig 6 5B Co axial 60 100 mm Supplied with a straight flanged adapter a co axial elbow and a co axial pipe with terminal this kit allows for a vertical rise of 0 5 m from the boiler In all circumstances the flue terminal must dis charge horizontally and the equivalent flue length must not exceed 10 metres Elbows 45 amp 90 Fig 6 5C Co axial 60 100mm Elbow kits enable the standard flue kits to be offset to overcome obstructions or ensure the correct clearances for the flue terminal
44. ler it is necessary to press the boiler reset button 7 Fig 3 2 6 7 Fig 3 2 For the first lighting up and following maintenance procedures for the gas supply it may be necess ary to repeat the resetting operation several times so as to remove the air present in the pipework After five consecutive resetting attempts the reset button is inhibited To restore its function it is necessary to switch the boiler off and on from the electrical mains using the fused spur isolation switch fitted adjacent to the appliance Safety lock out may occur even in case of an blockage of the condensate drainage e g plugged drain pipe It is advisable to check the condensate drainage pipe and traps for cleanness In this case and in case of persistent lock out call a competent and responsible service engineer If noises due to air bubbles are heard during operation Useful advice you should check that the pressure on the tem perature and pressure gauge Fig 2 2 on page 4 is not below the correct setting If required top up the system correctly as de scribed in the section 2 2 of this manual Bleed any air present in the radiators ifnecessary If the pressure on the temperature and pres sure gauge 4 on page 2 has gone down it is necessary to top up the appliance with water again so as to raise the pressure to an adequate level as described in the section 2 2 of this manual If topping up with wat
45. llation of this product you can contact our Technical Helpline on tel 0121 506 1350 TABLE OF CONTENTS 1 Appliance description 2 2 4 C h circuit temperature 5 1 1 Overview o ocooocooccoc 2 2 5 D h w temperature 6 1 2 Control panel 2 2 6 Extinguishing 7 1 3 Isolation valves 2 2 7 Builtin time switch 7 1 4 Technical data 2 E aee 3 Usefuladvice 10 1 PPM qe Sonet png do te 3 1 Central heating 10 2 Instructions for use 4 3 2 Frost protection 10 2 1 Warnings onser Arta rrt 4 3 3 Periodic maintenance 10 2 2 Refilling procedure 4 3 4 Externalcleaning 10 2 3 AA ahs ar igs aro ae ar poa 4 3 5 Operational faults 10 4 Technical information 12 6 4 Overall dimensions 4 1 Overview Lseusss 12 6 5 POUNS o need RE ER z 4 2 Main diagram 13 6 6 Mounting the boiler le 4 3 Technical data mod M110 24SM 14 6 7 Fitting the flue system E 4 4 Technical data mod M110 32SM 16 6 8 Choice offlue q 4 5 Hydraulic specifications 18 6 9 Electrical connections m 4 6 Expansion vessel 18 6 10 External frost protection a i 6 11 External temperature probe o 5 General requ
46. mum condensing kW 6 3 BTU h 21 494 INSTALLATION Max Min mbar 17 1 mbar approximately equals 10 mm H20 Central heating Maximum flow temp C Minimum flow temp C Maximum pressure kPa bar Minimum pressure kPa Restrictors references e 1000 ida in 1000 I h bar Seasonal efficiency band A referred to the net calorific value at 15 C and 1013 25 mbar G 20 34 02 MJ m3 B referred to the gross calorific value at 15 C and 1013 25 mbar G 20 37 78 MJ m3 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body D Values subject to tolerance 14 Technical information Electrical Data CO contents Voltage V CO content 9 0 9 8 range min max At nominal heat input of 25 0 kW W E CO content 96 range min max At minimum heat input of 6 0 kW AXE Frequency Hz Power consumption W Protection degree External fuse rating Internal fuse rating Other flue gas figures Flue design At nominal heat input non condensing Flue pipe diameter O content 26 4 8 Coaxial mm 60 100 i e CO content ppm 150 Twin split pipes mm 80 z Exhaust temperature C 85 Roof 80 125 mm Nominal heat flow rate kW 25 0 A E Other specifications IS Exhaust temperature E 85 Height mm 42 Width INSTALLATION mm Smoke productio
47. n E kg h Depth mm Weight dry kg Water volume in the boiler I kg up to 1 bar E Values refer to tests with a 1 m chimney working at the nominal heat input 15 Technical information 4 4 Technical data Domestic hot water mod M110 32SM Maximum temperature Minimum temperature Maxi ressure Nominal kW 33 5 ie oat a BTU h 114 295 kW 37 2 BTU h 126 920 Minimum kW BTU h minimum l min kW 30 rise D l min BTU h 35 rise D l min 40 rise D l min Maximum kW 32 7 BTU h 111 566 Gas supply pressure G20 Minimum kW 10 6 Norm BTU h 36 165 Maximum condensing kW 35 1 BTU h 119 754 Minimum condensing kW 11 6 BTU h 39 577 Minimum pressure Flow rate INSTALLATION Max Min mbar 17 1 mbar approximately equals 10 mm H20 Central heating Maximum flow temp C Minimum flow temp C Maximum pressure kPa bar Minimum pressure kPa Restrictors references e 1000 ida in 1000 I h bar Seasonal efficiency band A referred to the net calorific value at 15 C and 1013 25 mbar G 20 34 02 MJ m3 B referred to the gross calorific value at 15 C and 1013 25 mbar G 20 37 78 MJ m3 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body D Values subject to tolerance 16 Technical information Electrical Data CO contents
48. n of the service manual External temperature probe setting optional The external temperature probe if fitted allows to adjust automatically the temperature of the c h flow with reference to the external temperature The curves given in the chart of Fig 7 7 represent the c h flow temperature setting as a function of the external temperature measured by the exter nal temp probe The relationship between the external tempera ture and the c h flow temperature is represented by the coefficient K Fig 7 7 that can be set be tween 0 and 6 as hereafter explained E g to obtain a flow temperature setting of 60 C when the external temperature is 5 C K must be set to 1 5 dashed line in Fig 7 7 C h flow temperature C K 6 K 4 K 3 80 20 15 10 5 0 5 10 15 20 25 External temperature C Fig 7 7 The appropriate value of the coefficient K de pends on the design temperatures of the c h sys tem as the minimum external temperature and the corresponding c h flow temperature The coefficient K is factory set to 0 that is the setting for the operation with no external tem perature probe fitted To set the coefficient K 1 2 Turn on the electricity supply to the boiler switching on the fused spur isolation switch Set the function knob 8 as illustrated in Fig 7 8 On Fig 7 8 3 Keep pressed the reset button 7 for about 10 seconds until the lock out signal lamp
49. ngineer EXT Drain pipe inspection Check the soundness and integrity of the conden sate drain pipe Verify the cleanness and correct filling of the con densate traps EXI Visual inspection of appliance Visually inspect all water joints seals and connec tions for any evidence of leakage and retighten grease or replace them as necessary EXP Gas pressures and soundness Check appliance for gas soundness Recheck op erational pressures as described in section 7 7 page 32 of this manual EXE Water inhibitor concentration Where chemical products are used the level of water treatment should be checked on an annual basis and re treated after full or partial drain down Aconductivity meter can be used to check the cor rect concentration of inhibitor in the heating water 37 MAINTENANCE BENCHMARK No OPE EIE Benchmark GAS BOILER COMMISSIONING CHECKLIST GULLSUIIVE VAAK BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME 4 TEMPERATURE CONTROL TO HOT WATER _ CYLINDER T STAT 4 PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUT
50. plaints may be particularly susceptible to irritation High dust le vels are only likely to arise following harsh ab rasion In general normal handling and use will not present high risk follow good hygiene prac tices wash hands before touching eyes consum ing food drinking or using the toilet First aid Medical attention must be sought fol lowing eye contact or prolonged reddening of the skin Thermostat Temperature gauge Description Sealed phial and capillary contain ing liquid Known hazards irritating to skin eyes and throat Vapour is harmful Inflammable do not extinguish with water Precautions Do not incinerate Avoid contact with broken leaking phials Do not purposely puncture First aid medical attention must be sought follow ing eyes skin contact wash with clean water Country of destination United Kingdom GB Ireland IE This appliance conforms with the EEC directive 90 396 and consequently it has the right to make use of theC brand name Moreover the appliance conforms with the EEC directive 87 308 relative to the prevention and elimina tion of radio disturbances The appliance is built to comply with the regulation now in force regarding gas appliance s safety and the European regulation now in force relative to safety of household and similar electrical appliances The manufacturer in the continuous process to improve his products reserves the rightto modify the
51. r Authority Mains water feed hot water supply The domestic section of the boiler is designed to withstand an internal domestic water pressure of 10 bar Where it is likely that the mains domestic water pressure may exceed 5 bar it is possible due to internal water hammer effects that the pressure within the domestic system can increase to a level in excess of the 10 bar limit In these circumstances it is therefore recom mended that a 3 bar pressure reducing valve be fitted to the incoming mains water supply and a mini expansion vessel installed on the domestic circuit These devices will protect the boiler and the do mestic system from damage due to excessive do mestic water pressure Filling A method for initially filling the system and replac ing water lost during servicing must be provided 21 Z O E 3 E E zZ Z O E 3 E E lt General requirements and it must comply with local water authority regu lations The correct method is shown in Fig 5 3 The temporary connection must be removed immediately after filling Control valve Double check valve Temporary rA connection Control valve Supply pipe cold water inlet C h return pipe Fig 5 3 The installer should ensure that no leaks exist either inside the boiler or on the system as fre quent filling of the system could cause premature scaling of the heat exchanger EX Domestic water The domesti
52. ration Press the enter button C to confirm the setting and to continue programming the OFF time Set the OFF time as explained above for the ON setting and confirm by pressing the enter button C Proceed in the same way for other settings Setting example shown in Fig 2 16 A ON time 7 45 day Monday to Friday B OFF time 10 30 day Monday to Friday mal A B Fig 2 16 Activating the timed settings Set the mode selector switch A tothe AUTO posi tion shown in Fig 2 17 The current time and day appears in the display The ON OFF display J indicates the current state of operation according to the settings O O 0 0 6 0 0 Fig 2 17 Note when the mode selector switch A is in the AUTO position and the boiler is switched off atthe fused spur isolation switch the display J indicates only the OFF state The other indications are blanked Reading the timed settings Set the mode selector switch A to the C1 position The symbols shown in Fig 2 15 appears in the display Press the enter button C Each time the button is pressed the display showsthe details of the next setting The day display H gives a flashing indication ofthe active day or group of days Changing or deleting the timed settings Set the mode selector switch A to the C1 position The symbols shown in Fig 2 15 appears in the display Press the enter button C until the display shows the setting to be modified or delete
53. ration of the boiler LU u m short pulse every 4 seconds stand by condition Function selector in position Anti freeze system active 1 second pulse every 2 seconds normally operating boiler Function selector in Or position C h operation 2 O IQQ D h w operation O D h w operation O QO X Excessive temperature on primary circuit Frost protect operation If the lights combination observed is not included in the above table a fault may be indicated Reference should be made to the following table In this case switch off the boiler as described in section 2 6 on page 7 and call a competent and re sponsible service engineer Appliance description 7 pd DN vi I N Vly ZN x Faulty c h temperature probe NTC O10 Vly I N Sis slz IN Faulty d h w temperature probe NTC IN vit N oO Faulty primary circuit no water or absence of flow IN vi LTN IN vl O LS Lack of burner ignition 4 5 x x vit PON AE LS pd DN pd Safety thermostat lock out IN vi rN Faulty fan control system x vl LS DN 7 Flue temperature probe NTC lock out x O 4 Open flue temperature probe NTC 010 0 s vi CS ce rN vl els ce ZN Faulty external temp probe if fitt
54. rly set by the installer as described in section 7 9 of this man ual and the c h flow temperature control knob must be positioned as illustrated in Fig 2 8 To satisfy temporary changes or different room temperatures the c h water temperature can also be manually increased or decreased within a range of 15 C by turning the knob 8 Fig 2 8 More details are given in section 7 9 of this man ual Fig 2 8 PEEN D h w temperature The temperature of the d h w leaving the boiler can be varied from a minimum of about 35 C to a maximum of about 55 C Fig 2 9 by turning the temperature control knob 9 Maximum Fig 2 9 Adjustment of the d h w temperature is complete ly separate from that of the c h circuit The adjustment system integrated within the boiler automatically controls the flow of gas to the burner in order to keep the temperature of d h w delivered constant between the limits of maxi mum and minimum output Where the demand is at a low level or with the tem perature set to the minimum it is normal to see a cycle of lighting and extinguishing of the burner when running Adjustment It is advisable to adjust the d h w temperature to a level commensurate with the demand minimis ing the need to mix with cold water In this way the automatic control facilities will be fully exploited Where lime scale is present in the water supply hard water areas it is also advisable not to e
55. rn c h flow D h w outlet Pressure relief valve Condensate drain 25 plastic Tab 6 1 sizes in mm o d XGM Mounting the boiler 1 Take the protective caps off the boiler pipe work 2 Thoroughly clean the connections 3 Mount the boiler on its bracket 4 Fixthec h valves A and gas cock B to the boiler using the gaskets Fig 6 3 5 Fixtheg 22 mm pipes C c h circuit to the c h valves A and the 22 mm pipe D gas to the cock B using the 34 gaskets 6 Repeatthe above procedure for the d c w inlet utilising the 1 2 cold water inlet valve E the y 15 mm copper tail F with its connection nut and two 2 gaskets 7 Fixthe o 15 mm copper tail G with the 72 con nection nut and a Y gasket KS DC e 22 D d Y F ae wo vc i ge ak Ge AT Fig 6 3 8 Connect the pipe H Fig 6 4 from the pres sure relief valve to the safety discharge pipe work 9 Fit the condensate drain 11 Fig 6 4 in the air brake connected to the drainage pipework See also section 5 7 in this manual Installation Fig 6 4 Fitting the flue system Refer to the assembly instructions contained with in the chosen flue kit packaging for the correct as sembly and installation In general it has to be taken in consideration that the horizontal sections of the flue pipe must have an horizontal sloping not less than 1 5 deg 25 mm per metre towards the boiler In the standard hor
56. t be installed near to the boiler Refer to section 6 9 in this chapter for the electrical connec tions In no circumstances will the manufacturer be held responsible if the warnings and in structions contained in this manual have not been complied with EB Precautions for installation For the installation proceed as follows The boiler must be fixed to a strong wall The dimensions for the exhaust fume duct de tailed in section 6 7 and the correct procedures for installing the duct depicted in the instruc tion leaflet included with the flue kit must be complied with during installation To allow maintenance procedures it is necess ary to leave the minimum gaps indicated in Fig 6 1 200 200 Fig 6 1 all dimensions in mm When installing the boiler in a cupboard cover or alcove allow at least 50mm permanent clear ance from the front face of the boiler Also en sure sufficient clearance to allow free access for servicing and the lowering of the front con trol panel If the boiler is installed outside cover the ap pliance to protect it against the elements and add some special anti freeze neutralised to the c h system Before installing the boiler on an existing c h system flush it out thoroughly before fitting the boiler so as to remove muddy deposits Itis advisable to equip the system with a sedi ment filter or use a water treatment product in the circulating wat
57. t may invali Filling the d h w system date the manufacturers guarantee 1 Close all hot water draw off taps 14 13 Open position O E 3 E E Z For Ireland IE it is necessary to complete a 2 Open the cold water inlet valve 13 Fig 7 1 Declaration of Conformity to indicate com 3 Slowly open each draw off tap and close it pliance to 1 S 813 2002 only when clear water free of bubbles flows out FAM Electrical installation EN n Preliminary electrical system checks to ensure ae ng Orie system electrical safety shall be carried out by a compet 1 Open the c h flow and return valves ent person i e polarity earth continuity resis 2 Remove the front and side panels of the case tance to earth and short circuit see the section 8 2 in this manual and the If a fault has occurred on the appliance the fault find sealed chamber lid ing procedure should be followed as specified inthe 3 Unscrew the condensing heat exchanger air service manual purger valve 17 Fig 7 2 Gas supply installation 1 Inspect the entire installation including the gas meter test for soundness and purge all as de scribed in BS 6891 For Ireland IE refer to 1 5 813 2002 2 Open the gas cock 14 Fig 7 1 on the appliance and check the gas connector on the appliance for leaks Fig 7 2 4 Unscrew the cap on the automatic air purger valve 25 Fig 7 3 one full turn and leave open permanently 3
58. turning the knob 8 Adjustment of the boiler temperature alters the gas flow atthe burner according tothe thermal de mand in the system So it is usual to see the burner lit at the minimum level for more or less long periods It is possible to fit to this boiler an optional outside temperature sensor which helps to manage and control the boiler and system efficiency The fol lowing instructions indicate how to set the output temperature of the c h water depending on whether the optional outside sensor has been fitted Minimum Maximum Fig 2 6 Adjustment WITHOUT the external tempera ture probe optional fitted In order to achieve optimal settings for economy and comfort we recommend adjusting the oper ating temperature of the c h water according to the outside temperature positioning the knob as follows Instructions for use From 5 to 15 C Between 5 and 5 C Lower than 5 C Fig 2 7 Your qualified installer will be able to recommend the most suitable adjustment for your system The temperature and pressure gauge 4 Fig 1 3 on page 2 will allow you to check that the set tem perature is obtained Adjustment WITH the external temperature probe optional When the boiler is connected to the external tem perature probe optional the temperature of the c h flow is automatically adjusted with reference to the external temperature In this case the boiler must be prope
59. ulty with the oper ation of the boiler switch off the boiler immedi ately at the fused spur isolation switch and contact your Installer or an approved Service Engineer Air introduced into the boiler during this filling pro cess will vent through the automatic air purger fitted to the boiler You may also find it necessary to vent air from your radiator circuit using your radiator key however be aware that excessive venting will cause the pressure in the system to drop Always ensure that the pressure gauge is set at the required pressure FEN ignition 1 Check that the valves located in the lower part of the boiler are open Fig 2 3 Instructions for use a AS AG id Za Open position lt lt Fig 2 3 2 Turn on the electricity supply to the boiler switching on the fused spur isolation switch The appliance operation light 10 Fig 2 4 will flash every 4 seconds stand by condition 3 Ifthe boiler isto be used for c h and d h w posi tion the function selector 8 as in Fig 2 4 The appliance operation light 10 will flash every 2 seconds operating boiler Fig 2 4 4 If d h w supply only is required position the function selector 8 as in Fig 2 5 The appliance operation light 10 will flash every 2 seconds operating boiler 24 C h circuit temperature The output temperature of c h water is adjustable from a minimum of about 25 C to a maximum of about 85 C Fig 2 6 by
60. witching off the boiler yourself see the in structions Your boiler allows heating up of water to a temperature less than boiling point must be connected to a central heating system and or a hot water supply system compatible with its performance and output can be used only for those purposes for which it has been specially designed must not be touched by children or by those unfamiliar with its operation must not be exposed to weather condi tions 1 During the operation it is quite normal that the boiler produces a white plume of condensation vapour from the flue terminal This is due to the high efficiency of the ap pliance and may be particularly evident with low outdoor temperatures Safe handling of substances Biasi products are manufactured in accordance with ISO 9000 and do not and will not contain any hazardous materials or substances such as as bestos mercury or C F C s The appliance packaging does not contain any substances which may be considered a hazard to health Combustion chamber panels Material mineral fibres Appliance category l2 Gas G20 20 mbar Known hazards Some people can suffer red dening and itching of the skin Fibre entry into the eye will cause foreign body irritation which can cause severe irritation to people wearing contact lenses Irritation to respiratory tract Precautions Dust goggles will protect eyes People with a history of skin com
61. x ceed the setting position ofthe d h w temperature control knob 9 as indicated in Fig 2 10 This will help to minimise the incidences of scale deposits clogging the domestic hot water heat exchanger of the boiler Fig 2 10 Instructions for use In these cases however it is advisable to install a small water treatment device or softener With such a device you should avoid periodic descal ing Consequently the d h w heat exchanger will keep its performance consistent for a longer period of time with resulting gas savings If the demand for d h w is so great as to prevent reaching ahigh enough temperature have the ap propriate output limiting valve installed by your in staller or an Authorised Service Engineer PUN Extinguishing To turn the boiler off set the function selector 8 to the position shown in Fig 2 11 The appliance operation light 10 will flash every 4 seconds Fig 2 11 When you donot expectto use the boiler for along period 1 Switch off the electricity supply to the boiler by means of the fused spur isolation switch 2 Shut off the gas supply cock 14 and the valves for the water circuits fitted under the boiler Fig 2 12 3 Empty the water circuits if necessary as shown in the installation instructions in the sec tion maintenance 14 Closed position Fig 2 12 Built in time switch The combi boilers are equipped with a built in elec tronic time switch

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