Professional Documents
Culture Documents
&
capriz 28
Condensing
Wall Mounted
Combination Boiler
Installation, Servicing
& User Instructions
www.heatline.co. uk
Contents
Section
Page
Preface
1. Installation Regulations
2. Technical Data
3. Boiler Characteristics
4. Operation
5. General Installation
6. Appliance Siting
10
10
12
9. Electrical Connections
13
15
16
17
17
14. Commissioning
18
18
19
20
22
24
32
Appendices
Spare Parts List
33
User Instructions
34
38- 39
Page 1
Preface
Warnings
Manual Handling:
02
IMPORTANT NOTE
Speed 2 is the factory default setting
for the Pump.
This setting should be suitable for
most of your applications.
3
NOTE: Cables on the cap ; 1- Ionisation cable
2 - Earth cable
3 - Condensate hose
Page 2
03
Handling
This appliance is heavy, truck if possible and obtain assistance if required.
To remove the appliance :
1. Carefully slit or remove the scaling tape being careful not to scratch the appliance door.
2. fully open the carton lid and remove any instructions & components.
3. Read the instructions carefully before installation of the appliance.
4. Roll the carton onto its open face.
5. Lift the carton free of the inner packaging.
6. Remove the mounting bracket and valve package.
7. Stand the boiler on its base within the styrene block and remove the top packaging piece.
8. If you wish to remove the stryene base lie the appliance on its back to do so.
Page 3
1. Installation Regulations
1.1. Correctly may invalidate your guarantee and may
lead a dangerous situation.
1.2. Your CORGI registered engineer should carry a
CORGI ID card containing their registration
number, which should be recorded in your
BENCHMARK Log Book, which is supplied with
the Instructions. You can check the validity of
this ID number by contacting CORGI on 0800 915
0480.
1.3. This appliance must be installed in accordance
with the Gas Safety (Installation and Use)
Regulations, current Building Regulations,
Building Standards (Scotland), I.S.813 Installation
of Gas Appliances (Ireland), IEE Wiring
Regulations (BS 7671), Health and Safety
Document No. 635 (Electricity at Work
Regulations) and Local Water Authority Bye
Laws.
1.4. On installation the following British Standards
must also be considered:
04
Page 4
2. Technical Data
Capriz 25
(25 kW)
05
Capriz 28
(28 kW)
Capriz 25
(25 kW)
Capriz 28
(28 kW)
kW
25.7
28.5
Maximum heating
temperature
85
85
kW
24.7
27.6
64
64
kW
11
11
PMS
Nominal
(Min)
3
1.5
(0.8)
3
1.5
(0.8)
kW
10.2
10.2
Useful efficiency at
100% load
96
PMS
(Min)
8
(0.25)
8
(0.25)
102.4
103.3
Litres
Burner injector
mm.
1.20 NG
0.75 LPG
1.15 NG
0.75 LPG
bar
Burner Pressure
(Natural Gas)
mbar
Max 12.5
Min 2.5
Max 14
Min 2.3
11
13.12
mbar
Burner Pressure
(Propane)
Power Supply
Max. power
consumption
Level of Protection
Case Dimensions
Input 220~240V-50Hz
Watt
220
IPX 4 D
96.8
Expansion Vessel
Pre-charge Pressure
220~240V-50Hz
mm
100/125
100/125
mm
60/80
60/80
3.0
(60/100)
7.0
(80/125)
3.0
(60/100)
7.0
(80/125)
20
(80/80)
22
(80/80)
1.0
1.0
1.5
1.5
Net weight
kg
37
38
Gross Weight
kg
40
41
220
IPX 4 D
Page 5
13
14
15
t t h e r ea
Figure 1
t t h e r ea
16
12
11
10
9
17
8
18
7
6
19
20
21
22
t t h e r ea
06
23
24
1
A
25
E
A - Heating Flow
B - D.H.W. Outlet
C - Gas Inlet
D - Cold Water Inlet
E - Heating Return
(22mm)
(15mm)
(22mm)
(15mm)
(22mm)
Key
1 - D.H.W. Sensor
2 - Diverter Valve Motor (Three Way Valve Motor)
3 - Diverter Valve (Three Way Valve)
4 - Condensate Trap
5 - Limit Safety Thermostat
6 - Expansion Vessel (At rear of the boiler)
7 - Burner
8 - Flame Sensor (Ionisation) Electrode
9 - C.H. Sensor (Heating Sensor)
10 - Combustion Chamber
11 - Primary Heat Exchanger
12 - Fan Hood
13 - Fan
Page 6
3. Boiler Characteristics
3.1 The Capriz 25 / 28 is a fan flued, wall- mounted
condensing type combination boiler that supplies both
central heating and mains fed domestic hot water.Being
room sealed the boiler may be installed in any room or
internal compartment without the need for purpose
made combustion ventilation. However, if the boiler is
installed in a compartment it is recommended that the
compartment is ventilated for cooling purposes. A
functional diagram of the boilers principal
components is given as figure 1. A functional diagram
of the boilers principal components is given as
07
4. Operation
4.1 Using the operating switch the boiler can be set to
operate either on domestic hot water only or
domestic hot water and heating.
Note: Domestic hot water demand draws preference
over heating. During heating periods the boiler will
automatically revert back to heating mode, after
a draw off of hot water, but there will be a 45sec
delay if the No.3 dipswitch is set to the OFF position.
See figure 21.
Figure 2a
Page 7
5. General Installation
4.3 DOMESTIC HOT WATER MODE:
On opening a hot water outlet the boiler
automatically responds to fire the boiler and
supply the water-to-water heat exchanger with hot
water via the three port valve, located on the
hydro-block. The boilers electronic control unit
automatically modulate the burners output to
maintain the required temperature at the faucet.
Hot water will continue to flow until the faucet is
closed and the boiler automatically shuts down.
Note that the pump will continue to run for a
further 10secs to dissipate the residual heat from
the boiler.
Figure 2b
08
Page 8
09
Page 9
6. Appliance Siting
6.1 If the boiler is to be installed in any room or
compartment, it requires no purpose made ventilation
for combustion air. If sited in a room containing a bath
or shower then particular reference is drawn to the
requirements of British Standard 7267 (confirm)
(I.E.E. Wiring Regulations) and Building Regulations.
6.2 If the boiler is installed in a compartment there
must be purpose made ventilation for cooling purposes.
6.3 The boiler is not suitable for external installation
unless protected by a purpose made building such as a
boiler house.
10
Page 10
Figure 4
11
Internal Corner
L o c a ti o n
A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
Notes:
External Corner
Double Corners
D e s c r i p ti o n ( S e e d i a g r a m )
C le a r a n c e (m m )
B e low a n ope ning ( S e e N ote 1 )
300
A bove a n ope ning
300
H oriz onta lly to a n ope ning
300
B e low gutte rs , s oil pipe s or dra in pipe s
75
B e low e a ve s
200
B e low ba lc ony or c a r port roof
200
F rom a ve rtic a l dra in pipe or s oil pipe
150
From an internal or external corner or to a boundary alongside the
300
terminal (See Note 2)
A bove ground, roof or ba lc ony le ve l
300
From a surface or a boundary facing the terminal (See Note 2)
600
F rom a te rmina l fa c ing the te rmina l
1200
F rom a n ope ning in the c a r port into the building
1200
V e rtic a lly from a te rmina l on the s a me wa ll
1500
H oriz onta lly from a te rmina l on the s a me wa ll
300
F rom a s truc ture on the roof or a nothe r roof te rmina l
600
F rom a ve rtic a l flue te rmina l to a n a dja c e nt wa ll
300
From a vertical flue terminal to an adjacent wall which includes an
1000
opening window (See Note 3)
1. An opening here means an opening element, such as an openable window, or a
fixed opening such as a air vent. However, in addition, the outlet should not be
nearer than 150mm to an opening into the building fabric formed for the purpose
of accommodating a built in element, such as a window frame.
2. Boundary as defined in the Building Regulations (England & Wales) or the
Building Standards (Scotland) Regulations.
3. Where the wall adjacent to a vertical flue terminal includes an opening window,
the clearance between the terminal and any part of the opening window must
not be less than 1000 mm.
Page 11
C42-C52
80/80
24 kW
80
80
80
28 kW
80
82
82
C12-C32
60/100
80/125
C42-C52
80/80
24 kW
>1 m
>2 m
28 kW
>1 m
>2 m
12
WARNING!
ONLY A HEATLINE APPROVED FLUE IS TO BE
USED WITH HIS PRODUCT.FAILURE TO COMPLY
WITH THIS REQUIREMENT WILL INVALIDATE YOUR
GUARANTEE AND COULD LEAD TO A DANGEROUS
SITUATION.
Page 12
9. Electrical Connections
9.1 The boiler is supplied factory wired complete with
1.5 m of mains fly lead. All electrical connections to
the mains supply must be made in full accordance
with the current I.E.E. regulations.
9.2 The boiler must be connected to an effective earth
system. Using the cable supplied the boiler may be
connected via a 3 amp fused three pin plug to an
unswitched shuttered socket outlet. However if the
boiler is installed in a room containing a bath or
shower regulations dictate that disconnection must be
incorporated in the fixed wiring with a switch provided
for disconnection from the mains supply having a
contact separation of at least 3 mm on all poles and
fused at 3 amp.
13
Figure 7
FITTED
BRIDGE
BRIDGE PLUG
Important Note
Connection to the mains electrical supply must be
maintained at all times in order to provide domestic
hot water, frost protection and pump over-run
facility. Ensure that the boilers electrical supply is
not interrupted by any external controls.
PRINTED CIRCUIT
BOARD
Figure 8
Page 13
HALL
EFFECT SENSOR
r
r
AIR PRESSURE
SWITCH
GAS CONTROL
VALVE
FAN
r
PUMP
g g
g/y
LIMIT
SAFETY
THERMOSTAT
DOMESTIC
HOT WATER
SENSOR
w
w
w
w
g
WATER
PRESSURE
SENSOR
IGNITION
ELECTRODES
FLAME
(IONISATION)
ELECTRODE
THREE WAY
VALVE
CENTRAL HEATING
SENSOR
r
r
WATER
FLOW
SENSOR
OVERHEAT
THERMOSTAT
r
w
g/y
CHASSIS
EARTH
g/y
FUSES (2A)
br
r w g
br
r
w
r
bk
F1 F2
b br
br
PRINTED
CIRCUIT
BOARD
r
r w
w
b
g/y
g/y
g/y
g/y
b
w w
w
24V ROOM
THERMOSTAT
CONNECTION
(low voltage)
r r
w w
5 4 3 2 1
14
230V ROOM
THERMOSTAT
CONNECTION
(high voltage)
24V TIME
CLOCK
(low voltage)
USER
INTERFACE
KEY
br
b
g/y
g
gn
bk
m
r
w
BROWN
BLUE
GREEN/YELLOW
GREY
GREEN
BLACK
MAUVE
RED
WHITE
L E N
230V~50Hz PERMANENT
MAINS SUPPLY
FUSED AT 3A
FUSE RATINGS:
F1: 2 A
F2: 2 A
Figure 9
Page 14
Dimension
A
B
C
Capriz 25
405
169
60/100
Capriz 28
430
169
60/100
15
Figure 12
10.4 When cutting the flue hole it is recommended that a
105mm diameter core drill is used where both internal
and external access for the flue installation is available.
Where only internal access is available a 125mm
diameter core drill should be used. (Note: Please take
adequate precautions to prevent debris entering the
boiler via the flue outlet).
330
10.5 Using a 85mm drill bit, drill the holes for fixing jig
(optional) and hanging bracket. Locate and secure the
supplied wall mounting bracket in position (figure 13 ).
130
130
Figure 13
720
BOILER
CONDENSATE
CONNECTION
50
98
10.6 Mount the boiler onto the fixing bracket via the
boiler mounting slots, (figure 13 ).
SDV
outlet
(CONDENSING)
86
86
151
151
A
CENTRAL HEATING
DOMESTIC WATER
Figure 10.
Page 15
(Figure 16).
Figure 16
L+20 mm
Figure 14
Waste
CONDENSATE
TRAP
CONDENSATE
OUTLET PIPE
External
wall face
Figure 15
16
10.11 Cut the outer air duct only to the required length
ensuring that the cut is square and free from burrs.
10.12 Measuring from the back of the terminal
connection, mark distance 'L' + 20mm (figure 14 ) onto
the inner flue duct and cut the duct to size, ensuring
that the cut is square and free from burrs.
Page 16
bar
23
22
21
20
24
17
18
19
bar
14
15
16
13
12
11
8
10
Figure 18
1- Timer
4- C.Heating temperature control
2- D.H.W. temperature control 5- System pressure gauge
3- Function switch
6- LED display
17
Figure 17
12.7 When the system is bled of any air it must be refilled until the pressure shown on the display gauge
indicates a system pressure of 1.5 bar.
12.8 If the pressure shown on the gauge exceeds 1.5
bar discharge the excess pressure from the system via
a radiator valve or pipe connection. Do not use the
safety discharge valve as the valve seat may become
contaminated with debris and fail to re-seal.
Boiler Stand-by
Indicator
ON
30
Water
Temperature
40
50
70
80
90
bar
Flashing
Fault on CH
sensor
Flashing
Fault on
Outdoor sensor
Flashing
Fault on
DHW sensor
Page 17
60
bar
Flashing
Fault on Air
Pressure Switch
Flashing
Low System
Pressure
Flashing
Flames or Gas
Failure
Flashing
Overheat
Themostat
Important Note.
In order to maintain the appliances warranty and
so as to comply with the Domestic Heating
Compliance Guide; when the boiler is to be
installed to an existing central heating system,
the system must be properly cleansed using a
proprietary cleanser before the boiler is
connected to the system. On all installations,
after connecting the boiler to the system and
initially filling with water, a proprietary inhibitor
must be added to the system water to prevent
corrosion.
14. Commissioning
Important Notice
18
P7
P5
POTENTIOMETER
ADJUSTMENT
COVER
POTENTIOMETERS
4 OFF
P2
P4
Figure 19
Page 18
Figure 20
Figure 23
QH Chart
7
6
POTENTIOMETERS
DIP SWITCHES
5
4
3
ON
1 2 3 4 5 6 7 8
Figure 21
P7
1
0
0.0
P5
0.5
1.0
1.5
2.0
2.5
3.0
3.5 Q
POTENTIOMETERS
4 OFF
P2
19
P4
DIP SWITCH
ON POSITION
ON
DIP
ON
DIP
3 4
ON
1 2 3 4 5 6 7 8
8 DIP SWITCHES IN
THE OFF POSITION
DIP SWITCH
OFF POSITION
DIP
3 4
Figure 22
Page 19
Create demand
S
T
A
R
T
Yes
No
Yes
Mains LED ON ?
No
Yes
No
Go to Chart 3
If boiler temperature
> 6 C frost
protection activated
Yes
Is pump running ?
No
Check pump wiring
connections & voltage
Is 240 Vac present at
pin X15 on PCB ?
Repressurise system
No
Go to Chart 2
Yes
Go to Chart 2
No
Yes
Replace PCB
No
20
No
LED ON?
S
T
A
R
T
Is Central Heating
LED flashing ?
Yes
No
Is overheat LED
flashing ?
Yes
Check overheat
thermostats
No
Is the pump running
?
Yes
Go to Chart 3
No
Check wiring /
connections mains
voltage @ pin X12
pin X16 & X17
Yes
No
Replace pump
Replace PCB
Page 20
Yes
Yes
Go to Chart 4
No
Check fan / tubes /
flue assembly and
case seals
No
Yes
Yes
Replace Fan
Yes
No
Check the air
pressure switch
operation
Yes
Replace PCB
Replace PCB
No
FAULT FINDING CHART 4
21
S
T
A
R
T
Does appliance
perform a prepurge of fan &
pump ?
Yes
Yes
Yes
Go to Chart 5
No
No
Are any LED faults
indicated ?
Does sparking
commence ?
Yes
Replace PCB
Yes
Go to Chart 2
Yes
No
Does the boiler
attempt to light 3
times in 1 minute
intervals
No
Yes
Does boiler
go to lock out ?
Yes
Reset by turning to
standby for 15 secs
Yes
Go to
Chart 5
No
No
Is flame present
before lock out?
Check burner /
injectors gas
pressures & probe
No
Check gas valve /
gas supply and
pressu res
Check ignition and ionisation
probes for correct position &
damage
Go to
Chart 5
Go to
Chart 5
Page 21
Yes
Normal operation
No
RETAINING
LUGS
Yes
No
INNER
CASING
PANEL
Replace PCB
Figure 26
VIEWING
WINDOW
22
SECURING
SCREWS
Figure 27
SECURING
SCREWS
(4 OFF)
SIDE PANELS
SECURING
SCREWS (6 OFF)
Figure 28
Figure 25
COMBUSTION
CHAMBER
COVER
SECURING
SCREWS
Page 22
VIEWING
WINDOW
Figure 31
18.7 Disconnect the electrical leads and air pressure
switch connection tube from the fan, remove the fan
screws and withdraw fan from fan hood with its 56
bend. (Figure 29)
ELECTRICAL
CONNECTIONS
HALL
EFFECT
SENSOR
PRESSURE SWITCH
CONNECTION TUBE
SECURING SCREW
Figure 29
FAN
EARTH
LEAD
SECURING
SCREW
PRESSURE SWITCH
CONNECTION TUBE
FAN HOOD
23
from
the
BURNER
RIGHT HAND
SIDE OF BURNER
SENSING TUBE
Important.
GROMMET
Figure 30
32)
Carefully disconnect the leads from the sensor.
Figure 32
CAUTION!
24
DOMESTIC HOT
WATER SENSOR
CENTRAL HEATING
SENSOR
ELECTRICAL
CONNECTIONS
Figure 33
Page 24
19.8 Burner
Note.
The replacement burner is supplied as component
parts and requires assembly on site.
Remove the burner assembly from the combustion
chamber as detailed in Section 18.7 retaining all
washers/gaskets for use on re-assembly.
WARNING!
Ensure that the earth lead is re-connected.
INJECTOR
BURNER
INJECTOR BAR
25
Figure 35
BRACKET
SECURING
SCREWS (2 OFF)
ELECTRICAL
CONNECTIONS
SENSING TUBES
(2 OFF)
AIR PRESSURE
SWITCH
Figure 34
Page 25
RETAINING CLIPS
Figure 36
CONTROLS FASCIA
N L
RETAINING CLIPS
Figure 40
Fit the replacement motor in reverse order ensuring
correct polarity of the electrical connections.
Re-open the isolating valves on the flow and return
connections, refill, vent and re-pressurise the
system and check for leakage.
19.10b Replacing the pump body:
CONTROLS CIRCUIT
BOARD COVER
Figure 37
Remove the motor as described above.
Remove the secondary water-to-water
exchanger as detailed in (19.12).
F1 F2
26
heat
PRINTED
CIRCUIT
BOARD
SCREW
OFF
19.10 Pump
Figure 38
(Figure 41)
UNION
NUT
CLIP
COVER
EXPANSION
VESSEL
PIPE
Figure 39
SECURING
SCREW
CLIP
PUMP
HEAD
PUMP
BODY
Page 26
PRESSURE
GAUGE
CONNECTION
PUMP
BODY
Figure 41
SECURING
SCREWS
SECURING
SCREW
Figure 42
Remove the pump assembly.
Remove the pump body from the hydraulic
assembly by releasing the clip.
27
SECURING SCREWS
Figure 44
Remove the exchanger from the gap on the left hand
side.
Figure 45
LOW WATER
PRESSURE
SENSOR
THREE WAY
VALVE MOTOR
Figure 43
Fit the new heat exchanger checking that the plate
numbers are the same and reassemble the boiler in
reverse order ensuring all washers are fitted or
replaced as required.
ELECTRICAL
CONNECTIONS
Page 27
SECURING
SCREWS (6 OFF)
MODULATING
COIL
SCREW
COMBUSTION
CHAMBER
COVER
19.13
28
VIEWING
WINDOW
ELECTRICAL
AND EARTH
CONNECTIONS
Figure 46
(Figure 48)
Rotate the gas pipe and withdraw gas valve
assembly.
Refit in reverse order to removal, the polarity of the
wires to the modulating coil is not important,
replace any damaged washers as required.
Check gas soundness and correct boiler operation.
Figure 47
ELECTRICAL
PLUG
GAS
ISOLATION
VALVE
SECURING
SCREWS
Page 28
Figure 48
SECURING NUT
40
60
20
80
mbar
Figure 49
Figure 50
Figure 52
29
Lift the vessel out of boiler from the gap over the
chasis (Figure 53 ) and fit the replacement vessel to
the boiler in reverse order to removal, ensuring that
sealing washer is fitted to pipe connection before
tightening, replace the washer if necessary.
Using a pressure gauge, ensure that expansion
vessel charge pressure is 05bar (75psi)
Figure 53
Figure 51
Open the isolating valves on the flow and return
connections, refill, vent and pressurise the boiler
ensuring all joints are sound.
PRESSURE
SAFETY RELIEF
VALVE
UNSCREW
TO REMOVE
(Figures 54a& b)
Disconnect the electrical connections from
the thermostat.
LIMIT SAFETY
THERMOSTAT
DISCHARGE
PIPE
Figure 54a
ELECTRICAL
CONNECTIONS
R.H. HYDRAULIC
BLOCK
Figure 55
19.19 Hydroblock
Drain the boilers hydraulic circuit as detailed in
(19.2).
Remove the secondary heat exchanger as
described in (19.12)
PIPE CLIP
30
Figure 54b
PRIMARY
HEAT
EXCHANGER
OVERHEAT SAFETY
THERMOSTAT
Figure 56
ELECTRICAL
CONNECTIONS
DOMESTIC HOT
WATER SENSOR
FLOW
SENSOR
ELECTRICAL
CONNECTION
Figure 59
Figure 57
UNCLIP
TO REMOVE
31
Figure 58
19.20 Filter.
ELECTRICAL
CONNECTION
CLIP
Figure 60
THREE WAY
VALVE MOTOR
Page 31
32
Check the
pressures.
minimum
and
maximum
burner
Important.
Attach the labels supplied as follows:
Replace the adhesive User Instruction label.
Stick the LPG label in a prominent position within the
boiler.
Stick the foil label over the existing gas type on the
data plate of the boiler.
SHOULD YOU SMELL GAS: Turn the gas valve off at the
Gas Meter or Gas Cylinder, ventilate the room by opening
windows and doors (EXTINGUISH ANY NAKED FLAMES,
DO NOT OPERATE ANY ELECTRICAL SWITCHES) and call
Transco on 0800 111 999 or if you use LPG call your gas
supplier.
Page 32
APPENDICES
SPARE PARTS LIST
33
PART No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
DESCRIPTION
HYDROBLOCK THREE WAY VALVE PART
HYDROBLOCK PUMP PART
LOW PRESSURE SWITCH
SAFETY VALVE
PU M P
EXPANSION VESSEL
GAS VALVE
BURNER (WITH MANIFOLD-24 kW NG)
BURNER (WITH MANIFOLD-28 kW NG)
CONTROL PANEL
PCB COVER
ELECTRONIC CONTROL BOARD
SECONDARY HEAT EXCHANGER 24 kW
SECONDARY HEAT EXCHANGER 30 kW
INTERFACE CARD
CH SENSOR
WATER PRESSURE GAUGE
OVERHEAT SAFETY THERMOSTAT
IGNITION ELECTRODE - RIGHT
IGNITION ELECTRODE - LEFT
FLAME SENSE ELECTRODE
FAN
AIR PRESSURE SWITCH
FRONT PANEL CAPRIZ 25
FRONT PANEL CAPRIZ 28
CONDENSATE TRAP
TURBO EXCHANGER
WIRING HARNESS
Page 33
ORDER CASE
3003200017
3003201529
3003200038
3003200019
3003201336
3003200028
3003200419
3003202153
3003202154
3003202178
3003200084
3003202166
3003200026
3003200025
3003200183
3003200152
3004090673
3002185050
3003202200
3003202201
3003202102
3003202165
3003200032
3003200176
3003200177
3003201775
3003200486
3003202174
25 &
34
28
Condensing
Wall Mounted
Combination Boiler
User Instructions
www.heatline.co.uk
35
Page 35
bar
23
22
21
20
24
17
18
bar
14
15
16
13
12
11
8
10
36
19
Figure 2
1- Timer
4- C.Heating temperature control
2- D.H.W. temperature control 5- System pressure gauge
3- Function switch
6- LED display
or
Figure 1
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3.
4.
5.
6.
7.
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www.heatline.co. uk
Heatline
Nottingham Road,
Belper,
Derbyshire,
DE56 1JT
Tel: 01773 596 099
Fax: 01773 828 123
Email: sales@heatline.co.uk