installation and
servicing
mini HE
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
Model
Serial No.
C24,C28,C32
For users guide see reverse of book
When replacing any part of this appliance, use only spare parts that you can be assured
conform to safety and performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised by Ideal Boilers
17962.1155.1
*1796211551*
1307 68A4 GB
For the very latest copy of literature for specification purposes please visit our website
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from book reference.................17962.1155.1 4206
F Page 10 -- Sentinel company name & address amended
Caradon Ideal Limited reserve the right to vary specification without notice
3
mini HE --- Installation & Servicing
GENERAL
Ta b l e 1 --- B o i l e r D a t a
mini HE C24
mini HE C28
mini HE C32
Gas supply type & connection
II
G20 20mbar, G31 37mbar, 22 mm copper
2H3P
Inlet / Outlet connection --- Domestic Hot Water
Flow & return connection --- Central Heating
15 mm copper
22 mm copper
100 (4)
Flue terminal diameter
Average Flue Temp. --- Mass Flow Rate
Max working pressure (sealed system)
Max DHW water inlet pressure
Min DHW water inlet pressure
Electrical supply
mm (in.)
Deg C
|
2
g/s
90
18.8
90
21.1
3.0 (43.5)
90
21.5
bar (lb/in )
2
bar (lb/in )
10.0 (145.0)
0.3 (4.4)
2
bar (lb/in )
230 Vac 50 Hz
150
Max power consumption
External fuse rating
W
140
150
3 A
Internal fuse rating
F1---F2 3.15 AF
2.2 (0.48)
0.2 (0.044)
44.5 (98.1)
Water content --- CH
litre (gal.)
litre (gal.)
kg (lb.)
2.1 (0.46)
42.5 (93.7)
37.5 (82.7)
2.2 (0.48)
Water content --- DHW
Dry weight
44.5 (98.1)
39.5 (87.1)
Size: Height / Width / Depth
Lift weight
mm (in.)
kg (lb.)
803 (31 5/8”) / 400 (15 3/4”) / 345 (13 9/16”)
39.5 (87.1)
Ta b l e 2 --- P e r f o r m a n c e D a t a --- C e n t r a l H e a t i n g
mini HE C24
mini HE C28
Max
mini HE C32
Max
Max
Min
Min
Min
Burner pressure (Hot)
G20 mbar
G31 (in.w.g.)
10.8 (4.3)
35.5 (14.2)
1.5 (0.6)
7.7 (3.1)
10.0 (4.0)
36.0 (14.4)
1.6 (0.6)
7.7 (3.1)
13.0 (5.2)
36.0 (14.4)
2.7 (1.1)
7.3 (2.9)
Input based on nett CV
Input based on gross CV
kW (btu/h) 25.0 (85 295) 11.0 (37 530) 29.0 (98 942)
13.0 (44 353) 33.3 (113 620) 15.7 (53 568)
kW (btu/h) 27.7 (94 516) 12.2 (41 628) 32.2 (109 871) 14.4 (49 135) 37.0 (126 244) 17.4 (59 368)
Output Non Condensing G20 kW (btu/h) 24.6 (83 973) 10.2 (34 936) 28.3 (96 488)
G31 23.7 (80 894) 10.2 (34 936) 27.4 (93 599)
12.1 (41 284) 32.2 (109 866) 15.0 (51 180)
12.1 (41 284) 32.2 (109 866) 15.0 (51 180)
Output Condensing
G20 kW (btu/h) 26.6 (90 754) 11.1 (37 871) 30.7 (104 602) 13.2 (44 965) 34.4 (117 374) 15.6 (53 227)
G31 26.6 (90 754) 10.8 (36 997) 30.7 (104 602) 12.9 (44 016) 34.4 (117 374) 15.6 (53 227)
3
Gas consumption (Hot) G20 l/s (ft /h)
G31 l/s
0.72 (91.5)
0.30
0.31 (39.5)
0.13
0.83 (105.5)
0.34
0.37 (47.0)
0.14
0.95 (121.0)
0.39
0.45 (57.2)
0.18
Seasonal efficiency*
G20 (SEDBUK)
G31
Band B 87.7
Band B 87.0
Band B 87.6
Band B 87.1
Band B 86.8
Band B 88.8
%
NOx classification
Class 2
*The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been certified by a notified body.
Ta b l e 3 --- P e r f o r m a n c e D a t a --- D o m e s t i c H o t W a t e r
mini HE C24
mini HE C28
mini HE C32
Maximum
Burner pressure (Hot)
G20
G31
mbar
(in.w.g.)
10.8 (4.3)
35.5 (14.2)
10.0 (4.0)
36.0 (14.4)
13.0 (5.2)
36.0 (14.4)
Input based on nett CV
Input based on gross CV
kW (btu/h)
kW (btu/h)
kW (btu/h)
25.0 (85 295)
27.7 (94 516)
29.0 (98 942)
32.2 (109 871)
33.3 (113 620)
37.0 (126 244)
Output Non Condensing G20
G31
24.6 (83 973)
23.7 (80 894)
28.3 (96 488)
27.4 (93 599)
32.2 (109 866)
32.2 (109 866)
Output Condensing
G20
G31
kW (btu/h)
26.6 (90 754)
26.6 (90 754)
30.7 (104 602)
30.7 (104 602)
34.4 (117 374)
34.4 (117 374)
3
Gas consumption (Hot) G20
G31
l/s (ft /h)
0.72 (91.5)
0.30
0.83 (105.5)
0.34
0.95 (121.0)
0.39
l/s
Flow 35 ûC temp. rise
l/m (gpm)
10.0 (2.2)
11.9 (2.6)
11.7 (2.6)
13.9 (3.1)
13.1 (2.9)
14.6 (3.3)
Domestic hot water specific rate l/m (gpm)
Note: the gas consumption is calculated using a calorific
Key to Symbols:
3
3
3
value of 38.7 MJ/m (1038 Btu/ft ) gross or 34.9 MJ/m (935
3
Btu/ft ) nett.
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
To obtain the gas consumption at different calorific value:---
C
C
C
= a room sealed appliance designed for
12 32 52
a. FOR L/S --- divide the gross heat input (kW) by the gross
connection via concentric ducts to a horizontal or vertical
terminal or twin flue system.
3
C.V. of the gas (MJ/m )
3
b. FOR FT /H --- divide the gross heat input (Btu/h) by the
II
= appliance designed for use on 2nd family gas group
2H3P
3
gross C.V. of the gas (Btu/ft )
H or 3rd family gas group 3P
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning
of this appliance care should be taken handling edges of sheet steel components.
4
mini HE --- Installation & Servicing
GENERAL
CONTENTS
mini HE
Boiler size
G.C. appliance No.
(Benchmark No.)
PI No.
Air supply
9
Benchmark Commissioning Checklist
Boiler clearances
Boiler exploded view
Electrical connections
Electrical supply
62
6
mini HE C24
mini HE C28
mini HE C32
47---348---38
47---348---39
47---348---41
87BQ81
87BQ81
87BQ81
14
25
10
51
27
16
33
7
Destination countries: GB, IE
Fault finding
Flow wiring diagram
Flue fitting
Gas conversion
Gas safety regulations
Gas supply
8
Installation
15
7
Mandatory requirements
Replacement of components
Safe handling
38
7
Servicing
34
59
12
23
9
Short list of parts
Thermostatic radiator valves
Water connections
Water treatment
Wiring diagrams
26
For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer’s instructions. Self---certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
BENCHMARK COMMISSIONING CHECKLIST DETAILS
Boiler
Page
Boiler
Page
Burner operating pressure
Central heating flow temp.
Central heating return temp.
measure and record
measure and record
measure and record
Make and model
5
14
4
Appliance serial no. on data badge
SEDBUK No. %
For combination boilers only
Controls
Scale reducer
Hot water mode
Heat input
Max. operating burner pressure
Max. operating water pressure
Cold water inlet temp
Hot water outlet temp.
Water flow rate at max. setting
12
Time and temperature control to heating
Time and temperature control to hot water
Heating zone valves
TRV’s
Auto bypass
28/29
28/29
N/A
12
to be calculated
measure and record
measure and record
measure and record
measure and record
measure and record
12
Boiler interlock
12
For all boilers
Flushing to BS.7593
Inhibitor
9
9
For condensing boilers only
Condensate drain
24
Central heating mode
For all boilers:
complete, sign & hand over to customer
Heat input
to be calculated
For assistance see Technical Helpline on the back page
NOTE TO THE INSTALLER: COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
5
mini HE --- Installation & Servicing
GENERAL
1
BOILER WATER CONNECTION
Pipe size
O.D. mm
CH flow
22
22
22
15
15
CH return
Gas inlet
Wall
mounting
Plate
400
DHW cold inlet
DHW hot outlet
50
257
35
16
Condensate
drain
connection
area
Side and Rear Flue
2
BOILER CLEARANCES
All dimensions in mm (in.)
a. Provided that the flue hole is cut accurately, e.g. with a core
drill, the flue can be installed from inside the building where
wall thickness does not exceed 600 mm (24”).
The following minimum clearances must be maintained for
operation and servicing. Additional space will be required for
installation, depending upon site conditions.
Where the space into which the boiler is going to be installed
is less than the length of flue required the flue must be fitted
from the outside.
200 (7 7/8”)
installation from inside ONLY
b. If a core boring tool is to be used inside the building the
space in which the boiler is to be installed must be at least
wide enough to accommodate the tool.
25 (1”)
50 (2”)
273 (10 3/4”) 127 (5”)
190 (7 1/2”)
200 (7 7/8”)
Bottom clearance
The bottom clearance, after installation, can be reduced to
20mm. However, 200mm must be available for servicing.
Front clearance
The minimum front clearance when built into a cupboard is
50mm (2”) from the cupboard door. However 450mm
(17 3/4”) overall clearance is still required, with the cupboard
door open, to allow for servicing.
6
mini HE --- Installation & Servicing
GENERAL
During all manoeuvres and handling actions, every attempt
INTRODUCTION
mini HE C24, mini HE C28 and mini HE C32 are wall
mounted, low water content, balanced flue, condensing
combination gas boilers.
should be made to ensure the following unless unavoidable
and/or the weight is light.
F Keep back straight.
F Avoid twisting at the waist.
Central heating (CH) output and domestic hot water (DHW)
output are both fully modulating:
F Avoid upper body/top heavy bending.
F Always grip with the palm of the hand.
F Use designated hand holds.
F Keep load as dose to the body as possible.
F Always use assistance if required.
--- between 10.2 (34 936) and 24.6* (83 973) kW (btu/h) for
model mini HE C24;
--- between 12.1 (41 284) and 28.3* (96 488) kW (btu/h) for
model mini HE C28.
DHW OPERATION
--- between 15.0 (51 180) and 32.2* (109 866) kW (btu/h) for
model mini HE C32.
With no call for CH the boiler fires only when DHW is drawn
off. When there is a call for CH, the heating system is supplied
at the selected temperature until DHW is drawn off. The
output is then directed by the diverter valve to heat the
secondary heat exchanger and supply a maximum draw---off
of:
* outputs for G31 (propane) are slightly different. See section
Boiler Data at page 4 for detailed figures.
Due to the high efficiency of the boiler a plume of water
vapour will form at the terminal during operation.
mini HE C24 10.0 (2.2) l/min (gpm) at 35 degree rise.
mini HE C28 11.7 (2.6) l/min (gpm) at 35 degree rise.
mini HE C32 13.1 (2.9) l/min (gpm) at 35 degree rise.
The boilers are suitable for connection to fully pumped,
pressurised sealed water systems ONLY.
A system bypass is not required when TRV’ s are fitted to all
radiators (see Frame 5). The boiler incorporates an automatic
bypass.
The nominal DHW temperature is 55 ûC, but water drawn off
when the boiler has been on for central heating may be hotter
than this, for a short period of time.
A circulating pump, pressure gauge, safety valve and heating
expansion vessel are provided.
GAS SAFETY
The CH flow temperature is controlled by a temperature
probe. In DHW mode the boiler modulates to sustain a
nominal adjustable water flow temperature of 55 ûC.
Current Gas Safety (Installation and Use)
Regulations or rules in force
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
The boiler casing is of white painted mild steel with a
drop---down controls access door.
The boiler temperature control is located behind the control
panel door.
The main heat exchanger is made of copper.
F Gas Safety (Installation and Use) Regulations
F The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland),
Building Regulations (Northern Ireland).
The condensing heat exchanger (recuperator) and the DHW
heat exchanger are stainless steel.
The system pipework must include drain cocks in appropriate
places. Pipework may be taken downwards.
F The Water Fittings Regulations or Water byelaws in
Scotland.
For upwards pipework installation an additional frame
(optional) must be used (see frame 25).
F The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
OPTIONAL EXTRA KITS
Programmer Kit fits neatly within the casing. Separate fitting
instructions are included with the kit. Note. If using an
alternative programmer read Frame 33 first.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current edition of
I.S.813 ”Domestic Gas Installations”, the current Building
Regulations and reference should be made to the current
ETCI rules for electrical installation.
Horizontal Concentric Extension Ducts
Up to 2,7 m (8’ 10”) for mini HE C24, mini HE C28 models.
Up to 1,8 m (5’ 11”) for mini HE C32 model.
Other available kits are listed in frame 9.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS 5440:1
Flues (for gas appliances of rated input not
exceeding 70 kW).
SAFE HANDLING
BS 5440:2
Ventilation (for gas appliances of rated input
not exceeding 70 kW).
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler
may include the use of a sack truck and involve lifting,
pushing and pulling.
BS. 5449
BS. 5546
Forced circulation hot water systems.
Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)
Caution should be exercised during these operations.
BS 6700
BS. 6798
BS. 6891
Design, installation testing and maintenance of
services supplying hot water for domestic use.
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions
should be considered:
Installation of gas fired hot water boilers of
rated input not exceeding 70 kW.
F Grip the boiler at the base.
F Be physically capable.
Low pressure installation pipes.
F Use PPE as appropriate, e.g. gloves, safety footwear.
Health & Safety Document No. 635.
7
mini HE --- Installation & Servicing
GENERAL
The Electricity at Work Regulations, 1989.
F For the minimum clearances required for safety and
subsequent service, see the wall mounting template and
frame 2. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
The manufacturers notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Caradon Ideal Ltd. in writing. If in doubt
please enquire.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used
without prior consultation with the local gas supplier.
Natural gas boilers must be installed on a gas supply with a
governed meter. A gas meter can only be connected by the
local gas supplier or by a registered CORGI engineer.
Any direct connection of a control device not approved by
Caradon Ideal Ltd. could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas
Safety Regulations and the above regulations.
Propane gas boilers MUST be installed with pipes, cylinders
and pressure regulators fitted in accordance with BS.5482.1.
Bulk tank installations MUST comply with the Home Office
code of practice for storage of liquefied petroleum gas at fixed
installations. The complete installation MUST be tested for
gas tightness and purged as described in the above code.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler in its
manufacture.
The boiler is adjusted at the factory for use with the relevant
supply gas. A working gas pressure equal to that stated in
Table 1 MUST be available at the boiler inlet.
LOCATION OF BOILER AND FLUE OUTLET
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
Where applicable, the appliance can be converted for
G20 --- N atural Gas or G31 --- Prop ane Gas b y using the
appropriate conversion kit.
IMPORTANT Installation pipes MUST be fitted in accordance
with BS. 6891. In IE refer to I.S. 813.2002.
Pipework from the meter to the boiler MUST be of an
adequate size, i.e. not less than 22 mm O.D. copper or 3/4”
BSP iron.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary, unless
required by the local authority.
The boiler must not be fitted outside.
Timber Framed Buildings
FLUE INSTALLATION REQUIREMENTS
The flue must be installed in accordance with the
recommendations of BS. 5440---1 2000.
In IE refer to I.S. 813.2002.
If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7, 1998.
The following notes are intended for general guidance.
Bathroom Installations
1
2
3
The boiler MUST be installed so that the terminal is
exposed to external air.
It is important that the position of the terminal allows the
free passage of air across it at all times.
Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in
Table 4.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of
the current I.E.E. (BS.7671) Wiring Regulations and, in
Scotland, the electrical provisions of the building regulations
applicable in Scotland with respect to the installation of the
boiler in a room or internal space containing a bath or shower.
For Ireland reference should be made to the current ETCI
rules for electrical installations and I.S.813:2002
4
5
6
Where the lowest part of the terminal is fitted less than 2m
(6’6”) above a balcony, above ground or above a flat roof
to which people have access then the terminal MUST be
protected by a purpose designed guard.
Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains electricity
should be so situated that it cannot be touched by a person
using the bath or shower.
Ensure that the guard is fitted centrally.
Where the terminal is fitted within 850mm (34”) of a plastic
or painted gutter or 450mm (18”) of painted eaves then an
aluminium shield at least 750mm (30”) long should be
fitted to the underside of the gutter or painted surface
fitted centrally above the flue.
The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1”) to
combustible material. Detailed recommendations on the
protection of combustible material are given in BS.
5440---1:2000. In IE refer to I.S. 813.2002.
Note. It is not permissible to install a mains socket in a
bathroom.
Where installation will be in an unusual location, special
procedures may be necessary and BS 6798 gives detailed
guidance on this aspect.
Compartment Installations
A compartment used to enclose the boiler should be
designed and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
Table 4 --- Balanced flue terminal position
Terminal position Minimum spacing
1
2
Directly below, above or along side 300 mm (12”)
of an openable window, air vent or
other ventilation opening
In both cases details of essential features of cupboard /
compartment design, including air cupboard installation, are
to conform to the following:
Below guttering, drain pipes or soil 25 mm ( 1”) ***
pipes
F BS 6798 (No cupboard ventilation is required --- see “Air
supply” for details)
3
4
Below eaves
25 mm ( 1”) ***
25 mm ( 1”) ***
F The position selected for installation MUST allow
Below balconies or a car port roof
adequate space for servicing in front of the boiler.
8
mini HE --- Installation & Servicing
GENERAL
WATER CIRCULATION SYSTEM
5
6
From vertical drain pipes or soil
pipes*
25 mm ( 1”) ***
The boilers are designed for connection to pressurised, fully
pumped, sealed water central heating systems ONLY. The
domestic hot water (DHW) calorifier is incorporated within the
combi boiler and only requires connection to the mains water
supply.
From an internal or external corner 25 mm ( 1”) ***
or to a boundary along side the
terminal
7
8
9
Above adjacent ground, roof or
balcony level
300 mm (12”)
600 mm (24”)
1200 mm (48”)
Additional Pumps.
The boiler is supplied with an integral circulating pump. If the
boiler is to be used in conjunction with any additional
circulating pumps, please contact the Technical Helpline for
advice on application.
From a surface or a boundary
facing the terminal.
From a terminal facing a terminal
10 From an opening in a car port (e.g. 1200 mm (48”)
door or window) into dwelling
IMPORTANT
A minimum length of 1m of copper pipe MUST be fitted to
both flow and return connections from the boiler before
connection to any plastic piping.
11 Vertically from a terminal on the
same wall
1500 mm (60”)
Ensure that the mains water supply pressure is adequate to
provide the required DHW flow rate. Refer to Table 1 on
page 4.
12 Horizontally from a terminal on the 300 mm (12”)
wall
* If the terminal is within 150mm of any vertical soil or drain
pipe, an aluminium shield at least 400mm (15 3/4”) long
should be fitted equi---distant from the terminal and close to
the pipe.
The central heating system should be in accordance with BS.
6798 and, in addition, for smallbore and microbore systems
BS. 5449.
The domestic hot water system should be in accordance with
BS. 5546 and BS. 6700.
*** Only 1 spacing down to 25mm is allowable per
installation.
Copper tubing to BS 2871:1 is recommended for water
carrying pipework and MUST be used for pipework carrying
potable water.
Vertical Terminals
13 Above the roof pitch with roof
slope of all angles.
300 mm (12”)
Any soldered joints on potable water pipework MUST NOT be
made with solder containing lead.
300 mm (12”)
600 mm (24”)
Above flat roof
Ancillary pipework not forming part of the useful heating
surface should be lagged to prevent heat loss and any
possible freezing --- particularly where pipes run through roof
spaces or ventilated underfloor spaces.
14 From single wall face
1000 mm (40”)
From corner wall faces
Draining taps should be at least 1/2” BSP nominal size and
be in accordance with BS 2879.
Twin Flue Applications
15 Centre distance between air inlet
and flue outlet ducts
120mm (5”) **
WATER TREATMENT
Central Heating
** Where the twin flue ducts are positioned at or near the above
minimum centres the wall sealing gaskets should be trimmed to
allow them to fit flat to the wall. This should be done for both in-
side and outside wall gaskets
Antifreeze fluid, corrosion and scale inhibitor fluids suitable for
use with boilers having copper heat exchangers may be used
in the central heating system.
IMPORTANT
Terminals guards are available from boiler suppliers --- ask for
Tower Flue Guard, Model K6. In case of difficulty seek advice
from:
The application of any other treatment to this product
may render the guarantee of Caradon Ideal Limited
INVALID.
Grasslin UK Ltd.,Tower house, Vale Rise, Tonbridge,
Kent TN9 1TB Tel. +44 (0) 1732 359 888 Fax No. +44 (0)
Caradon Ideal Limited recommend Water Treatment in
accordance with the Benchmark Guidance Notes on Water
Treatment in Central Heating Systems.
Caradon Ideal Limited recommend the use of Fernox, GE
Betz Sentinel or Salamander water treatment products, which
must be used in accordance with the manufacturers
instructions.
IMPORTANT It is absolutely ESSENTIAL to ensure, in
practice, that products of combustion discharging from the
terminal cannot re---enter the building or any other adjacent
building through ventilators, windows, doors other sources of
natural air infiltration, or forced ventilation / air conditioning.
Notes.
1. It is most important that the correct concentration of the
water treatment products is maintained in accordance with
the manufacturers’ instructions.
If this should occur the appliance MUST be turned OFF,
labelled as “unsafe” until corrective action taken.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
BS 7593:2006 details the steps necessary to clean a
domestic heating system.
AIR SUPPLY
It is NOT necessary to have a purpose---provided air vent in
the room or internal space in which the boiler is installed.
Neither is it necessary to ventilate a cupboard or
compartment in which the boiler is installed, due to the low
surface temperatures of the boiler casing during operation;
therefore the requirements of BS6798, Clause 12, BS 5440:2
and in IE I.S. 813:2002 may be disregarded.
3. In hard water areas, treatment to prevent lime scale may be
necessary --- however, the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
9
mini HE --- Installation & Servicing
GENERAL
Domestic Hot Water
Fernox
Calmag Ltd.
Cookson Electronics
Forsyth Road
Sheerwater
Unit 4---6 Crown Works
Bradford Road
Sandbeds
In hard water areas where mains water can exceed 200ppm
Total Hardness (as defined by BS 7593:2006 Table 2) a scale
reducing device should be fitted into the boiler cold supply
within the requirements of the local water company. The use
of artificially softened water, however, is NOT permitted.
Woking
Keighley
Surrey
West Yorkshire
BD20 5LN
+44 (0) 1535 210320
GU21 5RZ
Caradon Ideal Limited recommend the use of Fernox
Qantomat, Sentinel Combiguard and Calmag CalPhos I scale
reducing devices, which must be used in accordance with the
manufacturers’ instructions.
+44 (0) 1799 550811
Salamander (Eng) Ltd
Reddicap Trading Estate
Sutton Coldfield
West Midlands
Sentinel Performance
Solutions
For further information contact:
The Heath Business &
Technical Park
Runcorn
B75 7BY
Cheshire
WA7 4QX
+44 (0) 121 378 0952
+44 (0) 800 389 4670
The point of connection to the mains should be readily
accessible and adjacent to the boiler, except for bathroom
installations where the point of connection to the mains MUST
be situated outside of the bathroom.
3
ELECTRICAL SUPPLY
Warning. This appliance must be efficiently earthed.
Note. Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains
electricity should be so situated that it cannot be touched by
a person using the bath or shower.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be
made to the current ETCI rules for electrical installations.
4
Filling the system
4
SEALED SYSTEM REQUIREMENTS
Central Heating
Fill the system through a temporary hose connection from a
draw---off tap supplied from a service pipe under mains
pressure. Where the mains pressure is excessive a pressure
reducing valve shall be used to facilitate filling.
Note. mini HE boilers are suitable for fully pumped
pressurised sealed systems only.
When installing the filling connection provided with the boiler
an additional WRAS approved valve must be fitted to the
mains water supply upstream of the double check valve to
fully comply the Water Regulations
REQUIREMENTS
1
General
The installation must comply with the requirements of
BS. 6798 and BS. 5449.
Stop valve
Additional stop valve
Hose unions
2
Flow Temperature
Mains
Water
Supply
The installation should be designed to work with flow
temperatures of up to 90 ûC.
3
Working Pressure
Double check valve
assembly
Temporary hose
All components of the system must be suitable for a working
(disconnect
after filling)
2
pressure of 3 bar (45 lb/in ) and temperature of 110 ûC. Extra
Note direction of flow
care should be taken in making all connections so that the
risk of leakage is minimised.
System filling and make---up
The following components are incorporated within the
appliance:
Proceed with the following:
a. Circulating pump.
F Thoroughly flush out the whole of the system with cold
water before fitting the boiler.
b. Safety valve; with a non---adjustable pre---set lift pressure of
F Fill and vent the system until the pressure gauge registers
2
3 bar (45 lb/in ).
2
1.5 bar (22 lb/in ). Examine for leaks.
c. Pressure gauge; covering a range of 0---4 bar.
F Release water from the system until a pressure of 1 bar
2
(15 lb/in ) is reached.
d1. 6 litre expansion vessel; with an initial charge pressure of
To avoid getting debris on the valve seat, do not use
the safety valve to do this.
2
0.7 bar (10.5 lb/in ) for mini HE C24 and mini HE C28.
F Light the boiler and heat the system to the maximum
d2. 7 litre expansion vessel; with an initial charge pressure of
2
working temperature. Examine for leaks.
1.0 bar (15 lb/in ) for mini HE C32.
F Turn off the boiler and drain the system while still hot.
F Refill and vent the system.
For further details refer to BS.5449:1 and the British Gas
Corporation publication ’Specifications for Domestic Central
Heating and Hot Water’.
F Re---pressurise the system to the desired charge pressure
(see Table 5).
10
mini HE --- Installation & Servicing
GENERAL
Table 5 mini HE C24, mini HE C28
Table 6 mini HE C32
System charge pressure
(bar)
0.5
0.7
1.0
System charge pressure
(bar)
0.5
0.7
1.0
Safety valve setting
3.0
0.7
Safety valve setting
3.0
0.7
Vessel pre---charge pressure
(bar)
Vessel pre---charge pressure
(bar)
System volume (litres)
Volume of expansion vessel
in addition to 6 litre unit
fitted to boiler
System volume (litres)
Volume of expansion vessel
in addition to 7 litre unit
fitted to boiler
75
---
0.3
---
0.8
---
1.4
75
---
---
---
---
---
0.4
100
125
150
175
200
225
250
275
300
100
125
150
175
200
225
250
275
300
1.8
2.5
3.2
0.8
1.6
2.3
3.4
4.2
5.0
2.5
3.4
4.1
5.0
6.0
7.0
4.0
5.1
6.0
6.5
7.6
8.7
5.6
6.8
7.8
8.1
9.3
10.6
12.4
14.3
16.1
0.074
7.2
8.6
9.7
9.6
11.1
12.8
14.5
0.069
8.8
10.3
12.0
13.7
0.069
11.5
13.4
15.2
0.074
11.2
12.8
0.063
10.3
11.9
0.063
Multiply this factor by
system volume and deduct
6 litres to obtain size of
additional vessel for other
system volumes.
Multiply this factor by
system volume and deduct
7 litres to obtain size of
additional vessel for other
system volumes.
For the system water expansion to be contained by the 7 litre
5
Size of expansion vessel
expansion vessel fitted to the following model:
For the system water expansion to be contained by the 6 litre
expansion vessel fitted to the following models:
mini HE C32
the cold system volume must not exceed:
111 litres when pressurised to 0.5 bar (cold)
101 litres when pressurised to 0.7 bar (cold)
95 litres when pressurised to 1.0 bar (cold)
mini HE C24, mini HE C28
the cold system volume must not exceed:
96 litres when pressurised to 0.5 bar (cold)
88 litres when pressurised to 0.7 bar (cold)
81 litres when pressurised to 1.0 bar (cold)
If the pressure exceeds 2.65 bar when the boiler is up to
temperature with all radiators in use then an additional
expansion vessel MUST be installed on the return pipework.
If the pressure exceeds 2.65 bar when the boiler is up to
temperature with all radiators in use then an additional
expansion vessel MUST be installed on the return pipework.
For expansion volumes see Table 6.
Guidance on vessel sizing is given in BS 7074:1 and BS 5449
For IE refer to the current edition of I.S. 813.
For expansion volumes see Table 5.
6
Hydraulic Loss
7
Draining the system
Remaining pump capacity
Draining taps MUST be located in accessible positions to
permit the draining of the whole central heating system,
including the central heating side of the boiler. The taps
should be at least 1/2” BSP nominal size and be in
accordance with BS 2879.
m H2O
6
5
4
3
2
1
0
0
200
400
600
800
1000
1200
1400
Flow rate l/hour
11
mini HE --- Installation & Servicing
GENERAL
For further information refer to “Good Practise Guide 143” a
5
BOILER CONTROL INTERLOCKS
publication of the energy efficiency office, available from the
building research establishment Garston Watford WD2 7JR
tel: +44 (0) 1923 664258
Thermostatic radiator valves.
Caradon Ideal Ltd. support the recommendations made by
leading manufacturers of domestic heating controls that
heating systems utilising full thermostatic radiator valve
control of temperature in individual rooms should also be
fitted with a room thermostat controlling the temperature in a
space served by radiators not fitted with such a valve as
stated in BS5449. Such an arrangement will provide for a
more efficient control of the environment and will also avoid
the continuous running of the circulation pump during
programmed heating ON periods, saving electrical energy.
The boiler is fitted with an automatic internal bypass. No
further system bypass is required.
Typical installation
TRV
TRV
Room
TRV
T/stat
It is therefore strongly recommended that, when thermostatic
radiator valves are used, the space heating temperature
control over a living/dining area or a hallway, having a heat
requirement of at least 10% of the boiler output, is achieved
using a room thermostat whilst other rooms are individually
controlled by thermostatic radiator valves as stated in
BS5449.
A
D
B
Balancing valve
5
When connecting to suitable showers, i.e. those designed
for modulating domestic hot water, ensure that:
6
DOMESTIC HOT WATER
REQUIREMENTS
The domestic hot water service must be in accordance
with BS 5546 and BS 6700.
For the minimum and maximum working pressures of the
mini HE C24, mini HE C28 and mini HE C32 domestic
hot water circuit refer to Table 1, page 4.
The cold water supply pipe should be flushed before
fitting the boiler.
a. The cold inlet to the boiler is fitted with an approved
anti---vacuum or syphon non---return valve.
1
2
b. Hot and cold supplies are of equal pressure.
6
Hard water areas
3
4
In areas where the water is ’hard’ it is recommended that
a proprietary scale---reducing device is fitted into the boiler
cold supply, within the requirements of the local water
company.
The boilers are suitable for connection to most types of
washing machine and dishwashing appliances.
12
mini HE --- Installation & Servicing
GENERAL
7
8
9
Central heating flow cock
By --- p ass v alv e
Central heating (CH) return cock
7
BOILER WATER CIRCUIT DIAGRAM
35
34
24
25
10 3 bar pressure relief valve
11 Gas cock
12 Expansion vessel
13 Gas valve inlet pressure tap
14 Modulating gas valve
15 Burner pressure tap
16 Flame detection electrode
17 Ignition electrodes
18 Burner
23
21
22
20
27
1
19
33
19 Combustion chamber
20 Primary heat exchanger
21 Fan
22 Air pressure switch
23 Venturi device
28
18
29
30
16
15
17
36
26
31
24 Flue outlet pipe
25 Air intake pipe
14
5
2
12
26 Automatic air vent
27 Overheat thermostat
28 Pump
29 Pump vent plug
30 CH temperature probe
31 CH flow switch
37
10
6
13
32
8
11
9
7
4
3
1
2
3
4
5
6
Domestic hot water (DHW) heat exchanger
Domestic hot water (DHW) flow switch
Domestic hot water (DHW) outlet pipe
Domestic cold water inlet cock
Three---way diverter valve
32 DHW temperature probe
33 CH circuit temperature/pressure gauge
34 Recuperator
35 Flue temperature probe
36 Condensate trap
37 Condensate drain pipe
Main circuit drainage cock
13
mini HE --- Installation & Servicing
INSTALLATION
8
B O I L E R A S S E M B LY ---
Exploded View
39 40
1
2
38
37
3
4
5
36
35
6
7
34
33
32
31
8
9
30
10
11
29
26
12
13
28
27
14
15
25
24
23
20 19
18
17
16
22
21
1
2
3
4
5
Air pressure switch
Recuperator
Condensate trap
Overheat thermostat
Condensing to main heat
exchanger connection pipe
14 DHW flow switch
15 DHW temperature probe
16 Right hand panel
17 Boiler front panel
18 Appliance data badge (inside)
19 Left hand panel
20 CH circuit pressure gauge
21 Model identification & instructions
22 Control panel door
23 Electronic control pcb
24 CH temperature probe
25 CH flow switch
28 3 way diverter valve
29 DHW heat exchanger
30 Bypass pipe
31 3 bar pressure relief valve
32 Gas valve
33 Gas valve outlet pipe
34 Injector manifold
35 Burner
6
7
8
9
Primary heat exchanger
Inner case cover
Flame detection electrode
Ignition electrodes
36 Flue hood
37 Fan
10 Heat exchanger return pipe
11 Auto air vent
12 Main circuit drainage cock
13 Pump
38 Expansion vessel
39 Venturi
26 Heat exchanger flow pipe
27 Return manifold
40 Flue temperature probe
14
mini HE --- Installation & Servicing
INSTALLATION
I
Turret---air pipe gasket
9
UNPACKING
J
K
L
Flue pipe gasket
Boiler---turret gasket
Flue turret
The boiler is supplied fully assembled in one pack A, together
with a standard flue assembly for lengths up to 960 mm
(37” 3/4), rear or side flue outlet, in pack B.
M Self tapping screws 4,8x13 --- 4 off
Unpack and check the contents.
N
O
Wall finishing gasket --- internal (plastic)
Wall finishing gasket --- external (rubber)
Pack A contents
A
B
C
D
E
F
The boiler.
O
N
Hardware pack
Wall mounting plate
Wall mounting template
User’s, Installation & Servicing instructions.
Filling loop assembly
M
L
G
H
D
A
I
J
K
Optional extras, if ordered, are available in separate boxes.
F Electronic programmer kits --- 24 hrs & 7 day
F Extension duct kit pack D (ø 60/100)
F Flue support kits ø 80, 100, 125
F Vertical outlet flue kit with elbow (ø 60/100)
F 90û Elbow kit (ø 60/100)
B
F 45û Elbow kit (ø 60/100)
E
F Roof flue kit (ø 80/125)
C
F Universal weather collar (for roof flue kit)
F Flat roof weather collar (for roof flue kit)
F Extension duct kit (ø 80/125)
F 90û Elbow kit (ø 80/125)
F
Hardware pack contents
F 45û Elbow kit (ø 80/125)
F 22 mm CH connection pipe --- 2 off.
F 22 mm Gas supply connection pipe --- 1 off.
F 15 mm DHW cold inlet connection pipe --- 1 off.
F 15 mm DHW hot outlet connection pipe --- 1 off.
F 1/2” connection nut --- 2 off.
F 1/2” sealing washer --- 3 off.
F 3/4” sealing washer --- 6 off.
F 3/4” Gas supply isolating valve --- 1 off.
F 3/4” CH circuit isolating valve --- 2 off.
F 1/2” DHW cold inlet isolating valve --- 1 off.
F Condense drain vertical (ø 80/125)
F Twin pipe kit (ø 80) with air and flue terminals
F Extension duct kit (ø 80)
F 90û Elbow kit (ø 80) male---female
F 45û Elbow kit (ø 80) male---female
F Vertical condense drain (ø 80)
F Horizontal condense drain (ø 80)
F Condense trap
F Stand---off bracket
F Natural gas to LPG conversion kit
F LPG to natural gas conversion kit
F Condensate pump kit
F High level flue outlet kit (mini HE C24, mini HE C28 only)
F Pre---piping frame
Pack B contents
G
Air intake pipe ø 100 mm (4”), flue pipe ø 60 mm (2” 3/8)
with terminal grille assembly
H
Centring spring
10 PACKAGING
To unpack the boiler refer to the instructions on carton end
flap.
15
mini HE --- Installation & Servicing
INSTALLATION
Cut the flue duct at the same level of the air duct edge.
11 FITTING THE FLUE SYSTEM
The minimum and maximum equivalent length for
c o --- a x i a l p i p e s ø 6 0 --- 1 0 0 a n d ø 8 0 --- 1 2 5 m m a r e g i v e n i n
Table 7 for mini HE C24 and mini HE C28 and in Table 8
for mini HE C32 .
Cut this end
The minimum and maximum equivalent length for ø 80
mm twin pipe systems are given in Table 9 for mini HE
C24 and mini HE C28 and in Table 10 for mini HE C32.
Groove
Horizontal Concentric
For roof flue systems having a flue length greater than
3m and all twin pipe systems, a condensate drain kit
must be fitted at the lowest point in the system. See the
list of optional extras (frame 9) for available drain kits.
Air duct
Rear Outlet
Wall thickness + 125 mm
Rear outlet+Stand---off Wall thickness + 160 mm
Refer to the assembly instructions contained within the
chosen flue kit packaging for the correct assembly and
installation.
Side Outlet --- RH
Side Outlet --- LH
Wall thickness + Gap +62 mm
Wall thickness + Gap +208 mm
The horizontal sections of flue pipes must have a slope
not less than 1.5 deg. (25 mm per metre) towards the
boiler.
Twin pipe flue kits
For calculation of total flue length, the distance MUST be
measured from the centreline of the flue duct/air duct
connection to the end of the flue outlet grille/air inlet duct.
In the flue kit of pack B the flue pipe is angled within the air
duct therefore the air duct must be horizontally installed.
If one or more extensions need to be used they must be
adequately supported so that there is no sag in the flue pipe
and a minimum fall of 1.5 deg. (25 mm per metre) over the
whole length towards the boiler is ensured.
For each additional 45û M&F and 90û M&F flue bend used,
the maximum permissible length of flue system must be
reduced by 0,9m or 1,65m respectively.
The restrictor to be used and the lengths of allowable
equivalent flue outlet / air inlet ducts are indicated in Table 9
for mini HE C24, mini HE C28, in Table 10 for mini HE C32
and in the following graph.
Table 7 mini HE C24, mini HE C28
Minimum
Co --- ax ial 60 --- 100 0.3 (11.8”)
Co --- ax ial 80 --- 125 0.5 (19.7”)
Maximum
The restrictor size is marked on its body.
2.7 (8’ 10”)
8.5 (27’ 10”)
N.B.: The air intake and the flue outlet must not terminate on
opposite sides of the building.
Air intake adapter
Table 8 mini HE C32
Minimum
Maximum
1.8 (5’ 11”)
6.0 (19’ 8”)
Restrictor
Gasket
Co --- ax ial 60 --- 100 0.3 (11.8”)
Co --- ax ial 80 --- 125 0.5 (19.7”)
Co---axial Flue kits.
Horizontal.
For calculation of total flue length, the distance MUST be
measured from the centreline of the concentric elbow to the
end of the terminal.
Vertical outlet
For calculation of total flue length, the distance MUST be
measured from the centreline of the outlet connector at the
boiler top panel to the end of the terminal grille.
Table 9mini HE C24, mini HE C28
Equivalent pipe length
(air duct + flue duct)
Restrictor
ø 50 mm
For each additional 45û and 90û flue bend used, the
maximum permissible length of flue system must be reduced
by 1 m or 1,5 m respectively.
Between 1 (39“) and 15 m (49’ 2”)
More than 15 m (49’ 2”) up to 30 m (98’ 5”) ø 55 mm
Cutting lengths of flue and air ducts
Measure the wall thickness and, when using a side outlet, the
gap between the inner wall and the boiler side casing.
Use the following chart to calculate the cutting length of air
duct.
Table 10mini HE C32
Equivalent pipe length
(air duct + flue duct)
Restrictor
ø 50 mm
Between 1 (39“) and 24 m (78’ 9”)
Mark the air duct making reference on the groove.
16
mini HE --- Installation & Servicing
INSTALLATION
For the correct use of the restrictors with twin pipes refer to
Cutting lengths of flue and air ducts
the following diagram for the models mini HE C24, and mini
Measure the wall thickness and, when using a side outlet, the
gap between the inner wall and the boiler side casing. Use
the following chart to calculate the cutting lengths of both flue
and air ducts.
HE C28.
Flue exhaust ”a”
32
30
28
26
24
22
Mark the air duct and flue duct making reference on the
groove.
20
Allowed values
18
16
14
12
Groove
Groove
Restrictor
55 mm
10
8
Twin Pipe
6
Restrictor
50 mm
Air duct
4
2
Rear Outlet
Wall thickness + 130 mm
0
Rear outlet+Stand---off Wall thickness + 165 mm
0
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32
Air intake ”b”
Side Outlet --- RH
Side Outlet --- LH
Flue Duct
Wall thickness + Gap + 187 mm
Wall thickness + Gap + 93 mm
Refer to the following diagram for the model mini HE C32.
Flue exhaust ”a”
32
30
28
26
24
22
Rear Outlet
Wall thickness + 130 mm
Rear outlet+Stand---off Wall thickness + 165 mm
Side Outlet --- RH
Side Outlet --- LH
Wall thickness + Gap +67 mm
Wall thickness + Gap + 213 mm
20
Allowed values
18
16
14
12
10
8
6
Restrictor
4
2
0
50 mm
0
2
4
6
8
10 12 14 16 18 20 22 24 26 28 30 32
Air intake ”b”
12 REAR FLUE ASSEMBLY
1
Legend
2
1
2
3
4
5
6
7
8
9
Wall finishing gasket --- external (rubber)
Self tapping screw 4,2x13
Flue turret
Boiler---turret gasket
Flue pipe gasket
Turret---air pipe gasket
Centring spring
Air/flue pipe with terminal grille assembly
Wall finishing gasket --- internal (plastic)
3
9
8
7
4
6
5
17
mini HE --- Installation & Servicing
INSTALLATION
13 WALL MOUNTING TEMPLATE
(rear flue)
IMPORTANT
b
Detailed installation steps are given directly on the wall
mounting template
1
2
3
Tape the template into the selected position.
Ensure squareness by hanging a plumbline.
Mark onto the wall the following:
a. the wall mounting plate screw positions
b. the position of the flue duct.
(Mark the centre of the hole as well as the circumference)
a
4
Remove the template from the wall
14 WALL MOUNTING TEMPLATE
(side flue)
Extended centre
IMPORTANT
Detailed installation steps are given directly on the wall
mounting template
Spirit level
1
2
3
Tape the template into the selected position.
Ensure squareness by hanging a plumbline.
Mark onto the wall the following:
a. the wall mounting plate screw position
b. Extend the centre line as shown.
Mark the flue duct centre from the corner (see diagram
and template)
Note. mark the centre of the hole as well as the
circumference.
If extension duct kit pack D has to be used, the pipes must
have the correct slope as detailed in frame 11.
4
Remove the template from the wall
15 DRILLING THE WALL
Rear flue shown
5” diameter
flue hole
IMPORTANT
Ensure that, during the cutting operation, masonry falling
outside the building does not cause damage or personal
injury.
1
Cut the flue hole (preferably with a 5” core boring tool),
ensuring that the hole is square to the wall.
2
Drill the fixing holes with an 8mm (5/16”) masonry drill.
Fit suitable wall plugs (not provided).
Note. If the teminal is to be sited within 25---40 mm of a
corner or vertical pipe (refer to Table 4) then the hole MUST
be accurately cut and the rubber weather seal trimmed.
Section
through wall
Note: Check all of the hole
positions before drilling.
18
mini HE --- Installation & Servicing
INSTALLATION
16 CUTTING THE FLUE
Notes.
A
If using the extension ducts go to Frame 17.
B
If stand---off frame is used it is essential this is taken into
consideration when marking the flue (see Frame 11).
1
2
Measure and note the wall thickness.
For side flues measure and note the gap between the
casing and wall.
3
From the table in Frame 11, determine the flue length
required. Mark and cut both outer and inner tube.
Ensure the support spring clip is in position to facilitate
cutting.
Measure from
this
RING
4
To ensure the tube is cut square, mark the flue all the way
around.
17 FITTING THE EXTENSION KITS
1
1
2
3
Fit the inner flue extension duct onto the inner flue duct.
Fit the outer flue extension duct onto the outer air duct.
Repeat steps 1 and 2 if a second flue extension is
required.
2
4
Measure and mark the flue length required onto the flue,
measuring from the ring near the terminal. (Refer to Frame
11 for the detail of flue length calculation).
Measure from
this
RING
5
6
To ensure a square cut, mark the flue all the way around.
De --- b urr the cut ed ges.
19
mini HE --- Installation & Servicing
INSTALLATION
If the offset vertical option is used an elbow Kit is required. For
a full accessories list refer to Frame 9, Optional Extras.
18 FITTING THE OPTIONAL ROOF FLUE
KIT (Flat or Pitched)
Note.
A flat or pitched roof flashing plate (not supplied) is required
before proceeding with the installation of this kit.
This kit is suitable for both flat and pitched roof terminations,
using a concentric flue to run vertically from the top of the
boiler and terminating above roof level.
Connection to the top of the boiler is made using a separately
supplied vertical connector.
WEATHER PROOFING
Where the flue passes through the roof line an adequate seal
must be made. This is achieved by using either:
--- Flat roof weather collar
--- Universal weather collar.
ACCESSORIES
Flue Duct Extension Kits are available for flue lengths
extending beyond 1m. These packs contain 1m extension
ducts and may be cut to the desired length.
G
19 ROOF FLUE KIT
CONTENTS/OPTIONS
H
I
A
B
C
D
E
F
G
H
I
Flue assembly with terminal
Flue seal collar
3,5X13 screw
Pitched roof tile/flat roof tile weather collar
Vertical connector (80/125)
Retention screws
F
E
Roof flue extension duct kit (80/125)
90û elbow kit (80/125)
45û elbow kit (80/125)
A
D
C
B
20
mini HE --- Installation & Servicing
INSTALLATION
20 FLUE TERMINAL POSITION
The terminal should be positioned so that products of
combustion can safely disperse at all times.
Pluming may occur at the termination so, where possible,
terminal positions where this could cause a nuisance
should be avoided.
*
Minimum dimensions are shown below.
610 mm
min.
610 mm
min.
Terminal Position
Minimum Dimension
Directly below an opening,
air brick, windows, etc.
300 mm
300 mm
Below plastic / painted
gutters
Painted surface
300 mm
500 mm
Below eaves or balcony
21 FLUE ARRANGEMENT
80/125
Quantity
Part No.
Description
C24 C28 C32
n/a
Maximum Flue Length 8.5 8.5
(m)
6
201 548
Flue ext. 80/125
7
1
7
1
5
1
201 547 Terminal Vertical Roof
80/125
158 431 Weather Collar Pitched
Roof
1
1
1
1
1
1
158 432
Weather Collar Flat
Roof
201 550 90û Elbow kit (80/125)
4
4
1
4
4
1
4
4
1
201 551 45û Elbow kit (80/125)
202 708
Vertical Connector
Note.
The equivalent flue length resistance of the 90û elbow kit
(80/125) is 1.5 m and the 45û elbow kit (80/125) is 1.0 m.
21
mini HE --- Installation & Servicing
INSTALLATION
22 ASSEMBLING THE ROOF FLUE KIT
Determine the correct height that the flue should terminate
above the roof. If after calculating or measuring the overall
flue height from the top of the boiler, it is necessary to cut
both pipes of assembly A, then ensure they are cut equally
leaving the inner flue tube longer than the outer air tube as
supplied. (Refer to No. 6 below)
F
E
2
3
A
Ø 60
Ensure the cut pipe ends are free from any burrs.
A
Ø 100
1
Ensure the flue seal collar B is located onto the flue
assembly A.
D
2
Position the roof flashing plate D (supplied separately)
over the hole cut in the roof and insert flue assembly A
from the roof end.
D
3
Push fit the vertical connector E (supplied separately) into
the boiler flue connection and retain with the screws F
(supplied with the vertical connector kit). ENSURING THE
GASKETS IN THE BOILER FLUE OUTLET ARE
CORRECTLY FITTED.
4
5
“Push” fit extension duct J (if required (supplied
separately)) and the roof flue kit assembly A into the
connector E.
If the last extension duct requires cutting, measure the
distance (outer ducts) between the duct and the terminal
and add 100 mm to this dimension. This gives the length
of the last extension duct.
4
J
NOTE. Check the position of the inner flue duct relative to the
outer duct on the assembled extension duct(s) and ensure the
terminal flue duct is cut longer than the air duct to ensure
engagement in the final flue duct seal.
E
6
Slide down and position the flue seal collar B over the roof
plate D and secure it with the three screws C to the flue
assembly A.
7
8
Finally ensure the roof flashing plate D is correctly sealed
to the roof.
Flue over 3 meters long.
5
For flues over 3 m long a conensate drain and trap must
be fitted. The trap must be connected to a suitable waste
pipe. See frame 9 for available trap kit.
1
6
A
MAX LENGTH:
C24 --- 8. 5 m
C28 --- 8. 5 m
C32 --- 6 m
A
A
C
C
B
B
B
D
22
mini HE --- Installation & Servicing
INSTALLATION
23 FITTING THE WALL
MOUNTING PLATE
Refer to frame 25 for service connections.
Fit the wall mounting plate
Directly to the wall
F Offer up wall mounting plate.
F Screw through the fixing holes using 3 off no. 14x2”
screws (not provided).
F Check alignment with spirit level.
F Tighten screws.
24 MOUNTING THE BOILER
A
Lift the boiler onto the wall mounting plate locating the bar at
the rear of the back panel assembly into the bracket.
As added protection, the boiler should be lifted with the lower
polystyrene packaging in place.
Lower the boiler into position.
Remove the lower packaging. Remove the front and side
panels (refer to frame 30) and strip off the protective coating.
The panels may be placed to one side and re---fitted when the
installation is complete.
Note. Before fitting the flue system, fill the condensate trap
within the boiler by pouring a cupful of water into the flue
outlet A. Take care to ensure that the water is only poured into
the flue outlet, and does not spill into the boiler casing.
Fit the flue system referring to the instructions contained with
the kit.
Make good the internal wall surface using the seal provided.
25 CONNECTIONS
Fit the service valves, washers and tail pipes as shown.
Central Heating flow
Domestic hot
water outlet
Gas inlet
Domestic cold
water inlet
Central Heating return
Connect to the tail pipes by proprietory fittings.
The pipework may be directed down or through the rear wall
as required.
The pipework may be directed upwards by using the optional
stand off bracket kit. See illustration for upward pipework
routing
23
mini HE --- Installation & Servicing
INSTALLATION
1
26 CONNECTING THE FLUE TO THE
BOILER
2
145
Note. Before fitting the flue turret fill the condensate trap or
siphon trap within the boiler by pouring a cupful of
water into the flue outlet. Take care to ensure that the
water is only poured into the flue outlet, and does not
spill into the boiler casing.
2
1
Insert the flue assembly through the prepared hole in the
wall (ensuring the 145mm minimum dimension is
maintained).
5
2
3
Fit the inner (plastic) and outer (rubber) wall gaskets to the
flue terminal pipe.
Locate the gasket and flue turret on the top of the boiler.
CHECK THAT THE FLUE SEAL LOCATED IN THE TOP
OF THE RECUPERATOR IS SECURE AND GIVING AN
EFFECTIVE SEAL.
4
3
4
5
6
Locate the flue into the turret and push to ensure full
engagement.
Secure the flue turret on top of the boiler using the four
screws provided.
Flues over 1 meter long.
Fix the flue support bracket to the wall, using the two wall
plugs and wood screws provided.
Pressure
27 SAFETY VALVE DRAIN
relief valve
The discharge pipe should be positioned so that the
discharge of water or steam cannot create a hazard to the
occupants of the premises or damage to electrical
components and wiring.
Discharge pipe
through freezing) of external drainage pipework does not give
rise to spillage within the dwelling.
28 CONDENSATE DRAIN
Refer also to the British Gas document: “Guidance Notes
for the installation of Domestic Gas Condensing Boilers”
(1989).
If a part of the drainpipe runs externally this part should be
kept as short as possible and protected to reduce the risk of
freezing.
The condensate drain provided on the boiler must be
connected to a drainage point, preferably within the building.
IMPORTANT
If excessive external pipework cannot be avoided an
additional condensate removal pump (available as an
option) and insulation are recommended to prevent possible
freezing.
The boiler includes a trap that prevents combustion products
entering the drain. However an additional trap with a seal of at
least 75 mm and an air break between the traps is required if
the condensate drain pipe is connected to sanitary pipework.
The drain outlet on the boiler is a 25 mm o.d. plastic pipe.
This size must not be reduced below 21.5 mm o.d. (standard
overflow pipe) in any part of its length.
All pipework and fittings in the condensate drain system must
be made of plastic. No other materials may be used.
Condensate drain
Additional trap
To avoid condensate being trapped:
--- the drainpipe should be run with a fall of at least 2.5û (45
mm/m) away from the boiler;
--- the number of bends and joints should be kept at
minimum;
--- the drainpipe should be adequately fixed to pevent pipe
sagging.
The length of the condensate pipe should be kept at
minimum and must be arranged so that obstruction (e.g.
24
mini HE --- Installation & Servicing
INSTALLATION
For Ireland reference should be made to the current ETCI
rules for electrical installations.
29 ELECTRICAL CONNECTIONS
Warning. This appliance MUST be efficiently earthed
A mains supply of 230 V ~ 50 Hz is required.
The supply connection is intended to be made via a double
pole switch having a 3 mm (1/8”) contact separation in both
poles, serving only the boiler and system controls. A 3 pin
UNSWITCHED socket may, alternatively, be used.
Mains wiring should be 3 core PVC insulated flexible cord
The external fuse rating should be 3A.
2
NOT LESS than 0.75 mm (24 x 0.2mm) and to BS. 6500,
2
Table 16. (0.5mm flex is not acceptable --- for mechanical,
For external controls wiring see frame 33.
Note: the switch contacts of any external programmer,
room or frost thermostat must be volt free.
Connecting a switched live feed to external controls
terminal block may be dangerous and will result in
serious damage to the boiler.
not electrical reasons.)
Mains wiring external to the boiler MUST be in accordance
with the current I.E.E. (BS7671) Wiring Regulations and any
local regulations.
4
Remove the side panels or move the lower part of the side
panels and pull the control panel forward.
30 ELECTRICAL CONNECTIONS
Incoming mains wiring detail
To gain access to the power supply and external controls
terminal blocks:
1
Remove the screws A and the front panel of the case.
When completely pulled out, the panel can rotate 45û
downwards to facilitate the operations on the internal parts.
5
Loosen the screws D and remove the service panel.
D
A
2
3
Remove the screws B.
Loosen the screws C.
Mains
Volt free contacts
Thermostat link
L
N
Remove when wiring external
thermostats.
Power supply
terminal block
Refer to frame 33
B
3
2
1
External controls
terminal block
C
B
Note: Ensure that the lengths of the current conductors are
shorter than the earth conductor so that if the cable slips in its
anchorage the current carrying conductors become taut
before the earth conductor.
C
25
mini HE --- Installation & Servicing
INSTALLATION
31 PICTORIAL WIRING
mini HE C24, mini HE C28, mini HE C32
Wiring diagram for boiler equiped with electronic control p.c.b. type: Bertelli & Partners DIMS11---SA03/16740
Electric supply External controls Three way
terminal block terminal block diverter valve
Pump
Fan
Ignition
Primary circuit Air pressure
Flame detection
electrode
electrodes
flow switch
switch
L
N
1
2
M
~
M
~
M
~
3
3
2
1
gy
bk
bk
NO
gy
NC
COM
Condensate
trap
X3
X6
X7
X1
F2
F1
3.15AF 3.15AF
K1
K3
K4
X5
X2
K2
bn
X8
bu bu
X4
bk
wh
wh
rd
rd
gy
gy
bk
bk
X11
P4
LD4
LD3 LD2 LD1
SB1
P5
Electronic control P.C.B.
ye
gy
rd
wh
wh
wh
rd
rd
bu
bn
bk
bk
t
wh
t
t
gn
bu
rd
bk
D.h.w. flow C.h. temperature
Safety
Flue
D.h.w. temperature Time switch
probe NTC
Modulating
gas valve
switch
probe NTC
thermostat temperature
probe NTC
1
2
3
4
5
6
7
8
9 10 11 12 13 14
X3
15
39
16
X6
X7
X1
F2
F1
K1
K4
K3
bn = brown
bu = blue
bk = black
wh = white
rd = red
X5
17 18
X2
K2
X8
X4
19
20
21
22
23
gy = grey
gn = green
ye = yellow
vt = violet
og = orange
24
25
26
Electronic
27
control p.c.b.
Pin position ref. numbering
gnye = green/yellow
P4
LD4
LD3LD2LD1
SB1
P5
26
mini HE --- Installation & Servicing
INSTALLATION
32 FUNCTIONAL FLOW DIAGRAM
mini HE C24, mini HE C28, mini HE C32
L
CH flow
switch
DHW flow
switch
bk bk
wh rd
bu
29 28
34 32 33
1
bn
bu
11
12
35
36
8
gy
ye
bu
bn
bk
rd
Gas Valve
(on---off operators)
Gas Valve
(modulation coil)
bk
bu
13
14
Three way
div. valve
7
Fan
6
gy
23
Electronic
37
38
30
31
9
DHW temp.
probe NTC
Air pressure switch
control pcb
rd
gy
25
bu
bu
bn
CH temp.
probe NTC
bk
bk
26
27
Safety
thermostat
wh
wh
Pump
19
20
Flue
temperature
probe NTC
10
bu
39
16 15
2
Ignition
electrodes
Detection
electrode
N
Condensate
trap
27
mini HE --- Installation & Servicing
INSTALLATION
thermostat should be wired into the system.
33 EXTERNAL ELECTRICAL CONTROLS
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations.
To maintain frost protection with the programmer selector
switches set to OFF, all the controls MUST be left in the
running position.
For Ireland reference should be made to the current ETCI
rules for electrical installations.
The frost thermostat should be sited in a cold place but where
it can sense heat from the system.
The external fuse rating should be 3A.
Wiring should be as shown, with minimal disturbance to other
wiring.
Route the electrical supply flexible cord and the external
control flexible cord as illustrated.
Lock the flexible cords in place with the clamps provided.
External Programmers
On the combi boilers, this should be of the single channel
type (as this boiler does not incorporate a pre---heat facility for
the instantaneous hot water service).
Programmers with room thermostat --- see diagram B.
230V supply
Note. lf the boiler is installed in a garage it may be necessary
to fit a pipe thermostat, preferably on the return pipework.
Earths are not shown for clarity but must never be omitted.
Optional frost’stat Room thermostat
A
L
N
T
T
ELECTRICAL CONNECTIONS FOR A
COMBI BOILER
Power supply
terminal block
Optional Programmer Kits
2
1External controls
Optional digital programmer kits are available with their
relevant instructions.
terminal block
3
Both 24hr and 7day kits are available.
Note: the switch contacts of any external programmer,
room or frost thermostat must be volt free.
Connecting a switched live feed to external controls
terminal block may be dangerous and will result in
serious damage to the boiler.
B
External programmer
Optional frost’stat
Room thermostat
Room Thermostat
L
N
This should be wired as shown in diagrams A.
Frost protection
T
T
Central heating systems fitted wholly inside the house do not
normally require frost protection as the house acts as a
‘storage heater’ and can normally be left at least 24 hours
without frost damage.
Power supply
terminal block
2
1
This appliance is provided with a built in anti---freeze system
that operates the boiler when the temperature is below 5 ûC.
Therefore, when the boiler is not lit and used in cold weather,
with consequent risk of freezing do not isolate the boiler
from the electricity supply or close the gas inlet cock.
External controls
terminal block
3
However, if parts of the pipework run outside the house or if
the boiler will be left off for more than a day or so then a frost
N.B. These diagrams are schematic only and do not show
external terminal strips etc.
28
mini HE --- Installation & Servicing
INSTALLATION
34 INITIAL LIGHTING
A
B
C
D
E
F
G
Central Heating flow
Domestic hot
water outlet
Gas inlet
Domestic cold
water inlet
Central Heating return
Legend
A
B
C
D
E
F
Appiance On lamps
Domestic hot water temperature control
Main switch and radiator temperature control
Boiler reset button
Lock---out signal lamp
Programmer (optional)
G
System pressure and temperature gauge
IMPORTANT Before lighting the boiler you should note
especially that:
1
Check that all the drain cocks are closed and any valves
in the flow and return are open.
7
8
Check that the gas service cock is ON.
Switch the electricity supply ON and check that all
external controls are calling for heat.
Set the main switch C to ’ON’. Following a pre---purge
period the gas control solenoid valve should open and the
spark commence, continuing until the burner is
established.
2
Check that the system has been filled and pressurised
and that the boiler is not air locked.
3
4
Remove boiler front panel.
Ensure the dust cap on the automatic air vent is open at
least one full turn and leave this permanently open
9
5
Ensure that the pump is free to rotate
10 Check that the burner lights smoothly. If this does not
occur within 20 seconds, turn the main switch to ’O’
position, wait for 5 seconds then try again by pressing the
reset button ’D’. If the burner still does not light, refer to
the ’Fault Finding’ section.
11 Test for gas tightness around ALL boiler gas components,
using leak detection fluid.
12 Operate the boiler for 10 minutes to stabilise the burner
temperature.
13 Check that the burner pressures are correct. The boiler is
factory pre---set and should not need adjustment.
However if adjustment is required refer to frame 35.
i
Remove the vent plug
ii Using a screwdriver, rotate the shaft several times
iii Replace the vent plug
Note. Some slight water leakage will occur
6
Remove the screw in the burner pressure test point
indicated on the following picture and connect a gas
pressure gauge via a flexible tube.
Be sure to select the correct pressure test point. Refer to
Tables for pressures.
14 Set the boiler main switch to ’O’.
15 Remove the pressure gauge and tube. Replace the
sealing screw in the pressure test point. Ensure a gas
tight seal is made.
16 Refit the boiler front panel using the screws previously
removed.
17 Switch the boiler on again.
29
mini HE --- Installation & Servicing
INSTALLATION
(burner pressure).
By rotating clockwise the pressure increases.
35 TO ADJUST PRESSURES
Nomenclature of the parts on the gas valve
10 Turn the boiler off and re---connect the wire to the
modulating operator.
H
I
Modulation operator’s electric connectors
Minimum gas pressure adjustment
Maximum gas pressure adjustment
On---off operators electric connector
On---off operators
11 Start the boiler and check again the maximum gas
pressure setting.
J
K
L
12 Turn the boiler off and disconnect the gauge and close the
gas valve outlet pressure test point N
Important: after the gas pressure checks and any
adjustment operations, all of the test points must be
sealed and replace the adjustment protection cap.
M Gas valve inlet pressure test point
N
Burner pressure test point
Ignition rate adjustment
1
2
Turn on the boiler.
Check that the boiler lights up uniformly and adjust the
ignition gas pressure, if necessary.
N
I
To adjust the ignition gas pressure:
3
Open the gas valve outlet pressure test point N and
connect the gauge.
4
Rotate the radiator temperature control C as indicated in
the next figure and ensure that the room thermostat, if
fitted, is set to “heat demand”.
5
Run the boiler in c.h. mode (do not open any d.h.w. tap)
J
A
B
C
D
E
6
7
Press and hold the reset button D for about 10 seconds
until the lock---out signal light E blinks.
H
M
The lamps A should give the indication of the next figure;
if not then press the reset button D until you obtain it.
K
L
Where:
Lamp ON
1
2
Remove the front panel of the case.
Open the gas valve inlet pressure test point M at the valve
input, connect a suitable pressure gauge and check the
gas pressure of the supply network.
Lamp OFF
8
Press and hold the reset button D for about 5 seconds
until the lock---out signal light E is switched off.
3
4
Remove the gauge and close the pressure test point M.
Open the burner pressure test point N and connect the
gauge.
The boiler runs in c.h. mode and the lights A give the follow
indication:
5
6
Remove the protection cap from the mechanical pressure
adjustment components (I and J)
Where:
Flashing lamp, alone
or simultaneously with
an other lamp.
Start the boiler at its maximum power.
Operate the boiler in DHW mode or ensure that the boiler
is not range rated if the test is carried out in CH mode.
Lamp OFF
Maximum valve setting
7
If necessary, rotate the maximum gas pressure
adjustment J using a spanner until you obtain the
required pressure as indicated on Table 1 at page 4
(burner pressure).
9
Rotate the DHW temperature control B on a position
corresponding to an adequate ignition pressure. By
rotating clockwise the pressure increases.
By rotating clockwise the pressure increases.
Suggested ignition pressures:
Minimum valve setting
Natural gas G20 --- 6 (2,4) mbar (in w.g.)
Propane G31 --- 13 (5,3) mbar (in w.g.)
8
Turn the boiler off and disconnect one of the two
connectors H.
10 Make a note of the position of the DHW temperature
control B.
9
Start the boiler and if necessary, rotate the minimum gas
pressure adjustment I using a spanner until you obtain the
required pressure as indicated on Table 1 at page 4
11 Turn the boiler off and on positioning the main switch C as
indicated in the next figure.
30
mini HE --- Installation & Servicing
INSTALLATION
Where:
Lamp ON
Lamp OFF
14 Turn the DHW temperature control B to the minimum (fully
counterclockwise) and then on the position noted on step
10. By turning the control B the lock---out signal lamp E
blinks quickly (2 per second) indicating that the setting
has changed and must be memorized.
A
B
C
D
E
15 To memorize the setting press and hold the reset button D
for about 5 seconds until the lamps A briefly blink
simultaneously.
16 To reset the boiler to the normal operation turn it off and
on by the main switch C checking the ignition pressure
and that the burner lights up uniformly. The boiler
automatically resets to its normal operation after 10
minutes if the above reset operation is not performed.
12 Press and hold the reset button D for about 10 seconds
until the lock---out signal lamp E blinks.
13 Press the reset button D repeatedly (4 times) until the
lamps A give the follow indication:
The lamps A will flash a number of times corresponding to the
setting.
36 ANTI CYCLING SETTING
It is possible to set the minimum delay time that must pass
between two ignitions of the burner in c.h. function mode.
4
To change the setting turn the DHW temperature control B
to a position corresponding to the desired delay. By
turning the control B, the lock---out signal lamp E blinks
quickly (2 per second) indicating that the setting has
changed and must be memorized.
1
Turn the boiler on positioning the main switch C as follow:
4
5 1/2
3
4
3
5
1 1/2
0
7
2
6
7
1
8 1/2
A
B
C
D
E
2
3
Press and hold the boiler reset button D for about 10
seconds until the lock---out signal lamp E blinks
The lamps A should give the indication as in next figure
(reignition frequency). If not, press the reset button D
repeatedly to obtain it.
Delay (minutes)
Setting No.
B
5
6
To memorize the setting press and hold the reset button D
for about 5 seconds until the lamps A briefly blink
simultaneously.
Where:
Lamp ON
To reset the boiler to the normal operation turn it off and
on by the main switch C. The boiler automatically resets to
its normal operation after 10 minutes if the above reset
operation is not performed.
Lamp OFF
At this time it is possible to determine the current setting by
keeping the reset button D pressed for more than 5 seconds.
The factory setting anti cycling time is 3 minutes.
B. Gas Installation
37 COMMISSIONING AND TESTING
1
The whole of the gas installation, including the meter,
should be inspected and tested for tightness and purged
in accordance with the recommendations of BS. 6891. In
IE refer to I.S. 813:2002.
The benchmark Logbook or equivalent self certification
should be completed and signed to demonstrate compliance
with Building Regulations.
2
3
Purge air from the gas installation by loosening the gas
cock union and purge until gas odour is detected.
Retighten the union and test for gas tightness.
A. Electrical Installation
Checks to ensure electrical safety should be carried out
by a competent person.
WARNING. Whilst effecting the required gas tightness
test and purging air from the gas installation, open all
windows and doors, extinguish naked lights and DO NOT
SMOKE.
ALWAYS carry out the preliminary electrical system checks,
i.e. earth continuity, polarity, resistance to earth and short
circuit, using a suitable test meter.
31
mini HE --- Installation & Servicing
INSTALLATION
If this check is not possible, ensure that the burner pressure
is:
38 GENERAL CHECKS
Make the following checks for correct operation:
mbar (in. w.g.)
models
1
Hot water.
10.8 (4.3)
10.0 (4.0)
13.0 (5.2)
mini HE C24
mini HE C28
mini HE C32
a. Fully open all DHW taps in turn and ensure that water flows
freely from them.
b. Close all taps except the furthest one from the boiler and
check that the boiler is firing at maximum rate.
4
Water circulation system
c. Ensure that DHW temperature of approximately 35 ûC rise
is obtained at the tap. This corresponds to a flow rate of about
Note. Fernox Superfloc flushing solution should be used
during the flushing procedure.
a. With the system HOT examine all water connections for
litres/min (gpm)
10.1 (2.2)
models
tightness.
mini HE C24
mini HE C28
mini HE C32
b. With the system still HOT, turn off the gas, water and
electricity supplies to the boiler and drain down, to complete
the flushing process.
11.7 (2.6)
13.1 (2.9)
c. Refill the system, adding inhibitor (see ’Water Treatment’), if
required.
d. Turn off the DHW tap.
Vent as necessary to clear all air and, again, check for water
tightness. After venting, repressurise as required.
2
Central heating (all models)
Operate each control separately and check that the main
burner or circulating pump, as the case may be, responds.
d. Balance the system. It is suggested that, initially, all radiator
handwheel valves (or TRVs if fitted) be set fully open, that all
lockshield valves be set a half---turn open.
3
Gas rate --- G20
Check the boiler gas rate when the boiler is at full output.
Make minor adjustments to each radiator to achieve the same
differential on all.
The gas rate checked at the gas meter, with no other
appliance in use will normally be:
5
Flue system
Check the integrity of the flue outlet and air inlet system to the
boiler ensuring no leaks are evident from piping joints or
flue/air sampling points.
3
litres/min (ft /min)
44.2 (1.56)
models
mini HE C24
mini HE C28
mini HE C32
Finally, set the system controls to the users requirements.
51.2 (1.81)
If an optional programmer kit is fitted refer to the instructions
supplied.
58.8 (2.08)
32
mini HE --- Installation & Servicing
INSTALLATION
Gas type
Setting No.
L.P.G.
4
39 GAS CONVERSION
1
Check that the gas cock fitted under the boiler is turned
off and the appliance is switched off at the mains isolating
spur.
NATURAL
GAS
1
2
3
4
Remove the front panel of the case.
Take off the lid of the sealed chamber.
B
Take the front panel of the combustion chamber off and
remove the burner as explained in frame 43.
Gas
Position of Approx. Max current through the
5
6
Carry out the conversion for the type of gas, replacing the
burner injectors correctly as explained in frame 51.
supply
knob B
modulator device
Re---assemble the burner, the front panel of the
combustion chamber and the lid of the sealed chamber.
Natural gas
L.P.G.
1
4
125 mA
165 mA
7
8
Switch on the appliance at the mains isolating spur.
13 To change the setting turn the DHW temperature control B
to a position corresponding to the gas used as shown in
the figure above.
Turn the boiler OFF positioning the main switch C as in
figure below.
By turning the control B, the lock---out signal lamp E
blinks quickly (2 per second) indicating that the setting
has changed and must be memorized.
14 To memorize the setting keep pressed the reset button D
for about 5 seconds until the lamps A briefly blinks
simultaneously.
15 Open the gas cock.
A
B
C
D
E
16 To reset the boiler to the normal operation turn it ON by
the main switch C on the desired operation and checking
the ignition pressure and that the burner lights up
uniformly. The boiler automatically resets to its normal
operation after 10 minutes if the above reset operation is
not performed.
9
Disconnect the CH temperature probe (24 on page 14).
10 Press and hold the reset button D for about 10 seconds
until the lock---out signal lamp E blinks.
11 Connect the CH temperature probe (24 on page 14).
The factory setting is Natural gas.
12 Press the reset button D repeatedly (4 times) until the
lamps A give the follow indication:
17 Calibrate the gas valve according to the instructions given
in this manual.
Where:
18 Set the correct gas pressure for central heating output
required.
Lamp ON
19 Stick the self---adhesive label (included with the
conversion kit, indicating the type of gas, and the gas
pressures to which the appliance has been set) over the
existing label on the bottom of the control panel and
replace the adjustment protection cap.
20 Replace the front panels of the case.
21 Check the correct operation of the boiler.
Lamp OFF
At this time it is possible to determine the current setting by
keeping the reset button D pressed for more than 5 seconds.
The lamps A will flash a number of times corresponding to the
setting of the DHW temperature control B (see next figure).
6
7
If a programmer is fitted, draw attention to the
Programmer Instructions and hand them to the
householder.
40 HANDING OVER
After completing the installation and commissioning of the
system, the installer should hand over to the householder by
the following actions:
After installation and commissioning please complete the
Commissioning Checklist before handover to
the customer.
For IE, it is necessary to complete a “Declaration of
Conformity” to indicate compliance to I.S. 813:2002.
1
Hand the User’s Instructions to the householder and
explain his or her responsibilities under the Gas Safety
(Installation and Use) Regulations 1994 and amendments
1996 or rules in force.
2
3
4
Draw attention to the Lighting Instruction label affixed to
the inside of the lower front door.
Explain and demonstrate the lighting and shutting down
procedures.
The operation of the boiler and the use and adjustment of
ALL system controls should be fully explained to the
householder, to ensure the greatest possible fuel
economy consistent with household requirements of both
heating and hot water consumption.
Advise the user of the precautions necessary to prevent
damage to the system and to the building, in the event of
the system remaining inoperative during frosty conditions.
8
Stress the importance of regular servicing by a CORGI
registered installer and that a comprehensive service
should be carried out AT LEAST ONCE A YEAR.
In IE, servicing work must be carried out by a competent
person.
Emphasise to the user that the boiler may stop working if the
system pressure is lowered by draining radiators to
decorate behind them. In particular, explain to the user how
the domestic hot water temperature varies with flow rate.
This is especially important when water is drawn off while
the boiler is already running for central heating.
5
33
mini HE --- Installation & Servicing
SERVICING
Note. If your meter reads CO in parts per million the figure
must be divided by 10,000 to convert it to a percentage.
41 SERVICING SCHEDULE
To ensure the continued safe and efficient operation of the
appliance it is recommended that it is checked at regular
intervals and serviced as necessary.
The frequency of servicing will depend upon the installation
condition and usage but should be carried out at least
annually.
It is the law that any service work must be carried out by a
registered CORGI installer.
In IE, servicing work must be carried out by a competent
person.
5
If the ratio of CO/CO is less than ,004 and the gas rates
2
measured in steps 3 and 4 are close to nominal then no
further action need be taken. If not, proceed to step 6.
6
7
8
9
Clean the main burner.
Clean the heat exchanger.
Check the injectors for blockage or damage.
Check that the flue terminal is unobstructed.
10 Check and clean the condensate trap and drain (see
frame 73).
1
Turn the heating controls to maximum so that the boiler
lights and remains running. Check that no other gas
appliances in the house are in use or likely to be used.
The servicing procedures are covered more fully in Frames 42
to 47 and MUST be carried out in sequence.
2
When the boiler has settled down check the gas rate at
the meter (if the meter is of the pointer type you should
time only complete revolutions of the pointer). Check the
gas rate against the figures given in Table 2 for CH
operation.
WARNING.
ALWAYS turn off the gas supply at the gas service cock, and
switch off and disconnect the electricity supply to the
appliance before servicing.
3
4
For a combination boiler, fully open a hot water tap. When
the boiler has settled down check the gas rate, as in step
2, checking the measured rate against the figures given in
Table 3 for HW operation.
Run the boiler and check the percentage of CO and CO2
in the flue gasses at the sampling point indicated in the
following drawing.
Switching the boiler on/off switch ‘off’ does not fully
isolate the boiler.
ALWAYS test for gas tightness and carry out functional
checks on reassembly.
IMPORTANT. When work is complete the boiler inner front
sealing panel MUST be correctly refitted, making a good seal.
DO NOT OPERATE THE BOILER IF THE SEALlNG PANEL
IS NOT FITTED.
Exhaust gas
Air intake
Sampling points
Sampling points
Complete the service section in the Benchmark
Commissioning Checklist.
34
mini HE --- Installation & Servicing
SERVICING
5
Remove the screws C and remove the boiler inner casing.
42 REMOVAL OF OUTER AND INNER
CASING
1
Turn off the gas supply at the gas service cock and
disconnect the electricity supply.
2
Remove the screws A and lift off the boiler front panel.
C
A
C
3
4
Loosen the screws B.
Bring the base of the panels away from the boiler and lift
them, freeing them from the top hooks.
B
B
35
mini HE --- Installation & Servicing
SERVICING
6
Undo the four screws F placed at the right and left sides of
the burner and extract it.
43 BURNER REMOVAL AND CLEANING
1
2
3
Disconnect the electrical supply.
Remove outer and inner casing (refer to frame 42).
Undo the screws A and remove the fan holder bracket B
and the combustion chamber panel C.
4
Remove the screws D and the plate E.
B
A
F
7
Brush off any deposits that may have collected on the
burner, ensuring that the flame ports are unobstructed.
Note: brushes with metallic bristles MUST NOT be used.
8
9
Inspect the spark and detection electrodes. Ensure they
are clean and in good condition; replace if necessary.
Check the spark electrodes gap is correct.
A
4 mm (5/32”)
C
10 mm
(3/8”)
E
D
Burner blade
Ignition
Male
Detection
Female
10 Check that the spark and detection electrodes leads are in
good condition and renew as necessary.
5
Disconnect the electrodes leads.
If the burner pressures are incorrect ensure the inlet pressure,
with the appliance running, is correct (refer Table 1).
44 BURNER PRESSURE CHECK
If the burner pressures require adjustment refer to frame 35
“To adjust pressures”.
After any servicing, reference should be made to:
--- Table 2 and Table 3 (or the data plate) which quote details
of the burner pressures.
If the appliance still does not operate correctly refer to the
appropriate fault finding chart.
2
6
Place a plastic sheet or similar beneath the heat
exchanger and remove all visible loose deposits from the
heat exchanger fins, using a suitable brush.
45 CLEANING THE HEAT EXCHANGER
1
Open the combustion chamber as explained in steps 1 to
3 of frame 43.
Refit the inner case cover.
IMPORTANT. Ensure the boiler sealing panel is correctly
fitted and that a good seal is made.
4 6 R E --- A S S E M B LY
Re---assemble the boiler in the following order:
3
4
Refit the burner.
Reconnect the electrodes to the electronic p.c.b.. See
frame 43 for correct connectors.
Refit the combustion chamber panel and the fan holder
bracket and plate E.
7
8
9
Refit the boiler side and front panels.
Turn on the gas supply at the gas service cock.
Reconnect the electrical supply.
5
36
mini HE --- Installation & Servicing
SERVICING
7
Check that the impeller runs freely. Clean with a soft brush
or renew as necessary. Refer to frame 58 for replacement.
47 FAN AND VENTURI REMOVAL AND
CLEANING
Note: Always take care when handling the fan, in order to
preserve the balance of the impeller.
1
2
3
4
Disconnect the electrical supply.
Remove outer and inner casing.
8
Check the venturi E for cleaness.
Disconnect the connectors A and the earth connection B.
E
Disconnect the pipe which connects the venturi device to
the air pressure switch.
5
Unscrew the screw C and remove the fan holder bracket
D.
B
A
9
Re---assemble in reverse order.
C
To correctly connect the venturi device to the air pressure
switch, refer to the following illustration.
D
---
+
6
Remove the fan by sliding it towards left (see the arrow).
37
mini HE --- Installation & Servicing
SERVICING
REPLACEMENT OF COMPONENTS
THE BOILER MUST NOT BE OPERATED IF THE INNER
CASE COVER IS NOT FITTED.
48 GENERAL
When replacing any component:
If the CH and/or the DHW circuits have been emptied:
1
Isolate the electricity supply at the switched spur.
N.B. Turning the boiler “ON/OFF” switch does not isolate
the live supply to the boiler.
3
Open the hydraulic circuit cocks, refill / re---pressurise
pipeworks and vent the system.
2
Turn off the gas supply.
4
5
Test fire the boiler
IMPORTANT. When work is complete the inner case cover
must be correctly fitted, ensuring that a good seal is made.
Disconnect the filling loop.
7
Check the spark gap.
4 mm (5/32”)
49 SPARK AND DETECTION
ELECTRODE REPLACEMENT
1
2
3
Disconnect the electrical supply.
Remove outer and inner casing (refer to frame 42).
Open the combustion chamber and disconnect the
electrodes leads.
10 mm
(3/8”)
4
5
6
Remove the burner. Refer to frame 43.
Undo the screws that hold the electrodes and remove.
Fit new electrodes as necessary following the sequence
illustrated.
Burner blade
Ignition
Ignition 1st
Male
Detection
Female
8
9
Re---assemble in reverse order.
Check the ignition and operation of the burner.
Ignition 2nd
Detection 3rd
3
Fit the electrodes on the new burner and check the spark
gap.
50 BURNER REPLACEMENT
1
Remove the burner as explained in frame 43
4
5
Re---assemble in reverse order.
Check the operation of the boiler.
2
Remove the spark and detection electrodes.
Refer to frame 49.
51 BURNER INJECTORS
REPLACEMENT
Injectors
Burner
1
2
3
Remove the burner. Refer to frame 43.
Unscrew the injectors from the gas manifold.
Check that the new injectors are of the correct size and fit
it using new gaskets.
Gas manifold
4
5
Re---assemble in reverse order.
Check the operation of the boiler.
38
mini HE --- Installation & Servicing
SERVICING
3
4
Disconnect the wiring C .
52 OVERHEAT THERMOSTAT
REPLACEMENT
Remove the spring D which holds the overheat thermostat
on the pipe of the primary heat exchanger and remove it.
1
Remove outer and inner casing (refer to frame 42).
2
Remove the screws A and the plate B.
C
D
B
A
5
6
Re---assemble in reverse order.
Apply an adequate quantity of heat conducting
compound between the pipe and the thermostat.
6
Fit the new probe/adaptor assembly into the recuperator
and re---assemble in reverse order.
53 FLUE TEMPERATURE PROBE
REPLACEMENT
1
2
3
Remove outer and inner casing (refer to frame 42).
Disconnect the wires from the flue temperature probe.
Unscrew the steel temperature probe adaptor A (complete
with the temperature probe) from the recuperator.
A
4
Ensure the probe is positioned as shown with the metal
sheath end level with the brass fixing nut B.
B
A
5
Ensure that on the probe, the length C that enters the
recuperator is 18 mm.
C
Replacement
54 TEMPERATURE PROBE
REPLACEMENT
5
Disconnect the leads from the probe to be replaced and
unscrew it .
1
Disconnect the electrical supply.
6
Screw in the new probe, using a new gasket, reconnect
and re---assemble in reverse order.
2
Remove the front and right hand side casing panels (refer
to frame 42).
Removal of CH temperature probe
3
To remove the CH temperature probe close off the
isolating cocks of the CH circuit at the bottom of the boiler.
4
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
Removal of DHW temperature probe
3
To remove the DHW temperature probe close off the
isolating cock of the DHW circuit at the bottom of the
boiler.
CH temperature
probe
DHW temperature
probe
Drainage cock
4
Empty the DHW circuit.
mini HE --- Installation & Servicing
39
SERVICING
8
9
Disconnect the earth wiring from the gas valve.
Unscrew the connectors C and remove the pipe D
55 GAS VALVE REPLACEMENT
Check
10 Unscrew the inlet connector.
1
2
3
Disconnect the electrical supply.
Remove the front casing panel.
11 Unscrew the screws E and remove the valve.
12 Fit the new gas valve in reverse order ensuring new
gaskets are fitted and check for gas tightness.
Disconnect the connector A and check the electrical
resistance of the coil referring to the following diagram
13 Check the operation of the boiler.
C
D
On --- off operator
approx. 4 180 Ω*
* at ambient temperature.
4
If the resistance of the coil is different from the value
stated by ±10% or greater, replace the unit as described
below.
Replacement
5
Turn off the gas supply at the gas service cock and
disconnect the electricity supply.
A
B
6
7
Remove the front casing panel (refer to frame 42).
Disconnect the connectors A and B.
E
56 WATER TEMPERATURE---PRESSURE
GAUGE REPLACEMENT
E
C
B
1
2
Disconnect the electrical supply.
Remove the front and right hand side casing panels (refer
to frame 42).
D
3
Release system pressure by opening the main circuit
drainage cock A
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
4
5
6
Remove the fork B and the probe holder spring C.
Pull out the control panel (see frame 30).
Squeeze the tabs D to release the temperature---pressure
gauge E and remove it.
A
7
Re---assemble in reverse order.
valve. It may cause debris within the system to foul
the valve.
57 EXPANSION VESSEL REPLACEMENT
If the CH expansion vessel is faulty, there are 2 options:
5
Completely unscrew the connection A, the locknut B and
remove the expansion vessel from the top of the boiler.
A
If it has a punctured diaphragm, but is otherwise leak free,
than it can be left in place and a new vessel added to the
return side of the system, external to the boiler, provided it
is of adequate capacity and pre---charge pressure.
B
A
B
If there is at least 400 mm (16”) clearance above the
boiler, the expansion vessel can be changed without
removing the boiler (rear exit flues will have to be
disturbed).
For option B, proceed as follows:
1
2
Disconnect the electrical supply.
Gain access to the controls area by removing the boiler
front panel (refer to frame 42).
3
4
Close off the isolating cocks of the CH circuit at the
bottom of the boiler.
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
6
Re---assemble in reverse order.
40
mini HE --- Installation & Servicing
SERVICING
6
7
Remove the fan by sliding it towards left (see the arrow).
Re---assemble in reverse order.
58 FAN REPLACEMENT
1
2
3
4
Disconnect the electrical supply.
Note: Always take care when handling the fan, in order to
preserve the balance of the impeller.
Remove outer and inner casing.
Disconnect the connectors A and the earth connection B.
Disconnect the pipe which connects the venturi device to
the air pressure switch.
To correctly connect the venturi device to the air pressure
switch, refer to the following illustration.
5
Unscrew the screw C and remove the fan holder bracket
D.
A
B
---
+
C
D
A
B
59 VENTURI REPLACEMENT
1
Remove the fan (see frame 58).
2
Remove and replace the venturi device A by unscrewing
the screw B.
3
Re---assemble in reverse order.
60 AIR PRESSURE SWITCH
REPLACEMENT
Two different types of air pressure switch may be used in the
boiler. Refer tho the following drawings in accordance with the
type of air pressure switch used.
N.O.
COM
”L” connection
N.C.
1
2
3
Disconnect the electrical supply.
Remove outer and inner casing as explained in frame 42.
”H” connection
(not used)
Disconnect the pressure sensing pipe from the air
pressure switch.
4
5
Disconnect the electrical harness from the air pressure
switch.
Undo the two screws which hold the air pressure switch to
the chassis and remove it.
6
7
Replace the switch.
Re---assemble in reverse order.
”H” connection
(not used)
To correctly connect the venturi device to the air pressure
switch, refer to the illustration of frame 58 and to the
following illustrations in accordance with the type of
pressure switch used.
”L” connection
mini HE --- Installation & Servicing
41
SERVICING
7
Remove the fork E and the connection of the capillary
61 PUMP REPLACEMENT COMPLETE
pipe of the pressure gauge.
1
Disconnect the electrical supply.
8
9
Remove the locking plate F.
2
Remove the front and right hand side casing panels (refer
to frame 42).
Completely loosen the connection G.
10 Unscrew the two screws H that hold the pump on the
frame
3
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
11 Remove the pump towards the front of the boiler
4
5
6
Disconnect the connector A.
Loosen the connector B.
Remove the fork C and the pipe D.
B
A
C
D
H
G
E
I
F
Re---assemble in reverse order.
When reassembling the pump, check the correct location of
the O---ring gasket in the inlet port of the pump that seals the
connection between the pump and the brass group .
If the motor only needs replacing, disconnect the connector
A, unscrew the 4 screws I and remove the pump motor
forwards.
42
mini HE --- Installation & Servicing
SERVICING
62 ELECTRONIC CONTROL/IGNITION
PCB REPLACEMENT
1
2
Disconnect the electrical supply.
Gain access to the controls area by removing the boiler
front panel and pulling the control panel (refer to frame
30).
3
4
Remove the screws A and remove the service panel
To gain access to the electronic control/ignition p.c.b.
remove the screws B and remove the control panel lid.
B
8
9
Unscrew the four screws that hold the electronic
control/ignition p.c.b. on to the control panel.
Remove it by lifting its rear edge and freeing it from any of
the wiring.
A
10 Re---assemble in reverse order.
Important
When re---assembling the electronic control/ignition p.c.b.:
11 Fit the p.c.b. into the control panel by first inserting the
front lower edge under the control knob shafts. Lower the
rear edge and ensure that no wiring is trapped beneath.
B
Control panel lid
12 Insert the spindles in the control panel knobs until the
notch C reaches the potentiometer edge. It is not
necessary to force them in the knob.
Service panel
13 While tightening the screws that fix the electronic
control/ignition p.c.b. on the control panel, keep the p.c.b.
towards the control panel fascia making sure of the
contact between the boiler reset button D and the tab E.
Replace the wiring connections ensuring correct
engagement in the sockets
5
Remove all the wiring connected to the electronic
control/ignition p.c.b.
To disconnect the connectors indicated, delicately flex the
hook present on one side of each socket.
C
D
E
C
6
To disconnect the connectors indicated in the next figure,
delicately press the hook present on one side of each
socket.
Attention
After installing the electronic control/ignition p.c.b.:
14 Make sure the CH (
) and DHW (
) temperature
adjustment knobs can move freely for the complete
range. If not, remove the spindle again as described at
step 7, turn the knob half a turn and re---insert the spindle.
15 Operate the boiler and close the gas inlet cock so that the
boiler goes into the safety lock---out state.
Verify the correct operation of the boiler reset button by
pressing and releasing it.
16 Open the gas inlet cock and check the boiler operates
correctly.
The replacement PCB is supplied pre---set for Natural Gas
and an anti cycling time of 3 minutes. If the installation
requires adjustment of these settings refer to frames 35 and
36 for the procedures
7
Remove the spindles of the CH and DHW temperature
adjustment knobs by delicately pulling them with pliers in
the direction shown by the arrows.
mini HE --- Installation & Servicing
43
SERVICING
If required, to check the PCB is set correctly for this boiler
type the following procedure should be followed.
22 Turn the knob B clockwise and then to minimum position.
By turning the knob B, the lock---out signal lamp E blinks
quickly (2 per second) indicating that the setting has
changed and must be memorized.
Boiler mode setting
17 Remove the front panel of the case.
18 Position the control knob C as in the figure below and
disconnect the C.h. temperature probe.
23 To memorize the setting press and hold the reset button D
for about 5 seconds until all the three lamps A briefly blink
simultaneously.
24 Press the reset button D (once) until the lamps A give the
indication as follow:
Where:
Lamp ON
Lamp OFF
A
B
C
D
E
At this time it is possible to determine the current setting by
keeping the reset button D pressed for more than 5 seconds.
If the lamps A flash once go to step 27; if not proceed as
follows:
19 Press and hold the reset button D for about 10 seconds
until the lock---out signal lamp E blinks.
20 Connect the c.h.temperature probe.
25 Turn the knob B clockwise and then to minimum position.
By turning the knob B, the lock---out signal lamp E blinks
quickly (2 per second) indicating that the setting has
changed and must be memorized.
21 Press the reset button D repeatedly (twice) until the lamps
A give the indication as follows (boiler mode).
Where:
Lamp ON
26 To memorize the setting press and hold the reset button D
for about 5 seconds until all the three lamps A briefly blink
simultaneously.
Lamp OFF
27 To reset the boiler to the normal operation turn it off and
on by the main switch and radiator temperature control C.
The boiler automatically resets to its normal operation
after 10 minutes if the above reset operation is not
performed.
At this time it is possible to determine the current setting by
keeping the reset button D pressed for more than 5 seconds.
If the lamps A flash once go to step 24; if not proceed as
follows:
44
mini HE --- Installation & Servicing
SERVICING
5
Re---assemble in reverse order.
63 CH FLOW SWITCH REPLACEMENT
Refer to the following illustration for the correct wiring
connectors on the switch
1
2
3
4
Disconnect the electrical supply.
Remove the front casing panel.
Remove the fork A.
C
N.O.
Open the box B and disconnect the switch.
do not use
A
B
Looking through the switch box B it is possible to verify the
position of the spindle C
C
Boiler OFF
Pump operating
concave side of the membrane towards the actuator plate
C and locate the reference hole in the membrane over the
pressure transfer nipple D.
64 CH FLOW SWITCH MEMBRANE
REPLACEMENT
1
2
3
Disconnect the electrical supply.
Remove front casing panel (refer to frame 42).
Close off the isolating cocks of the CH circuit at the
bottom of the boiler.
B
C
4
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
A
D
5
6
Remove the CH circuit flow switch (see frame 63).
Unscrew the four screws A, open the hydraulic operator
and remove the membrane B.
7
Re---assemble in reverse order.
When assembling the membrane, ensure to place the
mini HE --- Installation & Servicing
45
SERVICING
65 DHW FLOW SWITCH REPLACEMENT
1
2
3
Disconnect the electrical supply.
Remove the front panel of the case (refer to frame 42).
Disconnect the connector A and remove the switch B by
delicately levering it upwards with a screwdriver.
B
4
Replace the switch and re---assemble in reverse order
A
Flow limiter
66 DHW FILTER AND FLOW LIMITER
REPLACEMENT
The mini HE C24 model is factory fitted with a 10 litre/min.
flow limiter.
1
Disconnect the electrical supply.
2
Remove the front panel of the case and empty the DHW
circuit.
Remove the flow switch A (see frame 65).
Unscrew the body C and extract the flow switch group.
To remove the filter B from the flow switch group separate
it from the threaded ring by levering it.
The mini HE C28 model is factory fitted with a 12 litre/min.
flow limiter.
3
4
5
The mini HE C32 model is factory fitted with a 14 litre/min.
flow limiter.
Table 11
6
Re---assemble in reverse order.
Nominal flow rate (litres/min)
Colour
Yellow
Brown
Pink
A --- f lo w sw i t c h
10
12
14
C--- body
O --- r i n g
Spring
To install the threaded ring with the flow limiter:
1
2
Disconnect the electrical supply.
Remove the front panel of the case and empty the DHW
circuit.
Magnetic ring
Float
3
4
5
6
7
Remove the flow switch A (see frame 65).
Remove the flow switch group (see frame 66 above)
Unscrew the threaded ring and remove it from the body C.
Extract the flow limiter.
Flow limiter
Threaded ring
Fit the correct colour coded limiter (see Table 11 above)
and screw the threaded ring tight into the body C.
B --- f i lt e r
8
Re---assemble in reverse order.
46
mini HE --- Installation & Servicing
SERVICING
Fit the clip H with the arrow pointing upwards as
67 PRIMARY HEAT EXCHANGER
REPLACEMENT
illustrated in the drawing.
Do not force the connection F when tighting it.
1
2
3
Disconnect the electrical supply.
Remove outer and inner casing as explained in frame 42.
Close off the isolating cocks of the CH circuit at the
bottom of the boiler.
C
B
4
Release system pressure by opening the main circuit
drainage cock. Do not release CH pressure using the
pressure relief valve. It may cause debris within the
system to foul the valve.
5
Remove the combustion chamber panel A by unscrewing
the screws B and removing the fan holder bracket C.
G
M
6
7
Remove the screws D and the plate E.
F
I
Loosen the connection F and slightly move the pipe G
upwards.
A
B
H
8
9
Remove the clip H and the safety thermostat I. It is not
necessary to disconnect it from the wiring.
Completely unscrew the connection J and move the pipe
K downwards freeing it from the heat exchanger
connection.
K
L
E
10 Remove the clip L.
D
J
11 Move the pipe M upwards freeing it from the connection
and rotate towards right.
12 Remove the heat exchanger by sliding it forwards.
13 Re---assemble in reverse order.
68 RECUPERATOR REPLACEMENT
K
1
2
3
Disconnect the electrical supply.
Remove outer and inner casing as explained in frame 42.
C
B
A
J
Close off the isolating cocks of the CH circuit at the
bottom of the boiler.
F
4
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
G
5
Remove the fan A (see frame 58) and the air pressure
switch B (see frame 60).
L
E
6
7
Remove the flue temperature probe C (see frame 53)
Completely loosen the connection D and slightly move the
pipe E upwards.
H
I
8
9
Remove the clip F and move the pipe G downwards
freeing it from the connection, then turn it towards right.
D
Using pliers, remove the spring H moving it downwards
and disconnect the rubber pipe I.
10 Remove the bracket J by unscrewing the screws that hold
it on the frame.
11 Rotate the recuperator K as indicated by the arrow and
remove it towards the front of the boiler.
12 Remove the clip L and the pipe E.
13 Reassemble the recuperator carrying out the removal
operations in reverse order.
After reassembling ensure that the fan---exchanger and
exchanger---elbow gaskets are correctly mounted and
ensure a good sealing.
mini HE --- Installation & Servicing
47
SERVICING
69 DIVERTER VALVE ACTUATOR
REPLACEMENT
1
2
3
4
Disconnect the electrical supply.
Remove front casing panel (refer to frame 42)..
Disconnect the connectors A.
Remove the fixing spring B and remove the actuator C.
Re---assemble in reverse order.
When reassembling the actuator, refer to the wiring diagram
in frame 31 for the correct wiring connection.
C
B
A
70 DIVERTER VALVE INTERNAL PARTS
REPLACEMENT
1
2
Disconnect the electrical supply.
Remove front and left hand casing panels (refer to frame
42).
H
3
4
Close the isolating cocks of the CH circuit and DHW
supply at the bottom of the boiler.
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
I
J
(rear view)
5
Release the pressure of the DHW circuit by opening a hot
tap.
13 Refer to the following exploded view to remove the
internal parts of the three way diverter valve.
6
7
Remove the diverter valve actuator (see frame 69).
Remove the fork D and remove the primary circuit flow
switch E.
8
9
Disconnect both CH and DHW temperature probes F.
Unscrew the connector G, disconnect the CH flow and
DHW outlet isolator valves.
G
F
E
D
F
10 Remove the DHW heat exchanger (see frame 71).
11 Remove the fork H and move away the pipe I.
12 Unscrew the screw J and remove the diverter (flow)
group.
14 Re---assemble in reverse order.
48
mini HE --- Installation & Servicing
SERVICING
8
Move the exchanger towards the rear of the boiler and
71 DHW HEAT EXCHANGER
REPLACEMENT
extract it.
9
Re---assemble in the reverse order.
1
2
3
Disconnect the electrical supply.
Attention. When reassembling the exchanger be sure to
put the off center location/securing pin indicated towards
the left side of the boiler.
Remove outer casing (refer to frame 42).
Close the isolating cocks of the CH circuit and DHW
supply at the bottom of the boiler.
4
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
Release the pressure of the DHW circuit by opening a hot
tap.
5
6
7
Remove the diverter valve actuator (see frame 69).
Completely unscrew the two Allen key screws A which
hold the exchanger to the brass groups.
A
72 CH DRAIN COCK REPLACEMENT
1
2
Disconnect the electrical supply
Remove front and right hand casing panels
(refer to frame 42).
3
4
Close off the isolating cocks of the CH circuit at the
bottom of the boiler.
Release system pressure by opening the main circuit
drainage cock.
Do not release CH pressure using the pressure relief
valve. It may cause debris within the system to foul
the valve.
5
6
Remove the CH drain cock A from the return body.
Re---assemble in reverse order.
A
mini HE --- Installation & Servicing
49
SERVICING
10 Reassemble carrying out the removal operations in
reverse order.
73 CONDENSATE TRAP REPLACEMENT
1
Disconnect the electrical supply
2
Remove front and right hand casing panels
(refer to frame 42).
3
Disconnect the trap from the draining pipe.
To clean the condensate trap and drain
4
Unscrew the bottom cover and remove the inner fitting
and ball.
5
6
Check and clean all parts thoroughly.
Check and clean the discharge pipe from the boiler to the
drain.
To replace the condensate trap
7
8
9
Using pliers, remove the spring A moving it upwards.
Remove the nut B and lower the trap.
Disconnect the wirings from the trap.
A
B
4
5
Squeeze the hooks that hold the programmer on the
74 PROGRAMMER REPLACEMENT
(if fitted)
control panel fascia and withdraw the faulty programmer.
Re---assemble in reverse order.
1
2
Disconnect the electrical supply.
When reassembling the new programmer, refer to the wiring
diagram in frame 31 for the correct wiring connection.
Gain access to the electronic control/ignition p.c.b. (steps
1 to 4 of frame 62).
6
Replace the panels and check the operation of the new
programmer.
3
Disconnect the wiring at the programmer.
50
mini HE --- Installation & Servicing
FAULT FINDING
The following table gives a summary of the relationship
between each of the possible lamp combinations and their
meaning.
75 ELECTRONIC CONTROL/IGNITION
P.C.B. OPTICAL INFORMATION
The electronic control/ignition p.c.b. is provided with three
lamps (L.E.D. indicators) A, that give optical information
during the normal operation of the boiler or for service and
fault fiinding purpose.
Normally operating boiler
C.h. operation
Normal operation
D.h.w. operation
The green lamp on the left is directly visible on the control
panel fascia and it gives information during the normal
operation of the boiler. The other two lamps are normally
switched off.
Frost protect operation
D.h.w. operation
Excessive temperature on primary circuit
The following table gives the relationship between the visible
lamp indication and its meaning.
Faulty c.h. temperature probe NTC
Faulty d.h.w temperature probe NTC
Faulty flue temperature probe NTC
Boiler in stand---by condition.
(function control in
position).
Anti---freeze system active.
A short pulse every 4 seconds
1 second ON 1 second OFF
Boiler ON condition
(function control in
position)
or
Faulty primary circuit
(no water or absence of flow)
Faulty air pressure switch
Lack of burner ignition (no ignition signal from
the full seqence ignition device)
Overheat thermostat lock out
Flue temperature probe NTC lock out
Lack of power supply or fauly electronic
control p.c.b. *
Faulty Electronic control/ignition p.c.b.. *
Lamp
OFF
Lamp
ON
Flashing lamp, alone
or simultaneously
with an other lamp.
Flashing lamp,
alternate with
another lamp.
* These conditions are normal only for a short time when the
power supply is applied to the boiler.
If permanent they indicate a faulty p.c.b.
76 DIVERTER VALVE ACTUATOR
SPINDLE POSITION
Spindle
visible
Spindle fully
retracted
CH mode
DHW mode
To remove the diverter valve actuator refer to frame 69.
The following illustrations indicate the relationship between
the electric command coming from the main control p.c.b.
and the position of the brass spindle when the boiler operates
in either DHW mode or CH mode.
In both figures the relationship between the position of the
actuator and the resistance of the motor windings (the motor
must be disconnected from the wiring) is also given.
9,4 Kohm
Open circuit
9,4 Kohm
Open circuit
bn = brown
bu = blue
bk = black
51
mini HE --- Installation & Servicing
FAULT FINDING
With a fast pulse showing on LED 1 the boiler will continue to
operate with a reduced performance in some fault conditions.
77 FAULT FINDING
WARNING
Before commencing fault finding please check the following:
Care must be taken when conducting fault finding tests to
guard against the risk of electric shock.
Are all wiring connections OK ?
Are the function selector settings correct
(Refer to frame 35, 36 and 39)
230 Vac is the nominal UK supply voltage. This may vary
between 253 Vac and 196 Vac.
Pay attention that if the boiler locks out five times in an hour, it
is not sufficient to press the reset button to re---start the boiler
but it is necessary to disconnect the boiler from the main
supply and, after reconnect it, to press the reset button.
When checking continuity ensure power is off to the
appliance.
START
Ensure the room thermostat (if fitted) and programmer are calling for heat
Also that all services are on and the selector switch is set to heating*
no
no
no
Are only the two
green leds on front
fascia flashing
together or
Is there 230V between
Is there at least one of
Rectify external
wiring fault
Live and Earth at the
the led flashing?
mains connection in
the control box?
alternately?
yes
yes
yes
no
no
Replace faulty fuses
and check for wiring
fault
Is there continuity
Continued on page
54 of fault finding.
across the fuses on
the PCB?
no
Are only the two green
leds on front fascia
flashing alternatively?
Wait 60 seconds
yes
yes
Is there 230V at the
Live connection to PCB
pin 4?
Repair or replace
wiring fault
yes
no
no
With the boiler in heating
mode, what is the
Replace faulty PCB
Is the gas inlet
Rectify gas supply fault
maximum burner
pressure > 17 mbar?
pressure with boiler and
system cool ?
(pressure values are
given in Table 2 page 4
yes
no
no
no
Is there at least 15V dc
at the connections on
modulator coil?
Adjust the burner
pressure. refer to
frame 35. Can the max
burner pressure* be
achieved?
Is modulator harness
continuity O.K?
Repair or replace
faulty wiring
yes
Continued
from page 56.
yes
yes
Adjust max ’stop’ on Gas
Valve to achieve the max
burner pressure*
Replace faulty PCB
yes
yes
no
no
no
no
no
no
Is there 230V
between Blue
and Brown at
th e 3 --- way
valve
Disconnect DHW
flow sensor wiring.
Does the heating
flow pipe now
Is the continuity
of th e 3 --- way
valve harness
O.K?
Does the heating
flow pipe become
warm quickly?
Is it a
system
boiler?
Is there a
DHW tap
open?
Repair or
replace
faulty
wiring
become warm?
yes
yes
yes
connection?
yes
yes
yes
Replace faulty PCB
Close
DHW
tap
no
Replace faulty
motor assembly
Remove the motor
assembly, with 230V at
the connections is the
spindle visible? Refer
to frame 76.
yes
Replace faulty valve
body assembly
Replace the DHW flow
detector sensor body.
Does the heating flow
become warm?
no
no
Replace the faulty
DHW detector
valve
Dismantle the DHW
detector valve. Refer to
frame 66 and clean.
Wh en r e --- assembl ed
with DHW taps closed,
does the heating flow
pipe become warm?
yes
Faulty sensor now
replaced
yes
Continued on page
53 of fault finding.
* see Table 2 at page 4 for the correct value
52
mini HE --- Installation & Servicing
FAULT FINDING
Continued from page
52 of fault finding
no
no
no
no
Is there between 0V dc
and 16V dc at the
connections on the
modulating coil?
Is the continuity of the
modulator harness
O.K?
Repair or replace
faulty wiring
With the boiler and
heating circuit warm
does the burner
pressure reduce if the
heating temperature
setting is reduced to
minimum?
(0=min, 16=max)
yes
yes
Is the burner pressure
within min and max
value* with the boiler
running?
Adjust burner pressure.
Refer to frame 35.
yes
Repair faulty PCB
yes
Repair faulty gas
valve
no
no
Is the boiler mode
setting correct?
Follow the instruction
“Boiler mode setting”
(Refer to frame 62)
When a DHW tap is
opened and the DHW
temperature is set to
maximum, does the
water become hot?
(Refer to frame 62)
yes
no
no
no
yes
Is the red LED
illuminated on DHW
flow sensor?
Is there 5V dc between
Is the harness
continuity O.K?
Repair or
Red and Blue on
replace
faulty
wiring
connecting harness?
yes
yes
yes
no
no
Repair faulty PCB
Is there 230V
ac between
Blue and
Black at the
3 --- way val ve
connection?
Is the
Repair or
replace
faulty
continuity of
th e 3 --- way
valve
wiring
harness
O.K?
yes
yes
Repair faulty
PCB
Remove the
motor
assembly, with
230V at the
connections is
no
no
Repair or
replace
faulty DHW
detector
valve
the spindle fully
Replace the
Dismantle the
DHW detector
valve and clean.
Refer to frame 66.
Reassemble.
Does the DHW
water become
hot?
no
retracted? Refer
to frame 76.
sensor. Is
red LED
Replace
faulty motor
assembly
illuminated?
yes
yes
Replace
faulty valve
body
Faulty
sensor
now
yes
assembly
replaced
Continued on page
58 of fault finding
* see Table 2 at page 4 for the correct value
53
mini HE --- Installation & Servicing
FAULT FINDING
Continued from
page 52 of fault
finding. Is there at
least one of the
LEDs flashing?
no
no
no
no
Are LED2 and LED 3
flashing?
Are LED2 flashing
and LED 3 on?
Continued on page
55 of fault finding
Is LED 1 flashing with
LED 2 on ?
yes
yes
yes
no
Replace faulty
thermistor
Replace faulty
thermistor
Check resistance of
DHW temperature
probe. Is it between
12 kΩ and 1.5 kΩ ?
Check resistance of
CH temperature
probe. Is it between
12 kΩ and 1.5 kΩ ?
yes
yes
Repair or replace
faulty wiring
Repair or replace
faulty wiring
no
no
no
Is the heating circuit
pressurised to at least
1 bar and fully vented
of air?
Re---pressurise
system and vent
yes
Remove the pump
nut. Does the pump
rotate freely when
turned)
Replace faulty pump
yes
When the pump
runs does the
Replace faulty
diaphragm and clean
housing of debris, if any.
refer to frame 64.
spindle of the water
flow detector
extend to operate
the micro switch?
Refer to frame 63.
yes
no
no
Replace faulty micro
switch
Is there continuity
between C and NO
contacts on micro
switch when the
switch is operated?
yes
Is the continuity of
the micro switch
harness O.K?
Repair or replace
faulty wiring
yes
Replace faulty PCB
54
mini HE --- Installation & Servicing
FAULT FINDING
Are LED 1 and LED 3
flashing with LED 2
on, plus lockout LED
on the fascia on?
Continued on
page 57 of
fault finding
no
Continued from page 54
of fault finding
yes
no
no
Is there > 17 mbar at
the gas valve inlet?
Rectify gas supply
fault.
yes
Press reset button. Is
there 230V across the
Brown and Blue gas
valve connection
Is there
Is fuse
continuity
O.K. on
PCB?
yes
no
no
230V at
Replace
fuses
Brown and
Blue at
during ignition?
gas valve
harness
yes
connector
on PCB?
yes
Replace faulty PCB
Repair or
replace
faulty wiring
no
Is there between 0V dc
and 16V dc at the
connections on the
modulating coil?
no
Is the continuity of the
Is there a burner
pressure during
ignition period?
Repair or replace
faulty wiring
no
modulator harness
O.K?
(0=min, 16=max)
yes
yes
yes
no
Is the burner pressure
within min and max
value* with the boiler
running?
Adjust burner pressure.
Refer to frame 35.
Repair faulty PCB
yes
Repair faulty gas
valve
no
no
no
no
Is there ignition at the
burner?
Rectify
Are the ignition
leads
disconnected
or damaged
and sparking
to earth?
Is a spark
visible at the
burner during
ignition?
faulty
Are the ignition
leads correctly
connected to
PCB?
connection
yes
yes
yes
yes
Replace
faulty PCB
Replace
faulty
electrode
assy. Make
connection.
no
Adjust ignition burner
pressure
Is the ignition burner
pressure correct? Refer
to frame 35.
yes
Ensure the ignition electrode position and spark gaps are correct.
Rectify or replace. Refer to frame 49.
Continued on page 56 of
fault finding
* see Table 2 at page 4 for the correct value
55
mini HE --- Installation & Servicing
FAULT FINDING
Continued from page 55
of fault finding
no
no
no
Adjust the burner minimum
pressure refer to frame 35
Can the minimum burner
pressure be achieved ?
(Pressure values are given
in Table 2 on page 4)
Is the burner light on?
yes
Is the condense freely
discharged through the
condensate trap and
pipework?
Check the condensate trap
and discharge pipework for
cleanliness
yes
yes
Replace faulty PCB
no
no
no
Is the position of the
detection electrode
correct, and electrode
undamaged? Refer to
frame 49.
Rectify electrode
position or replace
faulty electrode.
Does the burner
remain alight more
than 10 seconds?
yes
yes
no
Is the lead connected ?
yes
Connect lead correctly
Is the resistance of the
detection electrode
assembly < 5Ω from tip to
connector ?
Replace faulty detection
lead assy.
yes
no
Is the polarity of
the mains correct?
Rectify wiring fault
yes
Replace faulty PCB
Is the burner pressure
within min and max
value* with the boiler
running?
no
Adjust burner pressure.
Refer to frame 35.
yes
Refer back to page 52 of
fault finding to continue.
* see Table 2 at page 4 for the correct value
56
mini HE --- Installation & Servicing
FAULT FINDING
Continued from
page 55 of fault
finding
no
no
no
no
no
yes
no
Is LED 1 and LED 2
on and LED 3
flashing?
Is LED 1 on and
Is LED 1 on and
LED 2 and LED 3
flashing?
Is LED 1, LED 2
and LED 3 on?
Replace faulty
PCB
Is LED 1 and LED 2
flashing and LED 3
on?
LED 2 flashing?
yes
yes
yes
yes
Is there continuity of
overheat thermostat
wiring at PCB
Has the main
overheat thermostat
operated? (Check
continuity)
Repair or replace
damaged wiring
connection?
yes
yes
Allow boiler to cool
and press re---set
Replace faulty gas
valve
no
no
Remove the flue
temperature probe.
Is the resistance of
the probe > 30 KΩ ?
Is the continuity of
the flue temperature
probe harness OK?
Replace faulty wiring
yes
yes
Replace the probe
and press the reset
button
Replace faulty PCB
Allow the boiler to
cool. Is the
resistance of the flue
temperature probe
< 600 Ω ?
no
no
Is the harness in
short circuit?
Check the
recuperator
yes
yes
Replace faulty wiring
Replace the probe
and press the reset
button
no
Is there continuity
between NC and C at the
Air Pressure Switch?
no
no
Is there 230V at
the fan
connections?
Replace faulty Air
Pressure Switch.
Wait for 1 minute. Is
the fan still running?
yes
yes
yes
no
Replace faulty fan.
Is there continuity of the
Air Pressure Switch
harness?
Repair or replace
faulty wiring.
yes
Replace faulty PCB
no
no
no
Is there continuity
across C and NO on
the Air Pressure
Switch?
Are the sensing
pipes undamaged
and connected?
Replace sensing
pipes.
yes
yes
Is the flue clear and
venturi O.K?
Clear flue
Repair or replace
venturi
yes
Replace faulty Air
Pressure Switch
no
no
Is the Air Pressure
Switch harness
continuity O.K?
Repair or replace
faulty wiring.
yes
Replace faulty PCB
Is the burner on?
yes
Repair or replace
faulty flame
detection signal
connection harness.
Refer to frame 49.
57
mini HE --- Installation & Servicing
FAULT FINDING
Continued from
page 53
no
no
no
Is there > 17 mbar
gas pressure at the
gas inlet?
Rectify gas supply
fault.
Is there max burner
pressure* when the
boiler first lights?
Is there a temperature rise
of 35 ûC across the DHW
circuit at:
10.0 L/min 24 kW model
11.7 L/min 28 kW model
13.1 L/min 32 kW model
yes
yes
yes
Adjust the max setting
on the gas valve. Refer
to frame 35. Check that
max burner pressure*
can be achieved.
no
no
Is the cold water supply
adequate? refer to frame
6 and Table 1 at page 4.
Rectify water supply
fault.
Is the maximum water
flow correct
10.0 L/min 24 kW model
12.0 L/min 28 kW model
14.0 L/min 32 kW model
yes
Check the DHW inlet
filter. Remove debris
and clean or replace
filter.
no
no
no
no
Is there between 0V dc and
16V dc at the connections
on the modulating coil?
(0=min, 16=max)
Is the continuity of the
Repair or replace
faulty wiring.
With the DHW hot
does the burner
modulator harness O.K?
pressure modulate if
the DHW temperature
setting is reduced to
minimum?
yes
yes
Is the burner pressure within
min and max value* with
the boiler running?
Adjust burner pressure.
Refer to frame 35.
yes
yes
Replace faulty PCB
Replace faulty gas
valve.
Boiler Operating
Correctly
* see Table 2 at page 4 for the correct value
58
mini HE --- Installation & Servicing
The following are parts commonly required as replacements,
due to damage or expendability. The failure or absence is
likely to affect the safety and/or performance of this
appliance.
The full list is held by British Gas, Caradon Plumbing Ltd.
distributors and merchants.
When ordering spares please quote:
1
2
3
4
5
Boiler model (see Data Plate)
Appliance G.C. number (see Data Plate)
Description
Quantity
Product No.
The list is extracted from the British Gas List of Parts which
contains all available spare parts.
Key
No.
G.C. No
Description
No. Off/
Boiler
Product No.
1
173---148 Burner (mod. mini HE C24)
1
1
075427
075535
173991
173992
174481
173993
075692
173---149 Burner (mod. mini HE C28, mini HE C32)
2
H 07 --- 337 Main heat exchanger + ’O’ rings (mod. mini HE C24)
H 07 --- 542 Main heat exchanger + ’O’ rings (mod. mini HE C28)
H 45 --- 153 Main heat exchanger + ’O’ rings (mod. mini HE C32)
H 07 --- 112 Recuperator
1
1
1
3
4
1
169---069 Injectors for natural gas (mod. mini HE C24)
Injectors for natural gas (mod. mini HE C28, mini HE C32)
E 01 --- 156 Injectors for LPG (mod. mini HE C24)
Injectors for LPG (mod. mini HE C28)
12
14
12
14
14
1
173982
H 45 --- 178 Injectors for LPG (mod. mini HE C32)
H 21 --- 048 Fan (mod. mini HE C24)
174483
173983
173984
174465
173236
173136
172494
174469
075419
174462
075421
172512
075460
075540
173813
174004
172551
174478
172505
173986
174461
172533
172532
172531
170977
075514
075415
174470
172496
173987
5
H 21 --- 049 Fan (mod. mini HE C28, mini HE C32)
H 44 --- 162 Gas valve + gaskets
1
6
7
1
169---127 Air pressure switch (mod. mini HE C24, mini HE C32)
H 08 --- 605 Air pressure switch (mod. mini HE C28)
E 83 --- 013 Safety valve
1
1
8
1
9
H 44 --- 169 Electronic regulation p.c.b.
1
10
11
12
13
14
E 00 --- 684 Primary circuit flow switch
1
E 83 --- 082 DHW flow switch
1
E 00 --- 688 Main. flow switch membrane
E 83 --- 101 Overheat thermostat
1
1
E 57 --- 048 DHW heat exchanger + ’O’ rings (mod. mini HE C24)
E 57 --- 049 DHW heat exchanger + ’O’ rings (mod. mini HE C28, mini HE C32)
H 20 --- 986 Automatic air purger valve
1
1
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
H 07 --- 840 Pump + ’O’ rings
1
E 83 --- 145 Temperature---pressure gauge
H 32 --- 598 Flue temperature probe
1
1
E 83 --- 086 Three way diverter valve (electric actuator)
H 21 --- 060 Sealed chamber gaskets kit
H 32 --- 550 Magnetic flow switch and filter
E 83 --- 127 Ignition electrode --- left
1
1
1
1
E 83 --- 126 Ignition electrode --- right
1
E 83 --- 122 Detection electrode
1
E 69 --- 243 Window (glass + rubber frame)
169---141 1/2” flat gasket
1
3
169---033 3/4” flat gasket
4
H 44 --- 170 Fuse 3,15 AF
2
164---026 Temperature probe (main or DHW circuit)
H 21 --- 052 Side case panel
1
2
59
mini HE --- Installation & Servicing
31
32
H 07 --- 858 Control panel door
H 07 --- 882 Front case panel
1
1
173988
173989
2
3
1
4
5
6
7
8
9
10
11
12
13
14
15
16
20
17
18
19
22
23
24
21
25
26
27
28
29
30
30
32
31
60
mini HE --- Installation & Servicing
In addition a change to Building Regulations (England and
Wales) requires the installer to notify
when installing a heating appliance, as from 1st April 2005.
INSTALLER
NOTIFICATION
GUIDELINES
IT IS A REQUIREMENT OF CORGI MEMBERSHIP
TO REGISTER EVERY GAS APPLIANCE
Install and commission
this appliance to
manufacturers’ instructions
Complete the
Benchmark Checklist
Competent Person’s
SELF CERTIFICATION SCHEME
Choose Buildings
Regulations
notification route
BUILDING CONTROL
If you notify via CORGI Scheme,
CORGI will then notify the Building
Control (LABC) who relevant Local
Authority Building Control (LABC)
scheme on members behalf
Contact your relevant Local
Authority Building Control (LABC)
who will arrange an inspection or
contact a government approved
inspector
Scheme members only:
Call CORGI on 0870 88 88 777 or
log onto:
LABC will record the data and will
issue a certificate of compliance
within 10 days
You must ensure that the
notification number issued by
CORGI is written onto the
Benchmark Checklist
IT IS A CONDITION OF THE
MANUFACTURERS WARRANTY
THAT THE BENCHMARK
CORGI will record the data and will
send a certificate of compliance to
the property
COMMISSIONING CHECKLIST IS
FULLY COMPLETED AND LEFT
WITH THE APPLIANCE
61
mini HE --- Installation & Servicing
BENCHMARK No.
GAS BOILER COMMISSIONING CHECKLIST
NOTIFICATION No.
BOILER SERIAL No.
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes
TIME & TEMPERATURE CONTROL TO HEATING
ROOM T/STAT & PROGRAMMER/TIMER
PROGRAMMABLE ROOMSTAT
COMBI BOILER
TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER
HEATING ZONE VALVES
FITTED
FITTED
FITTED
FITTED
NOT REQUIRED
HOT WATER ZONE VALVES
NOT REQUIRED
THERMOSTATIC RADIATOR VALVES
AUTOMATIC BYPASS TO SYSTEM
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 & RECORD
GAS RATE
m3/hr
ft/hr
mbar
°C
BURNER OPERATING PRESSURE (IF APPLICABLE)
CENTRAL HEATING FLOW TEMPERATURE
CENTRAL HEATING RETURN TEMPERATURE
N/A
°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 & RECORD
GAS RATE
m3/hr
N/A
ft/hr
mbar
°C
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)
COLD WATER INLET TEMPERATURE
HOT WATER OUTLET TEMPERATURE
WATER FLOW RATE
°C
lts/min
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER’S INSTRUCTIONS?
YES
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING
THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH PARTS 4 & 7 OF THE 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? N/A
YES
CO/CO2 RATIO
THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
PRINT
SIGN
CORGI ID No.
DATE
COMMISSIONING ENG’S NAME
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
DATE
DATE
SERVICE 1
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 2
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
DATE
DATE
SERVICE 3
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 4
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
DATE
DATE
SERVICE 5
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 6
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
DATE
DATE
SERVICE 7
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 8
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
DATE
DATE
SERVICE 9
ENGINEER NAME
COMPANY NAME
TEL No.
SERVICE 10
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
Technical Training
The Ideal Boilers Technical Training Centre offers a series
of first class training courses for domestic, commercial and
industrial heating installers engineers and system
specifiers.
For details of courses please ring: . . . . . . . 01482 498 432
the code of practice for the installation
commissioning & servicing of central heating systems
Ideal boilers
P.O. Box 103, National Ave, Kingston upon Hull
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137
Caradon Ideal Limited pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
Ideal Installer/Technical Helpline: 01482 498 663
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