Users Guide

Installation and Servicing Instructions

TP 23 - G.C. Number 47-116-32

TP 30 - G.C. Number 47-116-33

Manufacturered by Merloni TermoSanitari spa - Italy

Country of destination: GB - IE

TABLE OF CONTENTS

USERS GUIDE

1. GENERAL INFORMATION

2. OPERATING INSTRUCTIONS

3. BOILER SHUTDOWN SITUATIONS

4. TIME CLOCK

INSTALLATION AND SERVICING

INSTRUCTIONS

5.

GENERAL INFORMATION

5.1

General Instructions

5.2

Overall View

6.

INSTALLATION

6.1

Reference Standards

6.2

Siting the Appliance

6.3

Overall Dimensions

6.4

Clearances

6.5

Mounting the Appliance

6.6

Electrical Connection

6.7

Gas Connection

6.8

Water Connections

6.9

Flue Connection

6.10 Control Panel

6.11 Removing the front panel

6.12 Fitting the Time Clock

6.13 Room Thermostat Connection

6.14 Electrical/System Diagrams

6.15 Water Circuit Diagram

7. COMMISSIONING

7.1

Initial Preparation

7.2

Initial Start up

7.3

Operational Adjustments

7.4

Combustion Analysis

7.5

Product of Combustion Discharge Monitoring

7.6

Boiler Safety Systems

7.7

Draining the System

7.8

Completion

7.9

Operational checks

7.10 Instructing the End User

8. GAS ADJUSTMENTS

8.1

Changing the Type of Gas

8.2

Adjusting the gas pressure

9. MAINTENANCE

10. SERVICING INSTRUCTIONS

10.1

Replacement of Parts

10.2

To Gain General Access

10.2.1 Removing the Front Panel

10.2.2 Removing the Sealed Chamber Front Panel

10.2.3 Removing the Side Panels

10.3

Access to the Combustion Chamber

10.3.1 Removing the Combustion Cover

10.3.2

Removing the Burner and Jets

10.3.3 Removing the Electrodes

10.3.4 Removing the Main Heat Exchanger

10.3.5 Removing the Air Pressure Switch

10.3.6 Removing the Fan

10.4

Access to the Gas Valve

10.4.1 Removing the Spark Generator

10.4.2 Removing the Gas Valve

10.5

Access to the Water Circuit

10.5.1 Removing the D.H.W. (secondary) exchanger

10.5.2 Removing the Pump Pressure Switch

10.5.3 Removing the Safety Valve

10.5.4 Removing the Automatic Air Vent

10.5.5 Removing the Pump

10.5.6 Removing the Pressure Gauge

10.5.7 Removing the Expansion Vessel

10.5.8 Removing the Overheat Thermostat

10.5.9 Removing the Central Heating Temperature

Sensor (N.T.C.)

10.5.10Removing the D.H.W.Temperature Sensor (N.T.C.)

10.5.11Removing the D.H.W. Flow Switch

10.5.12Removing the Divertor Valve Actuator

10.6

Access to the Control System

10.6.1 Checking the Fuses

10.6.2 Removing the Time Clock

10.6.3 Removing the P.C.B.

11. FAULT FINDING

11.1 Fault Finding Guide (Flow-chart)

12. SHORT SPARE PARTS LIST

13. TECHNICAL INFORMATION

2

USERS GUIDE

1. General Information 2. Operating Instructions

This is a combined appliance f or the production of centr al 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 f or damage caused b y improper or negligent use.

Do not allow children or inexperienced persons to use the appliance without supervision.

If you smell gas in the room, do not turn on light switches, use the telephone or any other object which might cause spar ks.

Open doors and windows immediately to ventilate the room.

Shut the gas mains tap (on 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 v alve.

Before any intervention within the boiler it is first necessary to cut off the electrical power supply by turning the external switch to “OFF”.

Control Panel

K J I H G F E D

A B C

L

EGEND

:

A - On/Off button

B - Central heating temperature adjustment

C - Domestic hot water temperature adjustment

D - Heating system pressure gauge

E - Time clock

F - Central heating selector

G - Central heating L.E.D. (green)

H - Flue sensor L.E.D. (yellow)

I - Ignition failure (lockout) and/or overheat reset button

J - Overheat and/or ignition failure (lockout) L.E.D. (red)

K - ON/OFF L.E.D. (green )

Installation, start-up, adjustments and maintenance must be performed by a competent per son only, in accordance with the current Gas Saf ety (Installation & Use) Regulations and the instructions pr ovided. Improper installation ma y cause damage or injury to individuals, animals and personal property, for which the manufacturer will not be held liable.

To ensure efficient and saf e operation it is recommended that the boiler is serviced annually by a competent person.

If it is kno wn or suspected that a fault e xists on the appliance, it must not be used until the fault has been corrected by a competent person.

To get the most out of y our boiler, we have provided you with some useful advice on proper use and maintenance:

- Periodically check the system pressure using the pressure gauge “D”, make sure that the pressure is at 1.5 bar when the system is off and cool. If the pressure is belo w the minimum recommended value.

D

Consult your installer for checking and refilling the system.

- The outer panels of the units case must only be cleaned with a damp cloth. Do not use abr asive cleaners. The control panel can be wiped with either a damp or dr y cloth. Spray polishes must not be used on the control panel surf ace or knobs. Care must be taken in preventing any liquid entering the appliance.

- If the water is very hard, it is recommended that a water softener be added to the system so as to reduce the f ormation of limescale in the heat e xchanger. This will ensure that the effi ciency of the unit remains the same o ver time, reducing gas consumption and maintenance costs.

- If the boiler should be out of use f or a prolonged per iod, it is recommended that the electr ical power supply be disconnect ed and that the e xternal gas cock be closed. If low temperatures are expected, the boiler and system pipe work should be drained in order to prevent frost damage.

- To improve comfort and tak e full adv antage of the heat produced by the boiler, it is recommended that an external (room) thermostat be installed.

- It is good practice to clean and service the appliance and central heating system every year.

Call an Authorised Service Centre.

Ignition Procedure

Press button “A”. The green L.E.D. “K” will illuminate indicating that the boiler is ready to operate. The centralised electronic control unit will ignite the b urner, upon demand f or either

C.H. or D.H.W. If, after approximately 10 seconds, the b urner has not ignited, the boiler safety devices will shut off the gas and the red

L.E.D.

“I” illuminates. To reset the ignition system, the reset “J” must be pressed and released. Should the boiler f ail to ignite a second time, check that the e xternal gas coc k is open (see diagrams on the left). If the problem persists, contact a local Service Agent.

I

MPORTANT

!! Always wait 2 min utes before resetting each time.

K

A

I

J

3

3. Boiler Shutdown Situations

Winter and Summer Operating Modes

In the ‘winter operating mode’, the boiler will produce both Centr al Heating and Domestic

Hot Water. In the ‘summer operating mode’, the boiler will produce only domestic hot water.

Press button “F” to select winter mode . The green LED “G” will illuminate.

Adjusting the Heating

It is possib le to set the temper ature of the heating system by adjusting the knob “B”.

By positioning the indicator some where between MIN and MAX, a temper ature may be obtained which v aries from approximately

42°C to about 82°C.

B

G

F

External (Room) Thermostat Control

If an external (room) ther mostat is installed, it is recommended that the temperature of the heating system be set b y means of the knob “B”, leaving it at MAX position in order to obtain the best performance from the boiler and to allo w the regulation of the external temperature to function efficiently.

Setting the Hot Water for Domestic Use

Both in the winter and summer mode , the temper ature of the domestic hot water may be adjusted by rotating the knob “C”. A delivery temperature for the w ater may be selected between approx. 36°C to 54°C , depending on the flow rate of the water and the position of the knob betw een MIN and

MAX settings.

N

OTE

: Should the Domestic

Hot Water not be hot enough, it may be necessary to slow the flow rate from the hot water outlet being used.

C

The boiler is equipped with saf ety devices that intervene in certain situations and shut it off. Most of these situations are communicated by means of the LED’s and at times the user may be able to remedy them.

Shutdown Due To Ignition Failure

In the e vent that the automatic ignition of the burner has f ailed, the red LED .

“I” will illuminate. In order to reset the ignition, the b utton

“J” must be pressed and released. Should the boiler fail to ignite a second time, check that the external gas cock is open. If the problem persists, contact a local Ser vice Agent.

I

MPORTANT

!! Always wait 2 min utes before resetting each time.

Shutdown Due To Overheating

In the event that the safety limit is exceeded for the temperature of the w ater in the boilers exchanger, the ther mostat shuts off the boiler and the red LED “I” illuminates.

To remedy this situation, w ait a few minutes to allow the exchanger to cool do wn, then press and release the reset button “J”.

If this situation occurs frequently , contact a local Service Agent.

I

I

J

J

Temporary Shutdown Due To Defective

Discharge of Exhaust Fumes

The boiler is fitted with saf ety devices, which in the e vent of a defective discharge of exhaust products, automatically interrupts the gas supply, thereby shutting off the boiler.

The shut-off of the boiler is tempor ary and is indicated b y the illumination of the yellow L.E.D.

“H” for a period of about 15 minutes.

Once this time per iod has passed and the discharge state of exhaust system has retur ned to normal, the boiler automatically turns back on.

I

MPORTANT

!

If this situation occurs frequently, contact a local Service Agent so that they may check that the e xhaust fumes are being e xpelled correctly, that the flue is installed correctly and that the area is ventilated properly.

Turning Off the Central Heating

To turn off the Centr al Heating, press the Centr al

Heating button “F”; the respective green LED “G” will go off. The boiler will sta y in summer mode , only providing Domestic Hot Water

G

F

Turning Off the Boiler

To turn the boiler off , press the b utton “A”; the respective green LED “K” will go off.

K

A

4

3. Boiler Shutdown Situations 4. Time clock

Shutdown Due To Insufficient Circulation

I f the boiler is off , one possible cause for this state is an insufficient pressure of water in the system.

D

Check the system pressure on the pressure gauge “D” and if it is less than 0.5 bar , repressurise the system as instr ucted by your installer, should y ou be unsure some basic instructions are provided hereafter;

Ensure that the filling loop hose is connected to the cold w ater inlet pipe and to either the Centr al Heating flow or return

Open the handle/s or tap/s to allow water into the Central Heating system

Once the needle on the pressure gauge reaches 1 Bar, close the handle/s or tap/s and disconnect the filling loop hose

Should it still be unclear ho w to proceed, please consult y our installer.

If the boiler does not start up again, contact a local Service Agent.

If there are frequent drops in pressure within the system, ha ve a plumber check the heating system for possible water leaks.

Anti-frost Device

The boiler is fitted with a de vice which, in the event that the water temperature falls below 8°C the pump activ ates and runs until a temperature of 18°C is attained. In the event that the water temperature falls below 3°C, the diverter valve switches to Domestic

Hot Water and the burner fires and runs on minimum power until a temperature of 33°C is attained.

This device is only activated when the boiler is operating perfectly and

- the system pressure is sufficient;

- the boiler is powered electrically;

- gas is being distr ibuted.

UT011Ap

Note: the time clock is for central heating control only.

The time clock is provided with 96 switches, called riders, each of which covers a time interval of 15 minutes (four per hour).

When a rider is switched from the inside (off setting) to the outside of the clock border (on setting), the circuit is closed (s witch on) for a per iod of 15 min utes and then the boiler star ts if the room thermostat (if installed) or the heating ther mostat require heat (heating function on).

EXAMPLE

To set the heating of y our home in the time inter val from 7.00

am to 9.30 am and from 7.00 pm to 10.00 pm e very day:

- rotate the outer r ing of the cloc k in a cloc kwise direction until the correct time of da y (24h) lines up with the arro w on the clock (at approx. 2 o’clock position);

under no cir cumstances should the min ute hand be

moved manually;

- make sure all the s witches, i.e. the riders, are placed on the inside of the clock border;

- pull outward the riders for 7.00 am and 9.30 am, and then all riders between these two;

- repeat this for 7.00 pm and 10.00 pm.

Other heating intervals may be set in the same w ay.

The timer has approximately 150 hours of batter y back up for power failure.

The clock is provided with a selector s witch with three positions

(see figure):

1.

Position “I” CONSTANT: in this position, the clock circuit is always closed (switch on), therefore the boiler will constantly be on and will only shut off upon the request of the room ther mostat (if installed) or the heating ther mostat;

UT014A

2.

Position “O” HEATING OFF: in this position, the clock circuit is alw ays open (switch off) and the boiler will therefore never ignite for heating;

UT014A

5

3.

“Central” Position PROGRAMMING ACTIVE: in this position, the programming set by the user is active.

UT014A

INSTALLATION AND SERVICING INSTRUCTIONS

5. GENERAL INFORMATION

5.1

General Instructions

This manual is an integ ral and essential par t of the product. It should be kept with the appliance so that it can be consulted b y the user and our authorised personnel.

Please carefully read the instr uctions and notices about the unit contained in this man ual, as they provide important information regarding the safe installation, use and maintenance of the product.

For operating instructions please consult the separ ate Previous

User Guide.

Read the instructions and recommendations in these Installation

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 our Ser vicing Centre technicians or y our 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 f or damage caused b y 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 inf ormation shown on the data plate and the technical data section comply with the electric, water and gas mains of the property. You will find the data plate on the reverse of the control panel.

The gas with which this appliance oper ates is also shown on the label at the bottom of the boiler.

Do not install this appliance in a damp en vironment 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 light switches, use the telephone or any other object which might cause spar ks.

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 y our 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 v alve.

Always disconnect the appliance either by unplugging it from the mains or tur ning off the mains s witch 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 y our local A uthorised Servicing Centre and request the use of or iginal spare par ts. For in-guarantee repairs contact MTS (GB) Limited.

Check the following at least once a year:

1 - Check the seals f or the w ater connections; replace any faulty seals.

2 - Check the gas seals; replace any faulty gas seals.

3 - Visual check of the entire unit.

4 - Visual check of the combustion process or analysis of combustion by-products (see section 3.6) and cleaning of the burner if needed.

5 - If called for by point. 3, dismantling and cleaning of the combustion chamber.

6 - If called for by point. 4, dismantling and cleaning of the burner jets.

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

(overheat thermostat);

- safety device for maximum pressure (safety valve).

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 electr ical connection (make sure it complies with the instructions in the manual).

12- Check of domestic hot water production efficiency (flow rate and temperature)

13- General check of the comb ustion by-products of the dis charge/ventilation system.

14- Check of the general performance of the unit.

N

OTE

: T

HESE CHECKS ARE NOT EXHAUSTIVE

,

FURTHER HYDRAULIC

,

MECHANICAL

,

ELECTRICAL AND OPERATIONAL CHECKS MAY BE

REQUIRED AS NECESSARY

.

6

General Information

5.2

Overall View

1

2

3

4

5

9

10

11

12

13

14

6

7

8

Fig. 5.0

15 16 17 18 19

23

22

21

20

28

27

26

25

24

Legend:

1.

Flue connector

2.

Air intake for twin pipe flue systems

3.

Fan

4.

Combustion chamber hood

5.

Heat exchanger

6.

Safety thermostat

7.

Combustion chamber

8.

Combustion chamber insulation panel

9.

Detection electrode

10. Ignition electrodes

11. Pump pressure switch

12. Main circuit temperature probe

13. Safety valve (3 bar)

14. Domestic hot water temperature probe

15. Secondary exchanger

16. Gas valve

17. Spark generator

18. Domestic hot water inlet filter

19. D.H.W. flow switch

20. Drain valve

21. Circulation pump with automatic air release valve

22. Motorised diverter valve

23. Automatic By-pass

24. Burner

25. Expansion vessel

26. Air pressure switch tube

27. Air pressure switch

28. Combustion analysis points

7

6. INSTALLATION

6.1

Reference Standards

The technical information and instructions provided herein below are intended for the installer / Ser vicing Technician so that the unit may be installed and serviced correctly and safely.

In the United Kingdom the installation and initial star t up of the boiler must be b y a CORGI Registered Installer in accordance with the installation standards currently in eff ect, as well as with any and all local health and safety standards i.e. CORGI.

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.

This appliance must be installed by a competent installer in accordance with current Gas Saf ety (installation & use)

Regulations.

The installation of this appliance m ust be in accordance with the relevant requirements of the Local Building Regulations , the current I.E.E. Wiring Regulations, the b ylaws of the local w ater authority, in Scotland, in accordance with the Building Standards

(Scotland) Regulation and Health and Saf ety document No. 635

“Electricity at w ork regulations 1989” and in the Repub lic 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 ser vicing.

Installation should also comply with the following British Standard

Codes of Practice

6.2

Siting the Appliance

The appliance ma y be installed in an y room or indoor area, although particular attention is dr awn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland, the electr ical provisions of the Building Regulations applicab le in Scotland, with respect to the installation of the combined appliance in a room containing a bath or sho wer, the location of the boiler in a room containing a bath or sho wer should only be considered if there is no alternative.

Where a room-sealed appliance is installed in a r oom containing a bath or sho wer the appliance and an y electrical switch or appliance contr ol, utilising mains electricity should be situated so that it cannot be touc hed by a person using the bath or sho wer, specifically in accor dance with current IEE Wiring Regulations.

The location m ust permit adequate space f or servicing and air circulation around the appliance as indicated in Section 6.4.

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.

The type C appliances (in whic h the combustion circuit, air vent intake and comb ustion 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-comb ustible, permanent wall to prevent access from the rear.

BS 7593:1992 Treatment of water in domestic hot water central heating systems

BS 5546:1990 Installation of hot water supplies for domestic purposes

BS 5440-1:2000 Flues

BS 5440-2:2000 Air supply

BS 5449:1990 Forced circulation hot water systems

BS 6798:1987 Installation of gas fired hot water boiler s of rated input not exceeding 60kW

BS 6891:1989 Installation of low pressure gas pipe up to

28mm

BS 7671:2001 IEE wiring regulations

BS 4814:1990 Specification for expansion vessels

BS 5482:1994 Installation of L.P.G.

8

Installation

6.3

Overall Dimensions

6.5 M

OUNTING THE

A

PPLIANCE

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.

F

IG

. 6.1

Legend:

A = Central Heating Flow (3/4”)

B = Domestic Hot Water Outlet (1/2”)

C = Gas Inlet (3/4”)

D = Domestic Cold Water Inlet (1/2”)

E = Central Heating Return (3/4”)

6.4

Clearances

QT002A

F

IG

. 6.3

F

IG

. 6.2

DM001B

In order to allo w access to the inter ior of the boiler f or maintenance purposes, the boiler m ust be installed in compliance with the minimum clearances indicated in F

IG

. 6.2

Place the template in the position the appliance is to be mounted and after ensuring it is hanging squarely, use it to dr ill the holes for the hanging bracket and flue pipe(s) NB: For further information relating to the flue installation please refer to Section 6.9 Flue

Connection. (If the appliance is to be fitted on a w all of combustible material, the wall must be protected by a sheet of fireproof material).

If the appliance is to be fitted into a timber fr amed building, guidance should be sought from the IGE document R

EF

: IGE/UP/7.

9

Installation

6.7

Gas Connection

6.5.1. Drill the wall and plug using those supplied with the con nections kit, position the br acket and secure with the w all bolts supplied.

Note: It is highly recommended that a spirit level be used to position the appliance to ensure that it is perfectly level.

6.5.2. Position the appliance on the hanging bracket and connect the isolating valves supplied in the connection kit as shown on the w all template (see also Sections 6.7 Gas

Connections, 6.8 Water Connections & F

IG

. 6.3).

The local gas region contr actor connects the gas meter to the service pipe.

If the gas supply f or the boiler ser ves other appliances ensure that an adequate supply is a vailable both to the boiler and the other appliances when they are in use at the same time .

Pipe work must be of an adequate siz e. Pipes of a smaller siz e than the boiler inlet connection should not be used.

6.8

Water Connections

View of the Boiler Connections

6.6

Electrical Connection

For safety purposes, have a competent person carefully chec k 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 electr ical system is adequate f or the maxi mum 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 alter nating current, as indicated in the

Technical Information table in Section 13, where the maxim um 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.

I

MPORTANT

!

In the event that the power supply cord must be changed, replace it with one with the same specifications .

Note: The diagrams for the electrical system are indicated in section 6.13.

Warning, this appliance must be earthed.

External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E.

Regulations and applicable local regulations.

The appliance is supplied with a fly-lead already connected, this must be connected to a 240v supply fused at 3A and m ust 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 Electr icity 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 (see section 6.2).

Should external controls be required, the design of the e xternal electrical circuits should be under taken by a competent person, see section 6.12 for further information.

F

G

Fig. 6.4

TE020E

Legend:

A = Central Heating Flow

B = Domestic Hot Water Outlet

C = Gas Inlet

D = Domestic Cold Water Inlet

E = Central Heating Return

F = Safety Valve Outlet

G = Drain Valve

Pipe Work:

Copper tubing to BS EN 1057:1996 is recommended f or water pipes. Jointing should be either with capillar y soldered or compression fittings.

Where possible pipes should have a gradient to ensure air is carried naturally to air release points and w ater flows naturally to drain taps.

The appliance has a built-in automatic air release valve, however it should be ensured as f ar 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 b y-pass valve, which protects the main heat e xchanger in case of reduced or interr upted water circulation through the heating system, due to the closing of thermostatic valves or radiators.

S

YSTEM

D

ESIGN

:

This boiler is suitable for sealed systems only.

10

Installation

A

B

C

D

E

F

IG

. 6.5

Drain Cocks:

These must be located in accessible positions to permit the draining of the whole system and should be fitted at all low points. The taps must be at least 15mm nominal siz e and manufactured in accordance with BS 2870:1980.

Safety Valve Discharge:

The discharge should terminate facing downward on the exterior of the building in a position where discharging (possib ly boiling water & steam) will not create danger or nuisance, but in an easily visible position, and not cause damage to electr ical components and wiring.

The discharge must not be over an entrance or a window or any other type of public access.

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 volume when the system is heated.

It can accept up to 6 litres (1.3 gal) of e xpansion water. If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed e xpansion vessel with adequate capacity. This should be located on the return pipe work as close as possible to the pump inlet.

Mains Water Feed - Central Heating:

There must be no direct connection to the mains w ater supply even through a non-return valve, without the approval of the Local

Water Authority, therefore a temporary method for initially filling the system and replacing lost w ater during servicing in accordance with current Water Regulations and bylaws must be provided (F

IG

. 6.6).

Note: The installer should ensure that there are no leaks as frequent filling of the heating system can lead to premature scaling of the main exchanger and failure of hydraulic components.

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 f or water carrying pipe w ork and must be used f or pipe w ork carrying drinking water, a scale reducer should also be used to reduce the r isk of scale forming in the domestic side of the heat e xchanger.

C

ENTRAL

H

EATING

Detailed recommendations are giv en in BS 6798:1987 and BS

5449-1:1990, the following notes are given for general guidance.

Residual Head of the Boiler ∆

VR003A

T=20

°

C

F

IG

. 6.6

11

Installation

6.9

Flue Connections

F

LUE

S

YSTEM

The provision for satisfactory flue ter mination must be made in accordance with BS 5440-1.

The appliance must be installed so that the flue ter minal is exposed to outside air.

The terminal must not discharge into another room or space such as an outhouse or lean-to.

It is important that the position of the ter minal allows a free passage of air across it at all times .

The terminal should be located with due regard f or the damage or discolouration that might occur on b uildings in the vicinity and consideration must be given to adjacent boundaries.

In cold or humid w eather water vapour may condense on leaving the flue terminal. The effect of such “pluming” must be considered.

If the ter minal is less than 2 metres abo ve a balcon y, above ground or above a flat roof to which people ha ve access, then a suitable terminal guard must be fitted. When ordering a terminal guard, quote the appliance model number.

A suitable terminal guard is available from:

TOWER FLUE COMPONENTS

Morley Road

Tonbridge

Kent TN9 1RA

The minimum acceptable spacing from the ter minal to obstr uctions and ventilation openings are specified in F

IG

. 6.7.

IMPORTANT!

For all flue systems, a restrictor may need to be inserted into the exhaust manifold, the size of the restrictor and details of fitting requirements are sho wn in Table

6.1 (Page 18).

Ø 60/100 mm

FU003A

F

IG

. 6.8

Fitting the Coaxial Flue (Horizontal)

(For Telscopic Instructions see page 13 and for Vertical Flue and

Twin Pipe Instructions see page 14)

F

IG

. 6.7

FU010ARev1

T

ERMINAL

P

OSITION

A Directly below an openable window or other opening300

B Below gutters, solid pipes or drain pipes

C Below eaves

D Below balconies or car-port roof

E From vertical drain pipes and soil pipes

F From internal or external corners

G Above ground or balcony level

H From a surface facing a terminal

I From a terminal facing a terminal

J From an opening in the car por t

(e.g. door, window) into dwelling

K Vertically from a terminal in the same wall mm

1200

1500

L Horizontally from a terminal in the same wall 300

M Horizontally from an opening window 300

75

200

200

150

300

300

600

1200

N Fixed by vertical flue terminal

C

ONTENTS

:

1

X

S

ILICONE

O-R

ING

(60mm)

1

X

E

LBOW

(90

O

)

2

X

W

ALL

S

EALS

(I

NTERNAL

& E

XTERNAL

)

1

X

A

LUMINIUM

F

LUE

P

IPE INCLUDING

T

ERMINAL

(1

METRE

- 60/100)

2

X

F

LUE

C

LAMPS

8

X

S

CREWS

2

X

S

EALS

Once the boiler has been positioned on the wall, insert the elbow into the socket (F

IG

6.8) and rotate to the required position.

NOTE

:

It is possible to rotate the elbow 360 o on its vertical axis.

Using the flue clamps , seals and scre ws supplied (F

IG

6.8) secure the elbow to the boiler.

The 1 metre horizontal flue kit (705958) supplied is suitable for an exact X dimension of 823mm, and the 750mm horizontal flue kit

(705785) is suitable for an exact X dimension of 573mm.

N

OTE

: T

HE FLUE MUST NOT TERMINATE IN A PLACE LIKELY TO CAUSE

NUISANCE

12

Measure the distance from the f ace of the e xternal wall to the

Installation face of the flue elbo w (X - F

IG

6.8), add 22 mm to this measurement, you now have the total length of flue required (including the terminal), this figure m ust now be subtracted from 860mm, y ou now have the total amount to be cut from the plain end of the flue.

Cut the flue to the required length ensur ing that the distance between the inner and the outer flue is maintained (F

IG

6.10).

e.g. X = 508mm + 22mm = 530mm

860 - 530 = 330mm (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 g rey outer wall seal to the flue ter minal and push through the flue through the hole , once the w all seal has passed through the hole, pull the flue bac k 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.

Fitting the Telescopic Flue Kit (Horizontal)

C

ONTENTS

:

1

X

S

ILICONE

O-R

ING

(60mm)

1

X

E

LBOW

(90

O

)

2

X

W

ALL

S

EALS

(I

NTERNAL

& E

XTERNAL

)

1

X

A

LUMINIUM

F

LUE

P

IPE INCLUDING

T

ERMINAL

(T

ELESCOPIC

- 60/100)

2

X

F

LUE

C

LAMPS

8

X

S

CREWS

2

X

S

EALS

The telscopic flue is suitab le for use with an e xact minimum X

dimension of 270mm and an e xact maximum X dimension

470mm.

IMPORTANT!!

Do not extend the telescopic flue to an X dimension of more than 470mm. If longer lengths are required use e xtension pieces as necessary. Under no circumstances must the flue be cut.

The wall must then be made good around the flue (ensuring a fall of 1 o is maintained away from the boiler to the flue ter minal).

Once made good, place the inner (white) w all seal over the flue and push up to the wall, secure the flue to the elbow by using the clamp supplied.

For each additional 90 o elbow 1 metre must be removed from the total flue length (maximum 4 metres including the 1st elbow). For each additional 45 o elbow 0.5 metre must be subtracted from the total flue length ( F

IG

6.13).

Fitting the Coaxial Flue (Vertical)

(For Twin Pipe Instructions see page 14)

C

ONTENTS

:

1

X

S

ILICONE

O-R

ING

(60mm)

1

X

E

LBOW

(90

O

)

2

X

W

ALL

S

EALS

(I

NTERNAL

& E

XTERNAL

)

1

X

A

LUMINIUM

F

LUE

P

IPE INCLUDING

T

ERMINAL

(T

ELESCOPIC

- 60/100)

2

X

F

LUE

C

LAMPS

8

X

S

CREWS

2

X

S

EALS

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. (see F

IGS

6.12, 6.13).

13

25 mm

F IG 6.11

F

IG

25 mm

6.12

F

IG

6.9

25 mm

F

IG

6.10

WARNING

IT WILL BE NECESSARY

TO CONSULT

T

ABLE

6.1

ON PAGE

18

TO

DETERMINE WHETHER

THE FLUE RESTRICTOR

IS REQUIRED

IT NOT BE NEEDED

COLLAR

(F

IG

.

SHOULD

THE RESTRICTOR WILL

NEED TO BE REMOVED

FROM THE FLUE GAS

. 6.11).

,

Installation

The Vertical flue kits maxim um and minim um useable lengths with both flat and pitched roof flashings are indicated in (Figs.

6.14 & 6.15).

Before proceeding to fit the flue , ensure that the maxim um flue length has not been e xceeded and that all elbo ws and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90 o elbow 1 metre must be subtracted from the total flue length, and f or each 45 o 0.5 metres must be subtracted from the total flue length (the offset and height of 2 x 45 o can be seen in Fig. 6.16).

Mark the position of the flue hole in the ceiling and/or roof (see

F

IG

. 6.14 for distance from wall to the centre of the flue).

Cut a 110mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof.

Should it be necessary to cut the flue DO NOT cut the outer white ar inlet tube, cut the aluminium exhaust flue 6mm longer than the outer white air tube when used at minim um length.

DO NOT cut more that 250mm from the inner aluminium e xhaust flue.

To connect the v ertical flue kit directly to the boiler , place the adaptor (see F

IG

6.12) (supplied with v ertical flue kit) onto the exhaust manifold and secure with the clamp , the vertical flue kit must then be inser ted through the roof flashing, this will ensure that the correct clear ance above the roof is pro vided as the terminal is a fixed height.

Should extensions be required, the y are a vailable in 1 metre

(Part No. 705786), 500mm (Part No. 705790) and 160mm lengths (Part No. 705812), they must be connected directly to the boiler and secured with the clamp supplied 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 m ust be ensured that the distance betw een the inner and outer flue are k ept (Fig. 6.10).

When utilising the v ertical flue system, action m ust be taken to ensure that the flue is supported adequately to prevent the weight being transferred to the appliance flue connection.

When the flue passes through a ceiling or w ooden floor, there must be an air gap of 25mm 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 pre vent the passage of smok e or fire, irrespective of the structural material through which the flue passes.

Fitting the Flue (Twin Pipe)

Where it is not possib le to terminate the flue within the distance permitted for coaxial flues, the twin flue pipe can be used b y fitting a special adaptor to the flue connector and using the aperture for the air intake located on top of the comb ustion chamber.

Considerations necessary for twin flue installation;

It is most impor tant to a void any possible condense f ormation entering the appliance.

N OTE : M AX L ENGTH = a+a+a + b+b = a+a+a+0.5+0.5

C OMBINED L ENGTH NOT

TO EXCEED 4m

F

IG

6.14

F

IG

6.13

14

Installation

According to Table 6.1 (Page 18) decide if condensation will form within the flue. If yes, there are two options;

1) Where condense will form but can be negated with insulated flue, install the insulated flue with a fall of 5mm in every metre away from the boiler.

2) The exhaust flue will have a fall of 3 o back to the boiler and a suitable trap will be fitted on the exhaust as close to the boiler as possible, condense will then be suitably disposed of.

Where the flue runs through cold spots, i.e. loft areas, condense is likely to be formed, therefore a fall back to the boiler and a trap is required.

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:

Remove the ‘knockout’ of the air intake by cutting it with a suitable knife (F

IG

. 6.16).

Insert the elbow/flue pipe into the air intake until it stops.

The twin flue pipes can be fitted with or without additional elbows and need no clamps, simply ensure that the red o-r ing 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 con verted back to Coaxial flue to enab le vertical termination with a coaxial kit b y using the pipe br idge

(Twin - Coaxial Adaptor - P art No. 705767). When running the twin flue pipe vertically, a condense trap must always be used on the exhaust pipe.

It is not recommended that the pipe bridge be used 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

3 o back to the boiler , is suitab ly trapped and where the 60mm inner flue of the concentr ic terminal connects to the pipe br idge, this point m ust be adequately sealed with silicone sealant to avoid condense leakage at this point.

Note: Vertical twin flue installations m ust have a tr ap on the exhaust. MTS supply a suitable condense tr ap with float

Part No. 705774 and recommend that this be used in the event that the flue may not form condense.

When siting the twin flue pipe hor izontally, the air intak e and exhaust terminals must terminate on the same w all, the centres of the terminals must be a minimum of 280 mm apart and a maximum of 500mm, the air intak e must not be sited abo ve the exhaust terminal (refer to F

IG

. 6.19). The air intake pipe can be run horizontally, however, the ter minal 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 intak e pipe r un be constructed of insulated pipe to prevent condense forming on the outside of the tube.

The maximum permissible flue length f or twin flue is dependent on the type of run used.

F IG 6.15

WARNING

IT WILL BE NECESSARY TO CONSULT

T

ABLE

6.1

ON PAGE

18

TO DETERMINE WHETHER THE FLUE RESTRICTOR IS

REQUIRED

.

SHOULD IT NOT BE NEEDED

,

THE RESTRICTOR

WILL NEED TO BE REMOVED FROM THE FLUE GAS COLLAR

(F

IG

. 6.11).

Minimum offset distance when using 2x 45 o bends

F

IG

6.16

15

Installation

For flue runs with the intak e and exhaust pipes under the same atmospheric conditions (T ype 4) the maxim um length is 43 metres (80) and 28 metres (100), f or runs with the ter minals under different atmospheric conditions (Type 5) the e xhaust terminal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the e xhaust and air intak e pipes are located on the same side of the building). For Type 5 also, the maximum permissible combined length is 40 metres (80) and 51 metres (100).

The maximum length is reached by combining the total lengths of both the air intak e and e xhaust pipes. Therefore a maxim um length of 40 metres for example, will allow a flue run of 20 metres for the air intak e and 20 metres f or the exhaust pipes, also for each 90 o elbow 1.3 metres m ust be subtr acted from the total length and for each 45 o elbow 1 metre m ust be subtracted from the total flue length.

Some of the acceptable flue configurations are detailed on below

(F

IG

. 6.19).

For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 2418180.

F IG 6.17

F

IG

6.18

F IG 6.16

16

Installation

Type 1 Type 2 Type 3

F IG . 6.19

Type 4 Type 5

Note: Drawings are indicative of flueing options onl y.

AIR INTAKE MUST NOT BE

FITTED ABOVE THE EXHAUST

AIR INTAKE EXHAUST

AIR INTAKE

F

IG

6.20

17

Installation

TP 23

Exhaust

Type

Use the

ø 41 mm

Restrictor

Do not use the

Restrictor

Maximum

Flue

Length

Table 6.1

Risk of Condensation Forming

Coaxial

Systems

ø 60/100

T

YPE

1

T

YPE

2

T

YPE

3

Exhaust

Type

Between

345 mm - 1 m

Use the

ø 43 mm

Restrictor

Between

1 m - 4 m

4 m NOT APPLICABLE NOT APPLICABLE

Do not use the

Restrictor

Maximum

Flue

Length**

Risk of Condensation Forming With:

Standard Twin Pipe

After:

Insulated Twin Pipe

After:

Twin Pipe

Systems

ø 80/80

T

YPE

4

T

YPE

5

Up to 20 m

Up to 25 m

Between

20 m - 60 m

Between

25 m - 59 m

60 m

59 m

3 m* with a

ø 41 mm restrictor

3 m* with a

ø 41 mm restrictor

4 m* with a

ø 41 mm restrictor

4 m* with a

ø 41 mm restrictor

3 m* with a

ø 41 mm restrictor

3 m* with a

ø 41 mm restrictor

4 m* with a

ø 41 mm restrictor

4 m* with a

ø 41 mm restrictor

TP 30

Exhaust

Type

Use the

ø 42 mm

Restrictor

Do not use the

Restrictor

Maximum

Flue

Length

Risk of Condensation Forming

Coaxial

Systems

ø 60/100

T YPE 1

T YPE 2

T YPE 3

Exhaust

Type

Between

345 mm - 1 m

Twin Pipe

Systems

ø 80/80

T

T

YPE

YPE

4

5

Between

1 m - 4 m

4 m NOT APPLICABLE NOT APPLICABLE

Use the

ø 42 mm

Restrictor

Up to 4 m

Up to 11.5 m

Do not use the

Restrictor

Maximum

Flue

Length**

Risk of Condensation Forming With:

Standard Twin Pipe

After:

Insulated Twin Pipe

After:

Between

4 m - 47 m

Between

11.5 m - 42 m

47 m

42 m

2 m* with a

ø 42 mm restrictor

7.4 m* with a

ø 42 mm restrictor

7.5 m* without a

ø 42 mm restrictor

7.4 m* without a

ø 42 mm restrictor

2 m* with a

ø 42 mm restrictor

7.4 m* with a

ø 42 mm restrictor

7.5 m* without a

ø 42 mm restrictor

7.4 m* without a

ø 42 mm restrictor

*

**

Where there is no risk of condense forming (and, therefore no requirement for a condense collector), ensure a minimum fall of 5mm per metre away from the appliance.

Maximum Length = combined length of air intak e and exhaust pipes (less any equivalent lengths for elbows).

Note: Under some circumstances, condense may form at the exhaust terminal, special attention must be paid with regard to possible condense dripping from the terminal.

18

Installation

6.10 Control Panel

K J I H G F E D

2

A B C

L

EGEND

:

A - On/Off button

B - Central heating temperature adjustment

C - Domestic hot water temperature adjustment

D - Heating system pressure gauge

E - Time clock (knock out)

F - Central heating selector

G - Central heating L.E.D. (green)

H - Flue sensor L.E.D. (yellow)

I - Ignition failure (lockout) and/or overheat reset button

J - Overheat and/or ignition failure (lockout) L.E.D. (red)

K - ON/OFF L.E.D. (green )

To dismantle the front casing panel it is necessar y to:

1 - Remove the two screws “B”;

2 - Move the front casing panel up and lift f orward.

3

B

4

6.11 Removing the Front Panel

In order to access the inside of the boiler , it is necessar y to unscrew the fastening screws “A” of the control panel located on the lower part of the panel itself.

The control panel mo ves downward and when pulled f orward rotates on two lateral hinges.

The panel sta ys in a semi-hor izontal position, which allo ws access to the inner par ts of the boiler.

In order to increase the manoeuv ering space, it is possib le to raise the control panel and rotate it to a fully hor izontal position.

1

A

19

Installation

6.12 Fitting the Time Clock

To fit the mechanical time clock supplied with the boiler, it is necessary to proceed as follows:

1) Remove the fastening screws ‘A’ from beneath the boiler;

2) Rotate the control panel forward, if necessary, it is possible to lift the control panel up and rotate it to a fully hor izontal position;

3) Using a suitable knife, remove the knock out ‘B’ for the time clock;

4) Insert the clock into the control panel;

5) Secure the clock in place using the four screw provided;

6) Remove the two screws ‘C’ and remove the cover to allow access to the Printed Circuit Board;

7) Plug the clock cable into the connector on the Printed Circuit

Board and conect the cables to the clock as indicated in Fig.

6.21

1

4

5

A A

6

2

3

B

20

Installation

6.12 Fitting the Time Clock (continued)

7

MECHANICAL

TIME CLOCK

5 4 3 2 1

GREY

BLACK

RED

DIGITAL

TIME CLOCK

3 2 1

GREY

BLACK

RED

21

F

IG

. 6.21

Installation

6.13 Room Thermostat Connection

To connect a room thermostat, it is necessary to:

1. - Open the control panel as indicated in SECTION

6.11.

2.- Remove the link “A” from the terminal block on the reverse of the control panel.

3. - Insert the thermostat cable through the cable grommet and fasten it by means of the cable-clamp provided.

4. - Connect the ther mostat wires to the ter minal block

(Diagram A).

5.- If a remote time clock is to be fitted, disconnect the integ ral time clock from the P.C.B.

6. - Using a volt-free switching time clock, connect the switching wires from the time cloc k following points 1-4 abo ve

(Diagram B).

7. - If using an external time clock and room thermostat, these must be connected in series as points 1-7 above (Diagram C).

Note: Only a lo w voltage room thermostat capab le of v olt free switching must be used. Factory fitted integral wiring must not be disturbed when wiring e xternal controls.

Important!!

DO NOT install 240v wires and low voltage switching wires in the same cable/conduit, this may cause unwanted induced voltages in the low voltage switching system.

A

22

F

IG

. 6.22

Installation

6.14 E

LECTRICAL

/S

YSTEM

D

IAGRAMS

A

CN104

CN103

CN102

CN100

A CN101

2

B

1

5

4

3

G

FUSE

FUSE

P

Q

T

S

R

A

CN104

CN103

CN102

CN100

A CN101

2

B

1

5

4

3

L

K

M N

J

O

F

IG

. 6.23

A - Jumper:

1 Don’t move (jumper is factory set in position B)

2 Anti-cycling Device Adjustment for Heating

Position A = 0 mins Position B = 2 mins

3 Don’t move (jumper is factory set in position B)

4 Don’t move (jumper is factory set in position B)

5 Fan/Pump over-run selector

Position A = OFF Position B = ON

B - Central Heating Temperature Adjustment

C - Connector for Remote Control (Climate Manager)

D - Domestic Hot Water Temperature Adjustment

E - Soft-light Adjustment

F - Maximum Heating Adjustment

G - Time Clock Connector

H - On/Off Switch

I Fume Sensor L.E.D.

J - Central Heating Selector

K - Ignition Failure (Lockout) L.E.D.

L - On/Off L.E.D.

M - Reset Button

N - Central Heating L.E.D.

O - Transformer

P - Spark Generator I.C.

Q - Motorised diverter valve Relay

R - Gas Valve Relay

S - Circulation Pump Relay

T - Fan Relay

A01 - Circulation Pump

A02 - Fan

A03 - Spark Generator Supply

A04 - Gas Valve Supply

A05 - Motorised diverter Valve

A07 - Detection Electrode

A08 - Main Circuit Temperature Probe

A09 - Domestic Hot Water Temperature Probe

A10 - D.H.W. Flow switch

A11 - Pump Pressure Switch

A12 - Modulator

A13 - Air Pressure Switch

A14 - Safety Thermostat

A15 - External (Room) Thermostat

23

COLOURS:

Gr - Grey

Bi - White

Rs - Red

Mr - Brown

Bl - Blue

Nr - Black

Ro - Pink

9

10

7

8

4

5

6

Installation

6.15 Water Circuit Diagram

F

IG

. 6.24

1

2

3

11 12 13 14

21

19

18

17

16

15

20

Legend:

1.

Fan

2.

Heat Exchanger

3.

Overheat Thermostat

4.

Burner

5.

Detection Electrode

6.

Ignition Electrodes

7.

Main Circuit Temperature Probe

8.

Pressure Gauge

9.

Low Water Pressure Switch

10. Safety Valve

11. Domestic Hot Water Temperature Probe

12. Secondary Exchanger

13. Gas Valve

14. D.H.W. Flow Switch

15. D.H.W. inlet filter

16. Drain Valve

17. Motorised Diverter Valve

18. Automatic By-pass

19. Circulation Pump with Automatic Air Release Valve

20. Expansion Vessel

21. Air Pressure Switch

A. Central Heating Flow

B. Domestic Hot Water Outlet

C. Gas Inlet

D. Domestic Cold Water Inlet

E. Central Heating Return

24

7. COMMISSIONING

7.1

Initial Preparation 7.2

Initial Start-up

Preliminary electrical system checks to ensure electr ical safety must be carried out by a competent person i.e. polarity, earth continuity, resistance to earth and short circuit.

F

ILLING THE

H

EATING

S

YSTEM

:

Lower the control panel and remo ve the case panels (see

S

ECTION

6.11 for further information).

Open the central heating flow and return cocks supplied with the connection kit (there are tw o isolation points on the retur n connection).

Unscrew the cap on the automatic air release v alve 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 centr al heating system until w ater is heard to flo w, do not open fully.

Open each air release tap star ting with the lo west point and close them only when clear water, free of air, is visible.

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 , test for tightness and purge the supply as described in BS 6891:1988.

Open the gas coc k (supplied with the connection kit) to the appliance and check the gas connections on the appliance for leaks.

When the installation and filling are completed, flush the system while cold, refill, tur n on the Centr al Heating system ( Section

7.2) 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 w ater in domestic hot w ater central heating systems.

During this operation, we highly recommend the use of a centr al heating flushing detergent (F ernox Superfloc or equiv alent), whose function is to dissolv e any foreign matter that ma y be in the system.

Substances different from these could create serious pr oblems to the pump or other components.

The use of an inhibitor in the system such as F ernox MB-1 or equivalent is strongly recommended to pre vent corrosion

(sludge) damaging the boiler and system.

Failure to carry out this procedure may invalidate the appliance warranty.

T

HE CHECKS TO BE RUN BEFORE INITIAL START

-

UP ARE AS FOLLOWS

:

1. Make sure that:

- the screw on the automatic air valve has been loosened when the system is full;

- If the water pressure in the system is below 1 bar, bring it up to the appropriate level;

- Ensure that the gas cock is closed;

- Make sure that the electr ical connection has been made properly and that the ear th wire is connected to an efficient earthing system;

- Supply power to the boiler by pushing the On/Off button “A”

(see F

IG

. 6.16) - the L.E.D. “K” will illuminate. Then push the button “F” in for central heating - the L.E.D. “G” will illuminate. This will start the circulation pump. After 7 seconds, the boiler will signal a shutdown due to ignition failure. Leave the boiler as it is until all of the air has been b led from the system.

- Loosen the cap on the head of the pump to eliminate an y air pockets;

- Repeat the procedure for bleeding the radiators of air;

- Open the taps for a brief period;

- Check the system pressure and, if it has dropped, open the filling loop again to bring the pressure back up to 1 bar.

2. Make sure that all gate valves are open;

3. Turn on the gas cock and check the seals on the connections with an approved soap solution and eliminate any leaks.

4. Press the reset b utton “I” for the lighting system; the spark will light the main burner. If the burner does not light the first time, wait 1 minute and repeat the procedure.

5. Check the minimum and maximum burner pressure values; adjust if needed using the v alues indicated in the tab le in

S

ECTION

4.

7.3

Operational Adjustments

To access the areas in which adjustments are made , it is necessary to open the control panel, as indicated in Section 6.11, then remove the rear inspection cover by unscrewing the two screws.

Access is thereby provided to the P.C.B. and to the following components:

1. The power supply cable connector;

2. The fuses;

3. The soft-light potentiometer the setting f or which can r ange from the minimum thermal power to the maximum;

4. The maximum thermal heating po wer potentiometer adjustable by the minimum to maximum power (already calibrated in the factory to 70% of the maximum thermal power);

5. The jumper for adjusting the ignition dela y (anti-cycling) feature, which can be set from 0 to 2 min utes (set in the factory at two minutes);

6. Fan/Pump Over-run (Electrical Diagram). When the jumper is set to position A the F an and Pump o ver-run is activated. (The jumper is factory set in position B)

7. The time clock connector.

25

Commissioning

7.4

Combustion Analysis

The flue connector has two apertures, readings can be taken for the temperature of the combustion by-products and of the comb ustion air, as well as of the concentrations of O

2 and CO

2

, etc.

To access these intak es it is necessar y to unscre w the front screw and remove the metal plate with sealing gask et.

It is possible to activate the flue test mode (maxim um output) by pressing and holding the RESET b utton “I” for 10 seconds, the yellow L.E.D. “ H” will light. The boiler will return to normal operation after 5 minutes. The boiler can be retur ned to normal operation sooner by switching the boiler off and on again.

FU008A

7.5

Product of Combustion Discharge

Monitoring

In the boiler, it is possible to monitor the correct oper ation of the flue exhaust/air intake, checking for a loss of general pressure in the system. Through the use of a differential manometer connected to the test points of the comb ustion chamber, it is possible to detect the P of operation of the air pressure switch.

The value detected should not be less than 0.55 mbar (TP 23) -

0.90 mbar (TP 30) under conditions of maxim um thermal power in order for the boiler to function properly and without interruption.

7.6

Boiler Safety Systems

The boiler is fitted with the following devices (see S

ECTION

6.10

for references).

1 - Ignition Failure:

This indicates ignition f ailure when a flame is not detected within 7 seconds of starting an ignition sequence. The L.E.D.

“I” will illuminate to signal the shutdown status.

The system can be reset by pressing and releasing the button “J” after checking to mak e sure that the gas coc k is open.

2 - Insufficient System Pressure:

In the event of insufficient water pressure in the heating system, a safety device will shutdown the boiler. Check the system pressure on the pressure gauge “D” and if it is less than 0.4 bar refill the system to 1.5 bar . Once the system pressure is at the correct level the boiler will reset automatically.

3 - Overheating:

This control shuts off the boiler in the case where the pr imary circuit reaches a temperature in excess of 105°C.

The red L.E.D.

“I” will illuminate to signal this shutdown status.

The system can be reset b y waiting a few minutes for the primary exchanger to cool do wn and then b y pressing and releasing the “ J” button.

4.

Anti-frost device:

The boiler is fitted with a de vice which, in the e vent that the water temperature falls below 8°C the pump activ ates and runs until a temperature of 18°C is attained. In the event that the water temperature falls below 3°C, the div erter valve switches to Domestic Hot Water and the b urner fires and runs on minim um power until a temper ature of 33°C is attained.

This device is only activated when the boiler is operating perfectly and

- the system pressure is sufficient;

- the boiler is powered electrically;

- gas is being distr ibuted.

6.

Exhaust Discharge Anomaly Shutdown:

The boiler is fitted with safety devices, which in the event of defective discharge of exhaust products, automatically interrupts the gas supply, thereby shutting off the boiler.

The shutdown of the boiler is temporary and is indicated by the illumination of the yellow L.E.D.

“E” for a period of about

15 minutes.

Once this time period has passed and the discharge state of exhaust fumes has retur ned to normal, the boiler automatically turns back on.

7.

Pump Protection:

To prevent the pump from seizing the boiler will activ ate the pump for 20 seconds every 21 hours after it’s last operation.

FU009A

26

Commissioning

7.7

Draining the System

Draining the Heating System

The heating system must be drained as follows:

- Turn off the boiler;

- Attach a hose pipe and open the dr ain valve;

- Drain the system at the lowest points (where present). When the heating system is unused for an extended period of time, it is recommended that y ou add antifreeze with an eth ylene glycol base to the w ater in the heating pipe w ork and radiators if the ambient temper ature drops below 0°C during the winter.

This makes repeated draining of the entire system unnecessary.

Draining the Domestic Hot Water System

Whenever there is the danger of the temperature dropping below the freezing point, the domestic hot w ater system m ust be drained as follows:

- Turn off the general water valve for the household plumbing system;

- Turn on all the hot and cold w ater taps;

- Empty the remaining water from the lowest points in the system (where present).

7.8

Completion

For the Repub lic of Ireland it is necessar y to complete a

“Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in the current edtion of I.S. 813. In addition it is necessary to complete the Log Book.

7.10 Instructing The End User

1.

Hand over the copy of the End User Instr uctions supplied with the appliance , together with these instr uctions, and explain how to use the timeclock and room thermostat if fitted.

2.

Show the End User ho w to switch the appliance off quickly, and indicate the position of the electr ic supply isolator.

3.

Inform the End User of the location of all dr ains, isolating valves and air vents.

4.

Explain how to turn the appliance off for both short and long periods and advise on the precautions necessary to prevent damage in the event that the appliance is inoper ative when freezing conditions occur.

5.

Finally advise the End User that, for continued safe and efficient operation, the appliance must be serviced by a competent person at least once a y ear.

7.9

Operational Checks

1.

The flue system must be visibly checked for soundness.

2.

Run the Centr al Heating and manipulate the Centr al

Heating temperature control knob to chec k the gas pressures at high and low fire with a pressure guage/manometer, and adjust if necessary.

3.

Range rate the ther mal power for Central Heating, as detailed in S

ECTION

8.2

4.

Run the Domestic Hot Water, manipulate the Domestic Hot

Water temperature control knob to check the gas pressures at high and low fire with a pressure guage/ manometer, and adjust if necessary.

5.

Balance the Central Heating system until all retur n temperatures are correct and equal.

6.

Turn ON/OFF button OFF, disconnect the pressure Gauge , retighten screw and re-light boiler.

7.

Re-examine Central Heating, Domestic Hot Water and Cold

Water supplies for soundness.

8.

Check the appearance of the gas flame to assess the adequacy of the combustion air supply.

9.

If external controls have been disconnected, reconnect and test.

10. Refit boiler casing.

27

8. GAS ADJUSTMENTS

Model CATEGORY II2H3+

TP 23

TP 30

Lower Wobbe Index (15°C;1013mbar)

MJ/m 3 h

Nominal Delivery Pressure

Minimum Delivery Pressure

TP 23 Main Burner: n. 14 jets (ø)

Consumption (15°C; 1013mbar)

Consumption (15°C; 1013mbar)

Gas Burner Pressure max - min mbar mbar

Methane Gas

G20

Liquid Butane Gas

G30

Liquid Propane Gas

G31

45.67

20

20

80.58

29

28

80.58

37

36 mm m 3 /h

Kg/h mbar

1.25

2.80

----

11.3 - 2.0

0.72

----

2.09

28.1 - 5.0

0.72

----

2.06

35.6 - 6.8

TP 30 Main Burner: n. 14 jets (ø)

Consumption (15°C; 1013mbar)

Consumption (15°C; 1013mbar)

Gas Burner Pressure max - min mm m 3 /h

Kg/h mbar

1.35

3.49

---

11.5 - 2.2

0.80

---

2.60

26.8 - 5.3

0.80

---

2.56

34 - 6.5

8.1

Changing the Type of Gas

The boiler can be converted to use either methane (natural) gas (G20) or L.P.G. (G30

- G31) by an Authorised Service Centre.

The operations that m ust be performed are the following:

1. Replace the jets on the main b urner (see

table in section 8);

2. Adjust the maximum and minimum thermal capacity values for the boiler

(see table in section 8 and 8.2

Adjusting the Gas Pressures);

3. Adjust the maximum thermal power setting;

4. Adjust the soft-light f eature (see table

below for recommended pressure);

5. Adjust the ignition dela y feature for the heating system by adjusting the jumper 2 as shown in Section. 6.13 (can be set from 0 to 2 mins .).

CATEGORY

II2H3+

Recommended

Soft-light

Pressure

(mbar)

Model

Microcombi

Methane Gas

G20

Liquid

Butane Gas

G30

Liquid

Propane Gas

G31

TP 23

TP 30

8.2

5

4.5

12

12

Adjusting the Gas Pressures

12

12

1

B

A

Setting the minimum and the maximum power of the boiler

1. Check that the supply pressure and dynamic pressure to the gas valve is a minimum of 20 mbar for natural gas.

2. To do this, loosen the screw “A”.

Fit the pipe of the pressure gauge to the inlet pressure connection of the gas v alve “B” and check for the correct standing pressure, then oper ate the appliance and chec k for the correct working pressure.

When you have completed this oper ation, replace the scre w

“A” securely into its housing to seal off the gas (chec k for tightness).

3. To check the pressure supplied by the gas valve to the burner, loosen the screw “C”. Fit the pipe of the pressure gauge to the pressure outlet test point of the gas v alve “D”.

Disconnect the compensation pipe “D1” either from the gas valve or from the sealed chamber.

4. Push the On/Off b utton to “ON” position -green light- and ensure that the hot w ater temperature control knob is set to maximum.

Turn on the boiler by running a hot water tap.

Adjust the 10mm nut “E” on the modureg to set the maximum gas pressure, turn the nut clockwise to increase and anti clockwise to decrease the pressure until the required pressure is achieved (see TABLE A page 28).

28

Gas Adjustments

2

C

D

3

4

F

E

5. To set the minimum power, disconnect a supply terminal “F1” from the modureg and adjust scre w “F” (ensure that the

10mm nut is held in position). Turn the scre w clockwise to increase the pressure and anti-cloc kwise to decrease the pressure (displayed on the pressure gauge) corresponding to the minimum power (see TABLE A page 28).

6. When you have completed the above operations, turn off the hot water tap, reconnect the supply ter minal to the modureg on the gas v alve, reconnect the compensation pipe and replace the cap on the screw of the modureg.

Setting the maximum heating circuit power

7. To set the maxim um heating circuit po wer, push the On/Off button to the “ON” position -green light- and push the Heating button and set the time clock and any external controls to the

“ON” position -green light. Turn the knob of the heating thermostat clockwise to maximum.

8. Remove the inspection panel of the P .C.B. and fit a small cross-head screwdriver in to the right hand potentiometer (see below). Turn clockwise to increase the pressure or counterclockwise to reduce the pressure . Adjust the setting to the required heating pressure v alue (displayed on the pressure gauge), as indicated in the char ts shown on pages 28.

9. Turn off the boiler b y placing the main s witch to the "OFF" position.

Setting the pressure for soft-light ignition.

Disconnect the detection electrode connection close to the

P.C.B. (F

IG

. 6.13).

Start the boiler and during the ignition sequence adjust the left hand potentiometer until the gas pressure reads the required gas pressure (see the table on page 28).

Once the gas pressure is set turn off the boiler and re-connect the detection electrode to the P.C.B.

NB.: It may be necessar y to reset the flame f ailure reset a number of times during this operation.

10. Remove the pipe from the test point and tighten the screw “C” to the pressure test point in order to seal off the gas .

11. Carefully check the pressure test points f or gas leaks (valve inlet and outlet).

IMPORTANT!

Whenever you disassemble and reassemb le the gas connections, always check for leaks using a leak detection fluid.

Soft - Light

Adjustment

Max Heating

Adjustment

29

Gas Adjustments

T ABLE A

2.80

1.16

20

10.3

2.0

14 x 1.25

3.49

1.48

20

11.5

2.2

14 x 1.35

Regulating the heating power for natural gas (G20) model 23 model 30

2.09 Kg/h

0.87 Kg/h

28 mbar

28.1 mbar

5.0 mbar

14 x 0.72

2.06 Kg/h

0.85 Kg/h

37 mbar

35.6 mbar

6.8 mbar

14 x 0.72

2.60 Kg/h

1.10 Kg/h

28 mbar

26.8 mbar

5.3 mbar

14 x 0.80

2.56 Kg/h

1.09 Kg/h

37 mbar

34.0 mbar

6.5 mbar

14 x 0.80

Regulating the heating power for butane gas (G30)

CG011A model 23 model 30

CG010A

Regulating the heating power for propane gas (G31)

40

38

36

34 model 23 model 30

30

9. MAINTENANCE

It is recommended that the following inspections be carried out on the boiler at least once a y ear:

1 - Check the seals for the water connections; replace any faulty seals.

2 - Check the gas seals; replace any faulty gas seals.

3 - Visual check of the entire unit.

4 - Visual check of the combustion process or analysis of combustion by-products (see section 3.6) and cleaning of the burner if needed.

5 - If called for by point. 3, dismantling and cleaning of the combustion chamber.

6 - If called for by point. 4, dismantling and cleaning of the burner jets.

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

(overheat thermostat);

- safety device for maximum pressure (safety valve).

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 (flow rate and temperature)

13- General check of the combustion by-products of the discharge/ventilation system.

14- Check of the general performance of the unit.

31

10. SERVICING INSTRUCTIONS

To ensure efficient saf e 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 ser vicing, a comb ustion analysis should be made via the flue sampling point (please ref er to S

ECTION

3.4 for further details).

After servicing, preliminary electrical system checks must be carried out to ensure electr ical safety (i.e. polarity, earth continuity, resistance to earth and short circuit).

10.1 Replacement of Parts

The life of individual components v ary and they will need ser vicing or replacing as and when faults develop.

The fault finding sequence char t in S

ECTION

7 will help to locate which component is the cause of an y malfunction, and instr uctions for removal, inspection and replacement of the individual parts are given in the following pages.

10.2 To Gain General Access

All testing and maintenance oper ations on the boiler require the control panel to be lo wered. This will also require the remo val of the casing.

10.2.1 Removing the front panel

1. Loosen the fastening screws “A” of the control panel located on the lower part of the panel itself. (F

IG

. 10.1);

F

IG

. 10.3

2. The control panel moves downward and when pulled forward, rotates on two lateral hinges; the panel stays in a semi-hor izontal position, which allo ws access to the inner par ts of the boiler (F

IG

. 10.2);

3. In order to increase the manoeuvr ing space, it is possib le to raise the control panel and rotate it to a fully hor izontal position (F

IG

. 10.3);

4. Remove the screws “B” from the front panel bottom lip

(F

IG

. 10.4);

5. Lift the front panel up and forward from the raised screws at the the top of the casing (F

IG

. 10.5).

F

IG

. 10.4

B

F

IG

. 10.1

A

F

IG

. 10.2

F

IG

. 10.5

32

Servicing Instructions

10.2.2 Removing the sealed chamber front cover

1. Remove the screws “C” (F

IG

. 10.6);

2. Lift the sealed chamber front cover from the locating pins

(F

IG

. 10.7).

F

IG

. 10.6

10.2.3 Removing the side panels

1. Remove the four screws “D” for each side panel (F

IG

.10.8);

2. Pull the panel a way from the boiler at the base , then lift the panel up and remove from the boiler (F

IG

.10.9).

F

IG

. 10.8

D

C C

F

IG

. 10.7

F

IG

. 10.9

D

D

D

33

Servicing Instructions

10.3 Access to the Combustion Chamber

10.3.1 Removing the combustion cover

1. Remove the screws “E” (F

IG

. 10.10);

2. Lift off the combustion cover.

10.3.3 Removing the electrodes

Before carrying out this procedure, unscrew and slide the burner forward (see previous section).

1. Remove rubber gasket “G” (F

IG

. 10.13);

2. To remove the detection electrode disconnect the cab le at its connection point close to the P.C.B. (F

IG

. 10.14);

3. Remove screw “H” (F

IG

. 10.15);

4. Gently slide the electrode downward (F

IG

. 10.16).

F

IG

. 10.13

E

E

E

E

G

F

IG

. 10.10

10.3.2 Removing the burner and jets

1. Remove the screws “F” from the burner (F

IG

. 10.11);

2. Remove the burner (F

IG

. 10.12);

3. Disconnect the electrodes (see

SECTION

10.3.3);

4. Remove the jets using a No. 7 socket spanner;

5. Replace in reverse order.

F

IG

. 10.11

F

IG

. 10.14

F

Fig. 10.12

F

F

IG

. 10.16

F

IG

. 10.15

H

To replace, repeat the steps in reverse order, paying particular attention to the following:

a - Centre the electrode in the positioning hole carefully , otherwise the electrode ma y break;

b - Ensure that the left hand and right hand electrodes are located the correct w ay round (facing each other), to give the correct spark gap;

c - Check that the cab les have been connected correctly;

d - Check that the rubber gasket seals the cab le/ electrode connection point completely.

34

Servicing Instructions

10.3.4 Removing the main heat exchanger

1. Drain the boiler of water;

2. Remove the side panels (see 10.2.3)

3. Remove the overheat thermostat sensor “I” (F

IG

. 10.17);

4. Remove the clip “J” (F

IG

. 10.18);

5. Remove the “U” clip “K” (F

IG

. 10.19);

7. Pull down the pipe (F

IG

. 10.20);

4. Pull it straight out (F

IG

. 10.21).

Fig. 10.17

I

F

IG

. 10.21

F

IG

. 10.18

J

J

10.3.5 Removing the air pressure switch

1. Disconnect the electrical connections “L” and silicone pipes

“M” from their connection points (F

IG

. 10.22);

2. Remove screws “N” on the top of the sealed chamber (F

IG

.

10.23);

3. Lift out the air pressure switch (F

IG

. 10.24);

4. Unscrew to remove the switch from the plate.

F

IG

. 10.22

L

M

M

F

IG

. 10.19

F

IG

. 10.23

K

F

IG

. 10.24

N

F

IG

. 10.20

N

35

Servicing Instructions

10.3.6 Removing the fan

1. Disconnect electrical connections “O” and silicone pipe “P”

(F

IG

.10.25);

2. Remove screw “Q” and remove the fan collar clamp “R” (F

IG

.

10.26);

3. Remove screws “S” (F

IG

. 10.27);

4. Remove fan and mounting plate (F

IG

. 10.28).

F

IG

. 10.25

10.4 Access to the Gas Valve

10.4.1. Removing the spark generator

1. Disconnect ignition leads “T” by pulling upward

(F

IG

. 10.29);

2. Remove the screw “U” (F

IG

. 10.30);

3. Remove the spark generator by pulling forward from the gas valve (F

IG

. 10.31).

F

IG

. 10.29

O

O P

T

F

IG

. 10.26

R F

IG

. 10.30

Q

U

F

IG

. 10.27

S

S

F

IG

. 10.28

S

F

IG

. 10.31

36

Servicing Instructions

10.4.2 Removing the gas valve

Important! Before removing the gas valve, ensure the gas supply is turned off.

1. Disconnect all the cables from the solenoid and modureg;

2. Remove the spark generator (see previous section);

3. Release the nuts “V” (F

IG

. 10.32);

4. Remove the screws “W” from the bottom of the gas valve (F

IG

.

10.33);

5. Remove the gas valve (F

IG

. 10.34).

F

IG

. 10.32

10.5 Access to the Water Circuit

Important! Before any component is removed, the boiler must be drained of all water.

10.5.1 Removing the D.H.W. (secondary) exchanger

1.Remove the screws “X” (F

IG 10.35);

2.Disconnect the cable “Y” (F

IG 10.36);

3.Push the exchanger towards the rear of the boiler, and lift upwards and remove out of the front of the boiler

(F IG 10.37-10.38);

4.Before replacing the exchanger ensure that the O-rings are in good condition and replace if necessar y.

V

F

IG

. 10.35

V

X

X

F

IG

. 10.33

W W

F

IG

. 10.36

Y

F

IG

. 10.34

F

IG

. 10.37

37

F

IG

. 10.38

10.5.3 Removing the safety valve

1. Disconnect the discharge pipe work from below the boiler;

2. Unscrew and remove the valve “A1” (F

IG

. 10.41).

A1

10.5.2 Removing the pump pressure switch

1. Remove the pump pressure s witch electrical connections “Z”

(F

IG

10.39);

2. Unscrew the pump pressure switch by using a spanner on the nut (F

IG

10.40);

3. Remove the pump pressure switch .

F

IG

. 10.39

F

IG

. 10.41

10.5.4 Removing the automatic air vent

1. Remove the U-clip “B1” (F

IG

. 10.42);

2. Unscrew valve top and remove valve complete with float

(F

IG

10.43).

Z

B1

F

IG

. 10.40

F

IG

. 10.42

F

IG

. 10.43

38

Servicing Instructions

10.5.5 Removing the pump

1. Remove the electrical connection “ C1” (F

IG

. 10.44);

2. Remove the allen screw “D1” (F

IG

. 10.45);

3. Remove the pump (F

IG

. 10.46).

10.5.6 Removing the pressure gauge

1. Remove the U-clip “E1” (F

IG

. 10.47)

2. Push the pressure gauge through the control panel from the rear (F

IG

. 10.48).

F

IG

. 10.47

D1

C1

D1

F

IG

. 10.44

F

IG

. 10.48

E1

D1

D1

F

IG

. 10.45

F

IG

. 10.46

39

Servicing Instructions

10.5.7 Removing the expansion vessel

1. Release nuts “F1” and remove the gas pipe (F

IG . 10.49);

2. Release nut “G1” (F

IG . 10.50);

3. Remove back-nut “H1” (F

IG . 10.51);

4. Remove the expansion vessel (F

IG . 10.2).

F

IG

. 10.49

10.5.8 Removing the overheat thermostat

1. Disconnect the overheat thermostat electrical connections “I1”

(F

IG

. 10.53);

2. Then remove the ther mostat from its mounting b y releasing the securing clip (F

IG

. 10.54 /10.55).

F

IG

. 10.53

F1

F

IG

. 10.50

I1

F

IG

. 10.54

G1

F1

F

IG

. 10.55

F

IG

. 10.51

H1

F

IG

. 10.52

10.5.9 Removing the heating temperature sensor (N.T.C.)

1. Pull off the electrical connector and unscrew the sensor probe using a suitable spanner (F

IG

. 10.56).

F

IG

. 10.56

40

Servicing Instructions

10.5.10 Removing the D.H.W. temperature sensor (N.T.C.)

1. Pull off the electrical connector and unscrew the sensor probe using a suitable spanner (F

IG

. 10.57).

F

IG

. 10.57

6.5.12 Removing the divertor valve actuator

1. Unplug the electrical connector “L1” (F

IG

. 6.60);

2. Release the retaining clip “M1” and remove the divertor valve actuator (F

IG

. 6.61).

L1

F

IG

. 6.60

10.5.11 Removing the D.H.W. flow switch

1. Unplug the electrical connector “J1” (F

IG

. 10.58);

2. Unscrew the screws “K1” (F

IG

. 10.59);

3. Remove the D.H.W. flow switch.

F

IG

. 10.58

J1

F

IG

. 10.59

K1

M1

F

IG

. 6.61

41

Servicing Instructions

10.6 Access to the Control System

Important! Isolate the electr ical supply to the boiler bef ore accessing the control panel.

10.6.1 Checking the fuses

1. Remove the inspection co ver on the re verse of the control panel (F

IG

. 10.62);

2. Remove the fuses (F

IG

. 10.63).

F

IG

. 10.56

10.6.2 Removing the P.C.B.

1. Isolate electricity;

2. Remove the inspection co ver from the re verse of the control panel;

3. Unplug all electrical connections from the P.C.B.

4. Remove the screws “N1” (F

IG

. 10.64);

5. Separate the facia panel from the rear of the control panel ;

6. Remove the screws “O1” and remove the P.C.B.

(F

IG

. 10.65).

F

IG

. 10.64

N1

N1 N1

F

IG

. 10.63

F

IG

. 6.65

O1 O1

42

11. FAULT FINDING

11.1 Fault Finding Guide (Flow-charts)

These fault finding guides are not exhaustive. However, it is possible to detect and correct man y defects by using the standard fault finding diag rams described in this chapter , ensure these guides are carried out in the set order.

To ensure that the external controls do not interfere with the fault finding, disconnect the wires from the ter minal block on the rear of the control panel and pro vide a solid link betw een the ter minals.

43

Fault Finding

44

Fault Finding

45

Fault Finding

0.55mbar

(23kW)

0.90mbar

(30kW)

0.55mbar

(23kW)

0.90mbar

(30kW)

46

Fault Finding

47

16

17

18

19

20

21

22

10

11

12

13

14

15

8

9

5

6

7

2

3

4

12. SHORT SPARE PARTS LIST

1

69 68 67 66 65 64 63 62

56

70

61

57

60

59

58

56

70

304

304

71

56

70

73

72

70

56

125

124

126 301

7

123

74

75

76

77

77

78

79

79

122

22

19

93

94

90

83

82

80

81

84

85

87

88

89

91

91

25

92

94

95

96

97

98

50

99

33

100

86

58

117

118

116

112

113

114

115

120

119

103

96

101

106

105

103

102

104

121

108

107

39

109

104

25

111

110

93

302 303

55

54

25

53

52

51

50

33

49

48

47

46

23 24 25 26 27 28 29 30 31 32 33 34 35 17 36 37 38 39 40 41 42 43 44 45

48

Short Spares Parts List

Key

94

113

114

115

122

122

88

89

89

82

83

86

87

75

80

81

45

46

49

59

35

36

40

16

28

32

Part Number

65100297

999599

65100693

65100694

65100692

990685

995945

998458

573520

997089

65100514

61010017

61011136

65101294

995903

997088

65101390

995948

997147

996615

996123

995865

65100716

65100719

996065

65100521

Description

PCB

Pump Pressure Switch

Safety Valve (3 Bar)

Pressure Gauge

D.H.W. Flow Switch

3 Way Valve Motor

Pump Motor

Gasket (Pump Motor)

Auto Air Vent

Air pressure Switch

Fan

Overheat Thermostat

Clip (Overheat Stat)

Cable (Time Clock)

Time Clock

Ignition Electrode (RH)

Ignition Electrode (LH)

Detection Electrode

Secondary Exchanger (30 kW)

Secondary Exchanger (23 kW)

Temperature Probe

Gasket (3/4”)

Gas Valve (SIT 845 SIGMA)

Spark Generator

Main Exchanger (23 kW)

Main Exchanger (30 kW)

49

50

51

13. TECHNICAL INFORMATION

CE Certification

Heat Input

Heat Output

Efficiency of Nominal Heat Input

Efficiency at 30% of Nominal Heat Input

Heat Loss to the Casing (∆T=50°C)

Flue Heat Loss with Burner Operating

Flue Heat Loss with Burner Off

Max Discharge of Products of Combustion

(G20)

Residual Discharge Head

Consumption at Nominal Capacity(G20)

Gas Consumption after 10 Minutes*

(15°C, 1013 mbar) (G30-G31)

Kg/h mbar m m

3

3

/h

Kg/h

Temp. of exhaust fumes at nominal capacity °C

%

%

% max/min kW max/min kW

%

%

CO

2

Content

O

2

Content

CO Content

Minimum Ambient Temperature

Head Loss on Water Side (max) (∆T=20°C) mbar

Residual Head of System

Heating Temperature

%

% ppm

°C bar max/min °C

Domestic Hot Water Temperature (approx) max/min °C

D.H.W. Flow Rate ∆T=35°C

D.H.W. Minimum Flow Rate

Pressure of Domestic Hot Water

Expansion Vessel Capacity

Expansion Vessel Pre-load Pressure

Maximum Water Content of System

Maximum Heating Pressure

Nominal Pressure l/min l/min l max/min bar l bar bar

Natural Gas (G20) mbar

LPG (G30-G31) mbar

Electrical Supply

Power Consumption

Protection Grade of Electrical System

Internal Fuse Rating

Weight

V/Hz

W

IP

Kg

TP 23 MFFI

0694BO0090

25.6/11.0

24.8/9.7

92.9

91.1

1.0

6.1

0.4

49.5

0.96

2.72

0.32/0.39

2.02/2.00

123

7.2

7.5

51.9

+5

200

0.25

82/42

56/36

9.7

2.6

8/0.2

6

1

130

3

20

30-37

230 / 50

110

X4D

FAST 2 AT

30

TP 30 MFFI

0694BO0090

36.6/15.5

30.6/12.1

83.4

80.9

1.7

5.7

0.4

63.73

1.6

3.49

0.41

2.60/2.56

121.2

7.19

7.8

53

+5

200

0.25

82/38

56/36

12.5

2.5

8/0.2

7

1

130

3

20

28-37

230/50

148

X4D

FAST 2 AT

32

47-116-33 G.C. Number

*Calculated at 70% maximum output

47-116-32

Manufacturer: Merloni TermoSanitari S.p.A.

Technical Service Hot Line: 0870 241 8180

Customer Service Help Desk: 0870 241 8174

0 99 84 1869 000

52