Ariston GENUS HE 35 Plus Technical information

GENUS
HE 35
Plus
GENUS HE 35 Plus
BFFi
Installation and
Servicing
Instructions
Type C Boilers
G.C.N:
47-116-57 (35 kW)
LEAVE THESE
INSTRUCTIONS WITH THE
END-USER
Country of destination
GB
IE
TABLE OF CONTENTS
1.
General Information
16.
Gas Convertion
2.
Control Panel
17.
Maintenance
3.
How to Use
18.
Servicing Instructions
18.1
Replacement of Parts
4.
Anti-Frost Device
5.
Maintenance
6.
Trouble Shooting
7.
8.
Time Clock
8.1
8.2
Setting the Mechanical Clock
Setting the Digital Clock
9.
General Information for the Installer
9.1
Overall View
10.
Installation
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
Delivery
Reference Standards
Siting the Appliance
Clearances
Overall View
Mounting the Appliance
Electrical Connection
Gas Connection
Water Connections
11.
Connecting the Flue
11.1
11.3
11.4
Fitting the Coaxial Flue (Ø 60/100 mm Horizontal)
Fitting the Coaxial Flue (Ø 60/100 mm Vertical)
Fitting the 5” Flue (Ø 80/125 mm - Vertical)
Fitting the Twin Pipe (Ø 80/80 mm)
12.
Electrical Connections
13.
Electrical System Diagrams
14.
Water Circuit Diagrams
15.
Commissioning
15.1
15.2
15.3
15.4
15.5
15.6
15.7
Initial Preparation
Completion
Removal and Fitting of the Case - Servicing
Pressurisation
Commissioning
Settings
Operating Faults
11.2
2
Filling Instructions
18.2
To Gain General Access
18.2.1
18.2.2
Removing the front panel
Removing the control panel
18.3
Access to the Control System
18.3.1
18.3.2
18.3.3
18.3.4
Removing the main PCB
Removing the display PCB
Removing the fuses
Removing the time clock
18.4
Access to the Combustion Chamber
18.4.1
18.4.2
18.4.3
18.4.4
18.4.5
18.4.6
18.4.7
18.4.8
18.4.9
Removing the combustion chamber front panel
Removing the air gas assembly
Removing the burner
Removing the detection electrode
Removing the ignition electrode
Removing the fan
Removing the gas valve
Removing the heat exchanger
Removing the spark generator
18.5
Access to the Water Circuit
18.5.1
18.5.2
Drain down
Removing the 3 way valve
18.5.3
18.5.4
18.5.5
18.5.6
18.5.7
18.5.8
18.5.9
18.5.10
18.5.11
18.5.12
18.5.13
18.5.14
18.5.15
18.5.16
18.5.17
18.5.18
18.5.19
18.5.20
18.5.21
Removing the heating return filter
Removing the by-pass
Removing the pressure relief valve (3 bar)
Removing the pressure relief valve (7 bar)
Removing the temperature & pressure relief
valve (7 bar)
Removing & cleaning the condensate trap
Removing the pressure gauge
Removing the pump
Removing the heating expansion vessel
Removing the DHW expansion vessel
Removing the overheat thermostat
Removing the temperature sensors (N.T.C’s)
Removing the tank temperature sensor
Removing the water pressure gauge
Removing the flow switch
Removing the DHW temperature sensor
Removing the non return valve
Removing the plate heat exchanger
Removing the tank
19.
Fault Finding Guide
20.
Short Spares List
21.
Technical Information
1.
GENERAL INFORMATION
These instructions are suitable for the GENUS HE 35 Plus boilers :
Do not forget the Log Book!
MTS supports Benchmark, the heating industry code to ensure the correct installation, commissioning and servicing of
domestic central heating systems.
To The Householder
Make sure you have a completed Log Book for your boiler. This provides a record of the commissioning of your boiler.
It contains important information about your particular installation that may be required by service engineers. The Log Book will
also provide contact details for the installer should you need guidance in the use of this appliance or if there are any problems.
As with your car, your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service
check. The service history of the appliance will be recorded on the Log Book.
In the unlikely event of any problems with your boiler or system you should first contact your installer. If your installer cannot
resolve the problem he should telephone our national service helpline.
A charge may be made if MTS Service is called out to resolve a non-product related fault.
Your statutory rights are not affected.
To The Installer
As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the Householder. Please
ensure that your customer is aware of the importance of keeping the Log Book safe as a record of the installation and the
appliance service history.
Please ensure that your customer is aware of the correct operation of the system, boiler and controls.
MTS recommend the use of protective clothing, when installing and working on the appliance i.e. gloves.
CUSTOMER CARE
MTS, as a leading manufacturer of domestic and commercial water heating appliances is committed to providing high quality
products and a high quality after sales service.
Advice on installation or servicing can also be obtained by contacting the MTS Technical and Customer Service Departments
at High Wycombe.
TECHNICAL DEPARTMENT
CUSTOMER SERVICE DEPARTMENT
Tel:
0870 241 8180
Tel:
0870 600 9888
Fax:
01494 459775
Fax:
01494 459775
GUARANTEE
The manufacturer’s guarantee is for 2 years from the date of purchase. The guarantee is invalidated if the appliance is not
installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us
in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler
without delay.
CAUTION
In the United Kingdom, installation, start-up, adjustments and maintenance, must be performed by a competent person only, in
accordance with the current Gas Safety (Installation & Use) Regulations and the instructions provided.
In the Republic of Ireland, the installation and initial start up of the appliance must be carried out by a Competent Person in
accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Buidling Regulations, reference should
also be made to the current ETCI rules for electrical installation.
All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in
your boiler Log Book. You can check your installer is CORGI registered by calling CORGI direct on:- (01256) 372300.
Improper installation may cause damage or injury to individuals, animals and personal property for which the manufacturer will
not be held liable. To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a competent
person.
If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.
This instruction booklet is especially designed for appliances installed in the UK and the Republic of Ireland
3
USER INSTRUCTIONS
2.
CONTROL PANEL
26
48
29
27
30
46
Control panel (Fig. 2.1)
ON/OFF
31
2
1
24
23
12
5
21
6
I
7
19
9
20
8
18
9
17
32
28
COMFORT
22
4
3
RESET
37
15
14
13
10
16
6
12
11
34
33
35
36
26. - On/off push button
27. - Reset push button
28. - domestic hot water function and COMFORT tank on/off button
29. - burner operation green indicator light
30. - red indicator lock-out light
31. - yellow indicator - Comfort button
32. - Central Heating control knob
stop/mini/maxi
33. - DHW control knob /mini/maxi
34. - Increasing button +
35. - Reducing button 36. - Menu button
37. - Pressure gauge
46. - Time clock
48. - Display
FIG. 2.1
Connecting bracket
Taps shown in Open position (Fig. 2.2)
39
39 : Gas service tap
40 : Water service tap
41 : Central heating flow isolating valve
42 : Central heating return isolating valve
43 & 44: Filling taps
45 : Filling loop
42
40
41
44
43
Fig. 2.2
45
* Warning the flue analysis mode must only be selected by a qualified service engineer.
4
3.
HOW TO USE
39
Switching on
1. Check that the pressure in heating system is
adequate, i.e. the pressure gauge 37 shows 1
bar minimum and 1.5 bar maximum.
2. Check that the gas service tap 39 (Fig. 3.1) is
opened (Figs. 3.2 and 3.3) and that the mains
power is on, On/Off push button 26 Power
ON.
The boiler is now ready to use.
Note : If the boiler has been turned off for some
time, the presence of air in the gas pipe
may result in a lockout.
FIG. 3.2
FIG. 3.3
+
+
FIG. 3.1
GAS COCK CLOSED
ON/OFF
27
26
COMFORT
32
30
RESET
GAS COCK OPEN
Ignition procedure
Press the button ON/OFF 26, the electronic control unit will ignite the
burner without any manual intervention (only when there is a
demand for Domestic hot water or heating). If the burner does not
ignite within the safety period, the screen will display error code A01
and the warning light 30 will come on.
To reinitialise the ignition system, press the button RESET 27.
If ignition fails again, verify that the gas tap is open before calling a
qualified technician.
32
Summer and winter operation
The boiler produces hot water for heating and Domestic hot water.
Winter operation means the production of hot water for heating and
the production of Domestic hot water. Summer operation means the
production of Domestic hot water only. The boiler control panel
allows selection of winter or summer operation.
Keep the knob 32 in the
position to select summer operation. To
select winter operation, turn the knob 32 to a position between the
minimum value and the maximum value.
32
COMFORT
32
Heating temperature control
To adjust the heating water temperature, use the knob 32, position
the pointer between the minimum and maximum values; the
temperature obtained can vary between 42°C and 82°C or 25°C and
75°C.
The heating command is activated by a mechanical programmer, or
the room thermostat or a remote unit.
Installation with regulation by external temperature
(Only activated if the external sensor is installed)
In this case, by turning the knob 32, it is possible to change the heating outlet temperature and
therefore the ambient temperature of your home. When the knob is turned, the display indicates
P6 and the heating outlet temperature can be varied by - 20 °C to 20 °C.
However, the boiler can be controlled by the timeswitch, a Clima Manager remote control or a
room thermostat.
As soon as the desired temperature is reached, the burner is switched off and the circulation
pump stops or goes into post-circulation mode.
5
Regulation of Domestic hot water
To obtain Domestic hot water, press the button
(yellow LED comes on)
COMFORT
COMFORT 28
To adjust the Domestic hot water temperature in winter or summer
operation, use the knob 33. It is possible to determine the temperature of
water stored in the tank between 40°C and 70°C.
33
COMFORT
28
Interruption of heating
To interrupt heating, turn the knob 32 to the sun position .
The boiler will continue to operate in the summer position to provide
Domestic hot water only.
32
Switch-off procedure
ON/OFF
To switch the boiler off, press the button ON/OFF 26. Close the gas tap
located under the boiler and move the boiler external power supply switch
to the OFF position.
Display: display of current operations
Afficheur gauche
Afficheur droit
During operation of the boiler, in other words when it is performing its
normal functions, the left side of the display shows a series of characters
referring to the operations, as indicated below:
0 No heating command
C Heating
R c pump in post-circulation mode for heating
d Domestic hot water
h Pump in post-circulation mode for Domestic hot water
b Tank reheating
COMFORT
On the right, the display shows (2 characters):
- in heating mode: heating installation output temperature
- in Domestic hot water distribution mode: drawing-off temperature.
- in tank reheating mode: tank temperature or drawing-off temperature.
4.
ANTI-FROST DEVICE
The boiler is fitted with a device, which in the event that the water
o
temperature falls below 8 C the pump activates and runs until a
o
temperature of 18 C is attained. In the event that the water
o
temperature falls below 3 C, the diverter valve switches to Domestic
Hot Water and the burner fires on minimum power until a temperature
o
of 33 C is attained.s
This device is only activated when the boiler is operating perfectly and
- the system pressure is sufficient;
- the boiler is powered electrically;
- gas is available.
5.
MAINTENANCE
Schedule an annual maintenance check-up for the boiler with a CORGI
registered Service Engineeer in the UK and with a competent person
as described in I.S.813 for IE.
Correct maintenance always results in savings in the cost of running
the system.
6
6.
This boiler is fitted with safety devices which are activated in certain situations
and cause the boiler to stop operating.
TROUBLE SHOOTING
CONDITIONS FOR STOPPAGE OF THE BOILER There are two types of stoppage:
- Operating failure (A)
- Safety stop (E)
OPERATING STOPPAGE "A"
This type of stoppage is displayed in the form of a number preceded by a
letter (A) as shown in the following table.
To clear this type of stoppage, press the reset button (Reset).
In the table, each error code is associated with the problem causing it to
appear.
COMFORT
In the case of error A 02, before
calling a qualified technician, check
the pressure gauge to see if the
water pressure in the appliance is 1
bar. If necessary, restore the
pressure using the filling valve
located under the boiler and perform
an ON/OFF operation by pressing
the button. If the pressure falls
frequently in the appliance, have a
plumber check for water leaks.
AFFICHEUR
N.B. Warning! The boiler is always
connected to an electrical supply.
IMPORTANT
If this type of failure occurs too often,
call an approved after sales technical
service. For safety reasons, the
boiler will only allow 5 reignition
attempts in 15 minutes (pressing of
the RESET button). After the fifth
attempt, the boiler goes into safety
shutdown mode E 99.
This is therefore not a problem in the
case of sporadic or isolated
stoppages.
7.
CAUSE
A01
A03
Three ignition attempts
A07
Too many flame separations over a period during operation
A17
A18
A33
A97
A98
A99
Input water circulation fault
The output temperature exceeds 105°C during operation
No water circulation
Fan problem
Electronic control problem
Electronic control problem
Electronic control problem
SAFETY SHUTDOWN “E”
In the event of a safety shutdown, indicated by display of the letter E followed by a
number, there is no need to take action. The boiler will automatically attempt to reset and
restart. If this does not occur, call a qualified technician. Switch off the boiler as described
in the previous paragraph, close the gas tap and move the external electrical supply
switch to the OFF position.
Antilocking of pump and three-way valve
To prevent locking of the components, the appliance performs a self-test every 24 hours:
the pump starts up for 3 seconds and the diverting valve is operated.
A method for initially filling the system and replacing lost water
during servicing and initial filling (in accordance with current Water
Regulations), is provided as an integral part of the connection kit
(see Fig. 3.1).
FILLING INSTRUCTIONS
To fill the system and replace lost water it is necessary to proceed
as follows:
- Switch off the power to the boiler;
- Ensure that the flexible hose is connected to both the cold
water inlet connection and the C.H. flow connection;
- Open the black lever on the valve for the C.H. flow connection
and slowly open the black handle on the valve for the cold water
inlet until water is heard passing through the valves;
- Once the pressure gauge 37 (Fig. 2.1) reads between 1 and
1.5 bar close the levers on both the cold water connection and the
C.H. flow connection
- Switch the power to the boiler back on.
FIG. 7.1
NOTE: THE FLEXIBLE
BEEN FILLED.
HOSE MUST BE REMOVED ONCE THE SYSTEM HAS
7
8.
TIME CLOCK
8.1
Setting the Mechanical Clock
1. General layout
The mechanical clock covers a 24 hour period. Each tappet
represents 15 minutes A (Fig 8.1). An override switch is located on
the clock B (Fig 8.1).
2. To set the time
To set the time of day, grasp the outer edge of the dial and turn
slowly clockwise until the correct time is lined up with the arrow C
(Fig. 8.1).
3. To Set the "On" and "Off" times
The clock uses a 24hours system. e.g. 8 = 8.00 am and
18 = 6.00 pm "ON" periods are set by sliding all tappets between
the "ON" time and the "OFF" time to the outer edge of the dial.The
tappets remaining at the centre of the dial are the "OFF" periods.
4. For operation
Put the selector switch B to the
symbol to control the central
heating by the clock. Put the switch B to «I» to select permanent
operation or to «0» to turn the central heating off permanently.
A
2
1
24
23
22
4
3
12
5
21
6
7
19
9
20
I
C
B
8
18
9
17
6
16
15
14
13
10
12
11
FIG. 8.1
8
Setting the Digital Clock
Manual switch
Summer and
winter time
setting
Reset
Enter
switching
times
Enter
the hours
h
Prog
.
8.2
Weekdays
flash
m
Imput
time
Enter
minutes
Day
Enter
weekday/s
Automatic
Operation
Manual
Operation
Continuous
Operation
= ON
= ON
= Continuously ON
= OFF
= OFF
= Continuously OFF
The switching
times correspond to the
program
entered.
If the current
switching mode is
changed manually,
the next switching
time will be
carried out automatically again
according to the
entered switching
program.
Operating the time switch
The step marked with the symbol “
switching program.
You can only
return to automatic
mode from the
continuously-ON
and continuouslyOFF
switching
modes by
pressing the "
"
key.
” are necessary to carry out a
Preparing for Operation
Activate the “Res” switch (=RESET) to reset the time switch to its
default setting (activate using a pencil or similar pointed instrument).
Do this:
- every time you wish to “reset” the time switch
- to erase all switching times and the current time of day.
After approximately two seconds the following display appears:
Enter current time and weekday
- Keep the “ ” key pressed down
During the summer time period press the +/- 1h key once.
Enter the hour using the “h” key
Enter the minutes using the “m” key
Enter the day using the “Day” key
1 = “Monday”..............7 = Sunday
- Release the “ ” key.
Entering the switching times
You have 20 memory Iocations available. Each switching time takes
up one memory location.
Keep pressing the “Prog” key until a free memory location is shown in
the display “– –:– –”.
9
Programme ON or OFF with the “
” key:
“ ”= OFF; “ ”= ON
Enter the hour using “h”
Enter the minutes using “m”
If a switching command is to be carried out every day (1 2 3 4 5 6
7) then store using the “ ” key, otherwise select the day(s) it is to
be carried out by using the “Day” key.
When the day seIection is left bIank, the programmed switching
instruction operates at the
same time every day
1 2 3 4 5 6 = Monday – Saturday
12345
= Monday – Friday
67
=Saturday – Sunday
Selection of single days: 1 = Mon. .............. 2 =Tues.
Save the switching time with the “ ” key.
The time switch enters the automatic operating mode and displays
the current time of day.
Begin any further entry of a switching time with the “Prog” switch. If
your entry is incomplete, the segments not yet selected will blink in
the display. After programming is completed, and you return the
time clock to the current time display with the “ ” key, the time
clock will not activate any switching instruction required for the
current time. You may need to manually select the desired
switching state with the “
” key. Thereafter, as the unit
encounters further switching instructions in the memory in real time,
it will correctly activate all subsequent switching instructions.
Manual Override Switch “
”
With the “
” you can change the current setting at any time. The
switching program already entered is not altered.
Reading the programmed switching times
Pressing the “Prog” key displays the programmed switching times until
the first free memory location appears in the display “– – : – –”.
If you now press the “Prog” key once again, the number of free memory
Iocations will be displayed, e.g. “18”. If all memory locations are
occupied, the display “00” appears.
Changing the programmed switching times
Press the “Prog” key repeatedly until the switching time you want to
change is displayed. You can now enter the new data. See point
“Entering the switching times”.
Notes on storing switching times:
If you end your entry of the switching times by pressing the “Prog” key,
then the switching time you have entered will be stored and the next
memory location displayed.
In addition, a complete switching command is stored automatically
after around 90 seconds provided no other key is pressed. The time
switch then enters the automatic operating mode and displays the
current time again.
Deleting individual switching times
Press the “Prog” key repeatedly until the switching time you wish to
delete is shown in the display. Then set to “– –” using the “h” or “m” key
and keep the “ ” key pressed down for around 3 seconds. The
switching time is now erased and the current time is displayed.
AM / PM time display
If you press the “+/-1h” and “h” keys at the same time, the time display
switches into the AM/PM mode.
10
INSTALLER INSTRUCTIONS
9. GENERAL INFORMATION FOR THE INSTALLER
Read the instructions and recommendations in these Installation and Servicing Instructions carefully to ensure proper installation,
use and maintenance of the appliance.
Keep this manual in a safe place. You may need it for your own reference while Servicing Technicians or your installer may need
to consult it in the future.
This is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.).
This appliance must be used only for the purpose for which it is designed.
The manufacturer declines all liability for damage caused by improper or negligent use.
No asbestos or other hazardous materials have been used in the fabrication of this product.
Before connecting the appliance, check that the information shown on the data plate and the Technical Information (Section 21)
comply with the electric, water and gas mains of the property. You will find the data plate on the reverse of the control panel.
Do not install this appliance in a damp environment or close to equipment which spray water or other liquids.
Do not place objects on the appliance.
Do not allow children or inexperienced persons to use the appliance without supervision.
If you smell gas in the room, do not turn on or off light switches, use the telephone or any other object which might cause
sparks.
Open doors and windows immediately to ventilate the room.
Shut the gas mains tap (at or adjacent to the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately.
If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.
Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the
appliance or carrying out maintenance.
In the case of faults or failure, switch off the appliance and turn off the gas tap. Do not tamper with the appliance.
For repairs, call your local Authorised Servicing Agent and request the use of original spare parts. For in-guarantee repairs
contact MTS (GB) Limited.
Check the following at least once a year:
1 - Check the seal of water connections, replacing the gaskets if necessary.
2 - Check the seal of the gas connections, replacing the gaskets if necessary.
3 - Check the general condition of the appliance and of the combustion chamber visually.
4 - Visual check of the combustion: clean burners if necessary.
5 - With reference to point 3, dismantle and clean the combustion chamber if necessary.
6 - With reference to point 4, dismantle and clean the injectors if necessary.
7 - Visual check of the primary heat exchanger:
- check for overheating of the exchangers fins;
- clean the exhaust side of the exchanger and fan if necessary.
8 - Regulate the gas pressure, ignition pressure, partial flame, maximum flame.
9 - Check proper operation of the heating safety system:
- maximum safety temperature;
- maximum safety pressure.
10 - Check the proper operation of the gas safety system:
- gas or flame safety device;
- gas valve safety device.
11 - Check that the electrical connections have been made in compliance wit h the instructions shown in the Installation
Instructions.
12 - Check the efficiency of the hot water supply (flow and temperature).
13 - Check pressure in the Domestic Expansion Vessel and top up as necessary.
14 - Check manually by turning the test knob the Temperature & Pressure Relief Valve.
15 - Check manually by turning the test knob the Expansion Relief Valve.
16 - Check discharge pipes from both the central heating and domestic hot water for obstructions.
17 - Check general operation of the appliance.
18 - Check the exhaust system for the combustion products.
19 - Check all unvented domestic hot water controls and systems
NOTE: These checks are not exhaustive
11
9.1
OVERALL VIEW
1. - sheet steel casing
9
2. - pressurised expansion tank
1
12
24
4. - burner/exchanger assembly
5. - 24 V fan
4
6. - air/gas connection assembly
8
3
7. - ignition electrodes
13
7
8. - flame detection electrode
9. - stainless steel Domestic hot water tank
17
15
5
16
6
19
14
22
21
23
18
25
2
10
11
12
3.- sealed casing
20
FIG. 9.1
10. - circulation pump
11.- electronic control unit
12. - ignition transformer
13.- overheat cut-off
14. - gas valve
15. - tank sensor
16. - heating outlet sensor
17. - heating return sensor
18.- distributor valve
19. - stainless steel plate Domestic hot water
exchanger
20. - Domestic hot water flow rate controller
21. - Domestic hot water sensor
22. - silencer
23. - siphon
24. - Domestic hot water expansion cylinder
25. - pressure switch
10.
INSTALLATION
The technical information and instructions provided herein below are
intended for the installer / Servicing Technician so that the unit may be
installed and serviced correctly and safely.
10.1
Delivery
There will be two items:
1 - The fully assembled boiler
2 - A separately boxed connection kit
10.2
Reference Standards
WATER REGULATIONS
In GB it is necessary to comply with the Water Supply (Water Fittings)
Regulations 1999, for Scotland, The Water Bylaws 2000, Scotland. The
Genus 30 Plus is an approved product under the Water Regulations.
To comply with the Water Regulations, you attention is drawn to The Water
Regulations guide published by the Water Regulations Advisory Scheme
(WRAS) gives full details of the requirements.
In IE, the requirements given in the current edition of I.S.813 and the
current Building Regulations must be followed.
BUILDING REGULATIONS
These are a statutory document and take priority over all other regulations
and recommendations. The installation of an unvented hot water storage
cylinder is classified as a "Controlled Service" and Regulation G3 applies.
To meet the requirements of the Regulation, installation of an unvented
system should be undertaken by a "competent installer".
All installations of unvented hot water storage systems having a capacity of
more than 15 litres should be notified to the relevant Local Authority by
means of Building Notice or by the submission of full plans. It is important
to note that it is a criminal offence to install an unvented hot water storage
system without notifying the Local Authority.
The installation of this appliance must be in accordance with the
relevant requirements of the Local Building Regulations, the current
I.E.E. Wiring Regulations, the bylaws of the local water authority, in
Scotland, in accordance with the Building Standards (Scotland)
Regulation and Health and Safety document No. 635 “Electricity at work
regulations 1989” and in the Republic of Ireland with the current edition
of I.S. 813, the Local Building Regulations (IE).
C.O.S.H.H.
Materials used in the manufacture of this appliance are non-hazardous
and no special precautions are required when servicing.
Installation should also comply with the following British Standard
Codes of Practice:
BS 7593
BS 5546
BS 5440-1
BS 5440-2
BS 5449
BS 6798
BS 6891
BS 7671
BS 7074
BS 5482
Treatment of water in domestic hot water
central heating systems
Installation of hot water supplies for
domestic purposes
Flues
Air supply
Forced circulation hot water systems
Installation of gas fired hot water boilers
of rated input not exceeding 60kW
Installation of low pressure gas pipe up to
28mm
IEE wiring regulations
Specification for expansion vessels
Installation of L.P.G.
13
and in the Republic of Ireland in accordance with the following
Codes of Practice:
I.S. 813
Domestic Gas Installations
The following BS Standards give valuable information;
BS 5546
BS 5449
BS 7074
BS 7593
Installation of hot water supplies for
domestic purposes
Forced circulation hot water systems
Specification for expansion vessels
Treatment of water in domestic hot water
central heating systems
WARNING!!
The addition of anything that may interfere with the normal
operation of the appliance without express written permission of
the manufacturer or his agent could invalidate the warranty. In GB
this could also infringe the GAS SAFETY(Installation and Use)
REGULATIONS.
In the Republic of Ireland the installation and initial start up of the
appliance must be carried out by a Competent Person in
accordance with the current edition of I.S.813 “Domestic Gas
Installations”, the current Building Regulations, reference should
also be made to the current ETCI rules for electrical installation.
10.3
Siting the Appliance
The appliance may be installed in any room or indoor area,
although particular attention is drawn to the requirements of the
current I.E.E. Wiring Regulations, in Scotland, the electrical
provisions of the Building Regulations applicable in Scotland, and
in the Republic of Ireland, the current edition of I.S.813, with
respect to the installation of the combined appliance in a room
containing a bath or shower. The location of the boiler in a room
containing a bath or shower should only be considered if there is
no alternative.
Where a room-sealed appliance is installed in a room
containing a bath or shower reference should be made to the
relevant requirements.
In GB this is the current I..E.E. WIRING REGULATIONS and
BUILDING REGULATIONS. In IE reference should be made to
the current edition of I.S.813 and the current ETCI rules.
If the boiler is to be sited into a timber framed building, reference
must be made to the current edition of the Institution of Gas
Engineers Publication IGE/UP/7 (Gas Installations in Timber
Framed Housing).
The location must permit adequate space for servicing and air
circulation around the appliance as indicated in Section 10.4.
The location must permit the provision of an adequate flue and
termination.
For unusual locations special procedures may be necessary.
BS 6798-1987 gives detailed guidance on this aspect.
A compartment used to enclose the appliance must be designed
specifically for this purpose. No specific ventilation requirements
are needed for the installation within a cupboard.
This appliance is not suitable for outdoor installation.
14
The type C appliances (in which the combustion circuit,
air vent intake and combustion chamber are air-tight
with respect to the room in which the appliance is
installed) can be installed in any type of room.
Secondary ventilation is not required with this boiler. The
boiler must be installed on a solid, non-combustible,
permanent wall to prevent access from the rear.
In order to allow for access to the interior of the boiler for
maintenance purposes, the boiler must be fitted with a
clearance of 450 mm in front 400 mm below the boiler and
200mm above the boiler, and installed in compliance with the
clearance requirements indicated in Fig. 10.1.
10.4
Clearances
10.5
Overall Dimensions
195
500
925
950
57
470
54
450mm minimum for
servicing purposes
172
54 54
145
80
Legend:
38
180
135
43
317
42
41 40 39
595
44
280
188 39 =
40 =
41 =
42 =
43 =
38 =
Gas service tap
Heating return
Heating flow
Water service tap
Tank hot water flow
Water tank
discharge valve
44 = Central heating
discharge valve
FIG. 10.1
15
10.6
Mounting the Appliance
After removing the boiler from its packaging, remove the
template from the separate box containing the connection
kit. NOTE: Pay particular attention to any test water that
may spill from the appliance.
44
39
40
41
38
42
43
FIG. 10.2
Legend:
39 = Gas service tap
40 = Heating return
41 = Heating flow
42 = Water service tap
43 = Tank hot water flow
38 = Water tank valve
44 = Heating valve
10.7
Place the template in the position the appliance is to be
mounted and after ensuring it is hanging squarely, use it to
drill the holes for the hanging bracket, connection kit and
flue pipe(s) NB: For further information relating to the flue
installation please refer to Section 11 FLUE CONNECTION. (If
the appliance is to be fitted on a wall of combustible
material, the wall must be protected by a sheet of fireproof
material).
If the appliance is to be fitted into a timber framed building,
guidance should be sought from the Institute of Gas
Engineers document REF: IGE/UP/7.
10.6.1. Drill the wall and plug using those supplied with
the connections kit, position the hanging bracket and
secure with the wall bolts supplied, assembl the
connection kit and secure to the wall. NOTE: It is highly
recommended that a spirit level be used to position the
appliance to ensure that it is perfectly level.
10.6.2. Position the appliance on the hanging bracket
and connect the connection kit to the boiler connections.
(see also Sections 10.8 Gas Connections, 10.9 Water
Connections & FIG.10.2).
Electrical Connection
For safety purposes, have a competent person carefully
check the electrical system in the property, as the
manufacturer will not be held liable for damage caused by
the failure to earth the appliance properly or by anomalies
in the supply of power. Make sure that the residential
electrical system is adequate for the maximum power
absorbed by the unit, which is indicated on the rating plate.
In addition, check that the section of cabling is appropriate
for the power absorbed by the boiler.
The boiler operates with alternating current, as indicated in
the Technical Information table (Section 21), where the
maximum absorbed power is also indicated. Make sure
that the connections for the neutral and live wires
correspond to the indications in the diagram. The
appliance electrical connections are situated on the
reverse of the control panel (see the Servicing Instructions
Section 18 for further information).
FIG. 10.3
16
Important!
In the event that the power supply cord must be changed,
replace it with one with the same specifications. Make the
connections to the terminal board located within the control
panel, as follows:
- The yellow-green wire should be connected to the
terminal marked with the earth symbol; make sure to reuse the ferrule mounted on the other supply cord;
- The blue wire should be connected to the terminal
marked “N”;
- The brown wire should be connected to the terminal
marked “L”.
Note: The diagrams for the electrical system are indicated
in Section 13.
Warning, this appliance must be earthed.
External wiring must be correctly earthed, polarised and in
accordance with relevant regulations / rules. In GB this is the
current I.E.E. WIRING REGULATIONS. In IE reference should be
made to the current edition of the ETCI rules. This boiler is supplied
for connection to a 220 - 240 V~ 50 Hz supply.
The supply must be fused at 3 A.
The method of connection to the electricity supply must facilitate
complete electrical isolation of the appliance, by the use of a fused
double pole isolator having a contact separation of at least 3 mm in
all poles or alternatively, by means of a 3 A fused three pin plug
and unswitched shuttered socket outlet both complying with BS
1363.
The point of connection to the Electricity supply must be readily
accessible and adjacent to the appliance unless the appliance is
installed in a bathroom when this must be sited outside the
bathroom.
10.8
Gas Connection
The local gas region contractor connects the gas meter to the
service pipe.
The gas installation should be in accordance with the relevant
standards. In GB this is BS6891 and in IE this is the current edition
of I.S.813.
The connection the the appliance is a 22 mm copper tail located at
the rear of the gas service cock (Fig. 10.2).
If the gas supply for the boiler serves other appliances ensure that
an adequate supply is available both to the boiler and the other
appliances when they are in use at the same time.
Pipe work must be of an adequate size. Pipes of a smaller size than
the boiler inlet connection should not be used.
10.9
Water Connections
Central Heating
Detailed recommendations are given in BS 6798:1987 and BS
5449-1:1990, the following notes are given for general
guidance.
Pipe Work:
Copper tubing to BS EN 1057:1996 is recommended for water
pipes. Jointing should be either with capillary soldered or
compression fittings.
Where possible pipes should have a gradient to ensure air is
carried naturally to air release points and water flows naturally
to drain taps.
The appliance has a built-in automatic air release valve,
however it should be ensured as far as possible that the
appliance heat exchanger is not a natural collecting point for air.
Except where providing useful heat, pipes should be insulated
to prevent heat loss and avoid freezing.
Particular attention should be paid to pipes passing through
ventilated spaces in roofs and under floors.
By-pass:
The appliance includes an automatic by-pass valve, which
protects the main heat exchanger in case of reduced or
interrupted water circulation through the heating system, due to
the closing of thermostatic valves or cock-type valves within the
system.
17
System Design:
This boiler is suitable only for sealed systems.
Drain Cocks:
These must be located in accessible positions to permit the
draining of the whole system. The taps must be at least 15 mm
nominal size an manufactured in accordance with BS 2870:1980.
Safety Valve Discharge (Primary Water):
The discharge should terminate facing downwards on the exterior
of the building in a position where discharging (possibly boiling
water & steam) will not create danger or nuisance, but in an easily
visible position, and not cause damage to electrical components
and wiring.
The discharge must not be over an entrance or a window or any
other type of public access.
Mains Water Feed - Central Heating:
There must be no direct connection to the mains water supply
even through a non-return valve, without the approval of the Local
Water Authority, and must be in accordance with water supply
regulations. Your attention is drawn to, for GB: Guidance G24.2
and recommendation R24.2 of the water regulations guide and for
IE: the current edition of I.S.813.
Filling:
A temporary method for initially filling the system and replacing
lost water during servicing and initial filling (complying to current
water regulations and byelaws) is provided. The flexible hose
must be removed once the system has been filled.
Domestic Hot Water
Storage Discharge Pipe Work
1) The tundish must be installed directly below the discharge outlet
connection of the boiler. The tundish must also be in a position visible
to the occupants, and positioned away from any electrical devices.
The discharge pipe from the tundish should terminate outside in a
safe place where there is no risk to persons in the vicinity of the
discharge and to be of metal.
2) Discharge pipes from the temperature & pressure relief and
expansion relief valve are joined together within the appliance.
3) The pipe diameter must be at least one pipe size larger than the
nominal outlet size of the safety device unless it's total equivalent
hydraulic resistance exceeds that of a straight pipe 9m long.
i.e. Discharge pipes between 9m and 18m equivalent resistance
length should be at least 2 sizes larger than the nominal outlet size of
the safety device. Between 18 m and 27 m at least 3 sizes larger, and
so on.
Bends must be taken into account in calculating the flow resistance.
See fig. 10.4 (page 19) and Table 1 (page 20).
4) The discharge pipe must have a vertical section of pipe at least 300 m
in length, below the tundish before any elbows or bends in the
pipework.
5) The discharge pipe must be installed with a continuous fall.
6) The discharge must be visible at both the tundish and the final point of
discharge, but where this is not possible or practically difficult; there
should be clear visibility at one or other of these locations. Examples
of acceptance are:
i) Ideally below a fixed grating and above the water seal in a trapped
gully.
ii) Downward discharges at a low level; i.e. up to 100 mm above
external surfaces such as car parks, hard standings, grassed areas etc.
These are acceptable providing that where children may play or
otherwise come into contact with discharges, a wire cage or similar
guard is positioned to prevent contact, whilst maintaining visibility.
18
iii) Discharges at high level; I.e. into a metal hopper and metal down
pipe with the end of the discharge pipe clearly visible (tundish visible or
not).
Or onto a roof capable of withstanding high temperature discharges of
water 3 m from any plastic guttering systems that would take such a
discharge (tundish visible).
iv) Where a single pipe serves a number of discharges, such as in
blocks of flats, the number served should be limited to not more than 6
systems so that any installation can be traced reasonably easily.
Temperature & pressure
relief valve
Metal discharge pipe (D1) from
temperature & pressure relief valve.
to tundish.
Tundish
500 mm Max.
300 mm
Min.
Metal discharge pipe (D2) from tundish
with continuous fall. See Table 2 and worked
example.
Fig.10.4
Discharge below
fixed grating.
(see page 6 for
alternative points
of discharge).
Fixed grating
Trapped gulley
The single common discharge pipe should be at least one pipe size large
than the largest individual discharge pipe to be connected.
If unvented hot water storage systems are installed where discharges
from safety devices may not be apparent I.e. in dwellings occupied by
the blind, infirm or disabled people, consideration should be given to
the installation of an electronically operated device to warn when
discharge takes place.
Note: The discharge will consist of scalding water and steam. Asphalt,
roofing felt and non-metallic rainwater goods may be damaged by such
discharges.
Warning
The outlet from the temperature & pressure relief valve must not be
used for any other purpose.
The temperature & pressure relief valve must not be removed in any
circumstances. Any of the above will totally invalidate the warranty.
Note
The discharge from the central heating and domestic hot water systems
may be joined together after the tundish.
Air Release Points:
These must be fitted at all high points where air naturally collects
and must be sited to facilitate complete filling of the system.
The appliance has an integral sealed expansion vessel to
accommodate the increase of water value when the system is
heated.
19
It can accept up to 7l (1.5 gal) of expansion water. If the heating circuit
has an unusually high water content, calculate the total expansion and
add an additional sealed expansion vessel with adequate capacity.
Domestic Water:
The domestic water must be in accordance with the relevant
recommendation of BS 5546:1990. Copper tubing to BS EN
1057:1996 is recommended for water carrying pipe work and must be
used for pipe work carrying drinking water. The domestic hot water
temperature should be be adjusted to trip at 60˚C. This temperature
will prevent the formation of limescale in hard water areas.
Note: This appliance is capable of producing domestic hot water of
up to 70˚C. For extra security against scalding a thermostatic
blending valve may be installed on the domestic hot water
outlet.
Secondary Return:
The secondary return connection can be used as an option. A Non
Return Valve (not supplied) must be fitted to prevent back flow and a
Bronze Pump will be needed in conjunction with a Pipe Thermostat to
circulate the hot water (neither of which are supplied).
Table 1. Sizing of copper discharge pipe “D2” for
common temperature valve outlet sizes.
Valve outlet size
Minimum size of
discharge pipe D1*
Minimum size of
discharge pipe D2*
from tundish
Maximum
resistance allowed,
expressed as a
length of pipe (i.e.
no elbow or bends)
Resistance created
by each elbow or
bend
G 1/2
15 mm
G 3/4
22 mm
G1
28 mm
22 mm
28 mm
35 mm
28 mm
35 mm
42 mm
35 mm
42 mm
54 mm
Up to 9 m
Up to 18 m
Up to 27 m
Up to 9 m
Up to 18 m
Up to 27 m
Up to 9 m
Up to 18 m
Up to 27 m
0.8 m
1.0 m
1.4 m
1.0 m
1.4 m
1.7 m
1.4 m
1.7 m
2.3 m
Worked Example:
The example below is for a G 1/2 Temperature & Pressure Relief valve
with a discharge pipe (D2) having 4 no. elbows and length of 7 m from the
Tundish to the point of discharge.From Table 1
Maximum resistance allowed for a straight length of 22 mm copper
discharge pipe (D2) from G 1/2 T & P valve is 9m.
Subtract the resistance for 4 no. 22 mm elbows at 0.8m each = 3.2 m.
Therefore the maximum permitted length equates to: 5.8 m.
As 5.8m is less than the actual length of 7 m therefore calculate the next
largest size.
Maximum resistance allowed for a straight length of 28 mm pipe (D2) from
G 1/2 T & P valve equates to: 18 m.
Subtract the resistance for 4 no. 28 mm elbow at 1.0m each = 4 m.
Therefore the maximum permitted length equates to: 14 m
As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory.
20
o
Residual Head of the Boiler ΔT = 20 C
Operating Pressure
m/H2O
mCE
6
Minimum flow (thermostatic valves closed)
5
GV
4
3
PV
2
1
0
100
200
300
500
400
600
700
800
900
1000
1100
1200
l/h
Fig. 10.5
16
7
12
A
BC D E
F
6
5
1
3
Pressure
Reducing Valve
V
13
Cold Water Inlet
4
Other
Users
2
9
8
8
10
11
Drain Tap
(at lowest point)
Fig. 10.6
ABCDEF1234-
Gas Inlet
C.H. Return
C.H. Flow
D.H.W. Secondary Return
D.H.W. Flow
C.W. Inlet
Gas Meter Inlet Cock
Gas Meter
Gas Meter Outlet Cock
Internal Gas Cock
5678910 11 12 13 -
Appliance Gas Inlet Cock
Cold Water Inlet Cock
D.H.W. Expansion Vessel
Cock
Secondary Return Pump
Thermostat
Time Control Clock
T&P Valve
Tundish
21
11. Connecting the Flue
The boiler should only be installed with a flue system supplied by MTS (GB) Limited.
These kits are supplied separately to the appliance in order to respond to different installation solutions. For more information
with regard to the inlet/outlet accessories consult the accessory catalogue. The boiler is supplied ready for connection to a
concentric flue system.
NOTE: SEE PAGE 28 FOR MAXIMUM AND MINIMUM FLUE RUNS (TABLES A, B AND C)
IMPORTANT!!
BEFORE CONNECTING THE FLUE, ENSURE THAT
1/4
LITRE OF
WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION
TO FILL THE CONDENSATE TRAP .
SHOULD THE TRAP BE
EMPTY THERE IS A TEMPORARY RISK OF FLUE GASSES
ESCAPING INTO THE ROOM.
Warning
The exhaust gas ducts must not be in contact with or close to inflammable
material and must not pass through building structures or walls made of
inflammable material.
When replacing an old appliance, the flue system must be changed.
Important
Ensure that the flue is not blocked.
Ensure that the flue is supported and
assembled in accordance with these
instructions.
TERMINAL POSITION
A -
Fig. 11.1
Installation without extension
B
C
D
E
F
G
H
I
J
-
K
L
M
N
-
mm
Directly above or below an openable window
or other opening
Below gutters, solid pipes or drain pipes
Below eaves
Below balconies or car-port roof
From vertical drain pipes and soil pipes
From internal or external corners
Above ground or balcony level
From a surface facing a terminal
From a terminal facing a terminal
From an opening in the car port
(e.g. door, window) into dwelling
Vertically from a terminal in the same wall
Horizontally from a terminal in the same wall
Horizontally from an opening window
Fixed by vertical flue terminal
Level
150 mm
Installation with extension
slope
* pente
150 mm
slope 55mm
perpar
metre
* pente
mm
mètre
22
300
75
200
200
150
300
300
600
1200
1200
1500
300
300
NOTE: THE FLUE MUST TERMINAL MUST
LEAST 2 METRES FROM ANY
BE AT
136
OPENING IN A BUILDING OPPOSITE AND
SHOULD NOT DISCHARGE ACROSS
BOUNDARIES.
IN ADDTION TO THIS, THE
FLUE MUST NOT TERMINATE IN A PLACE
LIKELY TO CAUSE NUISANCE.
Fig. 11.2
In addition, it is also possible to use a split
system by fitting a special adapter to the flue
discharge collar and using one of the
apertures for the air vent intake located on
the top part of the combustion chamber.
Fig.11.3
Flue
Clamp
4m
Maximum Lenght = 3
Minimum Lenght = 370 mm
X
95 mm
153
107 mm
145 mm
100 mm
Fig.11.4
Ø 60/100 mm
54
23
11.1 Fitting the coaxial flue (Ø 60/100 Horizontal)
CONTENTS:
1X SILICONE O-RING (60mm)
1X ELBOW (90 )
2X WALL SEALS (INTERNAL & EXTERNAL)
1X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100)
1X FLUE CLAMP
1X SCREWS
1x Seal
Once the boiler has been positioned on the wall, insert the elbow into the socket and rotate to the required position.
possible to rotate the elbow 360o on its vertical axis.
O
NOTE:
It is
Using the flue clamp, seals and screws supplied (Fig 11.5) secure the elbow to the boiler.
The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact X dimension of 815mm.
Measure the distance from the face of the external wall to the face of the flue elbow (X - Fig 11.4), this figure must now be
subtracted from 815mm, you now have the total amount to be cut from the plain end of the flue.
Draw a circle around the outer flue and cut the flue to the required length taking care not to cut the inner flue, next cut the inner
flue ensuring that the length between the inner and outer flue is maintained. (Fig 11.5).
e.g.
X = 555mm
815-555 = 260mm (Length to be cut from the plain end of the flue).
Once cut to the required length, ensure that the flue is free from burrs and reassemble the flue. If fitting the flue from inside of
the building attach the grey outer wall seal to the flue terminal and push the flue through the hole, once the wall seal has
passed through the hole, pull the flue back until the seal is flush with the wall. Alternatively, the flue can be installed from
outside of the building, the grey outer seal being fitted last.
Clamp
Screws
Seal
24
Fig. 11.5
11.2 Fitting the Coaxial Flue (Ø 60 / 100 Vertical)
NOTE: SEE PAGE 28 FOR MAXIMUM AND MINIMUM FLUE RUNS.
CONTENTS:
1X SILICONE O-RING (60 mm)
1X CONICAL ADAPTOR (60/100 mm)
1X VERTICAL FLUE KIT (80/125 mm)
3X SCREWS
The vertical flue kit is supplied with a specially designed weather proof terminal fitted, it can be used either with a flat roof or a
pitched roof.
The Vertical flue kits useable lengths with the pitched roof flashings are indicated in Fig. 11.6.
Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables on Page 20) and
that all elbows and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90o
elbow 1 metre must be subtracted from the total flue length, and for each 45o 0.5 metres must be subtracted from the total flue
length (the height of the vertical adaptor and a 45o bend can be seen in Fig. 11.7).
Mark the position of the flue hole in the ceiling and/or roof (see Fig. 11.6 for distance from wall to the centre of the flue).
Cut a 120 mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof.
DO NOT cut the vertical flue kit.
To connect the vertical flue kit directly to the boiler, place the vertical starter kit (Part No. 3318079) (see Figs. 11.6 & 11.7)
onto the exhaust manifold and secure with the clamp, fit the vertical adaptor onto the vertical starter kit (note: there is no need
to use a clamp to secure this as it is a push fit connection), the vertical flue kit must then be inserted through the roof flashing,
this will ensure that the correct clearance above the roof is provided as the terminal is a fixed height.
Should extensions be required, they are available in 1 metre (Part No. 3318077), 500 mm (Part No. 3318078) and 160 mm
lengths, they must be connected directly to the vertical starter kit before connecting the adaptor to allow the vertical flue kit to
be fitted. In the event that extension pieces need to be shortened, they must only be cut at the male end and it must be
ensured that the inner and outer flue remain flush.
When utilising the vertical flue system, action must be taken to ensure that the flue is supported adequately to prevent the
weight being transferred to the appliance flue connection by using 1 flue bracket per extension.
When the flue passes through a ceiling or wooden floor, there must be an air gap of 25 mm between any part of the flue
system and any combustible material. The use of a ceiling plate will facilitate this. Also when the flue passes from one room
to another a fire stop must be fitted to prevent the passage of smoke or fire, irrespective of the structural material through
which the flue passes.
153
Fig. 11.6
Fig. 11.7
25
11.3 Fitting the 5” Flue (Ø 80 / 125 Horizontal/vertical)
Should the flue require extending, the flue connections are
push fit, however, one flue bracket should be used to secure
each metre of flue.
NOTE: SEE PAGE 28 FOR MAXIMUM AND MINIMUM FLUE RUNS.
Once the boiler has been positioned on the wall, it is
necessary to insert the Ø80/125 adaptor (FIG. 11.8) for both
horizontal and vertical flue runs into the boiler flue socket
(not supplied with flue kit - Part No 3318095).
Push the adaptor onto the boilers flue connection, grease
the seals then add extensions or elbows as required, secure
the adaptor, using the clamp and screws provided.
153
To fit extensions or elbows it is first necessary to ensure that
the lip seal is fitted correctly into the inner flue, once
verified, it is simply necessary to push them together, no
clamps are necessary to secure the flue components.
Before proceeding to fit the flue, ensure that the maximum
flue length has not been exceeded (See the tables on Page
20) and that all elbows and bends have been taken into
consideration, the maximum flue length is 10 metres, for
each additional 90o elbow 1 metre must be subtracted from
the total flue length, and for each 45o 0.5 metres must be
subtracted from the total flue length (the height of the
vertical adaptor and a 45o bend can be seen in Fig. 11.9
and a 90o bend in Fig. 11.10).
Fig. 11.8
NOTE: DO NOT CUT THE VERTICAL FLUE KIT.
Fig. 11.9
Fig. 11.10
26
11.4 Fitting the twin pipe (Ø80/80)
NOTE: SEE PAGE 28 FOR MAXIMUM AND MINIMUM FLUE RUNS (TABLE C)
Where it is not possible to terminate the flue within the distance permitted for coaxial flues, the twin flue pipe can be used by
fitting a special adaptor to the flue connector and using the aperture for the air intake located on top of the combustion
chamber.
Always ensure that the flue is adequately supported, avoiding low points. (MTS supply suitable clamps as Part No. 705778).
To utilise the air intake it is necessary to:
1) Take the air intake cover off
2) Assemble the flange on the header supplied with the boiler
3) Insert the restrictor if necessary, on the tube or the elbow
4) Insert the header on the tube or the elbow up until the lower stop
(you do not have to use the washer).
5) Insert the elbow/header in the boiler air intake hole and fasten it with screws
The twin flue pipes can be fitted with or without additional elbows and need no clamps, simply ensure that the red o-ring is
inserted in the female end of the flue pipe and push the extension piece fully into the previous section of flue pipe or elbow,
check that the o-ring is not dislodged when assembling the flue.
Twin pipe can also be converted back to Coaxial flue to enable vertical termination with a coaxial kit by using the pipe bridge
(Twin - Coaxial Adaptor - Part No. 705767). When running the twin flue pipe vertically.
It is not recommended that the pipe bridge for horizontal termination, however in the unlikely event that this proves to be a
necessity it is extremely important that the entire flue has a fall of 5mm in every metre back to the boiler, and where the 60mm
inner flue of the concentric terminal connects to the pipe bridge, this point must be adequately sealed with silicone sealant to
avoid condense leakage at this point.
When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the
terminals must be a minimum of 280 mm apart and the air intake must not be sited above the exhaust terminal (refer to Fig.
29). The air intake pipe can be run horizontally, however, the terminal and the final 1 metre of flue must be installed with a fall
away from the boiler to avoid rain ingress.
It is also strongly recommended that the air intake pipe run be constructed of insulated pipe to prevent condense forming on
the outside of the tube.
The maximum permissible flue length for twin flue is dependent on the type of run used.
For flue runs with the intake and exhaust pipes under the same atmospheric conditions (TYPE 4) the maximum length is 60
metres (24kW and 30kW), for runs with the terminals under different atmospheric conditions (TYPE 5) the exhaust terminal
must extend 0.5 metres above the ridge of the roof (this is not obligatory if the exhaust and air intake pipes are located on the
same side of the building). For TYPE 5 also, the maximum permissible combined length is 60 metres (24kW and 30kW).
The maximum length is reached by combining the total lengths of both the air intake and exhaust pipes. Therefore a maximum
length of 60o metres for example, will allow a flue run of 30 metres for the air intake and 30 metres for the exhaust pipes, also
for each 90 elbow 2.2 metres must be subtracted from the total length and for each 45o elbow 1.4 metres must be subtracted
from the total flue length.
Some of the acceptable flue configurations are detailed on page 29.
For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 241 8180.
Fig. 11.12
162
200
230 MIN *
132
123,5
B23
Fig. 11.13
C53
27
123,5
107
200
25
ø 100
Fig. 11.14
In the event that twin flue pipes are used, and the boiler
has a side clearance of less than 60mm from the wall, it
is necessary to cut a larger diameter hole for the flue
pipe, this should be ø100 mm, this will then allow for
easier assembly of the air intake elbow and the tube
outside the wall (see Fig. 11.14).
60 mm
Fig. 11.15
TABLE
A
TABLE
B
Concentric outlet
60/100
Min length
Max. length
35 kW
0.3 m
4m
Concentric outlet
80/125
Min length
Max. length
35 kW
0.3 m
10 m
Length
equivalency for
45o
elbow
0.5 m
90o
elbow
1m
45o
elbow
0.5 m
90o
elbow
1m
Twin flue outlet
35 kW
100
90
80
70
60
50
40
30
20
10
0
200
180
160
140
120
100
80
60
40
20
0
ZONE DEzone
Operating
FONCTIONNEMENT
0
10
20
30
40
50
60
70
80
FlueLongueur
gas length
in metres
fumées
mètre /
VERTICAL
vertical
TABLE
C
Flue
gas length
in metres
Longueur
fumées
mètre /
HORIZONTAL
Horizontal
ZONE
DE FONCTIONNEMENT
EN CONDUITS
35 kW
Operating
zone in separate
35 SEPARES
kW ducts
90
Air length AIR
in metres
Longueur
mètre
For coaxial systems, the maximum development value, mentioned in the table above also takes into account an elbow.
For twin flue systems the maximum development value, mentioned in the table includes the exhaust gas/air intake terminal.
Type 5 outlets should respect the following instructions:
1- Use the same ø 80 mm flue pipes for the gas intakes and exhaust gas ducts.
2- If you need to insert elbows in the gas intake and exhaust gas ducts, you should consider for each one the equivalent length
to be included in the calculation of developed length.
3- The exhaust gas duct should jut above the roof by at least 0.5 m.
4- The intake and exhaust gas ducts in Type 5 must be installed on the same wall, or where the exhaust is vertical and the air
intake horizontal, the terminals must be on the same side of the building.
28
TYPE 1
TYPE 4
TYPE 3
TYPE 2
TYPE 5
FIG. 11.16
NOTE: DRAWINGS ARE INDICATIVE OF FLUEING OPTIONS ONLY.
AIR INTAKE MUST NOT BE
FITTED ABOVE THE EXHAUST
AIR INTAKE
EXHAUST
AIR INTAKE
FIG. 11.17
29
12.
ELECTRICAL CONNECTIONS
The 220-240 V and earth connection are made by
using the lead provided C (Fig. 12.1)
C
IMPORTANT!!
CONNECTION
SHOULD BE MADE VIA A
3
AMP FUSED DOU-
BLE POLE ISOLATING SWITCH WITH CONTACT SEPERATION
3MM ON BOTH POLES. ALTERNATIVELY, A
3 PIN PLUG AND UNSWITCHED SOCKET MAY
BE USED, PROVIDED IT IS NOT USED IN A ROOM CONTAINING A BATH OR SHOWER. IT SHOULD ONLY SUPPLY THE
APPLIANCE.
OF AT LEAST
FUSED
3
AMP,
External Controls
Open the cover B with a screwdriver (Fig. 12.2)
The room thermostat is connected onto this connector B (Fig. 12.1)
THERMOSTAT AMBIANCE
ROOM THERMOSTAT
- remove the bridge S (Fig. 12.3)
- connect the thermostat in place of the bridge S (Fig.
12.3)
- If a remote time clock is to be fitted, using a volt-free
switching time clock, connect the wires from the time
clock following the points above. (see also Fig. 12.4)
B
FIG. 12.1
Note: Before connecting an external time clock, disconnect the internal time clock as described in Section 18.3.4 (page 49)
Room thermostat
Connector
B
Side view of the
Raccordement
côté
connection
to the pre
boîtier
électrique
cabled
electrical
box
pré-cablé
FIG. 12.2
30
FIG. 12.3
S
Outside sensor
NE
N
W
E
S
05/2006
H
1/2 H
05/2006
05/2006
FIG. 12.4
31
13.
ELECTRICAL / SYSTEM DIAGRAMS
1 White
2 Blue
12 Red
4 White
8 White
5 Purple
9 Purple
1 Grey
Heating return
thermistor
Room
thermostat
Pump
CN12 - 1
Tank thermistor
CN12
CN12 - 2
Pressure switch
Red
1
Blue
CN12 - 4
Overheating
safety device
CN1
2 Yellow
3 Brown
Fan
4 Black
5 Red
CN2
8 White
Ionisation
1 Red
CNF
CN3 /
CN31
32
2 Blue
CN12 - 3
Gas valve
Yellow
Mass / Ground
/ Green
CN8 - 8
6
CN2
CN8 - 9
CN8 - 4
Red
CN12 - 6
CN8 - 5
Domestic hot water
thermistor
4 Black
5
CN5 - 12
Three way
valve
Domestic hot water
flowswitch
2 Grey
3 Black
CN12 - 5
CN5 - 11
CNF - 2
CN8
2 Black
11 Black
M
Heating flow
thermistor
CNF - 1
10 Grey
CN12
CN1 - 1
CN1 - 4
CN1 - 3
CN1 - 5
CN1 - 2
1 Grey
CN8
CN8 - 11
CNF
Spark generator
CN8 - 10
CN8 - 2
7 Red
11 Blue
CN5 - 9
CN5 - 10
CN5 - 8
CN1
6 Black
CN5
5 Brown
CN8 - 1
Main supply
230V 50Hz
Interface
Card
CN5
CN5
4 Yellow
14.
WATER CIRCUIT DIAGRAMS
25
22
24
6
1
3
2
4
8
23
7
11
10
5
16
17
21
20
12
14
18
15
13
26
9
32
19
27
31
LEGEND :
1 – Main heat exchanger
2 - Burner
3 – Ignition electrodes
4 – Flame detection electrodes
5 – Modulating gas valve
6 – Spark generator
7 - Siphon
8 – Domestic hot water tank
9 – Water tank valve
10 – Heating flow thermistor
11 – Tank thermistor
12 – Hot water control thermistor
13 - Pump
14 – Secondary plate heat exchanger
15 – DHW activator
30
29
28
16 – Heating return thermistor
17 – Heating expansion vessel
18 – Three way valve
19 – Heating safety valve
20 – Pressure jauge
21 – Electrical box
22 – Overheat safety device
23 - Fan
24 – Fumes box
25 – Flue pipe
26 - By-pass
27 – Non return valve
28 – Gas tap
29 – Heating return tap
30 – Heating flow tap
31 – Water service tap
32 – DHW expansion kit
33
15.
COMMISSIONING
15.1
Initial Preparation
MTS (GB) Limited support the
initiative. Within the
information pack you will find a copy of the
Log Book. It is
important that this is completed in the presence of your customer,
they are shown how to use it, and it is signed by them. Please
instruct your customer that they must have their
Log Book
with them whenever they contact a service engineer or us.
Preliminary electrical system checks to ensure electrical safety
must be carried out by a competent person i.e. polarity, earth
continuity, resistance to earth and short circuit.
FILLING THE HEATING SYSTEM:
Lower the control panel and remove the case panels (see
SECTION 15.3 for further information).
Open the central heating flow and return cocks supplied with the
connection kit.
Unscrew the cap on the automatic air release valve one full turn
and leave open permanently.
Close all air release valves on the central heating system.
Gradually open valve(s) at the filling point (filling-loop) connection
to the central heating system until water is heard to flow, do not
open fully.
Open each air release tap starting with the lowest point and close
them only when clear water, free of air, is visible.
FIG. 15.1
Purge the air from the pump by unscrewing the pump plug
anticlockwise, also manually rotate the pump shaft in the
direction indicated by the pump label to ensure the pump is
free.
Refit the pump plug.
Continue filling the system until at least 1.5 bar registers on the
pressure gauge.
Inspect the system for water soundness and remedy any leaks
discovered.
FILLING OF THE D.H.W. SYSTEM:
Close all hot water draw-off taps.
Open the cold water inlet cock supplied with the connection kit.
Open slowly each draw-off tap and close them only when clear
water, free of bubbles, is visible.
GAS SUPPLY:
Inspect the entire installation including the gas meter and test for
soundness. The gas installation should be in accordance with the
relevant standards. In GB this is BS6891 and in IE this is the
current edition of I.S.813.
The connection to the appliance is a 15 mm copper tail located at
the rear of the gas service cock (Fig. 10.3).
If the gas supply for the boiler serves other appliances ensure
that an adequate supply is available both to the boiler and the
other appliances when they are in use at the same time.
Pipe work must be of an adequate size. Pipes less than the 22
mm should not be used.
Open the gas cock (supplied with the connection kit) to the
appliance and check the gas connections on the appliance for
leaks.
34
When the installation and filling are completed, flush the system while
cold, refill, turn on the Central Heating system (SECTION 3) and run it
until the temperature has reached the boiler operating temperature.
The system must then be immediately flushed through.
The flushing procedure must be in line with BS 7593:1992 code of
practice for treatment of water in domestic hot water central heating
systems.
During this operation, we highly recommend the use of a central
heating flushing detergent (Fernox Superfloc or equivalent), whose
function is to dissolve any foreign matter that may be in the system.
Substances different from these could create serious problems to
the pump or other components.
The use of an inhibitor in the system such as Fernox MB-1 or
equivalent is strongly recommended to prevent corrosion ( sludge)
damaging the boiler and system, following the flushing procedure..
Failure to carry out this procedure may invalidate the appliance
warranty.
15.2
Completion
For IE it is necessary to complete a “Declaration of Conformity” to
indicate compliance to I.S.813. An example of this is given in the
current edition of I.S.813. In addition it is necessary to complete the
“Benchmark” Log Book.
35
15.3
Removal and fitting of the case Servicing
A
A
Removal of the case
- undo the 4 case retaining screws (Fig. 15.2)
- disengage the clips
- remove the case
A
A
A
A
FIG. 15.2
detail
A
A
Fitting the case
Remove the protective film from the front and
rear of the case
- position the case (Fig. 15.3)
- engage both clips in the case (see detail)
- fasten the 4 retaining screws A on the front
FIG. 15.3
Servicing
To maintain the unit, it is possible to move the electrical
box without having to disconnect it. The electrical box
is clipped onto the heating outlet pipe or onto the
bottom of the chassis. (Fig. 15.4)
FIG. 15.4
36
15.4 Pressurisation
(fig. 15.5)
Domestic hot water circuit
- open cold water tap 40
- drain the hot water tank and appliance by
drawing off from the various hot water taps.
Heating circuit
- check that the heating outlet tap 41 and
heating return tap 42 are fully open
- open the filling taps 43 and 44
- close these taps when the needle of the
pressure gauge 37 (under the door of the
electrical unit cover) reaches the pressure
set in § 3
- drain the appliance and re-establish the
pressure
Gas circuit
- open the gas tap 39
- flush the gas circuit
- check the sealing over the whole gas circuit
39
42
40
41
44
43
45
WARNING :
Fig. 15.5
It is very important to fully bleed the main heat exchanger of air when filling the boiler.
You must continue to bleed the heat exchanger from pump through the automatic air vent, through several
central heating and hot water cycles to ensure the air is fully bled from the system.
Refer to the installation manual for detailed guidance.
Failure to adequately bleed the boiler may damage the appliance and invalidate the warranty.
15.5 Commissioning
(fig. 15.6)
- press the on/off button ON/OFF 26 on the control panel and
turn selector 32 to the “winter” operating mode. The boiler
pump will start up and three attempts will be made to ignite
the burner (display S01, then S02. After the third attempt,
the electronic control unit will shut the appliance down as
the gas supply has been cut off; the warning light 30 comes
on and “A01” appears on the display.
- leave the pump running until all the air has been
exhausted from the appliance.
- bleed the air from the radiators
- open the Domestic hot water circuit to eliminate all the air
from it
- check the appliance pressure, and if it has fallen, add
water to bring it back to 1 bar.
- check the exhaust gas evacuation duct.
- check that the ventilator inlets for the room are fully open
(type B appliances).
6. Reset the boiler by pressing the button RESET 27.
The burner comes on. If the first attempt fails, the gas pipe
must be purged;
repeat the operation until the burner ignites.
ON/OFF
27
26
COMFORT
32
RESET
30
33
Fig. 15.6
37
15.6 Settings
Display: display of operations in progress (fig. 15.7)
During operation of the boiler, in other words when it is performing its
normal functions, the left side of the display shows a series of characters
referring to the operations, as indicated below:
Left-hand display
< Right-hand display
R
0 No heat command
C Heating
c Pump in post-circulation mode for heating
d Domestic hot water
h Pump in post-circulation mode for Domestic hot water
b Tank reheating
COMFORT
Fig. 15.7
On the right, the display shows (2 characters):
- in heating mode: heating appliance output temperature
- in Domestic hot water distribution mode: drawing-off temperature.
- in tank reheating mode: tank temperature.
ON/OFF
RESET
COMFORT
The appliance is preset in the factory. The preset factory settings are
given in the menu table.
All the settings can be changed by the installer or a qualified professional.
The settings and information on the boiler are accessible by tilting door P
of the electrical unit (fig. 15.8).
Fig. 15.8
P
Operating adjustment (fig. 15.9)
The boiler has been designed to simplify the setting of the
operating parameters.
Adjustment menu
To access the adjustment menu, first press the Reset button
RESET 27 and, holding it down, press the Menu button
36
M
for 5 seconds.
By pressing the Reset button again, the screen will display the
parameters shown in the menu table.
To change the parameters, use the
and
programming
buttons.
27
ON/OFF
RESET
COMFORT
36
Fig. 15.9
38
MENU TABLE
Parameter Function
Adjustment range
Factory settings
55
1
Ignition power as %
00 to 99 %
(step: 1%)
2
Maximum heating power (%)
00 to 99 %
(step: 1%)
66
3
Anti-cycle timer (minutes)
00 to 07 minutes
(step: 1 minute)
02
4
Minimum heating outlet temperature
25° to 42 °C if parameter r = 00
42° to 81 °C if parameter r = 01
42
5
Maximum heating outlet temperature
26° to 75 °C if parameter r = 00
43° to 82 °C if parameter r = 01
82
6
Not used
00 to 99
45
tS
E@sy remote surveillance
0 or 1
Consult the manufacturer
before changing this
parameter
0
Do not alter if the E@sy
system is not connected
03 do not alter (boiler
with tank)
F
Type of boiler
00 to 03
E
External actuator (depending on system)
00 to 03
00 do not alter
P
Post-circulation with pump in heating mode
from 01 to 15 minutes or C0
02
C
Activation/deactivation of Domestic hot
water function
00 or 01
00
Pump speed control
U0 or U1
U1
r
Heating setpoint range
00 or 01
01
P
Temperature control by external sensor
90 or 91
90
- 20 to + 20 °C
0
0_1 to 5_0
0_9
PU
P6
Gradient shift
P5
Gradient adjustment
T
Test function
A
Not used
b0
Second zone set-point
b1
Not used
b2
Post Domestic hot water timer in minutes
b3
Not used
b4
Programmer action
b5
Not used
b7
Not used
b8
Not used
Not used
25 to 82
75
00 to 30
00
0 to 2
0 on heating and tank reheating
1 on tank reheating
2 on heating
0
Important!! The parameters P5, P6 and P9 are only activated if the external sensor is connected.
To return to the standard displays, press the Menu button.
39
Ignition power output setting1
This parameter limits the power of the boiler in the ignition phase.
Possibility of adjusting ignition between maximum power (display of
"99", i.e. 100%) and minimum power (display of "00", i.e. 0%).
The percentage expresses the usable power value between the
minimum and maximum power value.
Use the
and
buttons in menu 1 to select the required value.
The factory-set value is given in the menu table.
F
Maximum heating power regulation2
This parameter limits the power of the boiler in the heating phase.
The percentage expresses the power value between the minimum and
maximum power value.
Use the
and
buttons in menu 2 to select the required value.
The factory-set value is given in the menu table.
F
Anti-cycle timer3
This parameter sets the delay between 2 successive burner ignitions in
heating mode.
It is possible to select an ignition delay of between 1 and 7 minutes.
Use the
and
buttons in menu 3 to select the required value.
The factory-set value is given in the menu table.
Minimum heating outlet temperature4
This parameter sets the minimum heating outlet temperature in relation
to r.
Use the
and
buttons in menu 4 to select the required value.
The factory-set value is given in the menu table.
Maximum heating outlet temperature5
This parameter sets the maximum heating outlet temperature in
relation to r.
Use the
and
buttons in menu 5 to select the required value.
The factory-set value is given in the menu table.
Selection of boiler typeF
Pre-set in factory:
This parameter must not be altered.
40
Selection of Secondary Output operationE
Only activated if peripheral interface card connected (option)
For connection of peripherals to the motherboard, refer to the user
instructions for the Clima Manager or the external sensor. Parameter E
is altered by the
and
programming buttons.
00 Zone valve - factory setting
01 NOT USED
02 NOT USED
03 NOT USED
Circulation pump post-circulationP
The appliance allows variation of the post-circulation period of the
circulation pump after extinction of the burner. Adjustable from 1 to 15
minutes or continuous (CO).
Use the
and
buttons in menu P to select the required value.
The factory-set value is given in the menu table.
Comfort Function : activation/deactivation of the Domestic hot
water and tank reheating functionsC
00 Domestic hot water and tank reheating functions deactivated
01 Domestic hot water and tank reheating functions activated
When the function is activated, the yellow indicator light 31 comes on.
To deactivate the Comfort function, press the COMFORT button.
The yellow indicator light 31 goes out.
Use the
and
buttons in menu C to select the required value.
The factory-set value is given in the menu table.
Circulation pump speedP
U0 - Fixed speed operation
U1 - Variable speed operation
Use the
and
buttons in menu P to select the required value.
The factory-set value is given in the menu table.
F
F
Heating temperature range settingr
00 - possibility of adjusting the temperature from 25°C to x in menu 4
possibility of adjusting the temperature from x+1 to 75°C in menu 5
where x ≤ 44 °C
01 - possibility of adjusting the temperature from 42°C to y in menu 4
- possibility of adjusting the temperature from y+1 to 82°C in menu 5
where y ≤ 81 °C
Use the
and
buttons in menu r to select the required value.
The factory-set value is given in the menu table.
Temperature control by external sensorP
(Only activated if the external sensor is installed)
“90” Temperature adjustment by external sensor deactivated (external
sensor not installed).
“91” Temperature adjustment by external sensor activated (external
sensor installed).
Use the
and
buttons in menu P to select the required value.
The factory-set value is given in the menu table.
41
Adaptation of the selected thermal curveP 6
(Only activated if the external sensor is installed)
To adapt the thermal curve to the appliance requirements, by selecting
the P 6 parameter it is possible to perform a parallel shift of the curve
in order to alter the calculated outlet temperature and therefore the
environmental temperature.
When the screen displays P 6, by using the heating setting button it is
possible to perform a parallel shift of the curve as shown below. The shift
value between -20 and +20 is shown on the display.
ift
sh
rve
u
c
lel
ral
pa
e
as
cre
n
i
-
outlet T (°C)
ase
cre
de
ft
shi
rve
u
c
lel
ral
pa
outlet T (°C)
external T (°C)
Selection of thermal curvesP 5
(Only activated if the external sensor is installed)
If the external sensor is used, the microprocessor calculates
the most suitable heating outlet temperature taking the
external temperature and the type of installation into account.
The microprocessor can do this because it is possible to
establish a link between the external temperature and the
outlet temperature of the water. This link is expressed by a
“thermal curve”.
The type of curve must be chosen according to the type of
appliance and the heat losses present in the building.
external T (°C)
The screen first displays the P 5 parameter, then the curve selected.
To change the curve selection, use the
and
programming
buttons.
Note:
If the choice of curves is made using the Clima Manager remote
control, the available values are limited. Please refer to the remote
control user instructions.
Important
When selecting a curve for low-temperature appliances, it is vitally
important to connect an overheat safety device to the base output
which will be connected to the Flora room thermostat connector on the
boiler PCB.
42
Test functionT
The boiler can be turned to maximum or minimum power without activating the test
function by using the settings menu:
a - press the reset button RESET for 5 seconds to automatically turn the boiler to its
maximum power; the screen will display two dashes in the middle and to the right
of the screen. To deactivate this function press the RESET button again.
b - press the
and
buttons simultaneously to turn the boiler to its maximum
Domestic hot water power; the screen will display two dashes at the top and to
the right of the screen. To deactivate this function press the RESET button again.
c - press the
button to turn the boiler to minimum power; the screen will display
two dashes at the bottom and to the right of the screen. To deactivate this
function press the RESET button again.
To deactivate this function press the
Selection display
RESET
button again.
The boiler is designed to operate according to function and setting variables
using the control panel display. Press the M Menu button for 10 seconds
to access the function allowing you to read the main system variables. Press
the RESET button continuously to read the following information in sequence:
Value shown on
the left-hand display
Value shown on right-hand display
U/1
Heating outlet temperature (°C)
U/2
Return temperature (°C)
U/3
Domestic hot water drawing off temperature (°C)
U/4
External temperature (°C)
U/5
Tank temperature (°C)
U/6
Fan rotation speed (Value X 100 rpm)
U/7
NOT USED
E
Last safety shutdown
A
Last operating stoppage
To return to the standard displays, press the M Menu button.
The boiler will automatically return to the standard displays after 2 minutes.
Note 1:
U/1(U/2.....) indicates that the display alternately displays U and 1 (U and 2, etc.)
Note 2:
the value 100% is displayed as "00".
* only with external sensor connected
43
15.7 Operating faults
The boiler is protected against the risk of breakdown by internal checks
carried out by the microprocessor which, if necessary, will activate a
safety shutdown.
If the appliance stops working, the screen will display a code
corresponding to the type of stoppage and its cause.
There are two types of stoppage:
- SAFETY SHUTDOWN: this type of fault (indicated on the display by
the letters "E" or "S" ) is of the "VOLATILE" type, in other words it is
automatically cleared when its cause ceases.
As soon as the cause of the stoppage disappears, the appliance will
restart and resume normal operation. While the boiler is in safety
shutdown mode, it is possible to attempt to restore operation by
switching it off and then on again.
- OPERATING STOPPAGE: this type of fault is called "NON
VOLATILE" (indicated on the display by the letter "A" ) and in this
case, the appliance does not automatically restart.
To reset the boiler, press the RESET key 27. If, after several attempts
to reset, the appliance stops again, call a qualified technician.
The following is a list of the stoppage types and the corresponding
codes displayed on the screen.
F
Display
CAUSE
A01
Three ignition attempts
A03
The output temperature exceeds 105°C during operation
A07
Too many flame separations over a period during operation
A17
Input water circulation fault
A18
No water circulation
A33
Fan problem
A97
Electronic control problem
A98
Electronic control problem
A99
Electronic control problem
N.B.: In the case of an ignition fault, check that the gas tap is open.
IMPORTANT
If this type of failure occurs too often, call an approved after sales technical service. For safety reasons, the boiler will only allow
5 reignition attempts in 15 minutes (pressing of the RESET button). After the fifth attempt, the boiler goes into safety shutdown
mode E 99.
No problem in the case of sporadic or isolated stoppages.
44
Display
CAUSE
S 01
Flame not detected on first attempt
S 02
Flame not detected on second attempt
S 04
Open circuit on Domestic hot water sensor
S 05
Short circuit on Domestic hot water sensor
S 06
Flame separation
S 25
Tank sensor open
S 26
Tank sensor short circuit
S 27
Tank overheating
S 30
External sensor open circuit
S 31
External sensor short circuit
S 80
Open circuit or short circuit on room sensor of the Clima Manager remote control
Display
CAUSE
E 02
Insufficient water pressure
E 06
Open circuit on heating outlet sensor
E 07
Short circuit on heating outlet sensor
E 08
Open circuit on heating return sensor
E 09
Short circuit on heating return sensor
E 10
Contact open in the floor overheat safety device circuit (Flora room thermostat)
E 20
False flame detection with gas valve closed
E 94
Electronic control problem
E 95
Read error in heating outlet and return sensors
E 99
5 resets in less than 15 minutes. Resetting by a boiler ON/OFF operation
Antilocking of pump and three-way valve
To prevent locking of the components, the appliance performs a self-test every 24 hours: the pump starts up for 3 seconds and the
diverting valve is operated.
Frost protection
The boiler is fitted with an anti-freeze device, which checks the heating outlet temperature of the boiler: if this temperature falls
below 8°C, the pump starts up (circulation within the heating appliance) and runs for 2 minutes.
After two minutes' circulation, the microprocessor carries out the following check:
a - if the outlet temperature is > 8°C, the pump stops;
b - if the outlet temperature is > 3°C and < 8°C the pump continues for a further 2 minutes;
c - if the outlet temperature is < 3°C, the burner is ignited (in heating mode at minimum power) until a temperature of 33°C is
reached. Once this temperature is reached, the burner switches off and the circulation pump continues to operate for a further two
minutes.
It is possible to cause the pump to operate continuously using parameter P in the settings menu (see menu table).
The antifreeze protection is only activated if the boiler is in perfect working order,
in other words:
- the appliance water pressure is sufficient;
- the boiler is receiving an electrical supply;
- gas is being supplied.
45
16. GAS CONVERSION
In the event of converting to a gas type other than that for which the boiler has been designed, the parts delivered with
the conversion kit must be fitted.
17.
MAINTENANCE
It is recommended that the following checks be made on the
boiler at least once a year:
1 - Check the seals for the water connections; replacement of any
faulty seals.
2 - Check the gas seals; replacement of any faulty gas seals.
3 - Visual check of the entire unit.
4 - Visual check of the combustion process and cleaning of the
burners if needed.
5 - If called for by check no. 3, dismantling and cleaning of the
combustion chamber.
6 - If called for by check no. 4, dismantling and cleaning of the
injectors.
7 - Visual check of the primary heat exchanger:
- check for overheating in the blade assembly;
- clean the exhaust fan if needed.
8 - Adjustment of the flow rate of the gas: flow rate for lighting, partial load §
and full load.
9 - Check of the heating safety systems:
- safety device for maximum temperature;
- safety device for maximum pressure.
10 - Check of the gas safety systems:
- safety device for lack of gas or flame ionisation (detection
electrode);
- safety device for gas cock.
11 - Check of the electrical connection (make sure it complies with the
instructions in the manual).
12 - Check of domestic hot water production efficiency (delivery rate and
temperature)
13 - Check pressure in the Domestic Expansion Vessel and top up as
necessary.
14 - Check manually by turning the test knob of the Temperature &
Pressure Relief Valve.
15 - Check manually by turning the test knob the Expansion Relief Valve.
16 - Check discharge pipes from both the central heating and domestic
hot water for obstructions.
17 - Check of the general performance of the unit.
18 - General check of the discharge/ventilation of the combustion by
products.
NOTE: THESE CHECKS ARE NOT EXHAUSTIVE
46
18. Servicing Instructions
A
To ensure efficient safe operation, it is recommended that the
boiler is serviced annually by a competent person.
Before starting any servicing work, ensure both the gas and
electrical supplies to the boiler are isolated and the boiler is
cool.
Before and after servicing, a combustion analysis should be
made via the flue sampling point (please refer to Section 15.8).
After servicing, preliminary electrical system checks must be
carried out to ensure electrical safety (i.e. polarity, earth
continuity, resistance to earth and short circuit).
18.1 Replacement of Parts
The life of individual components vary and they will need
servicing or replacing as and when faults develop.
The fault finding sequence chart in Section 19 will help to locate
which component is the cause of any malfunction, and
instructions for removal, inspection and replacement of the
individual parts are given in the following pages.
Fig. 18.1
A
18.2 To Gain General Access
Fig.18.2
All testing and maintenance operations on the boiler require the
control panel to be lowered. This will also require the removal of
the casing.
18.2.1 Removing the front panel
1. Remove the 4 retaining screws “A” (see Fig. 18.1);
2. Disengage the 2 clips (see Fig. 18.2);
3. Remove the front panel from the rest of the casing (see Fig.
18.3).
4. Reassemble in reverse order.
Fig. 18.3
18.2.2 Removing the control panel
1. Remove the front panel as above;
2. Pull the control panel toward you to disengage it from the
bottom of the chassis (see Fig. 18.4);
3. Clip the top of the control panel onto the bottom of the
chassis. (see Fig. 18.5);
4. Reassemble in reverse order.
Fig. 18.4
Fig. 18.5
47
18.3
Access to the Control System
18.3.1 Removing the main P.C.B.
1. Isolate electricity and carry out step
18.2.1 ;
2. Open the control box by pushing on
the 2 right clips “B1” (see Fig. 18.6 );
3. Push on the pressure gauge to
disengage it;
4. Disconnect as possible the
connectors on the P.C.B. ;
5. Compress the three peripheral
plastic parts “B2” to unlock the fitting
P.C.B. , and pull it toward you
simultaneously (see Fig. 18.7);
6. Disconnect
the
remaining
connectors (see Fig. 18.8 );
7. Reassemble in reverse order.
B2
B1
B2
B2
Fig. 18.7
Fig. 18.6
Fig. 18.8
18.3.2 Removing the display P.C.B.
1. Isolate electricity and carry out step 18.2.1;
2. Open the control box as above (see Fig. 18.6);
3. Remove the three screws on the control box (see Fig.
18.9);
4. Remove the four screws on the P.C.B., then pull the
card toward you and remove the connector (see Fig.
18.10);
Fig. 18.9
Fig. 18.10
5. Reassemble in reverse order and carry out the good
positioning on the control box (see Fig. 18.11).
Fig. 18.11
48
18.3.3 Removing the fuses
1.
2.
3.
4.
Isolate electricity and carry out step 18.2.1;
Open the control box as in step 18.3.1 (see Fig. 18.6);
Remove the fuses “C” (see Fig.18.12);
Reassemble in reverse order.
C
Fig. 18.12
18.3.4 Removing the time clock
To fit the integral time clock it is necessary to proceed
as follows; (this should only be carried out by a
competent engineer)
1. Isolate the electrical supply to the appliance;
2. Remove the front panel as described in step 18.2.1;
3. Open the electrical box as in step 18.3.1 and remove
the plastic cover as in step 18.3.2 (see Fig. 18.13) ;
4. Pull out the wires;
NOTE: THE WIRES MAY BE TUCKED BEHIND THE
ELECTRICAL COVER.
5. Connect the time clock wires as follows and
reassemble in reverse order.
MECHANICAL MODEL (Fig. 18.14)
Red Wire
Black Wire
Black Wire
Grey Wire
-
Contact 1
Contact 2
Contact 3
Contact 5
NOTE: THE TWO BLACK WIRES ON CONTACTS 2 & 3 CAN BE
REVERSED
DIGITAL MODEL (Fig. 18.15)
Red Wire
Black Wire
Grey Wire
-
Contact 1
Contact 2
Contact 3
NOTE: SECOND BLACK WIRE IS NOT CONNECTED.
5 4 3
G
2
B
1
3
R
2
G B
1
R
Fig. 18.13
Fig. 18.14
Fig. 18.15
49
18.4 Access to the Combustion Chamber
18.4.1 Removing the combustion chamber front panel
1. Carry out step 18.2.1;
2. Unlock the three clamp locking bolts “D” and
remove the casing (see Figs. 18.16 and 18.17);
3. Reassemble in reverse order.
D
D
Fig. 18.16
Fig. 18.17
18.4.2 Removing the air gas assembly
1. Isolate the gas supply to the boiler;
2. Carry out step 18.2.1;
3. Remove the silencer (Fig. 18.18);
4. Disconnect the detection electrode
cable (Fig. 18.19);
5. Remove the earth cable from the
ignition electrode (Fig. 18.20), and
remove the ignition electrode cable
from the ignitor (Fig. 18.21)
Fig. 18.20
Fig. 18.19
Fig. 18.18
6. Unplug the gas valve and fan connectors (Figs. 18.22 and 18.23);
Fig. 18.21
Fig. 18.23
Fig. 18.22
7. Unscrew the 6 nuts “E1” on the
combustion chamber (Fig. 18.24);
8. Unscrew the gas valve nut “E2”
(Fig. 18.25);
9. Remove the air gas assembly and
combustion chamber front (Fig. 18.26);
10. Reassemble in reverse order.
E2
E1
Fig. 18.24
50
Fig. 18.25
Fig. 18.26
18.4.3 Removing the burner
1. Carry out step 18.2.1 and 18.4.1;
2. Remove the 3 screws “F” from the
air/gas manifold (Fig. 18.27);
3. Slide the burner out from the front,
taking care not to damage the
insulation (Fig. 18.28);
4. Reassemble in reverse order and
checking all seals are undamaged
and the burner is positioned
correctly (Fig. 18.29).
F
Fig. 18.28
Fig. 18.27
Fig. 18.29
18.4.4 Removing the detection electrode
1. Carry out step 18.2.1;
2. Remove the 2 screws “G” from the
electrode manifold (Fig. 18.30);
3. Pull the electrode from the
combustion chamber (Fig. 18.31);
4. Disconnect the detection electrode
cable (Fig. 18.32).
5. Reassemble in reverse order.
G
Fig. 18.31
Fig. 18.30
Fig. 18.32
18.4.5 Removing the ignition electrode
1. Carry out step 18.2.1;
2. Remove the earth cable from the
electrode (Fig. 18.33);
3. Remove the electrode cable “H” from
the ignitor (Fig. 18.34);
4. Unscrew the 2 screws “I” on the
electrode (Fig. 18.35);
H
I
Fig. 18.33
Fig. 18.34
Fig. 18.35
51
18.4.6 Removing the fan
1. Carry out step 18.2.1;
2. Remove the air gas manifiold as in
18.4.2 (Fig. 18.36);
3. Unscrew the two screws from the
venturi “J” and remove with the gas
valve (Fig. 18.37);
J
Fig. 18.36
4. Unscrew the three screws “K” on the
air/gas pipe and remove (Fig. 18.38);
5. Reassemble in reverse order.
K
Fig. 18.37
Fig. 18.38
18.4.7 Removing the gas valve
1. Carry out step 18.2.1;
2. Remove the air gas manifiold as in
18.4.2 (Fig. 18.39);
3. Unscrew the three screws “L” on the
air/gas pipe and remove (Fig.
18.40);
4. Unscrew the three screws holding
the gas valve on the venturi (Fig.
18.41);
L
Fig. 18.39
5. Remove the gas valve from the
venturi. (Fig. 18.42);
6. Reassemble in reverse order;
7. The gas valve settings will need to be
adjusted (see Section 14.3 page 28);
8. Reinstate the gas supply and test for
tightness on reassembly.
Fig. 18.42
52
Fig. 18.40
Fig. 18.41
18.4.8 Removing the heat exchanger
1. Carry out step 18.2.1;
2. Remove the air gas manifiold as in
step 18.4.2 (Fig. 18.43);
3. Unscrew the three bolts “M” from the
main heat exchanger (Fig. 18.44);
4. Remove the flow and return pipes
and the condense drain pipe from
the heat exchanger. (Fig. 18.45);
M
Fig. 18.43
Fig. 18.44
Fig. 18.45
5. Remove the heat exchanger from
the boiler by sliding out. (Fig. 18.46);
6. Reassemble in reverse order.
Fig. 18.46
18.4.9 Removing the spark generator
1. Carry out step 18.2.1;
2. Disconnect the earth cable from the
ignition electrode. (Fig. 18.47);
3. Disconnect the ignition electrode,
live, neutral and earth cables from
the ignitor. (Fig. 18.48);
4. Remove the two screws “N” from
the ignitor and remove (Fig. 18.49);
5. Reassemble in reverse order.
N
Fig. 18.47
Fig. 18.48
Fig. 18.49
53
18.5
Access to the Water Circuit
Important ! Before any component is removed (except the 3
way valve motor), the boiler must be drained of all water.
18.5.1 Drain down
For the primary circuit :
1. Carry out steps 18.2.1 & 18.2.2;
2. Open the pressure relief valve (on the pump) (see Fig.
18.50) or the drain screw “P1” on the right hydraulic block
(see Fig.18.51);
For the D.H.W. circuit :
1. Close the water inlet tap;
2. Open a D.H.W. hot water tap;
3. Open the drain screw “P2” on the boiler (see Fig. 18.51)
To drain the tank more quickly remove the cap on the
tank (see Fig. 18.52);
Important!! Take care when removing the cap to drain the cylinder
P2
Fig. 18.50
P1
Fig. 18.51
Fig. 18.52
18.5.2 Removing the 3 way valve
1. Carry out steps 18.2.1 and 18.2.2 ;
2. Remove the clip “Q1” and the three way valve motor
(see Fig.18.53);
3. Remove the two screws “Q2” (see Fig.18.54);
Q2
Q1
Fig. 18.53
4. Then pull up the three way valve shutter (see Fig.18.55).
5. Reassemble in reverse order.
Fig. 18.55
54
Fig. 18.54
18.5.3 Removing the heating return filter
18.5.4 Removing the by-pass
1. Unscrew 1/4 ball screw “R” (see Fig. 18.56);
2. Pull it down (see Fig. 18.57);
3. Reassemble in reverse order.
1. Carry out steps 18.2.1 and 18.2.2;
2. Remove the heating filter as in step 18.6.3 ;
3. Remove the clip and pull out the By-pass (see Fig.
18.58 and 18.59);
4. Reassemble in reverse order.
R
Fig. 18.56
Fig. 18.58
Fig. 18.57
Fig. 18.59
18.5.5 Removing the pressure relief valve (3 bar)
1. Carry out steps 18.2.1 and 18.2.2;
2. Remove the clip securing the valve and disconnect
the safety valve outlet (see Fig. 18.60) and pull it
toward the left;
Fig. 18.60
3. Disconnect the flexible pipe (see Fig. 18.61);
4. Reassemble in reverse order.
Fig. 18.61
18.5.6 Removing the pressure relief valve
(7 bar)
1. Carry out steps 18.2.1 and 18.2.2;
2. Remove the clip securing the valve and unscrew the
nut with a N°24 spanner (see Fg. 18.62);
3. Reassemble in reverse order.
Fig. 18.62
55
18.5.7 R e m o v i n g t h e t e m p e r a t u r e a n d
pressure relief valve (7 bar)
1. Unscrew the nut and then unscrew the valve (see Fig. 18.63);
2. Reassemble in reverse order.
Fig. 18.63
18.5.8 Removing & cleaning the condensate trap
1. Unscrew the cap of the condensate trap (see Fig. 18.64)
2. Empty the condensate products and rinse the
condensate trap with clean water (see Fig. 18.65)
3. Reassemble in reverse order and fill the condensate trap
with 1/2 litre of water before restarting the boiler.
Fig. 18.65
Fig. 18.64
18.5.9 Removing the pressure gauge
1. Remove the casing as in step 18.2.1;
2. Pull the pressure gauge out (see
Fig. 18.67);
3. Remove the clip “T4” securing
the pressure gauge (see Fig.
18.68 );
4. Reassemble in reverse order.
T4
Fig. 18.66
56
Fig. 18.67
Fig. 18.68
18.5.10 Removing the pump
1. Carry out step 18.2.1;
2. Open the electrical box cover as in
step 18.3.1 (Fig. 18.6);
3. Remove the pump plug from the
control board and earth plug from
earth socket “T1” (see Fig. 18.69);
4. Remove the pressure relief valve 3
bar as in step 18.6.5;
5. Unscrew the pump nut “T2” and
remove the two clips “T3” on the
pump volute (see Fig. 18.70);
6. Pull the pump toward you and
remove the clip “T4” securing the
pressure gauge (see Fig. 18.71 );
7. Reassemble in reverse order.
T3
T1
T2
T3
T4
Fig. 18.70
Fig. 18.69
18.5.11 Removing the heating expansion vessel
1. Carry out step 18.2.1;
2. Remove the screw “U1” (see Fig.
18.72);
3. Pull the expansion vessel toward
you and remove the nut “U2” with a
No.17 spanner (see Fig. 18.73);
Fig. 18.71
4. To ensure the easiest access to the
hydraulic parts, hang the expansion
vessel on the chassis without
removing the nut (see Fig. 18.74);
5. Reassemble in reverse order.
U2
U1
Fig. 18.72
Fig. 18.73
Fig. 18.74
3. Remove the “Pal” nut 1/2 “V2” with a
No.34 spanner (see Fig. 18.76);
4. Pull up the expansion vessel and
unscrew the second “Pal” nut (see
Fig. 18.77);
5. Reassemble in reverse order.
18.5.12 Removing the D.H.W. expansion vessel
1. Remove the casing as in step 18.2.1;
2. Remove the nut “V1” with a No.24
spanner (see Fig. 18.75);
V2
V1
Fig. 18.75
Fig. 18.76
Fig. 18.77
57
18.5.13 Removing the overheat thermostat
1. Remove the casing as in step 18.2.1;
2. Pull off the thermostat connections. Then remove the
thermostat from the pipe by releasing it’s securing
clip (see Fig. 18.78);
18.5.14 Removing the temperature sensors
(N.T.C’s)
1. Remove the casing as in step 18.2.1;
2. Pull off the NTC connections. Then remove the NTC
from the pipe by releasing it’s securing clip (see Fig.
18.79).
Fig. 18.78
Fig. 18.79
18.5.15 Removing the tank temperature sensor
18.5.16 Removing the water pressure gauge
1. Remove the casing as in step 18.2.1 ;
2. Pull off the NTC connections. Then remove the NTC
from the tank by removing the screws (see Fig.
18.80).
1. Remove the casing as in step 18.2.1 ;
2. Pull off the connections. Then remove the clip from
the pipe (see Fig. 18.81).
Fig.18.80
Fig.18.81
18.5.17 Removing the flow switch
1. Remove the casing as in step 18.2.1 ;
2. Remove electrical connection and the two clips fixing
the flow switch (see Fig. 18.82);
3. Pull down the lower pipe and remove the flow switch;
4. Reassemble in reverse order, the arrow must be
positioned correctly (see Fig. 18.83 and 18.84);
5. Reassemble in reverse order
Fig. 18.83
Fig. 18.82
58
Fig. 18.84
18.5.18 Removing the DHW temperature sensor
1. Carry out step 18.2.1;
2. Turn the sensor support anticlockwise to liberate it
(see Fig.18.85);
3. Remove the connections (see Fig.18.86);
4. Reassemble in reverse order.
Fig. 18.85
Fig. 18.86
18.5.19 Removing the non return valve
1. Carry out steps 18.2.1 and 18.2.2;
2. Remove the clip “X1” to liberate the DHW expansion
vessel (see Fig. 18.87);
3. Remove the two clips “X2” and remove the pipe (see
Fig. 18.87);
4. Remove the two screws from the bottom of the boiler
(see Fig. 18.88) and pull the block toward you;
5. Remove the limiter from the block (see Fig.18.89);
6. Reassemble in reverse order.
X2
X2
X1
Fig. 18.87
Fig. 18.88
Fig. 18.89
18.5.20 Removing the plate heat exchanger
1. Carry out step 18.2.1;
2. Remove the isolating cover by pulling
it toward you (see Fig. 18.90);
3. Remove the screw “Y1” with a N°8
spanner (see Fig.18.91);
4. Remove the two clips “Y2” on the
right part (see Fig.18.91);
5. Pull up the exchanger to disengage
it from the pipes and remove the
screw T20 “Y3” (see Fig.18.92);
6. Reassemble in reverse order.
Y3
Y2
Y1
Fig. 18.90
Fig. 18.91
Fig. 18.92
59
18.5.21 Removing the tank
1. Remove the casing as in steps 18.2.1 and 18.2.2;
2. Remove all clips, nuts (No. 24, 25, 30 spanner) and eletrical connections (sensor) from the tank (see Fig. 18.93 & 18.94);
- Temperature and relief valve (7bar) in step 18.5.6
- Pressure relief valve (7bar) in step 18.5.7
- DHW expansion vessel in step 18.5.12
- Tank temperature sensor in step 18.5.15
- DHW temperature sensor in step 18.5.18
- Plate heat exchanger in step 18.5.20
3. Remove the nut “Z1” (N°30 spanner) and the “Pal” nut “Z2” (N°34 spanner) on the bottom of the boiler to disengage the pipe
between the chassis and the thermal valve (see Fig. 18.95);
4. Remove the two screws “Z3” on the left side panel (see Fig. 18.96);
5. Remove the nut (No. 10 spanner ) on the top of the tank (see Fig. 18.97);
6. Pull up the tank to disengage it, and then toward you to remove it.
7. Reassemble in reverse order
Fig.18. 93
Z2
Fig. 18.94
Z3
Z1
Fig. 18.95
60
Fig. 18.96
Fig. 18.97
19. FAULT FINDING GUIDE (Flow-chart)
It is possible to detect and correct defects by using the standard fault finding diagrams described in this chapter.
NOTE: THESE CHECKS ARE NOT EXHAUSTIVE.
PRELIMARY CHECKS
MAKE SURE THAT:
1 - There is sufficient water in
the system
2 - The gas is turned on
3 - The electrical supply is
turned on
TURN THE SELECTOR
KNOB TO
IS
THE POWER
L.E.D.
ON?
NO
1 - Check the fuses
2 - Check the power supply
cable, plug and outlet
3 - Check/replace the power
supply to the P.C.B.
4 - Check/replace the P.C.B
YES
ESTAT E
TURN THE DHW
CONTROL KNOB TO MAX
AND PUSH ON COMFORT
BUTTON
NO
YES
IS DHW BEING
DRAWN
NO
YES
TURN THE CH
CONTROL KNOB TO MAX
NO
YES
IS CLOCK TURNED
ON AND THE ROOM
THERMOSTAT
TURNED UP
NO
YES
A
FC P012
61
A
IS THE PUMP
RUNNING?
NO
YES
POWER TO
THE PUMP?
NO
YES
1 - Check DHW flowswitch
2 - Check pump cable
3 - Check/replace P.C.B.
1 - Check that the pump
is not stuck
2 - Release/replace pump
IS THE FAN
RUNNING?
NO
YES
POWER TO
FAN ?
NO
1 - Check/replace
connection cable
2 - Check/replace P.C.B.
YES
1 - Replace fan
IS SPARK
GENERATION FOR
IGNITION
NORMAL?
NO
YES
IS THE BURNER
ALIGHT?
NO
1 - Check power supply of
gas valve
2 - Check/replace P.C.B.
3 - Check efficiency of
gas valve
4 - Replace gas valve
YES
1 - Check if flame strikes
detection electrode
2 - Check soft-light gas
pressure
3 - Check/replace detection
electrode
4 - Check/replace P.C.B.
YES
HAS THE
BOILER SAFETY
SHUTDOWN BEEN
ACTIVATED?
1 - Check/replace ignition
electrode
2 - Check ignition cable
3 - Check spark generator
4 - Check ignition electrode
cable
5 - Check/replace P.C.B.
NO
B
62
FC P013
B
IS
THERE STILL
A PROBLEM?
NO
FAULTS
YES
1 Drawing D.H.W:
When you turn on a tap
burner switches off
2 Drawing D.H.W:
radiators heat up in summer mode
3 Drawing D.H.W:
NORMAL
OPERATION
insufficient hot water
temperature
4 Drawing D.H.W:
noisy operation
5 Decrease/increase
heating circuit pressure
6 Repeated shutdowns
POSSIBILE CAUSES
- check temperature probes
- faulty D.H.W. flow switch
- faulty 3-way valve
- check temperature probes
- check gas pressures
- check water flow rate
- primary heat exchanger faulty or
lime-scale deposits
- low heating system water pressure
- check gas pressures
- check temperature probes
- check for leaks on the heating circuit
- faulty filling-loop
- expansion vessel faulty
- faulty detection electrodes
- check gas settings
- check flame detection electric circuit
7 Repeated intervention of safety thermostat - check temperature probes
- overheat thermostat not calibrated correctly
- air in primary water circuit
8 When cold water tap turned off, the boiler
ignites
9 Insufficient radiator temperature
- drop in pressure in the water mains, with
consequent water hammer
- check C.H. temperature probe
- check by-pass and pump speed
- check gas pressures
FC P014
63
20.
SHORT SPARES LIST
SHORT LIST
649
101
721
609
102
110
606
603
736
531
543
707
726
111
538
722
401
537
515
709
506
407
502
Key N°
64
Description
Manf. Pt. N°
0101
BURNER 35KW
61314834
0102
DOOR ASSY
61313614
0110
IGNITION ELECTRODE
61317432
0111
IONIZATION ELECTRODE
61317433
0401
GAS VALVE
61315410
0407
FAN ASSY
61314434
0502
MOTOR - THREE-WAY VALVE
61302483
0506
VALVE KIT
61303330
0515
BY-PASS
61305111
0531
AIR SEPARATOR HEAD ASSEMBLY
61304608
0537
PRESSURE RELIEF VALVE
61305113
0538
PUMP + AIR SEPARATOR 15/50
61301964
PUMP + AIR SEPARATOR 15/60
61303461
0543
STOPPED WATER THROTTLE
61304982
0603
THERMISTOR TEMPERATURE SENSOR
61314258
0606
OVERHEAT THERMOSTAT 100°C
61010572
0609
WATER/WATER HEAT EXCHANGER 16
61314111
0649
PRESSURE RELIEF VALVE 7 BARS
61314112
0707
P.C.B. (ACO-MCU)
65103508
0709
IGNITER
61002105-20
0721
P. C. B. (DISPLAY)
65102235
0722
PRINTED CIRCUIT BOARD
61314958
0726
FUSE 250V 2A
60054442
0736
CLOCK
999599
Other
277783
379075
264561
Type
G
EN
US
HE
PL
US
35
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Manf. date
from
to
BENCHMARK No.
GAS BOILER COMMISSIONING CHECKLIST
BOILER SERIAL No.
NOTIFICATION No.
CONTROLS To comply with the Building Regulation, 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
CYLINDER T/STAT & PROGRAMMER/TIMER
COMBI BOILER
HEATING ZONE VALVES
FITTED
NOT REQUIRED
HOT WATER ZONE VALVES
FITTED
NOT REQUIRED
THERMOSTATIC RADIATOR VALVES
FITTED
AUTOMATIC BYPASS TO SYSTEM
FITTED
TIME & TEMPERATURE CONTROL TO HOT WATER
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
ft3/hr
BURNER OPERATING PRESSURE ( IF APPLICABLE)
N/A
mbar
CENTRAL HEATING FLOW TEMPERATURE
°C
CENTRAL HEATING RETURN TEMPERATURE
°C
FOR COMBINATION BOILERS ONLY
HAS A WATER SCALE REDUCER BEEN FITTED?
YES
NO
WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED
FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD
GAS RATE
m3/hr
ft3/hr
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)
N/A
mbar
COLD WATER INLET TEMPERATURE
°C
HOT WATER OUTLET TEMPERATURE
°C
WATER FLOW RATE
Its/min
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER’S INSTRUCTIONS?
YES
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING
✂
THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH CURRENT BUILDING REGULATIONS
THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED
IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS
IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING?
THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
COMMISSIONING ENG’S NAME
N/A
PRINT
CORGI ID N°.
SIGN
DATE
YES
CO/CO2 RATIO
S E R V I C E I N T E R VA L R E C O R D
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below.
SERVICE 1 DATE
SERVICE 2 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 3 DATE
SERVICE 4 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 5 DATE
SERVICE 6 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 7 DATE
SERVICE 8 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 9 DATE
SERVICE 10 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
✂
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
21.
TECHNICAL INFORMATION
Model
GENUS HE 35 Plus
CE certificate
1312-BP-4082
Performance category
****
NoX class
5
Category
II2H3P
Heating output
80°C/60°C
Kw
6 to 30
Heating output
50°C/30°C
Kw
7 to 32
Variable hot water power
Pn max
Kw
35
Nominal gas flow rate (15 °C-1013 mbar)
min
Central Heating & DHW flow rate
max
Qn
kW
7
31
G 20 (NG H -Lacq)
34,02 MJ/m3 under 20 mbar
Vr
m3/h
0,74
3,28
G 31 (Propane)
46,4 MJ/kg 37 under mbar
Vr
kg/h
0,54
2,41
Membrane Diameter (mm)/marking
G 20
mm
without
G 31 (propane)
mm
5
Adjustable heating outlet temperature:
°C
25 to 75 or 42 to 82
Central heating minimum flow rate
I/h
300
Central heating circuit maximum pressure
Pw max
Central heating expansion vessel capacity
Expansion vessel inflation pressure
Adjustable hot water temperature
Stored D.H.W. cylinder capacity
DHW ignition flow rate
bar
3
L
7,1
bar
0,7
°C
40 to 70
L
42
l/min.
2
D
I/min.
21,0
DHW start minimum pressure
Pw min
bar
0,3
Maximum pressure of DHW circuit
Pw max
bar
7
DHW specific flow rate (ΔT: 30 K)
DHW expansion vessel
L
4
Electric voltage
Electrical input power
230 volt, single phase - 50 Hz
W
150
Electrical protection
Fresh air flow rate required for combustion
IP44
V
m3h.
Mass flow rate for combustion products
40
15,5
Fume temperature (60-80)
°C
67
Fume temperature (30-50)
°C
60
CO2 G20
%
9
CO2 G31
%
10
Dimensions
Weight
Height / Width / Depth (mm)
kg
Flue duct type
SEDBUK
950 / 595 / 470
59
C13 C33 C43 C53 B23
Band
A
This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.
67
MTS (GB) Limited
MTS Building
Hughenden Avenue
High Wycombe
Bucks HP13 5FT
Professional Team Limited
Suites 9 & 10, Plaza 256
Blanchardstown Corporate Park 2
Ballycoolin
Dublin 15
Telephone: (01494) 755600
Telephone: (01) 810 3723
Fax: (01494) 459775
Fax: (01) 810 3727
Internet: www.mtsgroup.com/uk
Internet: www.mtsgroup.com/ie
E-mail: info@uk.mtsgroup.com
E-mail: info@ie.mtsgroup.com
Technical Advice: 0870 241 8180
Technical Advice: (01) 437 0121
Customer Service: 0870 600 9888
Customer Service: (01) 437 0121
420010011201 - 07/2007
Commercial subsidiaries: