Ariston | AVL 108 | Technical information | Ariston AVL 108 Technical information

Ariston AVL 108 Technical information
Installation and Servicing Instructions
CLAS HE
Gas fired condensing wall hung
combination boilers
G.C.N : 47-116-51 (24 kW)
G.C.N : 47-116-52 (30 kW)
G.C.N : 47-116-53 (38 kW)
CLAS HE 24
CLAS HE 30
CLAS
HE 38
Country of destination GB, IE
The code of practice for the installation,
commissioning & servicing of central heating systems
overview
INDEX
Overview
General Information..................................................................................................3
Advice for the Installer..............................................................................................4
CE Labelling..................................................................................................................4
Data Plate Symbols....................................................................................................4
Safety Regulations.....................................................................................................5
Product description
Control Panel...............................................................................................................6
Display............................................................................................................................6
Overall View..................................................................................................................7
Overall Dimension.....................................................................................................7
Minimum Clearances................................................................................................7
Technical Information...............................................................................................8
Installation
Reference Standards.................................................................................................9
Installing the Boiler................................................................................................. 12
Gas Connection........................................................................................................ 13
Water Connection................................................................................................... 13
Instructions for Opening the Casing and Performing an
Internal Inspection.................................................................................................. 13
Connecting the Flue............................................................................................... 15
Fitting the Coaxial Flue (Ø 60/100 Horizontal).............................................. 16
Fitting the 5” Flue (Ø 80/125 Horizontal / Vertical)...................................... 17
Fitting the Coaxial Flue (Ø 60/100 Vertical).................................................... 18
Fitting the Twin Pipe (Ø 80/80)........................................................................... 19
Electrical Connections........................................................................................... 23
Peripheral Unit Connection................................................................................. 23
Room Thermostat Connection........................................................................... 24
Outdoor Sensor Connection............................................................................... 24
Electrical Diagram................................................................................................... 25
Commissioning
Initial Preparation.................................................................................................... 26
Electricity Supply..................................................................................................... 26
Filling the Heating System................................................................................... 26
Filling of the DHW System.................................................................................... 26
Gas Supply................................................................................................................. 26
Water Treatment...................................................................................................... 26
First Igniton Operation.......................................................................................... 27
Ignition procedure.................................................................................................. 28
Test Function and Combustion Analysis......................................................... 30
AUTO Function......................................................................................................... 31
Boiler Protection Devices
Boiler Protection Devices..................................................................................... 32
Anti-Frost Device..................................................................................................... 32
Table summarising error codes.......................................................................... 32
Settings - Adjustment - Problem Identification Menus
Accessing the Menus............................................................................................. 33
Maintenance
General Comments................................................................................................. 41
General Access......................................................................................................... 42
Electrical Unit............................................................................................................ 43
Hydraulic Unit........................................................................................................... 45
Main Heat Exchanger............................................................................................. 53
Burner Unit................................................................................................................ 54
Fan Unit....................................................................................................................... 57
Gas Valve..................................................................................................................... 58
Annual Maintenance.............................................................................................. 59
Spare Parts Short List............................................................................................. 60
Benchmark Commissioning Checklist............................................................. 61
Benchmark Service Interval Record.................................................................. 62
overview
These instructions are suitable for CLAS HE 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
overview
Advice for the installer
The installation and first ignition of the boiler must be
performed by qualified personnel in compliance with
current national regulations regarding installation, and
in conformity with any requirements established by
local authorities and public health organisations.
After the boiler has been installed, the installer must
ensure that the end user receives the declaration of
conformity and the operating manual, and should
provide all necessary information as to how the boiler
and the safety devices should be handled.
This appliance is designed to produce hot water for domestic
use.
It should be connected to a heating system and a distribution
network for domestic hot water, both of which must be compatible
with its performance and power levels.
The use of the appliance for purposes other than those specified is
strictly forbidden. The manufacturer cannot be held responsible for
any damage caused by improper, incorrect and unreasonable use
of the appliance or by the failure to comply with the instructions
given in this manual.
Installation, maintenance and all other interventions must be
carried out in full conformity with the governing legal regulations
and the instructions provided by the manufacturer. Incorrect
installation can harm persons, animals and possessions; the
manufacturing company shall not be held responsible for any
damage caused as a result. The boiler is delivered in a carton. Once
you have removed all the packaging, make sure the appliance is
intact and that no parts are missing. If this is not the case, please
contact your supplier.
Keep all packaging material (clips, plastic bags, polystyrene foam, etc.)
out of reach of children as it may present a potential hazard.
In the event of a fault and/or malfunction, turn the appliance
off, turn off the gas cock and do not attempt to repair it yourself.
Contact a qualified professional instead.
Before any maintenance or repair work is performed on the boiler,
make sure you have disconnected it from the electricity supply
by switching the external bipolar switch to the “OFF” position and
removing the fuse.
All repairs, which should only be performed using original spare
parts, should be carried out by a qualified professional. Failure
to comply with the above instructions could compromise the
safety of the appliance and invalidate all liability on the part of
the manufacturer.
In the event of any maintenance or other structural work in
the immediate vicinity of the ducts or flue gas exhaust devices
and their accessories, switch the appliance off by switching the
external bipolar switch to the “OFF” position and shutting off
the gas control valve. When the work has been completed, ask a
qualified technician to check the efficiency of the ducting and the
devices.
Turn the boiler off and turn the external switch “OFF” to clean the
exterior parts of the appliance.
Clean using a cloth dampened with soapy water. Do not use
aggressive detergents, insecticides or toxic products. If the
appliance is used in full compliance with current legislation, it
will operate in a safe, environmentally-friendly and cost-efficient
manner.
If using kits or optional extras, make sure they are authentic.
CE labelling
The CE mark guarantees that the appliance conforms to the following directives:
- 90/396/CEE
relating to gas appliances
- 89/336/CEE
relating to electromagnetic compatibility
- 92/42/CEE
relating to energy efficiency
- 73/23/CEE
relating to electrical safety
Symbols used on the data plate
MIN
MAX
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Brand
Manufacturer
Boiler model - code
Serial number - certification number
Destination country - gas category
Gas setting
Boiler type
Electrical data
Maximum domestic hot water pressure
Maximum heating pressure
NOx class
Efficiency
Max - min heat input
Max - min heat output
Max/min operating room temperature
Max. central heating temperature
Gases which may be used
overview
Safety regulations
Key to symbols:
Failure to comply with this warning implies the risk of
personal injury, in some circumstances even fatal
Failure to comply with this warning implies the risk of
damage, in some circumstances even serious, to property,
plants or animals.
Install the appliance on a solid wall which is not subject
to vibration.
Noisiness during operation.
When drilling holes in the wall for installation
purposes, take care not to damage any electrical
wiring or existing piping.
Electrocution caused by contact with live wires. Explosions,
fires or intoxication caused by gas leaking from damaged
piping. Damage to existing installations. Flooding caused
by water leaking from damaged piping.
Perform all electrical connections using wires which
have a suitable section.
Fire caused by overheating due to electrical current
passing through undersized cables.
Protect all connection pipes and wires in order to
prevent them from being damaged.
Electrocution caused by contact with live wires. Explosions,
fires or intoxication caused by gas leaking from damaged
piping. Flooding caused by water leaking from damaged
piping.
Make sure the installation site and any systems to
which the appliance must be connected comply with
the applicable norms in force.
Electrocution caused by contact with live wires which
have been installed incorrectly. Damage to the appliance
caused by improper operating conditions.
Use suitable manual tools and equipment (make sure
in particular that the tool is not worn out and that its
handle is fixed properly); use them correctly and make
sure they do not fall from a height. Replace them once
you have finished using them.
Personal injury from the falling splinters or fragments,
inhalation of dust, shocks, cuts, pricks and abrasions.
Damage to the appliance or surrounding objects caused
by falling splinters, knocks and incisions.
Use electrical equipment suitable for its intended use
(in particular, make sure that the power supply cable
and plug are intact and that the parts featuring rotary
or reciprocating motions are fastened correctly); use
this equipment correctly; do not obstruct passageways
with the power supply cable, make sure no equipment
could fall from a height. Disconnect it and replace it
safely after use.
Personal injury caused by falling splinters or fragments,
inhalation of dust, knocks, cuts, puncture wounds,
abrasions, noise and vibration. Damage to the appliance
or surrounding objects caused by falling splinters, knocks
and incisions.
Make sure any portable ladders are positioned
securely, that they are suitably strong and that the
steps are intact and not slippery and do not wobble
when someone climbs them. Ensure someone provides
supervision at all times.
Personal injury caused by falling from a height or cuts
(stepladders shutting accidentally).
Make sure any rolling ladders are positioned securely,
that they are suitably strong, that the steps are intact
and not slippery and that the ladders are fitted with
handrails on either side of the ladder and parapets on
the landing.
Personal injury caused by falling from a height.
During all work carried out at a certain height (generally
with a difference in height of more than two metres),
make sure that parapets are used to surround the work
area or that individual harnesses are used to prevent
falls. The space where any accidental fall may occur
should be free from dangerous obstacles, and any
impact upon falling should be cushioned by semi-rigid
or deformable surfaces.
Personal injury caused by falling from a height.
Make sure the workplace has suitable hygiene and
sanitary conditions in terms of lighting, ventilation
and solidity of the structures.
Personal injury caused by knocks, stumbling etc.
Protect the appliance and all areas in the vicinity of the
work place using suitable material.
Damage to the appliance or surrounding objects caused
by falling splinters, knocks and incisions.
Handle the appliance with suitable protection and
with care.
Damage to the appliance or surrounding objects from
shocks, knocks, incisions and squashing.
During all work procedures, wear individual protective
clothing and equipment.
Personal injury caused by electrocution, falling splinters
or fragments, inhalation of dust, shocks, cuts, puncture
wounds, abrasions, noise and vibration.
Place all debris and equipment in such a way as to
make movement easy and safe, avoiding the formation
of any piles which could yield or collapse.
Damage to the appliance or surrounding objects from
shocks, knocks, incisions and squashing.
All operations inside the appliance must be performed
with the necessary caution in order to avoid abrupt
contact with sharp parts.
Personal injury caused by cuts, puncture wounds and
abrasions.
Reset all the safety and control functions affected
by any work performed on the appliance and make
sure they operate correctly before restarting the
appliance.
Explosions, fires or intoxication caused by gas leaks or an
incorrect flue gas exhaust. Damage or shutdown of the
appliance caused by out-of-control operation.
Before handling, empty all components that may contain
hot water, carrying out any bleeding if necessary.
Personal injury caused by burns.
Descale the components, in accordance with the
instructions provided on the safety data sheet of the
product used, airing the room, wearing protective
clothing, avoid mixing different products, and protect
the appliance and surrounding objects.
Personal injury caused by acidic substances coming into
contact with skin or eyes; inhaling or swallowing harmful
chemical agents. Damage to the appliance or surrounding
objects due to corrosion caused by acidic substances.
If you detect a smell of burning or smoke, keep clear of
the appliance, disconnect it from the electricity supply,
open all windows and contact the technician.
Personal injury caused by burns, smoke inhalation,
intoxication.
product description
Control panel
1
17
2
16
15
3
14
4
3
2
1
24
4
22
5
21
6
�
20
7
9
19
8
18
9
15
14
13
10
16
6
12
11
6
11
10
7
8
9
Legend :
1. Display
2. Reset button
3. Red indicator locking light
4. Orange indicator Comfort fonction
5. Pressure gauge
6. Heating temperature regulation knob
7. button _
8. Menu/Ok button (Programming key)
9. Esc button
10. button +
12
17
5
13
23
12
11. Domestic Hot Water adjustment knob
12. Time clock
13. ON/OFF button
14. Blue indicator burner ON
15. Yellow indicator Auto fonction
16. Auto button (To active Thermoregulation)
17. Comfort button
product description
Overall view
1
25
2
24
3
23
22
4
21
6
5
20
7
8
19
18
9
10
17
11
16
12
15
1. flue connector
2. air pressure switch
3. burner
4. detection Electrode
5. overheat thermostat
6. C.H. Return temperature probe
7. C.H. Flow temperature probe
8. gas valve
9. secondary heat exchanger
10. D.H.W. temperature probe
11. siphon
12. C.H. pressure relief valve
13. electrical box
15. C.H. circuit filter
16. D.H.W. Flow switch
17. circulation Pump with air release valve
18. diverter valve
19. switch On-Off
20. silencer
21. modulating Fan
22. ignition electrodes
23. ignitor
24. thermal fuse
25. combustion Analysis Test Point
13
Overall Dimensions
24/30/38
200
120
180
Minimum clearances
In order to allow easy access to the boiler for
maintenance operations, The boiler must be installed
in accordance with the clearances stated below.
770
770
300
120
25
200
5
50
5
50
65
67 67 65
28
300
450
150
A. Central Heating Flow
B. Domestic Hot Water Outlet
C. Gas Inlet
D. Domestic Cold Water Inlet
E. Central Heating Return
product description
POWER SPECIFICATIONS
GENERAL NOTE
Technical Data
Model
CE Certification (pin)
KW
22,0/5,5
28,0/6,5
31,0/7,5
Max/min nominal calorific flow rate (Pcs)
Qn
KW
24,4/6,1
31,1/7,2
34,4/8,3
Domestic hot water max/min nominal calorific flow rate (Pci)
Qn
KW
25,0/5,5
30,0/6,5
38,0/7,5
Domestic hot water max/min nominal calorific flow rate (Pcs)
Qn
KW
27,8/6,1
33,3/7,2
42,2/8,3
Max/min power output (80°C-60°C)
Pn
KW
21,6/5,2
27,4/6,2
30,3/7,3
Max/min power output (50°C-30°C)
Pn
KW
23,5/6,0
30,0/6,9
33,1/8,0
Domestic hot water max/min power output
Pn
KW
25,0/5,0
30,0/6,0
38,9/7,1
Combustion efficiency (of flue gas)
%
97,9
97,9
98,0
Nominal calorific flow rate efficiency (60/80°C) Hi/Hs
%
98,0/88,2
98,0/88,2
97,6/87,9
Nominal calorific flow rate efficiency (30/50°C) (condensation) Hi/Hs
%
107,0/96,4
107,0/96,4
106,7/96,1
Efficiency at 30% at 30°C (condensation) Hi/Hs
%
108,0/97,3
108,0/97,3
109,1/98,2
Efficiency at 30% at 47°C Hi/Hs
%
101,0/90,9
98,2/88,4
103,1/92,8
%
95,0/85,5
95,6/86,1
96,8/87,2
Efficiency rating (dir. 92/42/EEC)
stars
Sedbuk class
class
****
A / 90,3
****
A / 90,3
****
A / 90,1
%
0,2
0,1
0,1
Loss of burner gas when operating
%
2,1
2,1
2,0
Available air pressure
Pa
137
141
132
EMISSIONS
Flue gas temperature (G20) (80°C-60°C)
class
5
5
5
°C
63
63
63
CO2 content (G20) (80°C-60°C)
%
9,0
9,0
9,6
CO content (0%O2) (80°C-60°C)
ppm
< 100
< 100
< 125
O2 content (G20) (80°C-60°C)
%
4,5
4,5
3,5
Kg/h
41,2
49,4
59,2
Excess air (80°C-60°C)
%
27
27
20
Expansion chamber inflation pressure
bar
1
1
1
Maximum heating pressure
bar
3
3
3
Expansion chamber capacity
L
6,5
6,5
6,5
Maximum water capacity with in the appliance (75°C-35°C)
L
100/300
100/300
100/300
Min/max heating temperature (high temperature range)
°C
35/82
35/82
35/82
Min/max heating temperature (low temperature range)
°C
20/45
20/45
20/45
Maximum flue gas flow (G20) (80°C-60°C)
HEATING CIRCUIT
B23-C13-C33-C43-C53-C83
Qn
NoX class
DOMESTIC HOT WATER
CIRCUIT
38 kW
Max/min nominal calorific flow rate (Pci)
Loss when stopped (∆T = 50°C)
ELECTRICAL
30 kW
0085BR0347
Boiler type
Minimum calorific flow rate efficiency (60/80°C) Hi/Hs
Domestic hot water max/min temperature
°C
36/60
36/60
36/60
Specific flow rate of domestic hot water (∆T=30°C)
l/mn
12,0
15,0
18,2
Quantity of hot water ∆T=25°C
l/mn
14,4
18,0
21,8
Quantity of hot water ∆T=35°C
l/mn
10,3
12,9
15,6
Hot water comfort rating (EN13203)
stars
***
***
***
Hot water minimum flow rate
l/mn
<2
<2
<2
Domestic hot water max/min pressure
bar
7/0,3
7/0,3
7/0,3
Power supply frequency/voltage
V/Hz
230/50
230/50
230/50
Total electrical power absorbed
W
114
115
150
Minimum ambient temperature for use
°C
+5
+5
+5
Protection level for the electrical appliance
PI
X5D
X5D
X5D
32
35
35,5
Weight
Dimension (L x H x D)
24 kW
kg
mm
440/820/385 440/820/455 440/820/455
installation
Reference Standards
In the United Kingdom, the installation and initial start-up of the
boiler must be by a CORGI registered installer in accordance with
the installation standards currently in effect, as well as with any
and all local health and safety standards i.e. CORGI.
building within the vicinity and consideration must also be given
to adjacent boundaries, openable windows should also be taken
into consideration when siting the flue.
The minimum acceptable clearances are shown below:
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” and the current Building Regulations, reference
should also be made to the current ETCI rules for electrical
installation.
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 by-laws of the local
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 and the Local Building
Regulations (IE).
C.O.S.H.H.
Materials used in the manufacture of this appliance are nonhazardous and no special precautions are required when
servicing.
Codes of Practive
Installation should also comply with the following British
Standards Code of Practice:
BS 7593:1992
BS 5546:1990
BS 5440-1:2000
BS 5440-2:2000
BS 5449:1990
BS 6798:2000
BS 6891:1989
BS 7671:2001
BS 4814:1990
BS 5482:1994
Treatment of water in domestic hot water central heating systems
Installation of hot water supplies for domestic purposes
Flues
Air supply
Forced cicrulation hot water systems
Installation of gas fired hot water boilers of rated input not exceeding 70kW
Installation of low pressure gas pipes up to 28mm
IEE Wiring Regulations
Specification for expansion vessels
Installation of L.P.G.
and in the Republic of Ireland in accordancce with the following
codes of practice:
I.S. 813
Domestic Gas Installations
Avoid installing the boiler where the air inlet can be polluted by
checmical products such as chlorine (swimming pool area), or
ammonia (hair dresser), or alkalin products (launderette).
Flue
Detailed information on flue assembly can be found in the
“Connecting the Flue” section.
The boiler must be installed so that the flue terminal is exposed
to the free passage of external air at all times and must not
be installed in a place likely to cause nuisance. It must not be
allowed to discharge into another room or space such as an
outhouse or closed lean-to.
Condensing boilers have a tendency to form a plume of water
vapour from the flue terminal due to the low temperature of
the flue gasses. The terminal should therefore be located with
due regard for the damage or discolouration that may occur to
- A Directly below an opening, window, etc
300 mm
- B Horizontally to an opening, window, etc
300 mm
- C Below gutters, soils pipes or drain pipes
75 mm
- D Below eaves200 mm
- E From vertical drain pipe or soil pipe
75 mm
- F From internal or external corner
300 mm
- G Above ground, roof or balcony level
300 mm
- H From a surface facing the terminal2500 mm
- I From a terminal facing a terminal2500 mm
- J Vertically from a terminal on the same wall
1500 mm
- K Horizontally from an terminal on the same wall
300 mm
- L Fixed by vertical flue terminal
Note: The flue must not be installed in a place likely to cause a
nuisance and positioned to ensure that products of combustion do not
discharge across a boundary
It may be necessary to protect the terminal with a guard, if this is
the case it will be necessary to purchase a stainless steel terminal
guard. Reference should be made to the Building Regulations
for guidance.
Ventilation
The room in which the boiler is installed does not require
specific ventilation. If the boiler is installed in a cupboard or
compartment ventillation is not required for cooling purposes.
Gas Supply
The gas installation and tightness testing must be in accordance
with the requirements of BS6891. Ensure that the pipe size is
adequate for demand including other gas appliances on the
same supply.
Electrical Supply
The appliance requires an earthed 230V - 50 Hz supply and
must be in accordance with current I.E.E. regulations. It must
also be possible to be able to completely isolate the appliance
electrically. Connection should be via a 3 amp douple pole fused
isolating switch with contact separation of at least 3mm on both
poles. Alternatively, a fused 3 Amp, 3 pin plug and unswitched
socket may be used, provided it is not used in a room containing
a bath or shower, it. It shoild only supply the appliance.
installation
Water Supply
The boiler is suitable for sealed systems only. The maximum
working pressure for the appliance is 6 bar. All fittings and
pipework for the appliance should be of the same standard. If
there is a possibility of the incoming mains pressure exceeding 6
bar, particularly at night, then a suitable pressure limiting valve
must be fitted.
The boiler is designed to provide hot water on demand to
multiple outlets within the property. If there is a requirement for
greater demands, for example if the boiler has several bathrooms
and cloakrooms, a vented or unvented hot water storage system
may be used.
Showers
Any shower valves used with the appliance should be of a
thermostatic or pressure balanced type. Refer to the shower
manufacturer for performance guidance and suitability.
Flushing and Water Treatment
The boiler is equipped with a stainless steel heat exchanger.
The detailed recommendations for water treatment are given in
BS 7593:1992 (Treatment of water in domestic hot water central
heating systems); the following notes are givent for general
guidance;
If the boiler is installed on an existing system, any unsuitable
additives must be removed.
Under no circumstances should the boiler be fired before the
system has been thoroughly flushed; the flushing procedure
must be in line with BS 7593:1992.
We highly recommend the use of a flushing detergent
appropriate for the metals used in the circuit. These include
cleansers produced by Fernox BetzDearbon, whose function is to
disolve any foreign matter that may be in the system;
In hard water areas or where large quantities of water are in the
system the treatment of water to prevent premature scaling of
the main exchanger is necessary.
The formation of scale strongly compromises the efficiency of
the thermic exchanger because small areas of scale cause a high
increase of the temperature of the metallic walls and therefore
add to the thermal stress of the heat exchanger.
Demineralised water is more aggressive so in this situation it
is necessary to treat the water with an appropriate corrosion
inhibitor.
Any treatment of water by additives in the system for frost
protection or for corrosion inhibition has to be absolutely
suitable for all metals used in the circuit.
The use of a corrosion inhibitor in the sysem such as Fernox
MB-1, BetzDearborn Sentinel X100 or Fernox System Inhibitor
is recommended to prevent corrosion (sludge) damaging the
boiler and system;
If anti-freeze substances are to be used in the system, check
carefully that they are compatible with the metals used in the
circuit.
MTS suggests the use of suitable anti-freeze products such as
Fernox ALPHI 11, which will prevent rust and incrustation taking
place.
10
Preiodically check the pH balance of the water/anti-freeze
mixture of the boiler circuit and replace it when the amount
measured is out of the range stipulated by the manufacturer (7
< pH < 8).
DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE
In under-floor systems, the use of plastic pipes without
protection against penetration of oxygen through the walls can
cause corrosion of the systems metal parts (metal piping, boiler
etc), through the formation of oxides and bacterial agents.
To prevent this problem it is necessary to use pipes with an
“oxygen proof barrier”, in accordance with standards DIN
4726/4729. If pipes of this kind are not used, keep the system
separate by installing heat exchangers of those with a
specific system water treatment.
IMPORTANT
Failire to carry out the water treatment procedure will
invalidate the appliance guarantee.
System Controls
The boiler is electrically controlled and is suitable for most
modern electronic time and temperature controls. The addition
of such external controls can be beneficial to the efficient
operation of the system. The boiler connections for external
contols are 12V DC and so only controls of 12V DC that have
voltage free contacts should be used. (page 24).
MTS supply a range of wired and wireless system controls.
Contact your supplier for more details.
Location
The boiler can be installed on any suitable internal wall
(suitable sound proofing may be required when installing
onto a stud partition wall). Provision must be made to allow
for the correct routing of the flue and siting of the terminal
to allow the safe and efficient removal of the flue products. A
compartment or cupbaord may be used provided that it has
been built or modified for this purpose. It is not necessary to
provide permanent ventillation for cooling purposes. Detailed
recommendations are given in BS 5440 Part 2. If it is proposed
that it is to be installed in a timber framed building then
reference should be made to British Gas Document DM2, IGE/
UP/7 or advice sought from CORGI.
Where a room sealed appliance is installed in a room
containing a bath or shower, the appliance and any electrical
switch or appliance control, utilising mains electricity should
be situated specifically in accordance with current IEE Wiring
Regulations.
For unusual locations, special procedures may be necessary. BS
6798:2000 gives detailed guidance on this aspect.
Codensate Discharge
The condensate discharge hose from the boiler must have a
continuous fall of 2.5o and must be inserted by at least 50mm
into a suitable acid resistant pipe - e.g. plastic waste or overflow
pipe. The condensate discharge pipe must have a minimum
diameter of 22mm, must have a continuous fall and preferably
be installed and terminated to prevent freezing.
The discharge pipe must be terminated in a suitable position:
i)
Connecting into an internal soil stack (at least 450mm above the invert of the stack). A trap giving a water seal of at least
75mm must be incorporated into the pipe run, there also
must be an air beak upstream of the trap.
installation
ii) Connecting into the waste system of the building such as a
washing maching or sink trap. The connection must be
upstream of the washing machine/sink. If the connection
is down stream of if the waste trap then an additional trap
giving a minimum water seal of 75mm and an air break must be
incorporated in the pipe run, as above.
3. External termination of condensate drainage pipe via internal
discharge branch (e.g. sink waste - proprietary fitting).
iii) Terminating into a gully, below the grid level but above the
water level
iv) Into a soakaway
Note:If any condensate pipework is to be installed externally
then it should be kept to a minimum and be insulated with a
waterproof insulation and have a continuous fall. The total length
of external pipe used should not exceed 3 metres.
Some examples of the type of condensate terminations can be
found below.
1. Internal termination of codensate drainage pipe to internal
stack.
4. External termination of condensate drainage pipe via
condensate siphon
2. External terminaton of condensate drainage pipe via internal
discharge branch (e.g. sink waste) and condensate siphon.
11
installation
Installing the Boiler
Please check that you are familiar with the installation
requirement before commencing work (pages 7 - 11).
The installation accessories described in the following list are
included in the boiler packaging:
- Hanging bracket
- A paper template (showing the dimensions of the boiler with
5 mm side clearances)
- Connection valves (Compression)
- Screws and washers
- Filling loop
- Installation, Servicing and Operating Instructions
- Flue gasket
Method of positioning the boiler on the wall
The paper template can be used to ensure the correct
positioning of kitchen cabinets etc.
The paper template has to be fixed to the wall and used to locate
the position of the hanging bracket and the centre for the flue
hole.
Drill and plug the wall and secure the hanging bracket using
the screws provided. Remove the boiler from it’s packaging and
remove the front casing panel.
Place the boiler on the hanging bracket.
Note: The appliance must not be fitted on a combustible wall surface.
Connecting the Boiler to the System
- Remove the boiler casing as described on page 13;
- Remove the caps and connect the valves to the boiler using
the washers provided;
- 4 x fibre washers for the CH flow and return, cold water inlet
and hot water outlet connections;
Safety Valve Discharge and Condense Outlet
The pressure relief valve tube is made of copper. It should
terminate below the boiler safely outside the premises. Care
should be taken that it does not terminate over an entrance or
window or where a discharge of heated water could endanger
occupants or passers by.
Note: Connections viewed from behind boiler
Fill the central heating and DHW system and bleed air from the
system as described in the Commissioning instructions (page
26).
The system should be carefully checked for leaks, as frequent
refilling could cause premature system corrosion or unnecessary
scaling of the heat exchanger. The pipe from the trap should be
connected to a drain as described in the relevant regulations.
Pay special attention not to bend the condensate silicone drain
pipe is such a way as to interrupt the flow. Please only use drain
pipe material compatible with condensate products (refer to BS
6798:2000).
The condensate flow can reach 2 litres/hour because of the
acidity of the condensate products (Ph close to 2), take care
before operation.
See page 11 for condensate discharge possibiities.
12
A
A
- remove the 2 screws A from the transport bar
- dispose of the transport bar and reassemble
the fixing screws.
installation
Gas connection
Make sure, using the labels on the packaging and the data plate
on the appliance itself, that the boiler is in the correct country
and that the gas category for which the boiler was designed
corresponds to one of the categories available in the country
where it will be used.
The gas supply piping must be created and measured out in
compliance with specific legal requirements and in accordance
with the maximum power of the boiler; you should also make sure
that the shut-off valve is the right size and that it is connected
correctly.
Check that the supplied gas corresponds to the type of gas for
which the boiler was designed (see the data plate located on the
appliance itself ).
It is also important to check that the pressure of the gas (methane
or LPG) you will be using to feed the boiler is suitable, because if it
is insufficient the power may be reduced, causing inconvenience
for the user.
Instructions for opening the casing and performing an
internal inspection
Before performing any work on the boiler, first disconnect it from
the electrical power supply using the external bipolar switch
removing the fuse and shutting off the gas valve.
To access the inside of the boiler, the following is necessary:
1. Remove the casing by unhooking it from the control panel (a)
2. Loosen the two screws on the front casing (b), pull it forwards
and unhook it from the upper pins (c)
3. Lower the control panel (d)
4. Unhook the two clips on the combustion chamber panel and
lift off (e).
(a)
(b)
Water connection
The illustration shows the connections for the water and gas
attachments of the boiler. See valves configuration on page 13.
Check that the maximum water mains pressure does not exceed 6
bar; if it does, a pressure reducing valve must be installed.
For the measuring of the pipes and of the heating bodies in the
heating system, the residual head value should be calculated as a
function of the requested flow rate, in accordance with the values
shown in the circulation pump graph.
(c)
(d)
E
D
C
F
B
(e)
H
A
I
A.Central heating Flow
B.Domestic Hot Water Outlet
C.Gas Inlet
D.Domestic Cold Water Inlet
E. Central Heating Return
F. Safety Valve Discharge
H. Drain Valve
I. Drain condensate
13
installation
To calculate the size of the heating installation, refer to the
"Available pressure" graph below.
Graph representing the available circulation pump pressure
ΔT20oC
Water circuit diagram
mbar
500
450
1
2
400
350
21
4
24 kW
250
22
3
30-38
30-35 kW
kW
300
200
150
100
50
5
20
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
l/h
Before the first time the equipment is used, the trap must
be filled with water. To do this, add approximately 1/4
litre of water via the flue outlet before fitting the flue
system, or unscrew the cap on the trap positioned underneath the boiler, fill it with water and refit it
Warning! insufficient water in the trap can temporarily
cause the flue gas to be expelled into the surrounding
ambient air
6
19
7
18
8
17
9
16
10
11
15
14
13
12
A
1.
2.
3.
4.
5.
6.
7.
8.
9.
G
E
D
C
F
B
H
A
I
Underfloor heating
For appliances with underfloor heating, fit a safety thermostat
onto the underfloor heating outlet. For the electrical connection of the thermostat see the section on “Electrical connections
- page 24”.
If the outlet temperature is too high, the boiler will stop both domestic hot water and the heating production and the error code 1
16 “floor thermostat contact open” will appear on the display. The
boiler will restart when the thermostat is closed during automatic
resetting.
If the thermostat cannot be installed, the underfloor heating equipment must be protected by a thermostatic valve, or by a by-pass
to prevent the floor from reaching too high a temperature.
14
10.
11.
B
C
Manual air vent
Overheat thermostat
Burner
Detection electrode
C.H. flow temperature
probe
C.H. return temperature
probe
Secondary heat exchanger
C.H. pressure relief valve
D.H.W.
temperature
probe
By-pass
Drain valve
D E
12.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Condensate trap
C.H. circuit filter
D.H.W. Flow switch
diverter valve
water pressure sensor
circulation Pump
expansion vessel
modulating Fan
ignition electrodes
thermal fuse
installation
Connecting the Flue
Flue System
The provision for satisfactory flue termination must be made as
described in BS 5440-1.
The appliance must be installed so that the flue terminal is exposed to outdoor 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 terminal allows a free
passage of air across it at all times.
The terminal should be located with due regard for the damage
or discolouration that might occur on buildings in the vicinity, it
must also be located in a place not likely to cause nuisance.
In cold or humid weather water vapour may condense on leaving
the flue terminal.
The effect of such “steaming” must be considered.
If the terminal is less than 2 metres above a balcony, above
ground or above a flat roof to which people have access, then a
suitable stainless steel terminal guard must be fitted.
The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig. 1.
Fig. 1
- A Directly below an opening, window, etc
300 mm
- B Horizontally to an opening, window, etc
300 mm
- C Below gutters, soils pipes or drain pipes
75 mm
- D Below eaves200 mm
- E From vertical drain pipe or soil pipe
75 mm
- F From internal or external corner
300 mm
- G Above ground, roof or balcony level
300 mm
- H From a surface facing the terminal2500 mm
- I From a terminal facing a terminal2500 mm
- J Vertically from a terminal on the same wall
1500 mm
- K Horizontally from an terminal on the same wall
300 mm
- L Fixed by vertical flue terminal
S4ee table on page 21
See table
118 mm
180
118 mm
Fig. 2
15
installation
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.
Installation without extension
118
Level
150 mm
Fig. 3
Installation with extension
Level
slope
* pente
150 mm
mètre
slope* 5pente
mm5 mm
perparmetre
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)
2x Flue Clamps
4x Screws
2x Seals
Once the boiler has been positioned on the wall, fit the rubber
flue seal into the internal flue turret (see diagram opposite),
insert the elbow into the socket and rotate to the required position. note: It is possible to rotate the elbow 360° on its vertical
axis.
Using the flue clamp, seals and screws supplied (Fig 4) secure the
elbow to the boiler.
The 1 metre horizontal flue kit (3318073) supplied is suitable for
an exact X dimension of 753mm.
Measure the distance from the face of the external wall to the
face of the flue elbow (X - Fig 2), this figure must now be subtracted from 753mm, 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 4).
16
e.g.
X = 555mm
753-555 = 198mm (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.
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 table for maximum and minimum flue runs.
installation
Clamp
Screws
Seal
Fig. 4
Fitting the 5” Flue
(Ø 80 / 125 Horizontal/vertical)
Once the boiler has been positioned on the wall, it is necessary
to insert the Ø80/125 adaptor (Fig. 5) 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.
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) and that all
elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90° elbow 1
metre must be subtracted from the total flue length, and for each
45° 0.5 metres must be subtracted from the total flue length (the
height of the vertical adaptor and a 45° bend can be seen in Fig.6
and a 90° bend in Fig. 7).
180 mm
Note: DO NOT cut the vertical flue kit.
Fig. 5
Fig. 6
Fig. 7
17
installation
Fitting the Coaxial Flue
(Ø 60 / 100 Vertical)
Note: See table for maximum and minimum flue runs.
Contents:
1x Silicone O-Ring (60mm)
1x Conical Adaptor (60/100mm)
1x Vertical Flue Kit (80/125mm)
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.
180 mm
The Vertical flue kits useable lengths with the pitched roof
flashings are indicated in Fig. 7.
Before proceeding to fit the flue, ensure that the maximum
flue length has not been exceeded (See the tables) and that
all elbows and bends have been taken into consideration, the
maximum flue length is see table, for each additional 90° elbow
1 metre must be subtracted from the total flue length, and for
each 45° 0.5 metres must be subtracted from the total flue length
(the height of the vertical adaptor and a 45° bend can be seen in
Fig. 8).
Mark the position of the flue hole in the ceiling and/or roof (see
Fig. 7 for distance from wall to the centre of the flue).
Fig. 7
Cut a 130mm 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 Fig. 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), 500mm (Part No. 3318078) and 160mm 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 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 prevent the passage of smoke or fire,
irrespective of the structural material through which the flue
passes.
Fig. 8
18
installation
Fitting the Twin Pipe (Ø80 / 80)
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. 10).
The air intake pipe can be run horizontally, however, the terminal
and the final 1 metre of flue must be installed either horizontally
or with a slight 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 (see table on page 21).
For further information relating to flue runs not illustrated, please
contact the Technical Department on 0870 241 8180.
Note: See table for maximum and minimum flue runs.
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, using one
flue bracket per extension and 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 the top of the appliance
2) Assemble the flange on the header supplied with the boiler
3) Insert the header on the tube or the elbow up until the lower
stop (you do not have to use the washer).
4) 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
(greasing the seal will aid assembly).
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. 3318089). When running the
twin flue pipe vertically.
It is not possible to terminate concentrically horizontally. Termination is only possible with separate air and exhaust terminals.
19
installation
180
105
195
120
Fig. 9
AIR INTAKE MUST NOT BE
FITTED ABOVE THE EXHAUST
AIR INTAKE
EXHAUST
AIR INTAKE
Fig. 10
For coaxial systems, the maximum development value, mentioned in the table below 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 air intakes and
exhaust gas ducts.
2- If you need to insert elbows in the air 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 C13 + C53 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.
20
installation
MAX
LENGTH
DIAMETER of
PIPE
24 kW
12 m
36 m
60/100
80/125
30 kW
10 m
30 m
60/100
80/125
38 kW
6m
18 m
60/100
80/125
24 kW
12 m
42 m
60/100
80/125
30 kW
10 m
35 m
60/100
80/125
38 kW
8m
21 m
60/100
80/125
24 kW
12 m
0m
60/100
80/125
30 kW
COAXIAL SYSTEM
10 m
0m
60/100
80/125
38 kW
Table of flue gas exhaust duct lengths
8m
0m
60/100
80/125
FLUE TYPE
C13
Flue gas exhaust and air suction duct
through external wall in the same range
of pressure
C 33
Flue gas exhaust and air suction duct
from outside with roof terminal in the
same range of pressure
C43
Individual or shared flue gas exhaust and
air suction through flue ducting built into
the building
21
installation
S1 = Air intake S2 = Flue gas exhaust
S1 = S2 - Air intake and flue gas exhaust equal lengths
S1 + S2 - Air intake and flue gas exhaust unequal lengths
24 kW
30 kW
35 kW
Flue gas exhaust leading outside and air
suction duct through external wall not in
the same range of pressure
24 kW
C53
60 m
(S1=S2)
30 kW
Flue gas exhaust andair suction duct from
outsidewithroof terminalin the same
range of pressure
18 m
(S1=S2)
50 m
(S1=S2)
35 kW
C 33
30 m
(S1=S2)
21 m
(S1=S2)
24 kW
Flue gas exhaust and air suction duct
through external wall in the same range
of pressure
36 m
(S1=S2)
84 m
(S1+S2)
30 kW
C13
22
MAX
DIAMETER of
LENGTH
PIPE
FLUE TYPE
70 m
(S1+S2)
35 kW
TWIN-PIPE SYSTEM
42 m
(S1+S2)
80/80
80/80
80/80
installation
WARNING
Before performing any work on the boiler, first
disconnect it from the electrical power supply using
the external bipolar switch and remove the fuse.
Electrical connections
For increased safety, ask a qualified technician to perform a
thorough check of the electrical system.
The manufacturer is not responsible for any damage caused by
the lack of a suitable earthing system or by the malfunctioning of
the electricity mains supply.
Make sure that the system is able to withstand the maximum
power absorbed by the boiler (this is indicated on the appliance
data plate). Check that the section of the wires is suitable and is
not less 1.5 mm2
The appliance must be connected to an effiecient earthing system
if it is to operate correctly.
The power supply cable must be connected to a 230V-50Hz
network, where the L-N poles and the earth connection are all
respected.
Important!
In the event that the power supply cable must be changed, replace
it with one with the same specifications.
Peripheral unit connection
To access peripheral unit connections carry out the following
steps:
- Disconnect the boiler from the power supply
- Remove the casing by unhooking it from the instrument
panel
- Rotate the control panel while pulling it forwards
- Unscrew the three screws on the back cover of the instrument
panel
- Unhook the right side clip and the right front clip; then lift the
flap
The terminal board (see figure) may be accessed in order to connect:
Outdoor sensor
Room thermostat 1
Optional P.C.B.s can also be installed for further accessories:
BUS P.C.B. Clima Manager
Modulating Room Sensor
Programmable Room Thermostat
Outdoor Sensor
- other plugs: for managing multi-zones multitemperatures, Solar kit, etc...
Power supply cable
120
H03V2V2-F
140
Important!
The appliance is supplied with a fly-lead already
connected, this must be connected to a 240V supply
fused at 3 Amp and must facilitate completed
electrical isolation of the appliance, by use od a fused
double pole isolator having a contact separation of
at least 3mm in all poles or alternatively by means of
a 3A fused three pin plug and unswitched shuttered
socket outlet both complying with BS1363.
The use of multiplugs, extension leads or adaptors is strictly
prohibited.
It is strictly forbidden to use the piping from the hydraulic, heating
and gas systems for the appliance earthing connection.
The boiler is not protected against the effects caused by lightning. If the
mains fuses need to be replaced, use 2A rapid fuses.
Caution!
For the connection and positioning of the wires
belonging to optional peripheral units, please refer to
the installation manuals of these units.
23
installation
Room Thermostat / Remote Clock Connection
To connect a room thermostat, it is necessary to:
Connector TA on PCB
(low voltage switching)
Connector TA on PCB
(low voltage switching)
Connector TA on PCB
(low voltage switching)
Outdoor sensor connection
- Introduce the outdoor sensor wires
- Loosen the cable clamp using a screwdriver and insert the
wires leading from the outdoor sensor one at a time.
- Connect the wires to the terminals as indicated in the figure
below;
- Make sure that they are well connected and that they are
not subject to stress when the control panel lid is opened or
closed;
- Close the flap again, then replace the control panel cover and
the front casing.
- Refer to page 39 for setting the parameters when using the
outdoor sensor.
Outdoor Sensor
Connector SE on PCB
Note:
24
When connecting the boiler to external controls, do
not run 240V cables and cables for switching circuits (which are low voltage) together, use seperate cables to prevent induced voltage on the low voltage circuits.
TA1
SE
Transmetteur BUS
(Optionnel)
CARTE CHAUDIERE
AMPC-GAL1
Emplacement
carte optionnelle
1. Open the control panel
2. Loosen the cable clamp using a screwdriver and insert the wires
leading from the room thermostat
3. Connect the wires to the terminals as indicated in the figure
below, removing the link
4. If a remote time clock is to be fitted, using a volt free switching
time clock connect the switching wires from the time clock
following points 1 - 3 above
5. If using an external time clock and room thermostat, these must
be connected in series as shown in diagram C,
6. Ensure that they are well connected and not subject to stress
when the control panel is closed
D.H.W
flow
Flussimetro
sanitario
switch
8 7 6 5 4 3 2 1
CN07
1
6
12 11 10 9 8 7 6 5 4 3 2 1
8
CN22
display
Display
EARTH
P
Water pressure
Pressostato
di minima
sensor
Sonda
NTC probe
D.H.W temp.
sanitario
thermostat
modulating
Ventilatore
fan
FLAME
C.H.NTC
flow
Sonda
mandata
risc.
temp. probe
detection
Elettrodo
Rilevazione
electrode
Term.
protezione
thermal
fuse
scambiatore
C.H. NTC
return
Sonda
temp.risc.
probe
ritorno
CN22
overheat therTermostato
sovratemperatura
mostat
Display
13 12 11 10 9 8 7 6 5 4 3 2 1
ON
Collegamento
schedino BUS
VALVOLA ACCENDITORE
GAS
4 3 2 1
gas
valve
Valvola gas ignitor
Accenditore
CN04
FAN 1
FUSE 2AT
11 10 9 8 7 6 5 4 3 2 1
8
11 10 9 8 7 6 5 4 3 2 1
1
CN04
1
1
4
2
3
Connessione
sonda solare
2
1 PUMP PUMP
ZONE1FILLING
SPEED
1
external
Sonda
Esterna
sensor
6
(optional)
5
bus-translator
bus translator
(optional)
4
circulation
Circolatore
pump
5
2 3
diverter
Valvola
dev.
valve
motorizzata
1
1
Predisposizione
N
Optional
board
plate
schede
opzionali
L
Low temperature
floor
Termostato
heating
room
impianti a
Termostato
thermostat
bassa temp.
Ambiente 11 thermostat
installation
Electrical diagram
For increased safety, ask a qualified technician to perform a
thorough check of the electrical system.
The manufacturer is not responsible for any damage caused by
the lack of a suitable earthing system or by the malfunctioning of
the electricity mains supply.
FLOW
25
commissioning
Initial preparation
MTS (GB) Limited support the benchmark initiative. On pages
pages 65 and 66 of this manual the Benchmark Commissioning
Checklist and Service interval Record can be found. 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 this manual
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.
Open the gas cock (supplied with the connection kit) to the
appliance and check the gas connection on the appliance for
leaks.
Water Treatment:
The boiler is equipped with a stainless steel heat exchanger.
The detailed recommendations for water treatment are given in
BS 7593:1992 (Treatment of water in domestic hot water central
heating systems); the following notes are given for general
guidance;
If the boiler is installed on an existing system, any unsuitable
Electricity supply
additives must be removed;
- Check that the voltage and frequency of the electricity supply
correspond to the data shown on the boiler data plate;
Under no circumstances should the boiler be fired before the
- Make sure that the earthing connection is efficient.
system has been thoroughly flushed; the flushing procedure
must be in line with BS7593:1992.
Filling the Heating System:
Switch the electrical supply to the boiler on in order to view the Firstly fill the central heating system with the power off, and
system pressure on the display;
flush through cold, fill the central heating system again, adding
Remove the front casing panel and lower the control panel as a flushing detergent, run the boiler on central heating until it
reaches its operating temperature and flush the system, refill the
described on page 13).
Open the central heating flow and return cocks supplied with the system with a suitable corrosion inhibitor,
connection kit;
Lift the cap on the automatic air release valve and leave open Note: Failure to carry out the flushing procedure will result in the
permanently;
warranty becoming void.
Close all air release valves on the central heating system;
Gradually open the valves at the filling point (filling loop) 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;
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 tightness and remedy any leaks
discovered.
Important!
Manually vent the heat exchanger at the manual air vent. Failure to
vent adequately may damage the heat exchanger (page 7, legend 2).
Filling of the DHW System:
Close all hot water draw off taps;
Open the cold water inlet cock supplied with the connection kit;
Slowly open 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 tightness. The entire installation should be in accordance with
the relevant standards. In GB this is BS 6891 and in IE this is the
current edition of I.S.813.
The connection on the the appliance is a 15mm nut and olive
located at the rear of the gas service cock.
If the gas supply 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 less than 22mm
should not be used, final connection being 15mm.
26
commissioning
FIRST IGNITION OPERATION
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Check the electrical supply.
2. Check the type of gas and
change the gas if necessary.
3. Check the gas tightness.
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
4. Measure the gas inlet.
5. Check the exhaust fume.
See section….
6. Fill the installation. See
section….
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
7. Check the hydraulic water
tightness.
8. Spin the pump.
9. Purge the air with once
pressing on ESC button
during 5 sec. See section….
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
10. Change the language in
the display (if necessary).
11. Set the hour, and the date.
See section….
12. Set the heating power. See
section….
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
13. Adapt the regulation at
the heating installation.
14. Balance the central
heating circuit.
15. Check the working in DHW
mode.
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
16. Adjust DHW flow rate on
the boiler (if necessary).
17. Make a combustion rate
with once pressing on
RESET button during 5 sec.
18. Check the ionisation
current.
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
Complete . . . . . . . . . . . . . . . . . . . .
19. Explain to the end user the
working of the boiler.
Complete . . . . . . . . . . . . . . . . . . . .
27
commissioning
Ignition procedure
Press the ON/OFF button on the control panel to switch on the
boiler. The display shows:
-
-
-
-
2.
3.
The operating mode will be indicated by the three figures marked
out on the diagram above.
The first figure indicates the operating mode:
0 XX - Stand-by, the scrolling text show the operation mode
selected “summer” or “winter”
C XX- “C.Heating active” - Central heating request
c XX- “CH Pump Overrun” - Heating post-circulation
d XX- “DHW Active” - Domestic hot water request
h XX - “DHW Pump Overrun” hot water post-circulation
F XX - “Pump Frost Prot” - circulation pump anti-freeze
protection enabled
- “Burn Frost Prot” - burner anti-freeze
protection enabled
The second and third figures indicate:
- the flow temperature when no heating requests have been made
- the flow temperature in central heating mode
- the set temperature of the hot water in domestic hot water
- the flow temperature in anti-freeze mode.
The indication of certain functions:
P 1- “Purge in progress” = Deaeration cycle started
Electricity supply
- Check that the voltage and frequency of the electricity supply
correspond to the data shown on the boiler data plate;
- Make sure that the earthing connection is efficient.
menu 2 - Boiler parameters
submenu 3 - parameter 1
Maximum Heating Power adjustment
submenu 2 - parameter 0
Soft light Ignition
submenu 3 - parameter 5
Heating ignition delay
First ignition
1. Make sure that:
- The gas valve is closed;
- The electrical connection has been properly carried out.
Make sure that, in any case, the green/yellow earthing wire is
connected to an efficient earthing system;
- Use a screwdriver to lift the cap on the automatic air relief
valve;
- Switch on the boiler (by pressing the ON/OFF button) and use
the Mode button to select the standby mode, where no hot
water or heating requests are made.
- Start the deaeration cycle by pressing Esc for 5 seconds
The boiler will start a deaeration cycle lasting about 7 minutes
28
(See below). If you need to stop it press Esc, alternatively it is
possible to manually vent the heat exchanger.
At the end, check that the system is completely deaerated
and, if not, repeat the procedure.
Bleed the air from the radiators;
The exhaust duct for combustion products should be suitable
and free from any obstructions;
Any necessary ventilation inlets in the room should be open
(type B installation).
Open the gas cock and check the connection seals, including
the boiler connection joints, making sure that the meter does
not detect any passage of gas. Eliminate any leaks.
Start the boiler by selecting the heating or domestic hot water
operation using the Mode button.
Description of Function
Deaeration cycle
During the filling stage or if there is excess air in the system, the
deaeration cycle can be activated by holding the Esc button for 5
seconds. The boiler will start a cycle which lasts approximately 7
minutes. When this is complete the menu screen will be restored.
The cycle may either be repeated, if necessary, or stopped by
pressing Esc. Press the Esc button until the normal display screen is
restored. If the cycle is stopped be sure to manually vent the appliance.
Maximum Heating Power adjustment
The maximum heating power can be adjusted to between the
maximum power allowed by the boiler and the minimum power).
The display shows the value between 100% (“99” on the display)
and 0% (“0”) of this interval.
To check the maximum heating power, access menu 2/sub
menu 3/parameter 1, check the value and, if necessary, modify it
as indicated in the Gas Regulation table. (See page 31 for more
details).
38
35
30
24
25
18
Checking slow ignition power
The soft light can be adjusted between the maximum power
(shown on the display as “99”, i.e. 100%) and the minimum power
(shown on the display as “1”, i.e. 1%).
To check the slow ignition power, access menu 2/sub menu 2/
parameter 0.
commissioning
Heating ignition delay adjustment
This parameter – menu 2/sub menu 3/parameter 5 - can be used
to manually (0) or automatically (1) set the delay time before the
subsequent reignition of the burner after it has switched off on
reaching the desired temperature in central heating mode.
By selecting manual, it is possible to set the delay in minutes using
the successive parameter (menu 2/sub menu 3/parameter 6), to a
time between 0 and 7 minutes.
Automatic selection means that the boiler will establish the delay
time based on the set-point temperature
gas setting
parameter
lower Wobbe index
(15°C, 1013 mbar) (MJ/m3)
24 kW
30 kW
38 kW
G20
G31
G20
G31
G20
G31
45,67
70,69
45,67
70,69
45,67
70,69
minimum fan speed(%)
233
05
05
01
01
01
01
maximum central heating fan speed (%)
234
85
85
80
80
70
70
maximum D.H.W fan speed (%)
232
98
98
89
89
89
89
NO
3,80
NO
4,50
NO
5,250
max D.H.W
2,65
1,94
3,17
2,33
4,02
2,95
max C.H.
2,33
1,71
2,96
2,17
3,28
2,41
min
0,58
0,43
0,69
0,50
0,79
0,58
gas valve restrictor(ø)
gas flow max/min
(15°C, 1013 mbar)
(nat - m3/h) (GPL - kg/h)
29
commissioning
Test function and combustion analysis
The boiler has two pressure taps to measure the combustion gas
temperature, the combustive air and the concentrations of O2
and CO2 on the outside of the flue gas header.
to access these pressure taps, unscrew the screw which holds the
blanking cover and its seal together.
Wait for the boiler to stabilise before carrying out the combustion
analyses. Check the CO2 value according to the table below.
Important: do not remove silencer 22
Maximum or minimum CO2
24 kW
30 kW
38 kW
G20
G31
9.0 ± 0.2
10.7 ± 0.2
CO2 (%)
9.0 ± 0.2
10.0 ± 0.2
9.4 ± 0.2
10.6 ± 0.2
N.B.: when the front combustion chamber panel is open, the
CO2 value drops by 0.3%.
If the values taken differ from the table, adjust the gas valve following the procedure described below.
Adjust the CO2 content to ± 0.2 by turning setting screw 50 (2.5
mm allen key)
- tighten to lower the CO2 value
- unscrew to increase the CO2 value
Set the content by turning the screw about a 1/4 of a turn then
wait after each change for approximately 1 minute for the CO2
value to stabilise, then repeat.
Checking the gas setting
To carry out analyses of combustion, the test function must be
activated.
8
2
Cleaning function
The PCB allows the appliance to be forced to minimum or
maximum power.
Activate the cleaning function by pressing the Reset button for
5 seconds, the boiler switches to maximum heating power, the
following appears on the display:
50
Only a 2.5 mm allen
key must be used. Do
not use a screwdriver
To select the function at maximum domestic hot water, press
the
button, the following appears on the display :
To select the function at minimum domestic hot water, press
the
button, the following appears on the display :
Minimum gas flow combustion analysis
Activate the cleaning function at minimum power in either
heating or domestic hot water production.
Wait for the boiler to stabilise before carrying out the combustion
analyses. Check the CO2 value according to the table above.
Important: do not remove silencer 22
N.B.: when the combustion chamber is open, the CO2 value
drops by 0.3%.
If the values taken differ from the table, adjust the gas valve following the procedure described below.
To adjust the CO2 value, remove cap 2, adjust the CO2 content to
± 0.2 by turning setting screw 51 (4 mm allen key)
- unscrew to lower the CO2 value
- tighten to increase the CO2 value
51
The function is automatically deactivated after 10 minutes or by
pressing the Reset button.
Note: the appliance can be forced to minimum or maximum
power from menu 7 (see the section on the display - setting diagnostics menu).
Maximum gas flow combustion analysis
Activate the test function at the maximum heating power t--
30
Only a 4 mm
allen key must be
used. Do not use a
screwdriver
Set the content by turning the screw about a 1/4 of a turn then
wait after each change for approximately 1 minute for the CO2
value to stabilise, then repeat.
Once the settings and analyses are complete, exit test mode, and
reposition the blanking cover and its seal correctly.
commissioning
AUTO function
This is a function which enables the boiler to automatically adapt
its operation routine (the temperature of the heating elements) in
line with the outdoor conditions, in order to achieve and maintain
the requested room temperature conditions.
Depending on the peripheral units connected and the number
of zones controlled, the boiler adjusts its flow temperature
automatically.
The various corresponding parameters should therefore be set
(see adjustments menu).
To activate the function, press the Auto button.
Example 1:
Single zone system (high-temperature) with on/off room Thermostat:
In this case the following parameters must be set:
4 21 - Activation of temperature adjustment using sensors
- Select 1 = Basic temperature adjustment
2 44 - Boost Time (optional)
The wait time for the flow temperature increase in steps of
4°C may be set. The value varies according to the type of
system and installation.
If the Boost Time value = 00 the function is not activated.
Example 2:
Single zone system (high-temperature) with on/off room Thermostat +
outdoor sensor:
In this case the following parameters must be set:
4 21 - Activation of temperature adjustment using sensors
- Select 3 = outdoor sensor only
4 22 - Temperature adjustment curve selection
- Select the relevant curve according to the type of
system, installation, heat insulation used in the building,
etc.
4 23 - Perform a parallel curve shift if necessary, increasing or
decreasing the set-point temperature (this may also be
modified by the user, using the heating temperature
adjustment knob, which, with the Auto function
activated, is used to shift the curve in a parallel manner).
Example 3:
Single zone system (high-temperature) with REMOCON remote Control +
outdoor sensor
In this case the following parameters must be set:
4 21 - Activation of temperature adjustment using sensors
- select 4 = outdoor sensor + room sensor
4 22 - Temperature adjustment curve selection
- Select the relevant curve according to the type of
system, installation, heat insulation used in the building,
etc
4 23 - Perform a parallel curve shift if necessary, increasing or
decreasing the set-point temperature. (This may also be
changed by the user by the encoder which, with the Auto
function activated, is used to shift the curve in a parallel
manner.)
4 24 - Influence of room sensor
- used to adjust the influence the room temperature has
on the calculation of the set-point flow temperature (20 =
maximum, 0 = minimum).
Note: See page 35 for details on accessing menus.
31
boiler protection devices
Malfunction warning
This warning is shown by the display in the following format:
5 P1 = FIRST IGNITION ATTEMPT UNSUCCESSFUL
the first figure indicating the operational assembly is followed by a P
(warning) and the code relating to the specific warning.
Important
If this shutdown occurs frequently, contact an authorised Technical Service
Centre for assistance. For safety reasons, the boiler will permit a maximum
of 5 resets in 15 minutes (5 presses of the RESET button); at the 6th attempt
within this 15-minute period the boiler will shut down and may only be
operated again after the electricity supply has been disconnected. If the
shutdown is occasional or an isolated event, this is not a problem.
Anti-frost Device.
The anti-frost function acts on the central heating flow temperature probe, independently from other regulations, when the electrical supply is
turned on.
If the primary circuit temperature is between 3°C and 8°C the
pump will run (with the diverter valve switching between central heating and hot water every 1 minute) until the temperature
reaches > 9°C.
If the flow temperature remains between 3°C and 8°C the pump will continue to run for a maximum of 20 minutes unless a temperature above >
9°C is detected in the central heating flow, after this the the burner will fire
(heating position) until a temperature of > 30°C is detected.
If the central heating flow temperature is < 3°C, the burner will fire (heating position) at minimum power until the temperature reaches > 30°C,
the burner will go out.
If lockout is caused by overheat the burner will not fire but the pump will
continue to run (heating position).
The anti-frost device activates only when (with the boiler operating correctly):
- the system pressure is correct;
- the boiler is electrically powered;
- there is a supply of gas.
32
Table summarising error codes
Central Heating circuit
Display Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
01
02
03
04
05
06
07
10
08
12
14
16
18
P1
P2
P3
Overheat
Pressure Sens Error
2
2
2
2
2
01
02
04
07
08
D.H.W. temp. probe circuit open / short circuit
Bottom storage temperature probe open / short circuit
Solar collector temperature probe open / short circuit
Solar collector overheating
Collector frost protection temperature
3
3
3
3
3
3
3
01
02
03
04
05
06
07
EEPROM error
Comunication error
Main P.C.B. error
Too many (> 5) resets in 15 minutes
Main P.C.B. error
Main P.C.B. error
Main P.C.B. error
Insufficient circulation
C.H. Flow temp. probe circuit open / short circuit
Insufficient water (request filling)
C.H. Return temp. probe circuit open / short circuit
External sensor circuit open / short circuit
Floor Thermostat contact open
Heating delevery probe problem
Insufficient circulation indication
D.H.W. circuit
Solar kit
(optional)
Boiler protection devices
The boiler is protected from malfunctioning by means of internal checks
performed by the electronic microprocessor P.C.B., which stops the boiler
from operating if necessary.
In the event of the boiler being shut off in this manner, a code appears on
the display which refers to the type of shut-off and the reason behind it.
There are two types of shut-off:
Safety shut-off
This type of error is “volatile”, which means that the boiler starts up again
automatically as soon as the problem which caused the shut-off is removed; the error is indicated by the «Err» symbol which appears on the
display and the error code.
In fact, soon as the cause of the shut-off disappears, the boiler starts up
again and continues to operate normally.
In the event of error 1 08 - Shut-off due to insufficient water pressure
inside the heating circuit - the boiler will perform a safety shut-off.
You can increase the pressure by filling the heating circuit.
In this case or if the re-balancing request is performed on a frequent basis,
switch the boiler off, turn the external electric switch to the OFF position,
shut off the gas cock and contact a qualified technician to check for any
leaks of water.
Shutdown
This type of error is “non-volatile”, which means that it is not removed
automatically. To restore normal operation press the
button on the
control panel.
The first figure of the error code (e.g. 1 01) indicates within which
operational assembly the error occurred.
1 - Primary Circuit
2 - Domestic Hot Water Circuit
3 - Internal Electronic Part
4 - External Electronic Part
5 - Ignition and Detection
6 - Air inlet - flue gas outlet
Internal P.C.B.’s
External P.C.B.’s
4 07
Room sensor circuit open 7 short circuit
5
5
5
5
5
5
No flame detected
Flame detected with gas valve closed
Flame lift
1st Ignition Failed
2nd Ignition Failed
Flame cut-off
Ignition and Detecion
01
02
04
P1
P2
P3
Air Inlet / Flue gas outlet
6 04
6 10
Insufficient fan speed
Thermofuse open
Multi-zone Heating (Heating Zone Modules - optional)
7
7
7
7
7
7
7
01
02
03
04
05
06
07
Zone 2 outgoing sensor defective
Zone 2 return sensor defective
Zone 3 outgoing sensor defective
Zone 3 return sensor defective
Hydraulic separation sensor defective
Zone 2 overheating
Zone 3 overheating
settings - adjustment - problem identification menus
Accessing the settings - adjustment - problem identification
menus
The boiler can be used to manage the heating and domestic hot
water production system in its entirety.
Navigation within the menus enables the boiler system +
connected peripheral units to be customised, optimising
operation for maximum comfort and maximum saving. It also
provides important information relating to the efficient operation
of the boiler.
The following menus are available:
2
Boiler Parameter
2
1
Service code (accesso riservato tecnico qualificato)
2
2
General setting
2
3
C.H. Parameters - Part 1
2
4
C.H. Parameters - Part 1
2
5
Domestic Hot Water
2
9
Menù 2 Reset to factory setting
3
Solar & Storage
3
0
General setting
3
1
Service code (accesso riservato tecnico qualificato)
3
2
Special setting
4
Zone 1 Parameters
4
0
Set-point Zone1
4
1
Service code (accesso riservato tecnico qualificato)
4
2
Zone 1 Setting
4
3
Diagnostics
4
4
Zone device mangement
5
Zone 2 Parameters
5
0
5
1
Service code (accesso riservato tecnico qualificato)
5
2
Zone 2 Setting
5
3
Diagnostics
5
4
Zone device mangement
5
5
Multizone
7
Test & Utilities
8
Service Parameter
8
1
Service code (accesso riservato tecnico qualificato)
8
2
Boiler
8
3
Boiler Temperature
8
4
Solar & Storage
8
5
Service
8
6
Statistics
8
7
E@sy - NOT ACTIVE
8
8
Error History
Set-point Zone2
The parameters relating to each individual menu are listed in the
following pages.
The various parameters can be accessed and modified using th
Menu/Ok button and programmation buttons
and
. (see fig.
below).
Programmation
button
Menu/Okbutton
To access the Menus, open the cover and proceed as follows:
1. Press the Menu/Ok button; the first figure 000 will flash on the
display.
2. Press the buttons
or
to select a menu, for example:
“200
3. Press the Menu/Ok button; the second figures on the display will
flash, e.g. “210.
Caution! The menus reserved for qualified technicians may only be
accessed after setting the access code.
4. Press the Menu/Ok button; 222 will appear on the display unit.
5. Press the buttons
or
to select code 234
6. Press the Menu/Ok button to select the sub menu; the second
figures will flash, e.g. “220”.
7. Press the buttons
or
to select a sub menu; for example:
“230
8. Press the Menu/Ok button to access the sub menu parameters; the
three figures will flash, for example: “230”.
9. Press the buttons
or
to select a parameter; for example:
“231
10. Press the Menu/Ok button to access the parameter; the display will
indicate the value, e.g “70”.
Note: The parameter value will be displayed for 20 seconds, then
will begin to flash in alternation with the parameter, e.g. “70 >
231.
11. Press the buttons
or
to select the new value, e.g. “75”.
12. Press Menu/Ok to save the change or press Esc to exit without
saving.
To exit, press the Esc button until the normal display screen is
restored.
For menus which do not require the access code, it is possible to pass
directly from the menu to the sub menu.
33
description
2 BOILER parameter SETTING
2 1 Entering access code
value
default setting
menu
sub-menu
parameter
settings - adjustment - problem identification menus
222 press the programming "+" button to select 234
and press the Menu button
2 2 BOILER General SETTING
2 2 0 Slow ignition
0 to 99
60 RESERVED FOR SAT
2 2 1 Minimum ambient temperature for
antifreeze activation
2 2 2 NOT PRESENT
from 2 to 10 °C
5
2 2 3 Underfloor thermostat or zone 2 ambient
thermostat selection
0 = Floor safety thermostat
1 = Zone 2 ambient thermostat
0
2 2 4 Mechanical timer connection authorisation 0 = Absent
1 = Present
2 2 5 Heating ignition delay
0 = Deactivated
1 = 10 seconds
2 = 90 seconds
3 = 210 seconds
0
0
Activated only with the modulating peripheral
device (optional)
to be modified if mechanical timer is present
(optional)
Activated only with zone 2 interface (optional)
2 2 6 NOT PRESENT
2 2 7 NOT PRESENT
2 2 8 Boiler Version
CANNOT BE MODIFIED
0 to 5
0
RESERVED FOR TECHNICAL ASSISTANCE Only if
the PCB is changed
2 3 BOILER Parameter - Part 1
2 3 0 NOT PRESENT
2 3 1 Maximum heating power setting
0 to 99
2 3 2 Domestic hot water maximum RPM
percentage
CANNOT BE MODIFIED
2 3 3 Minimum RPM percentage
CANNOT BE MODIFIED
2 3 4 Heating maximum RPM percentage
CANNOT BE MODIFIED
0 to 99
2 3 5 Selection of ignition delay type when
heating
0 = Manual
1 = automatic
1
2 3 6 Ignition delay when heating timer setting
from 0 to 7 minutes
3
2 3 7 Post-circulation when heating
from 0 to 15 minutes or OC (AC)
3
2 3 8 Circulation pump operating type
0 = Low Speed
1 = High Speed
2 = Modulating
2
2 3 9 Setting the Delta T
Circulation pump modulation
from 10 to 30 °C
20 to be set with operation of the circulation pump
in modulating mode
see the "gas setting" table, information on
Starting
RESERVED FOR TECHNICAL ASSISTANCE Only if
the gas or PCB is changed
see "gas setting" table
0 to 99
0 to 99
see section on "gas setting"
These parameters allow the flow and backflow temperature difference to be set, which determines whether the circulation
pump switches from low to high speed
E.g.: param. 239 = 20 and ∆T > 20°C- the circulation pump runs at high speed. If ∆T < 20 - 2°C the circulation pump runs at
low speed. The minimum waiting time for changing speed is 5 minutes.
34
2
2
2
2
2
4
4
4
4
4
description
BOILER PARAMETER - PART 2
0 NOT PRESENT
1 NOT PRESENT
2 NOT PRESENT
3 Post-ventilation after heating request
2 4 4 Time delay after heating temperature increase
value
0 = OFF
1 = ON
from 0 to 60 minutes
default setting
menu
sub-menu
parameter
settings - adjustment - problem identification menus
0
activated only with thermostat On/Off and
heating control activated (parameter 421 or 521
= 01
This parameter allows the time delay to be set before automatic increase of the flow temperature calculated in increments of 4°C (max 12°C). If this
parameter retains the value 00, this function is not active.
2 4 5 NOT PRESENT
2 4 6 NOT PRESENT
2 4 7 Device indicator for heating circuit pressure
0 = temperature sensor only
1 = pressure switch at minimum
2 = pressure sensor
16
1
RESERVED FOR TECHNICAL ASSISTANCE Only if the
PCB is changed
2 4 8 NOT PRESENT
2 5 DOMESTIC HOT WATER Parameter
2 5 0 COMFORT function
0 Timer = activated for 30 minutes after domestic
0 = deactivated
hot water draw-off
1 = timed
2 = always on
The appliance allows the hot water heating comfort to be increased via the “COMFORT” function.
This function keeps the secondary exchanger temperature stable when the boiler is not in use. When the function is active,
the display shows COMFORT
Note: this function can be activated and deactivated by pressing the COMFORT button
2 5 2 Hot water flow delay
2 5 3 Extinction of the burner in domestic hot water
from 5 to 200 (0.5 to 20
seconds)
0 = anti-scale (stop at > 67°C)
1 = + 4°C /setting
5
Anti "water hammering"
0
2 5 4 Post-circulation and post-ventilation after a 0 = OFF
0
domestic hot water draw-off
1 = ON
OFF = 3 minutes post-circulation and post-ventilation after domestic hot water
draw-off if the boiler temperature measured requires it.
ON = always on for 3 minutes post-circulation and post-ventilation after domestic
hot water draw-off.
2 5 5 Domestic hot water timer
from 0 to 60 minutes
0
2 9 RESET MENU 2
2 9 0 Automatically resetting to the default setting in Reset
OK = yes
menu 2
ESC = no
To reset all default parameter settings, press the
MENU button
35
3
3
3
3
3
3
default setting
menu
sub-menu
Parameter
settings - adjustment - problem identification menus
Description
value
BOILER WITH TANK (INTERNAL OR EXTERNAL) AND SOLAR APPLIANCE CONNECTION
0 General SETTING
0 0 NOT ACTIVATED
0 1 NOT ACTIVATED
0 2 NOT ACTIVATED
1 Entering access code
222 Turn the encoder clockwise to select 234 and
press the Menu button
3 2 SPECIAL SETTING
3 2 0 Anti-legionella function
0=OFF - 1 = ON
This function avoids the formation of the legionella bacterium wich sometimes develops in pipes and water tanks where the temperature is
included between 20 and 40°C. If the storage temperature remains more than 100 hours less than 59°C and the function is enable, the boiler
is light aan and the storage water is warmed up to 65°C during 30 minutes.
3 2 1 NOT ACTIVATED
3 2 2 NOT ACTIVATED
3 2 3 Collector delta temp pump ON
from 0 to 30°C
8
3 2 4 Collector delta temp pump OFF
from 0 to 30°C
2
only with Clip-In solar connected
3 2 5 Minimum collector temp pump ON
from 10 to 90°C
30 Enable
(option)
2 2 6 Collector kick
ON or OFF
OFF
3 2 7 Recooling function
ON or OFF
OFF
3 2 8 NOT ACTIVATED
-20
3 2 9 Collector frost protection temperature
from -20 to +5°C
36
description
4 ZONE 1 PARAMETER
4 0 ZONE 1 TEMPERATURE SETTING
4 0 0 Zone 1 comfort temperature setting
"Comfort ambience T"
4 0 1 Zone 1 reduced temperature setting
"Reduced ambience T"
4 0 2 Heating fixed temperature setting
"Heating fixed temp"
default setting
menu
sub-menu
parameter
settings - adjustment - problem identification menus
value
from 10 to 30 °C
19
from 10 to 30 °C
16
from 20 to 82 °C
70
4 1 Entering access code
Activated only with the modulating device connected (option)
Activated only with temperature control and fixed
temperature
222 turn the encoder clockwise to select 234 and
press the Menu/Ok button
4 2 ZONE 1 SETTING
1
select in the appliance type base
1
To activate heating control, press the AUTO button.
The display lights up the AUTO symbol, indicating
the peripheral device connected (if present)
1_5
3.5 3.0
2.5
2.0
1.5
1.2
1.0
60
0.8
50
0.6
40
0.4
0.2
30
Am 25
b
va ie
10
tems lorentde t 20
peetr i coem
atitnu ns p 15 °C
rga va egenra
amlubi a tur
eente e
5
0
-5
-10
-15
bassa tempertaura
low temperature
Flow Temperature
temperatura di mandata all’impianto
0 = from 20 to 45°C (low
temperature)
1 = from 35 to 85°C (high
temperature)
4 2 1 Basic heating control type selection type 0 = fixed flow temperature
depending on the peripheral devices 1 = device On/Off
connected
2 = ambient sensor only
3 = external sensor only
4 = ambient sensor + external
sensor
4 2 2 Slope
0_2 to 3_5
If the external sensor is used, the boiler
°C 100
calculates the most suitable heating flow
temperature taking the external temperature
90
and the type of appliance into account.
The type of curve must be chosen according
80
to the type of appliance radiator and the
heat losses present in the building.
70
High temperature
alta tempertaura
4 2 0 Heating appliance temperature value
setting
-20 °C
temperatura esterna
External temperature
4 2 3 Parallel shift
- 20 to + 20
0
To adapt the thermal curve to the appliance requirements, it is possible to perform a parallel shift of the curve in order to alter the calculated
flow temperature and therefore the ambient temperature.
The shift value between - 20 and + 20 is shown on the display. Each level corresponds to a 1°C increase in the flow temperature in relation
to the initial setting.
4 2 4 Compensation
4 2 5 Zone 1 heating maximum temperature
setting
4 2 6 Zone 1 heating minimum temperature
setting
4
4
4
4
3
3
3
3
DIAGNOSTICS
0 Zone 1 room temperature
1 Zone 1 set temperature
2 Zone 1 heat request
4 3 3 Pump status
4 4 ZONE DEVICE MANAGEMENT
4 4 0 Pump control
20
0 to + 20
if setting = 0, the temperature taken from the ambient sensor does not affect the calculation of
the setting. If setting = 20, the temperature taken has maximum influence on the setting.
35 to + 82°C
82 if parameter 420 = 1
20 to + 45°C
45 if parameter 420 = 0
35 to + 82°C
35
if parameter 420 = 1
20 to + 45°C
20
if parameter 420 = 0
display only
Activated only with the modulating device connected (option)
0=OFF
1=ON
0=OFF
1=ON
0=OFF
1=ON
Active only with MGZ/MCM kit
Active only with MGZ/MCM kit
37
description
5 ZONE 2 PARAMETER
5 0 ZONE 2 TEMPERATURE SETTING
5 0 0 Zone 2 comfort temperature setting
"Comfort ambience T"
5 0 1 Zone 2 reduced temperature setting
"Reduced ambience T"
5 0 2 Heating fixed temperature setting
"Heating fixed temp"
5 1 Entering access code
value
from 10 to 30 °C
from 10 to 30 °C
from 20 to 82 °C
default setting
menu
sub-menu
parameter
settings - adjustment - problem identification menus
19 Activated only with the modulating device connected
(option)
16
70 Activated only with temperature control and fixed
temperature
222 turn the encoder clockwise to select 234 and press
the Menu/Ok button
5 2 ZONE 2 SETTING
5 2 0 Heating appliance temperature value
setting
0 = from 20 to 45°C (low
1 select in the appliance type base
temperature)
1 = from 35 to 85°C (high
temperature)
0 To activate heating control, press the AUTO button.
5 2 1 Basic heating control type selection type 0 = fixed flow temperature
The display lights up the AUTO symbol, indicating the
depending on the peripheral devices 1 = device On/Off
peripheral device connected (if present)
connected
2 = ambient sensor only
3 = external sensor only
4 = ambient sensor + external
sensor
1_5
5 2 2 Slope
0_2 to 3_5
If the external sensor is used, the boiler calculates the most suitable heating flow
see graph on the previous page
temperature taking the external temperature and the type of appliance into
account.
The type of curve must be chosen according to the type of appliance radiator and the
heat losses present in the building.
0
5 2 3 Parallel shift
- 20 to + 20
To adapt the thermal curve to the appliance requirements, it is possible to perform a parallel shift of the curve in order to alter the calculated
flow temperature and therefore the ambient temperature.
The shift value between - 20 and + 20 is shown on the display. Each level corresponds to a 1°C increase in the flow temperature in relation to
the initial setting.
5 2 4 Compensation
5 2 5 Zone 2 heating maximum temperature
setting
5 2 6 Zone 2 heating minimum temperature
setting
0 to + 20
20
if setting = 0, the temperature taken from the ambient sensor does not affect the calculation of the
setting. If setting = 20, the temperature taken has maximum influence on the setting.
35 to + 82°C
82 if parameter 420 = 1
20 to + 45°C
45 if parameter 420 = 0
35 to + 82°C
35 if parameter 420 = 1
20 to + 45°C
20 if parameter 420 = 0
5 3 DIAGNOSTICS
5 3 0 Zone 2 room temperature
5
5
5
5
3
3
3
3
1
2
3
4
Heating flow outlet temperature
Heating return temperature
Zone 2 set temperature
Zone 2 heat request
5 3 5 Zone 2 Pump status
5 4 ZONE DEVICE MANAGEMENT
5 4 0 Operation mode test
5 4 1 Valve control
5 4 2 Pump control
5 5 MULTIZONE
5 5 0 Heating collector temperature
5 5 1 Heating collector flow outlet
temperature offset
38
Activated only with the modulating device connected
(option)
Active only with MGZ/MCM kit
0=OFF
1=ON
0=OFF
1=ON
Active only with MGZ/MCM kit
0=OFF
1=ON
2=manual
0=OFF
1=Open
2=Close
0=OFF
1=ON
0 to 120°C
0 to + 40°C
Active only with MGZ/MCM kit
0
5
Active only with MGZ/MCM kit
description
value
7 TEST & UTILITIES
7 0 0 Function test - Cleaning
t-- = funct. at Max heating
turn the encoder to select the operating power
mode
t-- = funct. at Max DHW power
t-- = funct. at Min power
7 0 1 Bleed cycle
press Menu
8 PARAMETER FOR TECHNICAL ASSISTANCE
8 1 Entering access code
default setting
menu
sub-menu
parameter
settings - adjustment - problem identification menus
t--
activation can also be obtained by pressing the Reset
button for 10 seconds. The function is deactivated after
10 minutes or by pressing Esc
222 turn the encoder clockwise to select 234 and press the
Menu button
8 2 BOILER
8 2 0 NOT PRESENT
8 2 1 Fan status
ON or OFF
8 2 2 Fan speed (x100) rpm
8 2 3 Circulation pump speed
OFF - LS - HS
8 2 4 Distribution valve position
Domestic hot water - Heating
8 2 5 Water flow rate (l/min)
8 2 6 NOT PRESENT
8 3 BOILER TEMPERATURE
8 3 0 Heating adjustment temperature (°C)
8 3 1 Heating flow temperature (in °C)
8 3 2 Heating backflow temperature (in °C)
8 3 3 Domestic hot water temperature (in °C)
8 4 SOLAR APPLIANCE AND TANK
8 4 0 Accumulated measured temperature
8 4 1 Solar collector temperature
8 4 2 Solar appliance water input temperature
8 4 3 Solar appliance low tank sensor temperature
8 4 4 Layered tank set temperature
activated only with the solar kit connected or external
tank
8 4 5 Total circulation pump operating time delay for solar appliance
8 4 6 Total solar collector overheating time delay
8 5 SERVICE - TECHNICAL ASSISTANCE
8 5 0 NOT PRESENT
8 5 1 NOT PRESENT
8 5 2 NOT PRESENT
8 5 3 NOT PRESENT
8 5 4 PCB hardware version
8 5 5 PCB software version
8 5 6 PUS peripheral device interface software version
39
Description
8 6 STATISTICS
value
default setting
menu
sub-menu
Parameter
settings - adjustment - problem identification menus
8 6 0 Number of hours burner operating in heater mode (xxh/10)
8 6 1 Number of hours burner operating in hot water mode (xxh/10)
8 6 2 Number of flame separations (nr/10)
8 6 3 Number of ignition cycles (nr/10)
8 6 4 Number of filling cycles performed
8 6 5 Average length of heating request (minutes)
8 7 E@SY HOTLINE NOT ACTIVE
8 7 0
8 7 1
8 8 ERROR LIST
8 8 0 10 last errors
from E00 to E99
This parameter allows the last 10 boiler errors flagged to be displayed, indicating the day, month and year.
When the parameter is accessed, the errors are displayed listed from E00 to E99.
For each error, the following sequence is displayed:
E00 - error number
108 - error code
A15 - A = day on which error E00 occurred - Only with the CLIMA MANAGER control unit connected (optional)
B09 - B = month during which error E00 occurred - Only with the CLIMA MANAGER control unit connected (optional)
C06 - C = year during which error E00 occurred - Only with the CLIMA MANAGER control unit connected (optional)
8 8 1 Error list reset
Reset
OK = yes
ESC = no
8 9 DATA - ASSISTANCE CENTRE
8 9 0 Enter the name of the assistance centre - it will be displayed if there is a fault which cannot be unlocked with the Reset button
"Assistance Centre Name" appears on the display, press the MENU button and start entering the letters by turning the encoder. To
insert each letter, press the MODE button to confirm it and move on to the next letter.
Enter the number of the assistance centre - it will be displayed if there is a fault which cannot be unlocked with the Reset button
"Assistance Centre Number" appears on the display, press the MENU button and start entering the digits by turning the encoder.
To insert each digit, press the MODE button to confirm it and move on to the next digit.
Press the Menu button to confirm.
40
maintenance
Important
Maintenance is an essential part of the safe and efficient operation
of the boiler and ensures its durability. It should be performed
according to the instructions given in current legislation. Perform
combustion analysis regularly in order to check the operating
efficiency of the boiler and to make sure any polluting substances
relased are within the boudaries set by current legislation.
Before beginning maintenance work:
- Disconnect the appliance from the electricity supply by
turning the external bipolar switch to the “OFF” position;
- Close the gas valve and the central heating and domestic hot
water system valve.
After the work has been completed the initial settings will be
restored.
General comments
It is recommended that the following inspections be carried out
on the boiler at least once a year:
1. Check the seals in the water part and, if necessary, replace the
gaskets and restore the seal to perfect working order.
2. Check the seals in the gas part and, if necessary, replace the
gaskets and restore the seal to perfect working order.
3. Visually check the overall condition of the boiler.
4. Visually check the combustion and, if necessary, disassemble
and clean the burner.
5. Following the inspection detailed in point “3”, disassemble
and clean the combustion chamber, if necessary.
6. Following the inspection detailed in point “4”, disassemble
and clean the burner and injector, if necessary.
7. Cleaning the primary heat exchanger
8. Make sure the following heating safety devices are operating
correctly:
- temperature limit safety device.
9. Make sure that the following gas part safety devices are
operating correctly:
- absence of gas or flame safety device (ionisation).
10. Check the efficiency of the domestic hot water production
process (test the flow rate and temperature).
11. Perform a general inspection of the boiler operation.
12. Remove oxide from the detection electrode using an emery
cloth.
13. These checks are not exhaustive. Further mechanical, electrical
and combustion maintenance checks may be required.
Operational test
After having carried out the maintenance operations, fill the
heating circuit at a pressure of approximately 1.0 bar and release
the air from the system.
Fill the domestic hot water system at the same time.
- Begin operating the boiler.
- If necessary, release the air from the heating system again.
- Check the settings and make sure all the command, adjustment
and monitoring parts are working correctly.
- Check the flue system is sealed and operating correxctly.
Draining procedures
The heating system must be drained using the following
procedure:
- Switch off the boiler, make sure the external bipolar switch is in
the OFF position and shut off the gas valve;
- Loosen the automatic air relief valve;
- Open the system drain off cock and collect the escaping water
in a container;
- Empty the water from the lowest points of the system (where
applicable).
If the system is to be left inactive in areas where the room
temperature may fall below 0°C during winter, we recommend
that anti-freeze liquid is added to the water in the heating system
in order to avoid the need for repeated draining; when this liquid
is used make sure it is compatible with the stainless steel used for
the bodywork of the boiler.
We recommend the use of anti-freeze products which contain
PROPYLENE GLYCOLS as these inhibit corrosion and that they
are used in conjunction with the anti-scaling and anti-corrosion
function, in the quantities suggested by the manufacturer, at the
mimimum temperature.
Regularly check the pH level of the water/anti-freeze mix in the
boiler circuit and replace it when the value measured is lower than
the limit prescribed by the manufacturer.
DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE.
The manufacturer will not be held liable for any damage caused
by the appliance or the system due to the use of inappropriate
anti-freeze substances or additives.
Draining the domestic hot water system and indirect cylinder
Every time there is a danger of freezing, the domestic hot water
system must be drained as follows:
- Shut off the water mains inlet valve;
- Open all the hot and cold water taps;
- Empty the water from the lowest points of the system (where
applicable).
WARNING
Before handling, empty all components which may contain hot
water, performing bleeding where necessary.
Descale the components in accordance with the instructions
provided on the safety data leaflet supplied with the product used,
make sure the room is well ventilated, wear protective clothing,
avoid mixing different products, and protect the appliance and
surrounding objects.
Seal all openings used to take a gas pressure reading or to make
any gas adjustments.
Make sure that the nozzle is compatible with the supplied gas.
If a smell of burning is detected or smoke is seen leaking from
the appliance, or there is a smell of gas, disconnect it from the
electricity supply, shut off the gas valve, open the windows and
call for technical assistance.
41
MAINTENANCE GUIDE
1. GENERAL ACCESS
MAINTENANCE GUIDE: CLAS HE
1.3
GENERAL ACCESS
GENERAL ACCESS
Tools
Time
3 min
1
Unclip the cover to remove
Remove the two screws
2
Lower the electrical box
42
Page. 6 of 24
Remove the combustion
chamber front panel by
releasing the clips
Remove the front panel
MAINTENANCE GUIDE
2. ELECTRICAL
UNIT
MAINTENANCE
GUIDE: CLAS HE
2 ELECTRICAL UNIT
2.1
CONTROL BOX ACCESS
CONTROL BOX ACCESS
Tools
Time
4 min
1
Remove the front panel as above
and pivot the electrical box
2.2
Remove the two screws and
unlock the four clamps to gain
access to the control box
FUSE
FUSE
Tools
5 min
Time
1
Open the control box as above
Remove the fuse
Page. 7 of 24
43
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
2.3
MAIN PCB
MAIN PCB
Tools
Time
7 min
Time
7 min
1
After opening the control box,
disconnect the electrical plug
connectors
2.4
Unscrew the two screws and
remove the PCB
DISPLAY PCB
DISPLAY PCB
Tools
1
Unclip the cover to remove
2
Disconnect the electrical plug
connectors, unlock the four
clamps, and remove the PCB
44Page. 8 of
24
Lower the door and remove the
two control knobs
Unscrew the four screws and
pull the assembly towards you
MAINTENANCE GUIDE: CLAS HE
3 HYDRAULIC
3. HYDRAULIC
UNIT
3.1
MAINTENANCE GUIDE
UNIT
RIGHT HAND HYDRAULIC BLOCK ASSEMBLY
LEGEND
1.
Diverter valve motor
2.
Diverter valve
3.
Auto air vent
4.
Primary water pressure switch
5.
Pump
6.
Central heating filter
7.
Not applicable in UK
8.
Non-return valve
9.
Non-return valve assembly
10. DHW flow switch assembly
11. Central heating return
12. Cold water inlet (DHW)
13. Central heating drain valve
3.2
3 WAY VALVE
3 WAY VALVE UNIT
Tools
Time
5 min
1
Unplug the diverter valve cable
Remove the clip and lift the motor from the
diverter valve body
Drain the boiler (see 3.3). Remove the clip and
lift the diverter valve from the assembly
When reassembling, ensure the diverter valve is
aligned correctly
2
Page. 9 of 24
45
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
3.3
DRAINING
DRAINING
Tools
Time
5 min
Time
5 min
1
Turn the drain valve anti-clockwise to open and drain the water
from the boiler.
3.4
AUTOMATIC AIR VENT
AUTOMATIC AIR VENT
Tools
1
Drain boiler (see 3.3). Remove the clip and lift the AAV from the
assembly
3.5
PRIMARY WATER PRESSURE SENSOR
PRIMARY WATER PRESSURE SENSOR
Tools
Time
1
Drain boiler (see 3.3). Remove the fixing clip, unplug the
electrical connector and lift the sensor from the assembly
46
Page. 10 of 24
5 min
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
3.6
PUMP
PUMP
Tools
Time
10 min
1
Drain boiler (see 3.3). Remove
the clip and the two screws
Disconnect the pipe and then
move the pump to the right
disengage
Remove the pump
2
Remove the sensor (see 3.5)
Remove the AAV (see 3.4)
MAINTENANCE GUIDE: CLAS HE
3.7
CH FILTER
CH FILTER
Tools
Time
5 min
1
Drain boiler (see 3.3)
Remove the clip
Remove the filter
Page. 11 of 24
3.8
DHW FLOW SWITCH ASSEMBLY
47
Drain boiler (see 3.3)
Remove the clip
Remove the filter
MAINTENANCE GUIDE
3.8
DHW FLOW SWITCH ASSEMBLY
DHW FLOW SWITCH ASSEMBLY
Tools
Time
5 min
1
Drain boiler (see 3.3). Remove the clip and pull the
flow switch assembly towards you
Twist the flow switch assembly to disengage
MAINTENANCE GUIDE: CLAS HE
3.9
LEFT HAND HYDRAULIC BLOCK ASSEMBLY
Page. 12 of 24
1. DHW temperature sensor
2. Left hand hydraulic block
3. By-pass assembly
4. Safety valve
5. Central heating flow
6. Domestic hot water outlet
3.10 DHW TEMPERATURE SENSOR
48
DHW TEMPERATURE SENSOR
1. DHW temperature sensor
2. Left hand hydraulic block
3. By-pass assembly
4. Safety valve
5. Central heating flow
6. Domestic hot water outlet
MAINTENANCE GUIDE
3.10 DHW TEMPERATURE SENSOR
DHW TEMPERATURE SENSOR
Tools
5 min
Time
1
Isolate the cold water supply
and drain the DHW circuit.
Unplug the DHW sensor and
remove the clip
Sensor without wire and clip
Lift the sensor from
the assembly
MAINTENANCE GUIDE: CLAS HE
Page. 13 of 24
3.11 SECONDARY HEAT EXCHANGER
SECONDARY HEAT EXCHANGER
Tools
Time
10 min
1
Drain primary and domestic hot water circuits. Remove the two
screws and remove the heat exchanger
3.12 CONDENSE TRAP
49
CONDENSE TRAP
MAINTENANCE GUIDE
Drain primary and domestic hot water circuits. Remove the two
screws and remove the heat exchanger
3.12 CONDENSE TRAP
CONDENSE TRAP
5 min
Tools
Time
1
Unscrew the condense trap from the condense
body
MAINTENANCE GUIDE: CLAS HE
3.13 SAFETY VALVE
Page. 14 of 24
SAFETY VALVE
Tools
5 min
Time
1
Drain boiler (see 3.3). Disconnect the
discharge pipe
Remove the first clip on the left and
pull the safety valve towards you
3.14 BY-PASS ASSEMBLY
BY-PASS ASSEMBLY
50
Tools
Time
5 min
Drain boiler (see 3.3). Disconnect the
discharge pipe
Remove the first clip on the left and
pull the safety valve towards you
MAINTENANCE GUIDE
3.14 BY-PASS ASSEMBLY
BY-PASS ASSEMBLY
Tools
Time
5 min
1
Drain boiler (see 3.3). Remove the
MAINTENANCE
GUIDE:
CLAS HE
second
clip and pull
the assembly
toward you
3.15
Push on the by-pass to disengage it
TEMPERATURE SENSORS & OVERHEAT THERMOSTAT
TEMPERATURE SENSORS & OVERHEAT THERMOSTAT
Tools
Time
5 min
Page. 15 of 24
1
OT
NTC1
NTC2
: White wires
: Black wires
: Grey wires
Unplug the electrical
connectors
Remove the clip and the
temperature sensor or
overheat thermostat together
IMPORTANT!!!! Do not use conducting paste for the contact sensors because it will alter the resistance value.
TEMPERATURE (°C)
RESISTANCE (kOmh)
0
10
20
25
30
40
50
60
70
80
27
17
12
10
8
5
4
3
2
1,5
51
50
60
70
80
4
3
2
1,5
MAINTENANCE GUIDE
3.16 MANUAL AIR VENT
MANUAL AIR VENT
Tools
Time
5 min
1
Drain boiler (see 3.3)
Remove
the
clip
and
lift the manual
MAINTENANCE GUIDE:
CLASair
HEvent from the exchanger
Page. 16 of 24
3.17 MAIN HEAT EXCHANGER
MAIN HEAT EXCHANGER
Tools
Time
20 min
1
Drain boiler (see 3.3). Remove
the four clips and disconnect the
Isolate the gas supply. Remove
two
pipes
between
the
the four screws and disconnect
exchanger and pump and
the gas pipe from the gas valve
between the exchanger and left
hand hydraulic block
Remove the four screws to free
the heat exchanger
2
Pull the heat exchanger towards
you
52
Remove the clip and lift the
manual air vent
Twist the thermal fuse to
remove
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
4 BURNER UNIT
LEGEND
1.
2.
3.
4.
5.
Burner
Fan
Silencer
Gas inlet
Air inlet
Page. 18 of 24
6.
7.
8.
9.
10.
Gas valve
Mixing tube
Detection electrode
Ignition electrode
Spark generator
53
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
4. BURNER UNIT
4.1
SPARK GENERATOR
SPARK GENERATOR
Tools
Time
5 min
1
Unplug the ignition electrode from
the spark generator
4.2
Remove the screw and the
spark generator
ELECTRODES
ELECTRODES
Tools
Time
5 min
1
Unplug the electrodes
54
Remove the screws and pull the
electrodes towards you.
Page. 19 of 24
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
4.3
BURNER
BURNER
Tools
15 min
Time
1
Remove the silencer
Isolate the gas supply. Remove the
four screws and disconnect the
gas pipe from the gas valve
Pull the assembly towards
you
2
Remove the three screws to free
the burner door
Pull the burner toward you
Replace any gaskets that are damaged or showing signs of
deterioration
2
1
3
1. Stainless Steel Burner
2. Ignition electrode
3. Detection electrode
Page. 20 of 24
Power
24 KW
30 KW
38 KW
Length
104.6 mm
135.8 mm
167 mm
Venturi
Ø 42 mm
/
/
55
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
4.4
FAN
FAN
Tools
15 min
Time
1
Remove the combustion
assembly (see 4.3)
Remove the three screws to free the
fan.
Twist the gas valve anti-clockwise to
disengage it from the fan
1. Venturi
2. Gasket
3. Fan
56
Fan & mixer venturi according to the model
Power
Fan
Venturi diameter
24 KW
EBM RG 128 45 W
Ø 17 mm
30 KW
EBM RG 128 45 W
Ø 21 mm
38 KW
EBM RG 128 45 W
Ø 25 mm
Page. 21 of 24
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
4.5
GAS VALVE
GAS VALVE
Tools
Time
15 min
1
Remove the combustion
assembly (see 4.3)
Twist the gas valve anti-clockwise to
disconnect it from the fan
Replacement Gas Valves are
not factory set and will need to
be set up (see page 34)
Bayonet
connection
1. Venturi
2. Gas valve
3. Solenoids
Page. 22 of 24
4. Inlet test nipple
5. Offset adjustment
6. Throttle adjustment
57
MAINTENANCE GUIDE
MAINTENANCE GUIDE: CLAS HE
5 ANNUAL MAINTENANCE
Plate heat exchanger
Maintenance Interval: As necessary
How: To measure specification of DHW performance.
By-pass & Safety valve
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Central heating filter
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Flow switch operation
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
/ Check flow rate
Expansion vessel
Maintenance Interval: Annually
How: Check air pressure is at 1 bar (System drained)
Ignition & detection electrodes
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary / Distance from the
burner / Ionisation current more than 1 µA
Burner
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Fan
Maintenance Interval: Annually
How : Visual inspection / Clean as necessary
Primary Heat exchanger
Maintenance Interval: Annually
How : Visual inspection / Clean as necessary
Page. 23 of 24
58
MAINTENANCE GUIDE
5. ANNUAL MAINTENANCE
MAINTENANCE GUIDE: CLAS HE
Condensate trap
Maintenance Interval: Annually
or after cleaning primary heat exchanger
How : Visual inspection / Clean as necessary /
Add water before replacing
Pump
Maintenance Interval: At the first ignition and annually
How: Check that the AAV is open /
Visual inspection / Clean as necessary
Page. 24 of 24
59
SHORT LIST
SHORT LIST
407
537
530
538
401
543
575
136
135
589
112
517
590
134
111
625
607
615
502
616
110
507
506
504
Key N
Description
Manf. Pt.N
Other
CL
AS
HE
CLAS
Type
24 30
0100
0110
0111
0112
0134
0135
0136
BURNER ASSEMBLY
0400
0401
0407
GAS SECTION
0500
0502
0504
0506
0507
0517
0530
0537
0538
0543
0575
0589
HYDRAULIC BLOCK
0600
0607
0615
0616
0625
ELECTRICAL BOX
IGNITION ELECTRODE
IONIZATION ELECTRODE
GASKET D:85-66.5-2.5
ELECTRODE GASKET
COMBUSTION CHAMBER LINING KIT
DOOR GASKET
GAS VALVE
FAN ASSY
MOTOR - THREE-WAY VALVE
OVERHEAT THERMOSTAT 100C
3-WAY SPRING KIT (D.H.W.)
TEMPERATURE PROBE + CLIP
LOW PRESSURE SWITCH
AUTO AIR VENT WITH O-RING
PRESSURE RELIEF VALVE
PUMP 6M 2V
SENSOR (REED)
NTC PROBE
SECONDARY EXCHANGER
IGNITER
PRINTED CIRCUIT BOARD
PRINTED CIRCUIT BOARD (DISPLAY)
60000537
60000622
...
...
...
...
...
...
...
...
61302483
61010572
65104314
990686
65105090
65104703
61312668
60000591
65104323
65104338
65104333
...
...
...
...
...
...
...
...
...
...
...
61002105-20
60000566
65104448
65104234
...
...
...
...
61317432
61317433
61314753
60000286
60000297
60000623
Manf. date
from
to
Ind 02 - 03/04/2007
PRESSURE GAUGE
38
60
!
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
Technical Advice: 0870 241 8180
Customer Service: 0870 600 9888
Technical Advice: (01) 437 0121
Customer Service: (01) 437 0121
420010097004 - 05/2009
Ariston Thermo UK Ltd
Hughenden Avenue
High Wycombe
Bucks HP13 5FT
Telephone: (01494) 755600
Fax: (01494) 459775
Internet: www.aristonthermo.co.uk
Professional Team Limited
Suites 9 & 10, Plaza 256
Blanchardstown Corporate Park 2
Ballycoolin
Dublin 15
Telephone: (01) 810 3723
Fax: (01) 810 3727
Internet: www.aristonthermo.ie
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