Ariston ACO 27 MFFI, ACO 32 MFFI, ACO 27 RFFI, ACO 32 RFFI Installation and Servicing Instructions

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Installation and Servicing Instructions

SERIES

Type C Boilers

ACO 27 MFFIG.C.N: 47-116-34 ACO 32 MFFIG.C.N: 47-116-35 ACO 27 RFFI G.C.N: 41-116-09 ACO 32 RFFI G.C.N: 41-116-10

LEAVE THESE INSTRUCTIONS WITH THE END USER

Country of destination: GB/IE

TABLE OF CONTENTS

1. GENERAL INFORMATION

1.1. GENERAL INFORMATION 3

1.2. TECHNICAL INFORMATION 4

1.3. OVERALL VIEW 6

2. INSTALLATION

2.1. REFERENCE STANDARDS 7

2.2. SITING THE APPLIANCE 7

2.3. OVERALL DIMENSIONS 8

2.4. MINIMUM CLEARANCES 8

2.5. MOUNTING THE APPLIANCE 9

2.6. ELECTRICAL CONNECTION 9

2.7. GAS CONNECTION 9

2.8. WATER CONNECTIONS 10

2.9. FLUE CONNECTIONS 13

2.9.1 FITTING THE COAXIAL FLUE (Ø 60 / 100 HORIZONTAL) 14

2.9.2 FITTING THE 5” FLUE (Ø 80 / 125 Horizontal/Vertical) 15

2.9.3 FITTING THE COAXIAL FLUE (Ø 60 / 100 VERTICAL) 16

2.9.4 FITTING THE TWIN PIPE (Ø80 / 80) 17

2.10. FITTING THE MECHANICAL/DIGITAL TIME CLOCK 20

2.11. SETTING THE MECHANICAL TIME CLOCK 22

2.11.1. SETTING THE DIGITAL TIME CLOCK 22

2.12. ACCESSORY CONNECTION 24

2.13. ELECTRICAL DIAGRAM 26

2.14. WATER CIRCUIT DIAGRAM 28

3. COMMISSIONING

3.1. INITIAL PREPARATION 30

3.2. REMOVING THE CASING 32

3.3. CONTROL PANEL 33

3.4. INITIAL START-UP 35

3.5. DISPLAY: MESSAGES SHOWN DURING NORMAL OPERATION 36

3.6. OPERATING PARAMETERS 37

3.6.1. REGULATION MENU TABLE 37

3.6.2. SETTINGS DISPLAY 43

3.6.3. GAS REGULATION CHECK 44

3.6.4. IGNITION DELAY ADJUSTMENT 45

3.6.5. ADJUSTING THE MAXIMUM HEATING POWER 45

3.6.6. SOFT LIGHT ADJUSTMENT 45

3.7. CHANGING THE TYPE OF GAS 45

3.8. ADJUSTING THE DOMESTIC HOT WATER FLOW RATE 45

3.9. BALANCING THE CENTRAL HEATING SYSTEM 45

3.10. BOILER SAFETY SYSTEMS 46

3.11. COMPLETION 47

3.12. DRAINING 47

PAGE PAGE

6. MAINTENANCE 52

6.1. GENERAL REMARKS 52

6.2. CLEANING THE PRIMARY EXCHANGER 52

6.3. CLEANING THE CONDENSATE TRAP 52

6.4. OPERATIONAL TEST 52

7. SERVICING INSTRUCTIONS 53

7.1. REPLACEMENT OF PARTS 53

7.2. TO GAIN GENERAL ACCESS 53

7.3. ACCESS TO THE COMBUSTION CHAMBER 54

7.3.1. REMOVING THE FAN 54

7.3.2. REMOVING THE AIR PRESSURE SWITCH 55

7.3.3. REMOVING THE BURNER 55

7.3.4. REMOVING THE ELECTRODES 56

7.3.5. REMOVING THE HEAT EXCHANGER 56

7.3.6. REMOVING THE CONDENSATE TRAP (TUBE)58

7.3.7. REMOVING THE CONDENSATE TRAP 58

7.4. ACCESS TO THE GAS VALVE 59

7.4.1. REMOVING THE GAS VALVE 59

7.4.2. REMOVING THE SPARK GENERATOR 60

7.5. ACCESS TO THE WATER CIRCUIT 60

7.5.1. REMOVING THE D.H.W. (SECONDARY) EXCHANGER 60

7.5.2. REMOVING THE SAFETY VALVE 61

7.5.3. REMOVING THE AUTOMATIC AIR VENT 61

7.5.4. REMOVING THE DIVERTER VALVE ACTUATOR 62

7.5.5. REMOVING THE DHW FLOW SWITCH (MFFI ONLY) 62

7.5.6. REMOVING THE PUMP 62

7.5.7. REMOVING THE PRESSURE GAUGE 63

7.5.8. REMOVING THE EXPANSION VESSEL 64

7.5.9. REMOVING THE D.H.W. TEMPERATURE PROBE (N.T.C. - MFFI ONLY)64

7.5.10. REMOVING THE C.H. FLOW TEMPERATURE PROBE (N.T.C.) 65

7.5.11. REMOVING THE C.H. RETURN TEMPERATURE PROBE (N.T.C.) 65

7.6. ACCESS TO THE CONTROL SYSTEM 66

7.6.1. CHECKING THE FUSES 66

7.6.2. REMOVING THE PRINTED CIRCUIT BOARDS 66

7.6.3. REMOVING THE TIME CLOCK 67

8. FAULT FINDING 68

8.1 FAULT FINDING GUIDE (FLOW-CHARTS) 68

9. SHORT SPARES PARTS LIST 72

10. ANNUAL MAINTENANCE CHECKLIST 76

4. ZONE VALVES 48

5. SEQUENCE OF OPERATION 51

5.1 CENTRAL HEATING MODE 51

5.2 DOMESTIC HOT WATER MODE 51

11. BENCHMARK COMMISSIONING CHECKLIST 78

12. SERVICE INTERVAL RECORD 79

1. GENERAL INFORMATION

1.1. GENERAL INFORMATION

This manual is an integral and essential part of the product. It should be kept with the appliance so that it can be consulted by the user and our authorised personnel.

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

For operating instructions please consult the separate Users Manual.

Read the instructions and recommendations in these Installation and Servicing Instructions carefully to ensure proper installation, use and maintenance of the appliance.

Keep this manual in a safe place. You may need it for your own reference while Servicing Technicians or your installer may need to consult it in the future.

The ACO MFFI range is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.).

The ACO RFFI range is an appliance for the production of Central Heating (C.H.) and is designed for use with an indirect cylinder for Domestic Hot Water (D.H.W.)

The ACO MFFI and RFFI range of boilers are domestic gas boilers and intended for domestic use only.

This appliance must be used only for the purpose for which it is designed.

The manufacturer declines all liability for damage caused by improper or negligent use.

No asbestos or other hazardous materials have been used in the fabrication of this product.

MTS recommends the use of protective clothing when installing and working on the appliance i.e. gloves.

Before connecting the appliance, check that the information shown on the data plate and the table in Section 1.2 (page 4) comply with the electric, water and gas mains of the property. You will find the data plate on the reverse of the control panel. The gas with which this appliance operates is also shown on the label at the bottom of the boiler.

Do not install this appliance in a damp environment or close to equipment which spray water or other liquids.

Do not place objects on the appliance. Do not allow children or inexperienced persons to use the

appliance without supervision.

If you smell gas in the room, do not turn on or off light switches, use the telephone or any other object which might cause sparks. Open doors and windows immediately to ventilate the room. Shut the gas mains tap (at or adjacent to the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately.

Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the appliance or carrying out maintenance.

In the case of faults or failure, switch off the appliance and turn off the gas tap. Do not tamper with the appliance. For repairs, call your local Authorised Servicing Agent and request the use of original spare parts. For in-guarantee repairs contact MTS (GB) Limited.

1.2. TECHNICAL INFORMATION

Name CE Certification Flue Type

General InfoEnergy Performance

Heat Input max (Domestic Hot Water) kW Heat Input max/min (Central Heating) kW Heat Output max (Domestic Hot Water) kW Heat Output max/min (Central Heating) kW Efficiency of Nominal Heat Input (60/80°C) % Efficiency of Nominal Heat Input (30/50°C) % Efficiency at 30% of Nominal Heat Input (47°C) % Efficiency at 30% of Nominal Heat Input (30°C) % Efficiency at Minimum Input % Efficiency (Dir. 92/42/EEC)** SEDBUK Rating Band / %

Heat Loss to the Casing (D T=50°C) % Flue Heat Loss with Burner Operating %

Max Discharge of Products of Combustion (G20) Kg/h Temp. of exhaust fumes at nominal capacity °C CO2 Content % O2 Content % CO Content ppm

Emissions

Nox Class

ACO 27 MFFI (COMBI)

0085BP0229

C13-C33-C43-C53-C83-B23-B33

30.0

25.5 / 8.9

27.0

22.5 / 7.7

88.2

91.8

92.9

96.8

86.7

A / 90.4

0.5

2.6

35.3 72

9.1

4.3

109

5 (70 mg/kW/h)

ACO 27 RFFI (SYSTEM)

0085BP0229

C13-C33-C43-C53-C83-B23-B33

-----------

25.5 / 8.9

-----------

22.5 / 7.7

88.2

91.8

92.9

96.8

86.7

A / 90.5

0.5

2.6

35.3 72

9.1

4.3

109

5 (70 mg/kW/h)

Head Loss on Water Side (max) (D T=20°C) mbar Residual Head of System bar Expansion Vessel Pre-load Pressure bar Maximum Heating Pressure bar Expansion Vessel Capacity l Maximum Water Content of System l Heating Temperature max/min (High temperature) °C

Central Heating

Heating Temperature max/min (Low Temperature) °C

Domestic Hot Water Temperature (approx) max/min °C Specific Flow Rate (10 minutes/DT 30°C) l/min D.H.W. Flow Rate D T=25°C l/min D.H.W. Flow Rate D T=35°C l/min D.H.W. Minimum Flow Rate l/min Pressure of Domestic Hot Water max/min bar

Domestic Hot Water

Max. Condensate produced l/h PH of condensate W

Nominal Pressure Natural Gas (G20) mbar Consumption at Nominal Capacity(G20) m3/h

Gas

Gas Consumption after 10 Minutes* m

Electrical Supply V/Hz Power Consumption W Minimum Ambient Temperature °C Protection Grade of Electrical System IP Internal Fuse Rating

Electrical Data

Weight Kg Casing Dimensions (D/W/H) mm

200

0.2

0.7 3 7

130 82 / 46 75 / 20

200

0.2

0.7 3 7

130 82 / 46 75 / 20

56 / 36

12.6

15.2

10.8

2.5

6 / 0.2

1.5

2.43

0.85

230/50

118

24D

2A Fast Fuse

280/450/750

1.5

2.43

0.85

230/50

118

24D

2A Fast Fuse

280/450/750

G.C. Number

* Calculated at 70% maximum output ** Calculated on Upper calorific value

47-116-34

41-116-09

Name CE Certification Flue Type

General InfoEnergy Performance

Heat Loss to the Casing (D T=50°C) % Flue Heat Loss with Burner Operating %

ACO 32 MFFI (COMBI)

0085BP0229

C13-C33-C43-C53-C83-B23-B33

32.0

31.6 /10.5

32.0

28 / 9.5

88.5

88.7

91.2

97.1

89.7

A / 90.4

2.7

ACO 32 RFFI (SYSTEM)

0085BP0229

C13-C33-C43-C53-C83-B23-B33

-----------

31.6 /10.5

----------28 / 9.5

88.5

88.7

91.2

97.1

89.7

A / 90.5

2.7

Max Discharge of Products of Combustion (G20) Kg/h Residual Discharge Head mbar Temp. of exhaust fumes at nominal capacity °C CO2 Content % O2 Content %

Emissions

CO Content ppm Nox Class

Central Heating

Heating Temperature max/min (Low Temperature) °C

Domestic Hot Water

Max. Condensate produced l/h PH of condensate W

45.7 1

76.4

8.7 5

5 (70 mg/kW/h)

200

0.2

0.7 3 7

130 82 / 46 75 / 20

56 / 36

15.3

18.3

13.1

2.5

6 / 0.2

1.8

45.7 1

76.4

8.7 5

5 (70 mg/kW/h)

200

0.2

0.7 3 7

130 82 / 46 75 / 20

1.8

Nominal Pressure Natural Gas (G20) mbar Consumption at Nominal Capacity(G20) m3/h

Gas

Gas Consumption after 10 Minutes* m

Electrical Supply V/Hz Power Consumption W Minimum Ambient Temperature °C Protection Grade of Electrical System IP Internal Fuse Rating

Electrical Data

Weight Kg Casing Dimensions (D/W/H) mm

G.C. Number

* Calculated at 70% maximum output ** Calculated on Upper calorific value

3.01

0.35

230/50

118

24D

2A Fast Fuse

280/450/750

47-116-35

3.01

0.35

230/50

118

24D

2A Fast Fuse

280/450/750

41-116-10

1.3. OVERALL VIEW

12 13 14 15 16

12 14 15 16

27/32 MFFI (COMBI)

27/32 RFFI (SYSTEM)

FIG. 1.0

LEGEND:

1. Flue connector

2. Mixer

3. Fan

4. Spark generator

5. Burner

6. Ignition and detection electrode

7. Air release valve

8. Main heat exchanger (aluminium)

9. Central Heating flow temperature probe

10. Automatic by-pass

11. Domestic Hot Water temperature probe

12. Safety valve (3 bar)

13. Secondary heat exchanger

14. Gas valve

15. Condensate discharge

16. Condensate trap inspection cap

17. Drain valve

18. Domestic Hot Water flow switch

19. Circulation pump with automatic air release valve

20. Condensate trap

21. Diverter valve

22. Condensate trap (tube)

23. Central Heating return temperature probe

24. Expansion vessel

25. Air pressure switch

26. Combustion analysis test point

2. INSTALLATION

2.1. REFERENCE STANDARDS

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

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.

In the Republic of Ireland the installation and initial start up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations, reference should also be made to the current ETCI rules for electrical installation.

This appliance must be installed by a competent installer in accordance with current Gas Safety (installation & use) Regulations.

The installation of this appliance must be in accordance with the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the bylaws of the local water authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635 “Electricity at work regulations 1989” and in the Republic of Ireland with the current edition of I.S. 813, the Local Building Regulations (IE).

2.2. SITING THE APPLIANCE

The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combined appliance in a room containing a bath or shower, the location of the boiler in a room containing a bath or shower should only be considered if there is no alternative.

Where a room-sealed appliance is installed in a room containing a bath or shower the appliance and any electrical switch or appliance control, utilising mains electricity should be situated so that it cannot be touched by a person using the bath or shower, specifically in accordance with current IEE Wiring Regulations.

The location must permit adequate space for servicing and air circulation around the appliance as indicated in Section 2.4. The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary. BS 6798-2000 gives detailed guidance on this aspect. A compartment used to enclose the appliance must be designed specifically for this purpose. No specific ventilation requirements are needed for the installation within a cupboard. This appliance is not suitable for outdoor installation.

The type C appliances (in which the combustion circuit, air vent intake and combustion chamber are air-tight with respect to the room in which the appliance is installed) can be installed in any type of room.

C.O.S.H.H.

Materials used in the manufacture of this appliance are nonhazardous and no special precautions are required when servicing.

Installation should also comply with the following British Standard Codes of Practice:

BS 7593:1992 Treatment of water in domestic hot water

central heating systems

BS 5546:1990 Installation of hot water supplies for

domestic purposes BS 5440-1:2000 Flues BS 5440-2:2000 Air supply BS 5449:1990 Forced circulation hot water systems BS 6798:2000 Installation of gas fired hot water boilers

of rated input not exceeding 70kW BS 6891:1989 Installation of low pressure gas pipe up to

28mm BS 7671:2001 IEE wiring regulations BS 4814:1990 Specification for expansion vessels BS 5482:1994 Installation of L.P.G.

and in the Republic of Ireland in accordance with the following Codes of Practice:

Secondary ventilation is not required with this boiler. The boiler must be installed on a solid, non-combustible, permanent wall to prevent access from the rear.

I.S. 813 Domestic Gas Installations

2.3. OVERALL DIMENSIONS

785

280

450

27/32 RFFI (SYSTEM)

FIG. 2.1

FIG. 2.0

LEGEND:

A = Central Heating Flow (3/4”) (22mm Copper Tail) B = Domestic Hot Water Outlet (1/2”) (15 mm Copper Tail) C = Gas Inlet (3/4”) ( 22mm Copper Tail) D = Domestic Cold Water Inlet (1/2”) (15mm Copper Tail) E = Central Heating Return (3/4”) (22mm Copper Tail) F = Condensate discharge SV outlet = 1/2” Female BSP (Not Shown)

27/32 MFFI (COMBI)

2.4. MINIMUM CLEARANCES

In order to allow access to the interior of the boiler for maintenance purposes, the boiler must be installed in compliance with the clearance requirements indicated in the diagram below.

27/32 MFFI/RFFI

FIG. 2.3

FIG. 2.2

85 mm

220 mm

2.5. MOUNTING THE APPLIANCE

After removing the boiler from its packaging, remove the template from the separate box containing the connection kit. NOTE: Pay particular attention to any test water that may spill from the appliance.

Place the template in the position the appliance is to be mounted and after ensuring it is hanging squarely, use it to mark the holes for the hanging bracket, connection kit and flue pipe(s) NB: For further information relating to the flue installation please refer to Section 2.9 FLUE CONNECTION. (If the appliance is to be fitted on a wall of combustible material, the wall m protected by a sheet of fireproof material). If the appliance is to be fitted into a timber framed building, guidance should be sought from the Institute of Gas Engineers document REF: IGE/UP/7.

2.5.1. Drill the wall and plug using those supplied with the connections kit, position the hanging bracket and secure with the wall screws supplied, assemble the connection kit and secure to the wall. NOTE: It is highly recommended that a spirit level be used to position the appliance to ensure that it is perfectly level.

2.5.2. Position the appliance on the hanging bracket and connect the connection kit to the boiler connections. (see also Sections 2.7 Gas Connections, 2.8 Water Connections & FIG.

2.5).

For safety purposes, have a competent person carefully check the electrical system in the property, as the manufacturer will not be held liable for damage caused by the failure to earth the appliance properly or by anomalies in the supply of power. Make sure that the residential electrical system is adequate for the maximum power absorbed by the unit, which is indicated on the rating plate. In addition, check that the section of cabling is appropriate for the power absorbed by the boiler.

ust be

Note: The diagrams for the electrical system are indicated in Sections 2.12 and 2.13.

Warning, this appliance must be earthed.

External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regulations and applicable local regulations. The appliance is supplied with a fly-lead already connected, this must be connected to a 240v supply fused at 3A and must facilitate complete electrical isolation of the appliance, by the use of a fused double pole isolator having a contact separation of at least 3 mm in all poles or alternatively, by means of a 3 A fused three pin plug and unswitched shuttered socket outlet both complying with BS 1363. The point of connection to the Electricity supply must be readily accessible and adjacent to the appliance unless the appliance is installed in a bathroom when this must be sited outside the bathroom (see Section 2.2). Should external controls be required, the design of the external electrical circuits should be undertaken by a competent person, see Sections 2.12 and 4 for further information.

2.7. GAS CONNECTION

The local gas region contractor connects the gas meter to the service pipe. If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time. Pipe work must be of an adequate size. Pipes of a smaller size than the boiler inlet connection must not be used.

2.6. ELECTRICAL CONNECTION

The boiler operates with alternating current, as indicated in the technical data table (Section 1.2), where the maximum absorbed power is also indicated. Make sure that the connections for the neutral and live wires correspond to the indications in the diagram. The appliance electrical connections are situated inside the electrical box (see Section 2.12).

IMPORTANT!

In the event that the power supply cable must be changed, replace it with one with the same specifications. Make the connections to the terminal board located within the control panel, as follows:

- The yellow-green wire should be connected to the terminal marked with the earth symbol; make sure to re-use the ferrule mounted on the other supply cable;

- The blue wire should be connected to the terminal marked “N”;

- The brown wire should be connected to the terminal marked “L”.

FIG. 2.4

100

200

300

400

500

0 200 400 600 800 1000 1200

(mbar)

(l/h)

2.8. WATER CONNECTIONS

VIEW OF THE BOILER CONNECTIONS

27/32 MFFI (COMBI)

Legend:

A = Central Heating Flow B = Domestic Hot Water Outlet C = Gas Inlet D = Domestic Cold Water Inlet E = Central Heating Return H = Condensate discharge I = Safety valve discharge J = Drain valve

FIG. 2.5

27/32 RFFI (SYSTEM)

RESIDUAL HEAD OF THE BOILER ∆T20°C

C E

Central Heating

Detailed recommendations are given in BS 6798:2000 and BS 5449-1:1990, the following notes are given for general guidance.

PIPE WORK:

Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing should be either with capillary soldered or compression fittings. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps. The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air. Except where providing useful heat, pipes should be insulated to prevent heat loss and avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

BY-PASS:

The appliance includes an automatic by-pass valve, which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system, due to the closing of thermostatic valves or cock-type valves within the system.

SYSTEM DESIGN:

This boiler is suitable only for sealed systems.

DRAIN COCKS:

These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15mm nominal size and manufactured in accordance with BS 2870:1980.

SAFETY VALVE DISCHARGE:

The discharge should terminate facing downwards on the exterior of the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, but in an easily visible position, and not cause damage to electrical components and wiring. The discharge must not be over an entrance or a window or any other type of public access.

CONDENSATE DISCHARGE:

A flexible hose is supplied for connection to the condensate discharge point from the boiler must have a continuous fall of 2.5° and must be inserted by at least 50 mm into a suitable acid resistant pipe - e.g. plastic waste or overflow pipe. The condensate discharge pipe must have a continuous fall and preferably be installed and terminated within the building to prevent freezing.

H (Fig. 2.5). The condensate discharge hose

FIG. 2.6

NOTE:THE FLEXIBLE CONDENSE HOSE SUPPLIED WITH THE

APPLIANCE CAN BE EXTENDED BY PULLING THE TUBE OPENING THE RIBBED PIPE.

The discharge pipe must be terminated in a suitable position:

i) Connecting in to an internal soil stack (at least 450 mm

above the invert of the stack). A trap giving a water seal of at least 75 mm must be incorporated into the pipe run, there also must be an air break upstream of the trap.

ii) Connecting into the waste system of the building such as

a washing machine or sink trap. The connection must be upstream of the washing machine/sink (If the connection is down stream of the waste trap then an additional trap giving a minimum water seal of 75 mm and an air break must be incorporated in the pipe run, as above.

iii) Terminating into a gully, below the grid level but above the

water level.

iv) Into a soakway.

OTE: If any condensate pipe work 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.

Some examples of the type of condensate drains can be found on pages 11 and 12.

AIR RELEASE POINTS:

These must be fitted at all high points where air naturally collects and must be sited to facilitate complete filling of the system. The appliance has an integral sealed expansion vessel to accommodate the increase of water value when the system is heated. It can accept up to 7 l (1.5 gal) of expansion water. If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity.

MAINS WATER FEED - CENTRAL HEATING:

There must be no direct connection to the mains water supply even through a non-return valve, without the approval of the Local Water Authority.

FILLING:

A method for initially filling the heating system is supplied with the connection kit. The filling loop is connected between the cold water inlet and the central heating flow connections, and incorporates a non-return valve. To operate the filling loop, it is necessary to open both quarter turn handles, once the required pressure has been achieved, close both handles and disconnect the hose in accordance with water byelaws and cap off with the cap supplied. NOTE: The installer should ensure that there are no leaks as frequent filling of the heating system can lead to premature scaling of the main exchanger and failure of hydraulic components.

DOMESTIC WATER

The domestic water must be in accordance with the relevant recommendation of BS 5546:1990. Copper tubing to BS EN 1057:1996 is recommended for water carrying pipe work and

must be used for pipe work carrying drinking water, a scale reducer should also be used to reduce the risk of scale forming in the domestic side of the heat exchanger.

UNDER FLOOR HEATING SYSTEMS:

In the event of an under floor heating system, fit a safety thermostat on the boiler flow (see Section 2.12). This thermostat should be positioned at a safe distance from the boiler to ensure the correct operation of the same. If the thermostat is positioned too close to the boiler, the water remaining in the boiler after domestic hot water has been drawn will flow into the central heating system and may cause the thermostat contact to open without there being any real danger of the system being damaged, this would lead to a boiler shutdown both in D.H.W. mode and C.H. mode, and the error code automatically when the thermostat contact closes on cooling. Should the thermostat fail to be installed as recommended, the under floor heating system can be protected by installing a thermostatic valve upstream from the thermostat in order to prevent the flow of excessively hot water towards the system.

“E08” would be displayed; boiler operation resumes

27/32 RFFI (SYSTEM)

1. Internal termination of condensate drainage pipe to internal stack

27/32 MFFI (COMBI)

2. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste) and condensate siphon

3. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste - proprietary fitting).

4. External termination of condensate drainage pipe via condensate siphon

WATER TREATMENT

The boiler is equipped with an aluminium alloy main 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 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 BS7593:1992. We highly recommend the use of a flushing detergent appropriate for the metals used in the aluminium alloy circuit. These include (Fernox Superfloc, BetzDearborn Sentinel X300 or X400), whose function is to dissolve 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 the water to prevent premature scaling of the main heat exchanger is necessary.

The formation of scale strongly compromises the efficiency of the thermic exchange 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 the metals used in the circuit including the aluminium alloys. The use of a corrosion inhibitor in the system such as Fernox MB-1Copal, BetzDeaborn Sentinel X100 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 aluminium. In particular, DO NOT USE ordinary ETHYLENE GLYCOL, since it is corrosive in relation to aluminium and its alloy, as well being toxic. MTS suggests the use of suitable anti-freeze products such as Fernox ALPHI 11, which will prevent rust and incrustation taking place. Periodically check the pH 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 system’s 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 exchanger

with a specific system water treatment.

s of those

IMPORTANT Failure to carry out the water treatment procedure will invalidate the appliance warranty.

2.9. CONNECTING THE FLUE

IMPORTANT!!

BEFORE CONNECTING THE FLUE, ENSURE THAT 1 LITRE OF

WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION TO FILL THE CONDENSATE TRAP (FIG.2.7). SHOULD THE TRAP BE

EMPTY THERE IS A TEMPORARY RISK OF FLUE GASSES ESCAPING INTO THE ROOM.

FIG. 2.7

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 2.1 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.

2.9.

FIG. 2.9

Ø 60/100 mm

TERMINAL POSITION mm

A - Directly below an open window or other opening 300 B - Below gutters, solid pipes or drain pipes 75 C - Below eaves 200 D - From vertical drain pipes and soil pipes 75 E - From internal or external corners 300 F - Above ground on a public walkway or patio 2100 G - From a surface facing a terminal 2500 H - From a terminal facing a terminal 2500

I - Vertically from a terminal in the same wall 1500 J - Horizontally from a terminal in the same wall 300 K - Horizontally from an opening window 300 L - Fixed by vertical flue terminal

Fig. 2.9

Warning



118

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

Installation with extension

2.9.1 FITTING THE COAXIAL FLUE (Ø 60 / 100 HORIZONTAL)

Level

Fig. 2.10

Level

Fig. 2.11

CONTENTS: 1

X SILICONE O-RING (60mm) X ELBOW (90

1 2X WALL SEALS (INTERNAL & EXTERNAL) 1X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100) 1X FLUE CLAMP 1X SCREWS 1x Seal

Once the boiler has been positioned on the wall, insert the elbow into the socket and rotate to the required position. NOTE: It is possible to rotate the elbow 360oon its vertical axis.

)

Using the flue clamp, seals and screws supplied (Fig 2.12) secure the elbow to the boiler.

The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact X dimension of 815mm.

Measure the distance from the face of the external wall to the face of the flue elbow (X - Fig 2.9), this figure must now be subtracted from 815mm, you now have the total amount to be cut from the plain end of the flue.

Draw a circle around the outer flue and cut the flue to the required length taking care not to cut the inner flue, next cut the inner flue ensuring that the length between the inner and outer flue is maintained. (Fig 2.12).

e.g.

X = 555mm 815-555 = 260mm (Length to be cut from the plain end of the flue).

Once cut to the required length, ensure that the flue is free from burrs and reassemble the flue. If fitting the flue from inside of the building attach the grey outer wall seal to the flue terminal and push the flue through the hole, once the wall seal has passed through the hole, pull the flue back until the seal is flush with the wall. Alternatively, the flue can be installed from outside of the building, the grey outer seal being fitted last.

Seal

2.9.2 FITTING THE 5” FLUE (Ø 80 / 125 HORIZONTAL/VERTICAL)

Clamp

Screws

Fig. 2.12

Should the flue require extending, the flue connections are push fit, however, one flue bracket should be used to secure each metre of flue.

NOTE: SEE PAGE 19 FOR MAXIMUM AND MINIMUM FLUE RUNS.

Once the boiler has been positioned on the wall, it is necessary to insert the Ø80/125 adaptor (FIG. 2.13) 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.

Fig. 2.13

To fit extensions or elbows it is first necessary to ensure that the lip seal is fitted correctly into the inner flue, once verified, it is simply necessary to push them together, no clamps are necessary to secure the flue components.

Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables on Page

19) and that all elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90 total flue length, and for each 45o0.5 metres must be subtracted from the total flue length (the height of the

vertical adaptor and a 45 and a 90obend in Fig. 2.15).

NOTE: DO

elbow 1 metre must be subtracted from the

bend can be seen in Fig. 2.14

NOT CUT THE VERTICAL FLUE KIT.

Fig. 2.14

Fig. 2.15

2.9.3. FITTING THE COAXIAL FLUE (Ø 60 / 100 VERTICAL)

NOTE:SEEPAGE19 FOR MAXIMUM AND MINIMUM FLUE RUNS.

CONTENTS: 1X SILICONE O-RING (60mm) 1X CONICAL ADAPTOR (60/100mm) 1X VERTICAL FLUE KIT (80/125mm)

X SCREWS

The vertical flue kit is supplied with a specially designed weather proof terminal fitted, it can be used either with a flat roof or a pitched roof.

The Vertical flue kits useable lengths with the pitched roof flashings are indicated in Fig. 2.16.

Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables on Page

19) and that all elbows and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90oelbow 1 metre must be subtracted from the total flue length, and for each 45o0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45obend can be seen in Fig. 2.17).

Mark the position of the flue hole in the ceiling and/or roof (see Fig. 2.15 for distance from wall to the centre of the flue).

Fig. 2.16

Cut a 120mm 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. 2.16) 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 be ensured that the inner and outer flue remain flush (Fig.

2.12)

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.

must only be cut at the male end and it must

Fig. 2.17

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.

2.9.4. FITTING THE TWIN PIPE (Ø80 / 80)

NOTE:SEEPAGE19 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.

When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals m intake must not be sited above the exhaust terminal (refer to Fig. 2.20). 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. For flue runs with the intake and exhaust pipes under the same atmospheric conditions (TYPE 4) the maximum length is 38 metres (27kW) and 48 metres (32kW), for runs with the terminals under different atmospheric conditions (TYPE 5) the exhaust terminal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the exhaust and air intake pipes are located on the same side of the building). For TYPE 5 also, the maximum permissible combined length is 51 metres (27kW) and 49 metres (32kW).

The maximum length is reached by combining the total lengths of both the air intake and exhaust pipes. Therefore a maximum length of 40 metres for example, will allow a flue run of 20 metres for the air intake and 20 metres for the exhaust pipes, also for each 90oelbow 2.2 metres must be subtracted from the total length and for each 45oelbow 1.4 metres must be subtracted from the total flue length.

ust be a minimum of 280 mm apart and the air

Some of the acceptable flue configurations are detailed on page 20.

For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 241 8180.

ø 100

60 mm

In the event that the air intake and exhaust are run to the left, it will be necessary to reduce the height of the air intake by cutting 20mm from the base of the air intake elbow (see Fig. 2.18)

In the event that twin flue pipes are used, and the boiler has a side clearance of less than 60mm from the wall, it is necessary to cut a larger diameter hole for the flue pipe, this should be ø10 cm, this will then allow for easier assembly of the air intake elbow and the tube outside the wall (see Fig. 2.19).

Fig. 2.18

Fig. 2.19

Fig. 2.20

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 5 must be installed on the same wall, or where the exhaust is vertical and the air intake horizontal, the terminals must be on the same side of the building.

27 MFFI

Exhaust Type

Maximum Extension

Exhaust/Air

(m)

Coaxial

Systems

Type 1 Type 1

Types 2 & 3

4 (Horizontal)

15 (Horizontal)

4 (Vertical)

15 (Vertical)

Type 4

Twin Pipe

Systems

Type 5

(Air Intake & Exhaust

Equal Lengths)

1+50 (Air Intake 1

Metre and Exhaust 50

Metres)

There are some different types of flue systems shown on Page 20. For additional information regarding the flue accessories, please consult the Flue Pipe Accessories manual.

32 MFFI

Exhaust Type

Maximum Extension

Exhaust/Air

(m)

Coaxial

Systems

Type 1 Type 1

4 (Horizontal)

10 (Horizontal)

Diameter

of Pipes

(mm)

Ø 60/100 Ø 80/125

Ø 80/80

Diameter

of Pipes

(mm)

Ø 60/100 Ø 80/125

Reduction

45o (m)

0.5

0.25

Reduction

45o (m)

0.5

Reduction

90o (m)

1 1

0.5

Reduction

90o (m)

1 1

Twin Pipe

Systems

Types 2 & 3

Type 4

Type 5

4 (Vertical)

10 (Vertical)

(Air Intake & Exhaust

Equal Lengths)

1+48 (Air Intake 1

Metre and Exhaust 48

Metres)

Ø 60/100 Ø 80/125

Ø 80/80

0.5

0.25

1 1

0.5

TYPE 1

TYPE 2

TYPE 3

TYPE 4

NOTE: DRAWINGS ARE INDICATIVE OF FLUEING OPTIONS ONLY.

2.10. FITTING THE MECHANICAL / DIGITAL CLOCK

FIG. 2.22

TYPE 5

The ACO MFFI (Combi) boiler is supplied with a factory fitted mechanical time clock. There is a digital clock available as an optional extra (code: 706348).

To fit the digital clock it is necessary to proceed as follows:-

1. Remove the outer casing

Fig. 2.21

2. Open the control panel (see Section 2.22);

3. Unplug the electrical connection from the PCB and unscrew the four screws (Fig. 2.26);

4. Remove the time clock (Fig. 2.27).

5. Connect the wires supplied with the clock to the digital time clock as shown in Fig. 2.28;

6. Reassemble in reverse order.

NOTE:THE MECHANICAL CLOCK HAS FOUR WIRES, THEREFORE THE

HARNESS WILL REQUIRE CHANGING ALSO.

The ACO RFFI (System) boiler is not supplied with a clock,

however a mechanical and digital clock is available as an optional extra (mechanical - code: 706349 and digital - code:

706348)

To fit the clock it is necessary to proceed as follows:-

1. Remove the outer casing

2. Open the control panel (see Section 2.22);

3. Unplug the electrical connection from the PCB and unscrew the four screws (Fig. 2.26);

FIG. 2.23

FIG. 2.24

4. Remove the time clock (Fig. 2.27).

5. Connect the wires supplied with the clock to the digital time clock as shown in Fig. 2.28;

6. Reassemble in reverse order.

FIG. 2.26

FIG. 2.27

DIGITAL MECHANICAL

FIG. 2.25

FIG. 2.28

2.11. SETTING THE MECHANICAL TIME CLOCK

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424

1212

Day

Manual switch

Summer and winter time setting

Reset

Enter

weekday/s

Enter the hours

Week- days flash

Enter minutes

Enter

switching

times

Imput

time

Fig. 2.29

1. General layout

The mechanical clock covers a 24 hour period. Each tappet represents 15 minutes A (Fig. 2.30). An override switch is located on the clock B (Fig 2.30).

2. To set the time

To set the time of day, grasp the outer edge of the dial and turn slowly clockwise until the correct time is lined up with the arrow C (Fig. 2.30).

3. To Set the "On" and "Off" times

The clock uses a 24hours system. e.g. 8 = 8.00 am and 18 = 6.00 pm. "ON" periods are set by sliding all tappets between the "ON" time and the "OFF" time to the outer edge of the dial.The tappets remaining at the centre of the dial are the "OFF" periods.

4. For operation

Put the selector switch B to the symbol to control the central heating by the clock. Put the switch B to «I» to select permanent operation or to «0» to turn the central heating off permanently.

2.11.1. SETTING THE DIGITALTIME CLOCK

Fig. 2.30

Operating the time switch

The steps marked with the symbol “ ” are necessary to carry out a switching program.

Preparing for Operation

Activate the “Res” switch (=RESET) to reset the time switch to its default setting (activate using a pencil or similar pointed instrument). Do this:

- every time you wish to “reset” the time switch

- to erase all switching times and the current time of day. After approximately two seconds the following display appears: “– – : – –”.

Enter current time and weekday

- Keep the “ ” key pressed down During the summer time period press the +/- 1h key once. Enter the hour using the “h” key Enter the minutes using the “m” key Enter the day using the “Day” key

1 = “Monday”..............7 = Sunday

- Release the “ ” key.

Automatic Manual Continuous Operation Operation Operation

The switching If the current You can only times corres- switching mode is return to automatic pond to the changed manually, mode from the program the next switching continuously-ON entered. time will be and continuously-  carried out auto- OFF switching  matically again modes by  according to the pressing the " "  entered switching key.  program.

= ON = ON = Continuously ON

= OFF = OFF = Continuously OFF

Entering the switching times

You have 20 memory Iocations available. Each switching time takes up one memory location. Keep pressing the “Prog” key until a free memory location is shown in the display “– –:– –”. Programme ON or OFF with the “ ” key: “ ”= OFF; “ ”= ON Enter the hour using “h” Enter the minutes using “m” If a switching command is to be carried out every day (1 2 3 4 5 6 7) then store using the “ ” key, otherwise select the day(s) it is to be carried out by using the “Day” key. When the day seIection is left bIank, the programmed switching instruction operates at the same time every day 1 2 3 4 5 6 = Monday – Saturday 1 2 3 4 5 = Monday – Friday 6 7 =Saturday – Sunday

Changing the programmed switching times

Press the “Prog” key repeatedly until the switching time you want to change is displayed. You can now enter the new data. See point “Entering the switching times”.

Notes on storing switching times:

If you end your entry of the switching times by pressing the “Prog” key, then the switching time you have entered will be stored and the next memory location displayed.

In addition, a complete switching command is stored automatically after around 90 seconds provided no other key is pressed. The time switch then enters the automatic operating mode and displays the current time again.

Deleting individual switching times

Press the “Prog” key repeatedly until the switching time you wish to delete is shown in the display. Then set to “– –” using the “h” or “m” key and keep the “ ” key pressed down for around 3 seconds. The switching time is now erased and the current time is displayed.

AM / PM time display

If you press the “+/-1h” and “h” keys at the same time, the time display switches into the AM/PM mode.

Selection of single days: 1 = Mon. .............. 2 =Tues.

Save the switching time with the “ ” key. The time switch enters the automatic operating mode and displays the current time of day. Begin any further entry of a switching time with the “Prog” switch. If your entry is incomplete, the segments not yet selected will blink in the display. After programming is completed, and you return the time clock to the current time display with the “ ” key, the time clock will not activate any switching instruction required for the current time. You may need to manually select the desired switching state with the “ ” key. Thereafter, as the unit encounters further switching instructions in the memory in real time, it will correctly activate all subsequent switching instructions.

Manual Override Switch “ ”

With the “ ” you can change the current setting at any time. The switching program already entered is not altered.

Reading the programmed switching times

Pressing the “Prog” key displays the programmed switching times until the first free memory location appears in the display “– – : – –”.

If you now press the “Prog” key once again, the number of free memory Iocations will be displayed, e.g. “18”. If all memory locations are occupied, the display “00” appears.

2.12. ACCESSORY CONNECTION

IMPORTANT!! Before carrying out any repairs to the appliance always ensure that the external power supply has been isolated. The boiler will remain live even when the ON/OFF knob is in the “O”(off) position.

In order to gain access to the external control connections, it is first necessary to remove the casing (as shown in Section 3.2) then proceed as follows:

1. Remove the cover of the main PCB box (Fig 2.31).

2. Access can now be gained to the following connectors (see Section 2.13): CN10 - Safety thermostat for underfloor heating (SP) CN 9 - Room Thermostat (TA) CN 11 - Time clock CN 6 - Interface PCB (FIG. 2.33)

FIG. 2.31

IMPORTANT!!

Only remove the links from SP and TA if they are to be connected to external controls.

CONNECTION OF ROOM THERMOSTAT OR EXTERNAL

TIME CLOCK

a. - Insert the thermostat cable through the cable grommet

and fasten it by means of the cable-clamp provided.

b. - Connect the thermostat wires to the terminal block

CN9 (Fig. 2.32 - Diagram A).

c.- If a remote time clock is to be fitted, supply 240V from

the same spur as the boiler for the clock motor supply, disconnect the integral time clock from the P.C.B. CN11

d. - Using a volt-free switching time clock, connect the

switching wires from the time clock following points AC above (Fig. 2.32 - Diagram B).

e. - If using an external time clock and room thermostat,

these must be connected in series as points A-D above (Fig. 2.32 - Diagram C).

NOTE: ENSURE LOW VOLTAGE AND HIGH VOLTAGE CIRCUITS ARE

CABLED SEPARATELY TO AVOID INDUCED VOLTAGES IN THE LOW VOLTAGE CIRCUITS.

FIG. 2.32

FITTING THE EXTERNAL SENSOR

The external sensor is supplied with the interface PCB (Fig. 2.33).

The external sensor should be sited no more than 50 m from the boiler and on an external north facing wall, between 2 and 2.5 metres above the ground. It should also be ensured that the external sensor is positioned out of direct sunlight.

To connect the external sensor, plug the interface PCB into connector CN6 on the main PCB (see Fig. 2.33).

To connect between the interface PCB and the external sensor, it will be necessary to use 2x 0.5mm2cable, connected to the two terminals on the external sensor and to Terminal B (Fig.

2.33) on the interface PCB.

Instructions on the activation and setting of the outdoor sensor are detailed on pages 41 and 42.

Parameter P activates the external sensor, Parameter P6 modifies the thermal curve and Parameter P6 selects the specific thermal curve for the type of system installed.

NOTE:WHEN USING THE ACO BOILERS TO HEAT AN INDIRECT

CYLINDER, DO NOT USE THE EXTERNAL SENSOR AS THIS WILL AFFECT THE RECOVERY TIME OF THE CYLINDER.

FIG. 2.33

2.13. ELECTRICAL DIAGRAM

Day

8 9

10 11 12

CN7

CN12

CN8

CN11

CN9

CN10

FLOOR

ROOM

TIMER

FUSE

CN16

CN4

1 2 1

3 4

123456789

1011

R/N

Mr Nr

CN1 CN12CN5

8 9

10 11 12

FS PA

TA TS

NTC1

NTC2

NTC3

CN8 CN11

123456789

101112

12345

CN9 CN10

CN5

CN1

CN2

CN3

CN6

AC WFS

The P.C.B. is fitted with 2 fuses, on the live and the neutral. The fuse holder contains:

- 5 x 20mm “3.15A Slow” glass fuses

FIG. 2.31

Legend:

A-ON/OFF button B-Green LED (Indicates burner on) C - COMFORT button D-Programming key + E-Central Heating temperature adjustment F - Menu button H-Programming key - I-Domestic Hot Water temperature adjustment (MFFI only) K - Comfort function LED (yellow) (MFFI only) L-Red LED (indicates lockout) M-Multifunction display N - Reset button O-EEPROM key P-Interface PCB (optional)

FS - Domestic hot water flow switch NTC1 - Central Heating flow temperature probe NTC2 - Central Heating return temperature probe NTC3 - Domestic Hot Water temperature probe

(mod. 27/32 MFFI)

- Connection for boiler thermostat (mod. 27/32 RFFI SYSTEM)

OP - Time clock VG - Gas valve M - Diverter valve (mod. 27/32 MFFI) CI - Circulation pump with automatic air release valve MV - Fan AC - Spark generator PA - Air pressure switch TA - Room Thermostat (optional) TS - Underfloor Heating Safety Thermostat (optional) CR* - Remote Control (optional) SE* - External sensor (optional)

*NOT SHOWN

CN1 = FAN

1: Start of coil (black) 2: End of coil (brown) 3: “Hall” sensor power supply 12V (red) 4: “Hall” sensor input (white) 5: “Hall” sensor neutral (blue) 6: Not used

CN2 = FLAME SENSOR

CN3 = Earth

CN4 =

1: Live (brown) 2: Neutral (blue)

CN5 = EQUIPMENT

POWER SUPPLY

CONNECTIONS

1: Gas valve neutral (blue) 2: Gas valve live (brown) 3: Not used 4: Pump (V1) live (red) 5: Pump (V2) live (black) 6: Pump (ON/OFF) live (brown) 7: Pump neutral (blue) 8: 3-way valve (C.H.) (red/black) 9: 3-way valve (D.H.W.)(brown) 10: 3-way valve Neutral (blue) 11: Spark generator Neutral (black)

12: Spark generator live (black)

CN6 = INTERFACE PCB

(OPTIONAL - see Section 2.12)

Accessories: External sensor Remote Control CLIMA MANAGER Secondary outlet (see Section. 2.12)

CN7 = DISPLAY

1: Power 5V 2: Display return 3: Display transmission 4: Earth

CN8 = SENSOR CONNECTOR

1: Central Heating flow sensor (white) 2: Central Heating return sensor (white) 3: Not used 4: DHW flow switch (grey) 5: DHW sensor (grey) 6: Air pressure switch (grey) 7: Not used 8: DHW flow switch earth (grey) 9: DHW sensor earth (grey) 10: C.H. flow sensor earth (white) 11: C.H. return sensor earth (white) 12: Air pressure switch (grey)

CN9 = ROOM THERMOSTAT (OPTIONAL - see Section 2.12)

CN10 = UNDERFLOOR HEATING

SAFETY THERMOSTAT (OPTIONAL - Section 2.12)

CN11 = TIME CLOCK

(see Section 2.12)

2.14. WATER CIRCUIT DIAGRAM

AB C DE

27/32 MFFI (Combi)

FIG. 2.32

LEGEND:

1- Fan 2 - Burner 3 - Ignition/detection electrode 4 - Air release valve 5 - Main heat exchanger 6 - Central heating flow temperature probe 7 - Condensate Tr ap 8 - Gas valve 9 - Pressure gauge 10 - Safety valve 11 - Secondary heat exchanger 12 - Domestic hot water temperature probe 13 - Drain valve

14 - Domestic hot water flow switch 15 - Motorised valve 16 - Automatic By-pass 17 - Circulation pump with automatic

18 - Expansion vessel 19 - Central heating return temperature probe 20 - Air pressure switch

air release valve

A - Central Heating Flow B - DHW Outlet C - Gas Inlet D - Cold Water Inlet E - Central Heating Return

27/32 RFFI (System)

FIG. 2.33

LEGEND:

1- Fan 2 - Burner 3 - Ignition/detection electrode 4 - Air release valve 5 - Main heat exchanger 6 - Central heating flow temperature probe 7 - Condensate Tr ap 8 - Gas valve 9 - Pressure gauge 10 - Safety valve 11 - Drain valve 12 - Automatic By-pass 13 - Circulation pump with automatic

air release valve

14 - Expansion vessel 15 - Central heating return temperature probe 16 - Air pressure switch

A - Central Heating Flow C - Gas Inlet E - Central Heating Return

3. COMMISSIONING

3.1. INITIAL PREPARATION

Manual Air Vent

MTS (GB) Limited support the initiative. In Sections 11 and 12 of this manual you will find the commissioning checklist (page 78) and the service interval record (Page 79), It is important the commissioning checklist 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.

FILLING THE HEATING SYSTEM:

Remove the case and lower the control panel (see section 3.2. for further information). Open the central heating flow and return cocks supplied with the connection kit. Unscrew the cap on the automatic air release valve one full turn and leave open permanently. Close all air release valves on the central heating system. Gradually open valve(s) at the filling point (filling-loop) connection to the central heating system until water is heard to flow, do not open fully. Open each air release tap starting with the lowest point and close it only when clear water, free of air, is visible.

Purge the air from the pump by unscrewing the pump plug and also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free.

FIG. 3.1A

IMPORTANT!! OPEN THE MANUAL AIR VENT AND ENSURE THAT THE PRIMARY

EXCHANGER IS FREE OF AIR. (See FIG. 3.1A)

Close the pump plug. Continue filling the system until at least 1 bar registers on the pressure gauge. Inspect the system for water soundness and remedy any leaks discovered.

FILLING OF THE D.H.W.SYSTEM:

Close all hot water draw-off taps. Open the cold water inlet cock supplied with the connection kit. Open slowly each draw-off tap and close it only when clear water, free of bubbles, is visible

GAS SUPPLY:

Inspect the entire installation including the gas meter, test for soundness and purge, all as described in BS 6891:1988. Open the gas cock (supplied with the connection kit) to the appliance and check the gas connector on the appliance for leaks.

Water Treatment

- If the boiler is installed in 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 BS7593:1992. Firstly fill the central heating system and boiler with the power

off and flush through cold, fill the central heating system again, add a flushing detergent, we highly recommend the use of a flushing detergent appropriate for the metals used in the aluminium alloy circuit. These include (Fernox Superfloc, BetzDearborn Sentinel X300 or X400), whose function is to dissolve any foreign matter that may be in the system, and run the boiler on central heating until it reaches its operating temperature, flush the system as instructed by the manufacturer of the flushing detergent and refill the system with a suitable corrosion inhibitor such as Fernox Copal MB1, or BetzDeaborn Sentinel X100 is recommended.

NOTE: FAILURE TO CARRY OUT THE FLUSHING PROCEDURE WILL RESULT

IN THE WARRANTY BECOMING VOID.

In hard water areas or where large quantities of water are in the system the treatment of the water to prevent premature scaling of the main heat exchanger is necessary.

- If anti-freeze substances are to be used in the system, check carefully that they are compatible with the aluminium. In particular, DO NOT USE ordinary ETHYLENE GLYCOL, since it is corrosive in relation to aluminium and its alloy, as well as being toxic. MTS suggests the use of suitable anti-freeze products such as Fernox ALPHI 11, which will prevent rust and incrustation taking place. Periodically check the pH 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

system separate by installing heat exchanger

with a specific system water treatment.

s of those

IMPORTANT Failure to carry out the water treatment procedure will invalidate the appliance warranty

3.2. REMOVING THE CASING

To remove the front casing panel, follow these steps:

1. Remove the screws “A” (FIG 3.1);

2. Remove the four screws from case hooks (two at the top

and two at the bottom) and rotate anti-clockwise (FIG 3.2);

3. Lift and unhook the case panel (FIG 3.3).

FIG. 3.2

FIG. 3.1

FIG. 3.3

3.3. CONTROL PANEL

27/32 MFFI (Combi)

FIG. 3.4

Button Description

ON/OFF Switch

“COMFORT” Function Push-button

Reset Button/ Flue Test**/ scroll through Functions Menu

Menu Switch

Programming “+” key

Programming “-” key

Description

Green LED (illuminated = burner on)

Time clock

Selector knob for Summer/Winter Central Heating Temperature Adjustment Knob

Control Panel Cover

Domestic Hot Water Temperature Adjustment Knob

Heating System Pressure Gauge

** IMPORTANT!! The Flue Test function will cause the boiler to run continuously on maximum power. This function must only be activated by an authorised engineer.

“COMFORT” Function L.E.D

Red LED (illuminated = boiler lockout)

Multi-function Display

27/32 RFFI (System)

FIG. 3.4

Button Description

ON/OFF Switch

Not used

Reset Button/ Flue Test**/ scroll through Functions Menu

Menu Switch

Programming “+” key

Programming “-” key

Description

Green LED (illuminated = burner on)

Time clock (Optional Extra)

Central Heating Temperature Adjustment Knob

Control Panel Cover

Heating System Pressure Gauge

Heating only L.E.D

** IMPORTANT!! The Flue Test function will cause the boiler to run continuously on maximum power. This function must only be activated by an authorised engineer.

Red LED (illuminated = boiler lockout)

Multi-function Display

3.4. INITIAL STA RT-UP

FIG. 3.5

1. Make sure that:

- the cap of the automatic air release valve is loosened;

- the system pressure is at least 1 bar on the pressure gauge “F” (Fig. 3.4);

- the gas cock is closed (Fig. 3.7);

- the electrical connection has been carried out in the correct manner.

To allow the air to escape from the system,

proceed as follows:

- push the On/off button and turn the knob “C” (Fig. 3.5) to the “winter” position. The boiler pump will start up and three consecutive attempts will be made to ignite the burner. After the third attempt, the electronic system will shutdown the boiler, because the supply of gas has been cut off. The message “A01” will appear on the display and the red LED “H” will illuminate;

- let the pump operate until all the air has escaped from the system;

- repeat the procedure for bleeding the radiators of air;

- draw hot water for a short while;

- check the system pressure and, if it has gone down, fill it with water until it returns to 1 bar.

2. Fill the boiler condensate trap with water, by pouring 1/2 a litre of water into the exhaust flue connector (see Section

2.9 Connecting the Flue). N.B. In the event of a prolonged period of system shutdown, the condensate trap should be filled before any renewed use. A shortage of water in the trap could temporarily lead to a small leakage of fumes into the air.

FIG. 3.7

FIG. 3.6

3, Ensure that the flue is fitted correctly.

4. Turn on the gas cock (Fig. 3.8) and check

the seals on the connections, including the one for the burner, making sure that the meter does not signal the passage of gas. Check the connections with a soap solution and eliminate any leaks.

5. Press the reset button , the boiler will attempt to light. If the burner does not light the first time, repeat the procedure. Note: Should the boiler fail to ignite check that no air is present in the gas pipe.

The boiler is configured in the factory for the gas type in question. To check the CO2 setting, please refer to Section

3.6.3.

6. Run the appliance in the DHW mode and check the correct

operation of the thermostat control.

7. Complete the commissioning checklist.

Fig. 3.8

3.5. DISPLAY:MESSAGES SHOWN DURING NORMAL OPERATION

During operation of the boiler, while it is carrying out its normal operations, the left-hand display shows a series of characters that refer to the operations indicated below:

No request for heat

Heating

Pump overrun for heating

Domestic hot water

Pump overrun for domestic hot water

The right-hand display (two-digit) shows:

- in CENTRAL HEATING mode: temperature of the Central Heating system flow;

- in DOMESTIC HOT WATER mode: temperature of the Domestic Hot Water (MFFI only).

LEFT RIGHT

FIG. 3.9

3.6. OPERATING PARAMETERS

The boiler has been designed to allow easy use of the operating parameters.

3.6.1 REGULATION MENU TABLE

Summary of the functions accessed when the RESET button

and the menu button are pushed at the same time for

5 seconds.

On the display will appear the parameters indicated on table 3A.

To switch between the different parameters press the button.

To modify the parameters push the programming keys and .

left display right display function factory setting

6600

from

00 to999

00 to7

Soft light

as % of maximum Heating Power (NG)

Maximum Heating Power (%)

Ignition delay (minutes)

Central heating minimum temperature

Central heating maximum temperature

5555

5522

(ACO 27 MFFI - RFFI )

4433

(ACO 32 MFFI - RFFI )

(ACO 27 MFFI - RFFI SYSTEM)

(ACO 32 MFFI - RFFI SYSTEM)

0022

4466

8822

Fig. 3.10

PD T rpm (Check of the temperature difference between the flow and return sensors for twelve seconds on initial start-up - DO NOT ADJUST)

SS00 toSS1

from

0011 to1155

from

OO00 to002

0000 to003

0000 to001

UU00 toUU1

NOT USED

Boiler types

Secondary outlet function

CCO

Pump overrun (Central Heating - mins)

Comfort function (only model MFFI)

Pump speed adjustment (modulating or

single speed)

0000

- ACO 27 /32 MFFI (COMBI)

0022

- ACO 27/32 RFFI (SYSTEM)

4455

SS00

0000

0022

0011

UU11

TABLE. 3A

left-hand display right-hand display Function factory setting

0011

0000 to001

from

selects low temperature systems

or standard systems

0000

Standard

Low Temperature

pp66

PP55

bb00

bb11

9900 to991

from

--2200 to++220

from

00__33 to33__0

from

2200

8811

Temperature regulation controlled by

external sensor

Correction of heat curve translation

Curve incline

Test Function

Bus Address (Do not modify)

Set-point second heating zone

GSM value (Do not modify)

NOT USED

9900

FIG. 3.11

3300

4400

5500

6600

7700

NOT USED

Important!! The parameters P5 and P6 are only enabled when the outdoor sensor is activated (Parameter P - page 41).

To return to the normal display, press the menu button .

Soft Light adjustment

The soft light can be adjusted between the maximum power (shown on the display as “00”, i.e. 100%) and the minimum power (shown on the display as “01”, i.e. 1%). The boiler is factory set to a value which is suitable for the ignition with any type of gas. The value set expressed as a percentage, can be displayed and adjusted as indicated in Section 3.6.1 (parameter 1)

FIG. 3.12

Maximum Heating Power adjustment

The maximum heating power can be adjusted between the maximum power allowed by the boiler (22.5kW - ACO 27 and 28kW - ACO 32) and the minimum recommended power (10kW

- ACO 27 and 13kW - ACO 32) indicated in the graph below (Parameter 2 = 20%). The value is factory set to 70% of the maximum power. The value set (expressed as a percentage) can be displayed and modified as illustrated in Section 3.6.1 (parameter 2). The display shows the value between 100% ("00" on the display) and 1% ("01").

Use the graph below as a guide to set the boiler heating power to suit the system load.

NOTE: MTS RECOMMEND THAT THE MINIMUM POWER NOT BE SET BELOW 20% AS INDICATED IN THE GRAPH BELOW..

FIG. 3.13

Heat Output

ACO 32

ACO 27

Display

Ignition Delay adjustment

The re-ignition delay for Central Heating can be adjusted to between 0 and 7 minutes. The delay is factory set to 2 minutes. The value set can be displayed and modified as illustrated in Section 3.6.1 (parameter 3)

Minimum Central Heating temperature

This parameter allows the setting of the minimum temperature for the central heating circuit. The value is factory set at 46°C and can be adjusted as illustrated in Section 3.6.1 (parameter 4).

FIG. 3.14

FIG. 3.15

Maximum Central Heating temperature

This parameter allows the setting of the maximum temperature for the central heating circuit. The value is factory set at 82°C and can be adjusted as illustrated in Section 3.6.1 (parameter 5).

Boiler types

Factory setting: 00 - ACO 27 / 32 MFFI (COMBI) 02 - ACO 27 / 32 RFFI (SYSTEM)

THIS PARAMETER MUST NEVER BE ADJUSTED.

FIG. 3.16

FIG. 3.17

Secondary outlet Function

(This parameter can be modified only with the interface PCB connected)

With the interface PCB connected, it is possible to set the boiler to operate with one of the following accessories, (see Section

2.12 for further information). The setting can be varied by pushing the and keys, the following options are available:

000

001

002

003

PUMP OVERRUN

The pump overrun time may be adjusted (after the burner has been turned off) by pressing the programming keys and . The following modes are available:

001

003

006

009

112

115

CCO

zone valve NOT USED NOT USED NOT USED

1 minute of pump overrun 3 minutes of pump overrun - factory setting 6 minutes of pump overrun 9 minutes of pump overrun 12 minutes of pump overrun 15 minutes of pump overrun Continuous pump overrun (NOT RECOMMENDED)

factory setting - (NOT USED IN UK)

FIG. 3.18

Comfort Function (MFFI model - Combi only)

The boiler allows the convenience level to be increased in the output of domestic hot water by means of the “COMFORT” function. This function keeps the secondary exchanger warm during the periods in which the boiler is inactive, thereby allowing the initial water drawn to be at a higher temperature. The function may be activated by pressing the COMFORT button key on the control panel (see section 3.3.). When the function is active, a yellow light

panel.

The comfort function can be activated or deactivated by pressing the and keys

000

Comfort function deactivated

001

Comfort function active for 30 minutes - factory setting.

It is possible to deactivate the comfort function by pressing the button . The yellow LED “G” will go out.

NOTE: During the overrun period of the pump, the “COMFORT” function, if selected, is temporarily deactivated. The L.E.D. light remains on to indicate that the boiler will return to the “COMFORT” mode once the pump overrun has finished.

Pump Speed Adjustment

By pressing the and keys it is possible to adust the operation of the pump, the two options are as follows:

“G” comes on, again located on the control

FIG. 3.19

UU0

- Single Speed Pump

UU1

- Modulating Pump -

factory setting

+20

-20

100

-20 +20

to increase the curve in parallel

to decrease

the cu

rve in parallel

FIG. 3.20

FIG. 3.21

FIG. 3.25

SETTING THE TEMPERATURE FIELD

Using the programming keys and it is possible to make the

following adjustments:

000

“

” signifies that the flow temperature (which may be set by

means of the knob on the front control panel) may be regulated from 20 to 75°C.

001

“

” signifies that the flow temperature (which also may be set by

means of the knob on the front control panel) may be regulated from 46 to 82 °C.

TEMPERATURE REGULATION CONTROLLED BY THE

EXTERNAL SENSOR

By pressing the and it is possible to make the following

adjustments:

990

“

” Temperature regulation controlled by the external sensor is

inactive (not installed).

991

“

” Temperature regulation controlled by the external sensor is

active (installed).

ADAPTING THE HEAT CURVE “

(Only enabled when the outdoor sensor is activated)

Should the external sensor be fitted it will be necessary to set the heating curve (see page 41) and may be necessary to adjust the parallel shift depending on the performance of the heating system used.

PP 6

”

FIG. 3.26

If the temperature in the house is too high, it will be necessary to decrease the parallel shift, whereas if the temperature is too low it will be necessary to increase the parallel shift as described below.

To set up the external sensor proceed as follows;

1. Access the settings menu by pressing the and buttons for five seconds;

2. Press the button 5 times to access Parameter 6

PP 6

will now appear in the left hand display

4. Adjust the parallel shift by turning the heating control knob clockwise to increase or anti-clockwise to decrease as shown below. The shift value can be read on the right hand display, from

-20 to +20 (Fig. 3.26).

Flow temperature (°C)

External temperature (°C)

FIG. 3.27

FIG. 3.28

PP 5

SETTING THE CURVE INCLINE

(Only enabled when an outdoor sensor is installed)

When using an outdoor sensor, the microprocessor-controlled P.C.B. calculates the most suitable flow temperature, taking into account the external temperature and the type of system. The microprocessor is capable of doing this because it is possible to establish a link between the external temperature and the flow temperature of the Central Heating system water. This link translates into a "thermal curve". The type of curve should be chosen in correspondence with the planned temperature of the system and the nature of the heat loss present in the building.

To select the type of curve access the Setting Menu by pressing the

and buttons for 5 seconds and proceed as follows;

1. Press the button four times to access Parameter 5;

2. P 5 will be shown on the left hand display;

3. Choose the curve required for the system from Fig. 3.31 and select by pressing the and buttons.

Fig. 3.31

With parameter P5 it is necessary to adjust the heat curve to one of those shown in Fig. 3.31. By using the programming keys

and , the curve may be changed to select the required curve

for the system.

The curves that can be selected are as follows:-

Convector radiator Curve 2.5 to 3 Steel radiator Curve 1.5 to 2 Oversized steel radiator Curve 1 to 1.2 Under-floor heating Curve 0.3 to 0.5(*)

WARNING (*) - If curve 0_3 or 0_5 is selected, a system safety thermostat must be connected to the main terminal board (see paragraph 2.12)

Test Function

The test function is used to enable the engineer/installer to check the combustion rate (see Section 3.6.3). The P.C.B. allows the boiler to be forced to the maximum or minimum power. Enable the test function, two dashes will appear on the right-hand display (see Fig. 3.29).

max power Central Heating

minimum power

FIG. 3.29

FIG. 3.30

To select operation at maximum power, press the programming key

, two dashes will appear at the top of the right-hand display (see Fig. 3.30). This function is disabled when you press reset key to quit the adjustments menu.

To select operation at minimum power, press the programming key

, two dashes will appear at the bottom of the right-hand display

(see Fig. 3.30). This function is disabled when you press reset key

“H” to quit the adjustments menu.

Note: The boiler can be forced to the maximum and minimum power

even without enabling the test function via the adjustments menu:

a - by pressing the Reset key for 5 seconds, the boiler is

automatically forced to test mode and t-- will be displayed, the boiler is now in the test mode for the maximum heating power, to force the boiler to maximum output for hot water it is necessary

max power DHW

to press the and keys together, two dashes appear at the top of the right-hand display (see Fig. 3.29). This function is disabled by pressing the reset key .

b - by pressing the key, the boiler is forced to operate at

minimum power, two dashes appear at the bottom of the righthand display (Fig. 3.31). This function is disabled by pressing the reset key.

FIG. 3.32

3.6.2 SETTINGS DISPLAY

The boiler is designed to monitor some operating variables and settings by means of the display on the front control panel. Keeping, at the same time, the reset and the menu key pressed for over 10 seconds will allow access to the “readout” function of the main system variables. By pressing the reset button repeatedly after that, it is possible to read the following information in sequence:

Indication on the

left-hand display

U//11

UU//2

UU//3

UU//4

UU//6

To return to the normal display, press the menu key. The boiler will automatically return to the normal display after no buttons have been pressed for 2 minutes.

NOTE 1: U/1 means that “ NOTE 2: the value 100% appears as “

* = Only displayed when an external sensor is fitted.

Value read on right-hand display

Flow temperature of the Central Heating circuit (°C)

Return temperature of the Central Heating circuit (°C)

Domestic Hot Water output temperature (°C)

Outdoor temperature (°C)*

Fan speed (% rpm)

Last safety shut-off (see section 3.10.)

Last shutdown (see section 3.10.)

” blink alternately on the display

” and “

000

” on the display

1 32 4



3.6.3 GAS REGULATION CHECK

Analysis cover plate

FIG. 3.32

SUPPLY PRESSURE (WORKING)

G20 methane 20 mbar G31 propane 37 mbar

CO2 SETTING MAXIMUM VALUE

CO2 at maximum power % vol 8.7 ±0.2 (NG)

% vol 10.2 ±0.2 (LPG)

CO2 SETTING MINIMUM VALUE (NAT GAS)

CO2 at minimum power % vol 9.2 ±0.2 (NG)

% vol 10.6 ±0.2 (LPG)

FIG. 3.33

TABLE 4D

Supply pressure check

1. Loosen screw “1” (Fig. 3.33) and connect the pressure gauge

connection pipe into the test point.

2. Turn the boiler on at maximum power, enabling the “flue sweep” function (press the key for 5 seconds and then press the programming keys and together ensuring the dashes are at the top of the display (see Fig. 3.30). The supply pressure should correspond to that shown for the type of gas the boiler is designed for methane gas G20 (see table below).

3. Disable the test mode by pressing the reset key.

4. When the check is over, tighten screw “1” and test for tightness.

NOTE:IF THE WORKING PRESSURE IS INSUFFICIENT CHECK THE GAS

METER, METER GOVERNOR, OR INSTALLATION PIPEWORK FOR ERROR.

SETTING THE GAS PRESSURES

IMPORTANT!

DO NOT PROCEED CHECKING AND ADJUSTING THE CO2 SETTINGS

UNLESS THE WORKING PRESSURE IS ADEQUATE.

NOTE:ALL SETTINGS ARE TO BE MADE WITH A CO2 METER WITH THE

PROBE FITTED TO THE FLUE GAS ANALYSIS POINT.

Setting the CO2 at minimum power

To check the air/gas ratio at minimum power, proceed as follows:

1. Connect the combustion analyser to the analysis point (Fig.

3.32) after removing the cover plate.

2. Set the boiler to minimum power via the test function (see paragraph 3.6.1) or by pressing the button for 5 seconds and then pressing the button on the control panel, ensure the dashes are at the bottom of the display (see Fig. 3.30). Ensure the CO2 value on the analyser corresponds with the value indicated in “2” (Fig.3.33) with a screwdriver in small intervals, allowing the reading to become stable before adjusting further, until you obtain the correct CO2 reading. Allow the reading to become stable for at least 4 minutes.

3. When the check is over, replace the cap on screw “2” (Fig. 3.33).

4. Disable operation at minimum power by pressing the key or press the key to check the maximum value (dashes at top of display see Fig. 3.31).

While the appliance is operating at maximum power, check the gas rate of the appliance at the gas meter

Setting the CO2 at maximum power

To check the air/gas ratio at maximum power, proceed as follows:

1. With the combustion analyser already connected to the analysis point, set the boiler to maximum power via the test function (see paragraph 3.6.1) or by pressing the button for 5 seconds and then the programming keys and ensuring the dashes at the top of the display (see Fig. 3.30). Ensure the CO2 value on the analyser corresponds with the value indicated in table 4D “4” with a screwdriver in small intervals allowing the analyser reading to stabilise before adjusting further (Fig. 3.33), until you obtain the correct CO2 reading. Allow the reading to become stable for at least 4 minutes.

2. Disable the test mode by pressing the button. The test mode is automatically disabled after 5 minutes.

3. Repeat the air/gas ratio at minimum power check (see

above).

4. Disconnect the analyser, remount the cover plate and check it is securely in place.

While the appliance is operating at minimum power, check the gas rate of the appliance at the gas meter

NOTE:WHEN MAKING ADJUSTMENTS, ADJUST SMALL AMOUNTS AND

WAIT FOR THE ANALYSER TO STABILISE BEFORE MAKING FURTHER ADJUSTMENTS.

table 4D. If this is not the case, adjust screw

. If this is not the case, adjust screw

3.6.4 IGNITION DELAY ADJUSTMENT

The ignition delay can be adjusted to between 0 and 7 minutes. The delay is factory set to 2 minutes. The value set can be displayed and modified as illustrated in paragraph 3.6.1 (parameter 3).

3.6.5 ADJUSTING THE MAXIMUM HEATING POWER

3.6.6 SOFT LIGHT ADJUSTMENT

3.7 CHANGING THE TYPE OF GAS

The maximum heating power can be adjusted between the maximum power allowed by the boiler (22.5kW - ACO 27 and 28kW

- ACO 32) and the minimum recommended power (10kW - ACO 27

and 13kW - ACO 32) indicated in the graph (parameter 2 = 20). The value is factory set to 70% of the maximum power. The value set (expressed as a percentage) can be displayed and modified as described in paragraph 3.6.1 (parameter 2) using the graph on Page 39.

NOTE: MTS RECOMMEND THAT THE MINIMUM POWER NOT BE SET BELOW 20% AS INDICATED IN THE GRAPH BELOW.

The soft light can be adjusted between the maximum power (shown on the display as "00", i.e. 100%) and minimum power (shown on the display as "01", i.e. 1%). The boiler is factory set to a value which is suitable for ignition with any type of gas. The value set (expressed as a percentage) can be displayed and modified as illustrated in paragraph 3.6.1 (parameter 1).

It is not possible to convert the ACO 27 & 32 MFFI/RFF to LPG. A specific LPG version is available as the following codes:

ACO 27 MFFI: 537061 ACO 27 RFFI: 537063 ACO 32 MFFI: 3300005 ACO 32 RFFI: 3300007

3.8 ADJUSTING THE HOT WATER FLOW RATE

3.9 BALANCING THE CENTRAL HEATING SYSTEM

To adjust the hot water flow rate, it is necessary to first open the hot water tap with the highest flow rate (normally the bath tap), adjust the cold water inlet valve until the correct temperature rise is

achieved at the stated flow rate (ACO 27 MFFI - D T=35°C @ 10.8 l/min and ACO 32 MFFI - DT=35°C @ 13.1 l/min.

Alternatively, you can advise the customer to restrict the water flow through each individual tap, by opening the tap and slowly closing it until the water reaches the desired temperature.

To balance the central heating system it is first necessary to close all radiator valves on the system, turn on the central heating, allow the boiler to reach operating temperature and then starting at the radiator furthest from the boiler, open the radiator valves until the radiator becomes hot and move to the next radiator on the circuit, working your way back to the radiator closest to the boiler.

3.10 BOILER SAFETY SYSTEMS

The boiler is protected from malfunctioning by means of internal checks by the P.C.B., which brings the boiler to a stop 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 SHUTDOWN: for this group of errors (characterised

on the display by the letter “ removed as soon as the cause behind it is resolved. As soon as the origin of the shutdown disappears, the boiler starts up again and returns to its normal operation.

SHUTDOWN: (characterised on the display by the letter “ not removed unless a manual intervention is made. The boiler may return to operation only if reset, press the

button located at the centre of the display. There follows a list of the shutdown modes and the respective codes shown on the display.

Shutdown (“ reset the boiler using the appropriate key. If this shutdown occurs frequently, your local Service Agent should be contacted.

Safety shutdown: In the event that a safety shutdown occurs, it is necessary to contact an Authorised Service Centre.

” type): if such a situation occurs, it is necessary to

”) the situation is automatically

”), is

DISPLAY CAUSE

AA0011

AA0022

AA0033

AA0077

AA3333

AA9977

AA9988

AA9999

NOTE: When there is no ignition (A01), check that the gas cock is

open and gas is available.

DISPLAY CAUSE

SS0011

SS0022

Too many attempts to ignite on start up

No water or no water circulation in central heating system

The heating flow temperature exceeds 105°C during operation

Too many failures to ignite in one period during operation

Problem with the fan

Problem with the electronic monitoring

Ignition failure on 1st attempt

Ignition failure on 2nd attempt

DISPLAY CAUSE

EE 0044

EE 0055

EE 0066

EE 0077

EE 0088

EE 0099

EE 1100

EE 2200

EE 3300

EE 3311

EE 3333

EE 3344

EE 8800

Domestic hot water temperature probe in open circuit

Domestic hot water temperature probe in short circuit

Heating flow temperature probe in open circuit

Heating flow temperature probe in short-circuit

Heating return temperature probe in open circuit

Heating return temperature probe in short-circuit

Under floor heating temperature probe in open circuit

Flame detected with gas valve closed

Outdoor sensor open circuit

Outdoor sensor in short circuit

Fan operation sensed with no demand for central heating or domestic hot water

Fan operation but air pressure switch does not close

Remote Control CLIMA MANAGER room sensor in open circuit or short circuit

EE 9944

EE 9955

EE 9999

Problem within the electronic system

Error reading flow or return temperature probe

Problem within the electronic system

DAILY TEST.

In order to prevent sticking components, the boiler carries out a selfdiagnosing test every 21 hours: the pump runs for 15 seconds and the diverter valve moves once. 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 falls below 8°C the pump will run for 2 minutes. After the two minutes of circulation (fixed) the boiler will check the following: a) if the central heating flow temperature is > 8°C, the pump stops; b) if the central heating flow temperature is between 3 and 8°C, the pump will run for another two minutes; c) if the central heating flow temperature is < 3°C, the burner will fire (heating position) at minimum power until the temperature reaches 33°C, the burner will go out and the pump will continue to run for two minutes. If the flow temperature remains between 3-8°C the pump will continue to run for two minutes for a maximum of 10 times unless a temperature above 8°C is detected in the central heating flow, after this the the burner will fire. If lockout is caused by overheat the burner is kept OFF.

NOTE: In all cases, the circulation takes place in the central

heating system. 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.

ANTI-SCALE DEVICE.

When producing domestic hot water, the burner shuts off whenever the output temperature of the hot water exceeds 61°C or the flow temperature of the primary circuit exceeds 78°C. It will not turn on if the temperature of the primary circuit is greater than 78°C.

3.11 COMPLETION

3.12 DRAINING

For the Republic of Ireland it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in the current edition of I.S. 813. In addition it is necessary to complete the commissioning checklist (Section 11, page 78).

The draining of the heating system must be carried out as follows:

- Turn off the boiler and the bipolar switch;

- Loosen the automatic air release valve;

- Open the system's discharge valve

- Empty out from the low est points of the system (where provided).

If the system is to be left active in areas where the room temperature may go below 0°C during winter, it is recommended that anti-freeze liquid be added to the water in the heating system in order to avoid the need for repeated draining.

Draining the domestic hot water system Every time that there is a danger of freezing, the domestic hot water system must be drained as follows:

- close the water mains stop-cock;

- open all the hot and cold water outlets;

- empty out from the lowest points (where provided).

4. ZONE VALVES

The boiler can be connected to a central heating system that uses two zone valves allow connection to an indirect storage cylinder.

There are two possible types of wiring diagram, one for the connection to an Unvented Cylinder (Diagram. A, page 49) and one for connection to an open vented cylinder (Diagram B, page 50).

In both cases the boiler connection is shown as TA, which relates to the terminal on the PCB for external controls (see FIG. 4.2).

When connecting the boiler to an external cylinder it is necessary to remove the integral clock from the boiler (see SECTION 7.6.3), do not run 240V cables and the TA cables together, use separate cables to prevent induced voltage on the low voltage switching circuit.

NOTE:THE USE OF A ‘Y’ PLAN SYSTEM IS NOT POSSIBLE WITH THE ACO

BOILER DUE TO THE LOW VOLTAGE SWITCHING OF THE APPLIANCE.

FIG. 4.1

IMPORTANT!! ENSURE THAT A BALANCING VALVE IS FITTED ON THE CYLINDER RETURN

AND BALANCED CORRECTLY AT COMMISSIONING STAGE.

FIG. 4.2

WIRING DIAGRAM FOR CONNECTION TO AN ARISTON

UNVENTED CYLINDER

DIAGRAM A

WIRING DIAGRAM FOR CONNECTION TO AN

OPEN VENTED CYLINDER

DIAGRAM B

5. SEQUENCE OF OPERATION

5.1 CENTRAL HEATING MODE

Activation of the time clock and/or room thermostat starts the boiler. The letter C is shown in the display followed by the flow temperature.

With the boiler in rest, the diverter valve is in the domestic hot water position, activation of the central heating changes the position of the motorised valve head, moving the diverter valve into the central heating position.

The start of the pump is delayed for 7 seconds to allow the movement of the diverter valve (when the pump starts it at speed 2). There then follows a temperature and flow rate check on the flow NTC (NTC1) and the return NTC (NTC2). The electronics check

NTC’s 1 and 2 for the correct D T (difference in temperature). The D T must be less than 5oC. If this is not correct after 40 seconds,

error code E95 is shown but the pump continues to run. When the check is correct the boiler automatically starts the sequence. Following the satisfaction of the temperature/NTC check the fan starts and an ignition attempt is then made for 3 seconds after the fan starts. The gas valve is energised and gas is delivered to the burner fixed in relation the the fan. The ignition gas pressure (soft light) is adjusted at Step 1 in the parameter adjustment mode (see Section 3.6.1). This value is factory set. (1= minimum fan speed and 00 = maximum fan speed). Soft light takes 4 seconds, the electronics check for flame ionisation during this time. Failure on ignition results in the error code A01.

For 12 seconds following the gas valve being energised, the ignition is checked and the temperature and flow through the boiler is

monitored by the electronics. The D T must increase by more than 50oC. To check the correct temperature and flow the boiler remains at a fixed output for 5 seconds, this value is 50 and can be viewed at Step 6 (Section 3.6.1.) Incorrect readings will result in the error code A02 being displayed and the pump stopping.

Following all checks the boiler is free to modulate the central heating output. The maximum heat output is set at Step 2 (see Section

3.6.1) and is adjustable between 1 and 00 (minimum and maximum output). The burner can activate up to a maximum of the set point at +4oC. reignition of the burner occurs once it has thermostatically turned off can be time delayed between 0 and 7 minutes, adjustable in Step 3 (Section 3.6.1), the factory setting is 2 minutes.

After correct operation is proven the pump speed changes to speed 3 (if the system is cold), if the system is warm the pump remains at speed 2.

In the event of overheating the display will show A03.

5.2 DOMESTIC HOT WATER MODE

When a hot water tap is turned on the domestic hot water flow switch is operated (if the diverter valve is in the central heating position it will motor into the domestic hot water position and the

boiler starts. The letter temperature of the domestic hot water leaving the appliance.

is shown in the display followed by the

The appliance will then follow the same operating logic as described in Central Heating Mode.

In domestic hot water mode NTC1 limits the maximum temperature to 78oC, reignition will occur at 74oC. The domestic hot water temperature is limited to 61oC, reignition will occur at 60oC.

6. MAINTENANCE

6.1. GENERAL REMARKS

IMPORTANT!!

Every time that the combustion chamber cover or the primary heat exchanger is removed from the boiler, the combustion chamber seal must be checked and where necessary replaced (code: 65102217). The silicone grease provided with the gasket must be spread around the area the gasket fits to ensure an airtight seal.

Only the grease provided must be used, however, should more grease be needed it must have a temperature range of between –40 deg C and +200 deg C”

DO NOT OPERATE THE BOILER WITH THE FRONT COMBUSTION

CHAMBER PANEL REMOVED!FAILURE TO OBSERVE THIS WILL

DAMAGE THE FAN AND AIR PRESSURE SWITCH AND WILL INVALIDATE ANY WARRANTY.

To ensure the validity of the 5 Year Guarantee, the boiler must be serviced annually by a CORGI registered gas engineer.

Provided the boiler was registered within the terms stated on the guarantee card, MTS (GB) Limited will write to the householder as the boiler becomes due for it’s annual service.

The requirements stated in the letter must be adhered to in order to ensure the continuation of the 5 year guarantee.

See Section 10 for annual maintenance requirements.

Note: Failure to comply with the annual service

requirements will result in the 5 year guarantee becoming void.

6.2. CLEANING THE PRIMARY EXCHANGER

6.3. CLEANING THE CONDENSATE TRAP

CLEANING THE EXHAUST SIDE Remove the combustion chamber inspection hatch (see section

7.3.5). Check that the exhaust passages between the blades of the block are free; if there are deposits present, wash the blades with compressed air, water or a vinegar-based detergent. NOTE: it is possible to use a brush in order to mechanically remove the residues.

Use of detergents:

- soak the blades well

- allow the detergent to act for about 20 minutes

- rinse with a strong jet of water to remove the deposits (the control panel must be kept closed)

- make sure that there are no traces of detergents in the exchanger.

CLEANING THE WATER SIDE Use detergents that dissolve CaCO3. Leave to act for a short time (in order not to damage the aluminum) and then rinse. Make sure that the detergent does not remain inside the exchanger.

To clean the condensate trap it is simply necessary to unscrew the lower part of the condensate trap and clean it. Lastly, fill it with water and replace the stopper.

IMPORTANT!!

If the boiler is not to be used for a prolonged period, the condensate trap should be filled before operating the boiler. A shortage of water in the trap will temporarily risk flue gasses escaping into the room.

6.4. OPERATIONAL TEST

After having carried out the maintenance operations, fill the heating circuit to a pressure of approx. 1.5 bar and release the air from the system. Also fill the domestic hot water system.

- Place the boiler in operation;

- If necessary, release the air again from the heating system.

- Check the settings and the correct functioning of all the control, regulation and monitoring parts;

- Check the seal and the correct functioning of the system for expelling fumes/drawing of combustion air;

- Check that the boiler ignites properly and carry out a visual check on the burner flame;

- Check the CO2 values are correct (see Section 3.6.3)

7. SERVICING INSTRUCTIONS

To ensure efficient safe operation, the boiler must be serviced annually by a competent person.

Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool.

Before and after servicing, a combustion analysis should be made via the flue sampling point (please refer to 3.6.3).

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

7.1. REPLACEMENT OF PARTS

7.2. TO GAIN GENERAL ACCESS

FIG. 7.1

The life of individual components vary and they will need servicing or replacing as and when faults develop. The fault finding sequence chart in chapter 2 will help to locate which component is the cause of any malfunction, and instructions for removal, inspection and replacement of the individual parts are given in the following pages.

All testing and maintenance operations on the boiler require the control panel to be lowered. This will also require the removal of the casing.

To lower the control panel and dismantle the front part of the casing, proceed as follows:

To remove the front casing panel, follow these steps:

1. Remove the screws “A” (Fig. 7.1);

2. Loosen the four screws ‘B’ from the case hooks (two

at the top and two at the bottom) and rotate anticlockwise (Fig. 7.2);

3. Lift and unhook the case panel (Fig. 7.3);

4. Lower the control panel (Fig. 7.4)

FIG. 7.3

FIG. 7.2

FIG. 7.4

7.3. ACCESS TO THE COMBUSTION CHAMBER

7.3.1. REMOVING THE FAN

1. Disconnect the electrical connector “C” (FIG. 7.5);

2. Disconnect the compensation tube “D” (FIG. 7.5);

3. Remove the clip “E” (FIG. 7.6).

4. Unscrew the four screws “F” (FIG. 7.7);

5. Remove the fan (FIG. 7.8).

FIG. 7.5

FIG. 7.6

FIG. 7.7

FIG. 7.8

7.3.2. REMOVING THE AIR PRESSURE SWITCH 7.3.3. REMOVING THE BURNER

1. Disconnect the electrical connector “G” (FIG. 7.9);

2. Disconnect the compensation tube “H” (FIG. 7.9);

3. Unscrew the two screws “I” (FIG. 7.10);

4. Remove the Air Pressure Switch

FIG. 7.9

FIG. 7.10

With the fan removed (see Section 7.3.1);

1. Remove the four allen screws “J” (FIG. 7.11);

2. Slide the burner from its housing (FIG. 7.12 - 7.13).

FIG. 7.11

FIG. 7.12

FIG. 7.13

7.3.4. REMOVING THE ELECTRODES

7.3.5. REMOVING THE HEAT EXCHANGER

1. Remove the two allen screws “K”, pulling off the ignition cable (FIG. 7.14);

3. Extract the electrodes (FIG. 7.15).

FIG. 7.14

FIG. 7.15

IMPORTANT!!

Only the grease provided must be used, however, should more grease be needed it must have a temperature range of between –40 deg C and +200 deg C”

1. Drain the boiler;

2. Remove the six nuts “L” (FIG. 7.16);

3. Remove the C.H. flow and return temperature probe

unscrewing the screws “M” (FIG. 7.16);

4. Remove the front cover;

5. Unscrew the two allen screws “N” (FIG. 7.17) and

remove the clip (7.18);

6. Remove the “U” clip “O” (FIG. 7.19) and remove the C.H. flow water pipe (FIG. 7.20);

7. Remove the “U” clip “P” (FIG. 7.21) and remove the C.H. return water pipe (FIG. 7.22);

8. Pull forward the heat exchanger (FIG. 7.23 - 7.24).

FIG. 7.16

FIG. 7.17

FIG. 7.18

FIG. 7.22

FIG. 7.19

FIG. 7.20

FIG. 7.23

FIG. 7.24

FIG. 7.21

7.3.6. REMOVING THE CONDENSATE TRAP (TUBE)

7.3.7. REMOVING THE CONDENSATE TRAP

1. Open the clamp “Q” and remove the condensate trap connection pipe (FIG. 7.25);

2. Unscrew the screw “R” (FIG. 7.26);

3. Remove the condensate tube.

FIG. 7.25

FIG. 7.26

1. Remove the condensate trap tube (see section 7.3.6);

2. Unscrew the screw “S” (FIG. 7.27);

3. Remove the blanking cap “T” (FIG. 7.28);

4. Remove the trap from the boiler.

NOTE: Take care when removing the blanking cap to

place a container under the boiler as this will release the contents of the condensate trap.

FIG. 7.27

FIG. 7.28

7.4 ACCESS TO THE GAS VALVE

7.4.1. REMOVING THE GAS VALVE

1. Remove the casing and lower the control panel as instructed in Section 7.1.

2. Press the release button “U” for the control panel (Fig.

7.29) and pull forward to remove from the boiler frame.

3. Clip the control panel onto the frame of the boiler. (Fig.

7.30).

FIG. 7.29

FIG. 7.30

1. Disconnect the electrical connection “V” from the gas valve (FIG. 7.31);

2. Release the top nut “W” (FIG. 7.31);

3. Remove the screws “X” from the bottom of the gas

valve pipe (FIG. 7.32);

4. Remove the gas valve (FIG. 7.33).

FIG. 7.31

FIG. 7.32

FIG. 7.33

7.4.2. REMOVING THE SPARK GENERATOR

7.5 ACCESS TO THE WATER CIRCUIT

1. Disconnect the electrical connection “Y” from the spark generator (FIG. 7.34);

2. Remove the screws “Z” from the bottom of the spark generator (FIG. 7.35);

4. Remove the spark generator.

FIG. 7.34

FIG. 7.35

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

7.5.1. REMOVING THE D.H.W. (SECONDARY) EXCHANGER (MFFI ONLY)

1. Remove the two allen screws “A1” (FIG. 7.36);

2. Push the exchanger towards the rear of the boiler, lift

upwards and remove from the front of the boiler (FIG.

7.37 - 7.38);

3. Before replacing the exchanger ensure that the O-rings

are in good condition and replace if necessary.

FIG. 7.36

FIG. 7.37

FIG. 7.38

7.5.2. REMOVING THE SAFETY VALVE

7.5.3. REMOVING THE AUTOMATIC AIR VENT

1. Remove the U-clip “A2” (Fig. 7.39);

2. Remove the valve (Fig. 7.40).

1. Remove the U-clip “A3” (FIG. 7.41);

2. Unscrew valve (FIG. 7.42);

3. Remove (FIG. 7.43).

FIG. 7.41

FIG. 7.39

FIG. 7.42

FIG. 7.43

FIG. 7.40

7.5.4. REMOVING THE DIVERTER VALVE ACTUATOR

1. Unplug the electrical connector “A4” (FIG. 7.44);

2. Release the retaining clip “A5” and remove the diverter

valve actuator (FIG. 7.45).

FIG. 7.44

FIG. 7.47

7.5.6. REMOVING THE PUMP

1. Unplug the electrical connection “A7” (FIG. 7.48);

2. Unscrew the four screws “A8” (FIG. 7.49);

3. Remove the pump (FIG. 7.50).

FIG. 7.45

7.5.5. REMOVING THE D.H.W. FLOW SWITCH (MFFI ONLY)

1. Unplug the electrical connector;

2. Unscrew the four screws “A6” (FIG. 7.46);

3. Remove the D.H.W. flow switch (FIG. 7.47).

FIG. 7.48

FIG. 7.46

FIG. 7.49

7.5.7. REMOVING THE PRESSURE GAUGE

1. Release U-clip “B1” (FIG. 7.51 - 7.52);

2. Ease the pressure gauge through the control panel

from the rear;

3. Remove the pressure gauge. (FIG 7.53).

FIG. 7.50

FIG. 7.51

FIG. 7.52

FIG. 7.53

7.5.8. REMOVING THE EXPANSION VESSEL

1. Unscrew the screws “B2” (FIG. 7.54);

2. Loosen nut “B3” (FIG. 7.55);

3. Unscrew the screw “B4” (FIG. 7.56);

3. Remove the expansion vessel (FIG. 7.57).

FIG. 7.54

FIG. 7.57

FIG. 7.55

7.5.9 REMOVING THE D.H.W. TEMPERATURE PROBE (N.T.C.) (MFFI ONLY)

1. Remove the electrical connector “B5” by pulling off (Fig. 7.58);

2. Unscrew and remove the D.H.W. temperature probe “B6” (FIG. 7.59).

FIG. 7.58

FIG. 7.56

FIG. 7.59

7.5.10. Removing the C.H. Flow Temperature Probe (N.T.C.)

7.5.11. REMOVING THE C.H. RETURN TEMPERATURE PROBE (N.T.C.)

1. Unscrew the two screws “B7” (Fig. 7.60);

2. Remove the electrical connection from the C.H. flow

temperature probe (FIG. 7.61).

FIG. 7.60

1. Unscrew the two screws “B8” (Fig. 7.62);

2. Remove the electrical connection from the C.H. flow

temperature probe (FIG. 7.63).

FIG. 7.62

FIG. 7.61

FIG. 7.63

7.6 ACCESS TO THE CONTROL SYSTEM

7.6.2. REMOVING THE P.C.B.S

7.6.1. CHECKING THE FUSES

1. Remove the inspection cover of the PCB box (FIG.

7.64);

2. Remove the fuses by pushing and rotating fuse holders “B9” (FIG. 7.65).

FIG. 7.64

1. Remove the inspection cover of the PCB box (FIG.

7.66);

2. Unplug all the electrical connections (FIG. 7.67);

3. Unscrew the screws “C1” (FIG. 7.67);

4. Pull forward the main PCB (FIG. 7.68);

5. Unscrew the screws “C2” (Fig. 7.69);

6. Remove the cover of the control panel (FIG. 7.70);

7. Unscrew the display P.C.B. mounting screws “C3” and

disconnect the P.C.B. connection cable “C4” (FIG. 7.71);

8. Remove the display P.C.B. (FIG. 7.72);

9. Replace either P.C.B. in reverse order.

FIG. 7.65

FIG. 7.66

FIG. 7.67

FIG. 7.68

FIG. 7.69

7.6.3. REMOVING THE TIME CLOCK

1. Open the control panel (see the paragraph “Removing the P.C.B.s”);

2. Unplug the electrical connection from the time clock

and unscrew the four screws (FIG. 7.73);

3. Remove the time clock (FIG. 7.74).

FIG. 7.73

FIG. 7.70

FIG. 7.71

FIG. 7.74

FIG. 7.72

8. FAULT FINDING

8.1. FAULT FINDING GUIDE (FLOW-CHARTS)

Model 27/32 MFFI

It is possible to detect and correct defects by using the standard fault finding diagrams described in this chapter.

NOTE:THESE CHECKS ARE NOT EXHAUSTIVE

Model 27/32 RFFI SYSTEM

9. SHORT SPARE PART LIST

137

3427 302925

373638 41 423935

104

103

102

100

101

RESET

CONFORT

ON/OFF

61 60

94 95

110

32 33 40

58 575

54 5253

111

109

112

113

134

122

128

136

126

121

124

133

107

108

106

105

118

117

123

122

119

120

130

132

131

129

135

56 55

125

116 115 114

127

205

ON/

OFF

CONF

ORT

RESET

208

207

210

215

216

202

201

205

204

203

212

213

214

206

211

209

cod. 65102191

27/32 (MFFI)

Key

no.

G.C. part

no.

Description

ARISTON

Part. No.

1 Flue restrictor 65102197 10 Spark generator 65102177 14 Main P.C.B. 65102236 18 Secondary heat exchanger (27 kW) 990685 18 Secondary heat exchanger (32 kW) 6510356 21 Temperature probe (DHW) 998458 29 Safety valve (3bar) 65103222 31 Pressure gauge 65102220 32 Gas valve 65102247 35 Flow switch (DHW) 995948 37 Motor (3-way valve) 997147 42 Pump 65102902 46 Automatic air vent 995865 54 Expansion vessel 995940 55 Air pressure switch 65102232 75 Hose clip 990662 90 Retaining clip (NTC CH) 65101007 91 NTC (CH) 990405

101 Repair kit (3-way valve) 65101288 107 Main exchanger (27 KW) 65103211 107 Main exchanger (32 KW) 65103219 125 Ignition electrode 65102198 129 Detection electrode 65102199 131 Fan 65102248 135 Burner (27kW) 65103221 135 Burner (32kW) 65103220 203 Cable (Mechanical Time Clock) 65102188 204 Mechanical Time Clock 999599 215 Display P.C.B. 65102235 216 Cable (Display P.C.B.) 65102185 109 Combustion Chamber Seal and Grease 65102217

123

24 272622 36 39 4037

RESET

ON/OFF

59 58

87 88

31 38

56 555

52 5051

120

108

114

122

112

107

110

119

104

103

109

108

105

106

116

118

117

115

121

54 53

111

102 101 100

113

353433

3029 32

205

ON/OFF

208 207

211

216

217

202

201

205

204

203

213

214

215

206

212

210

code 65102299

209

27/32 RFFI (SYSTEM)

Key

no.

G.C. part

no.

Description

ARISTON

Part. No.

1 Flue restrictor 65102196 10 Spark generator 65102177 14 Main P.C.B. 65102236 26 Safety valve (3bar) 65103222 28 Pressure gauge 65102220 31 Gas valve 65102247 39 Pump 65102902 43 Automatic air vent 995865 52 Expansion vessel 995940 53 Air pressure switch 65102232 74 Hose clip 990662 89 Retaining clip (NTC CH) 65101007 88 NTC (CH) 990405 93 Main exchanger (27 KW) 65103211 93 Main exchanger (32 KW) 65103219

115 Ignition electrode 65102198 118 Detection electrode 65102199 120 Fan 65102248 123 Burner (27kW) 65103221 123 Burner (32kW) 65103220 216 Display P.C.B. 65102235 217 Cable (Display P.C.B.) 65102185

98 Combustion Chamber Seal and Grease 65102217

10. ANNUAL MAINTENANCE

CHECKLIST

To ensure that the five year guarantee applies, the following checks must be carried out once a year and the service history completed in the Service Interval Record (Section 12, page 79) by a CORGI registered engineer:

1. Visually check the appliance for correct installation;

2. Check the appliance for the correct operation;

3. Check the flue and flue installation for correct siting, installation and that it is in good condition.;

4. Remove the casing as described in Section 7.2;

5. Check the operation of the safety devices:

- Air Pressure Switch;

- Overheat Thermostat;

- Safety Valve;

- Low Water Pressure Switch;

- Ionisation (Flame Detection);

6. Drain the boiler and check the pressure in the expansion vessel, ensuring it is 0.7 bar;

7. Remove, clean and refill the condensate trap and condensate hoses (see Section 7.3.6 and 7.3.7), check

the drain system for correct discharge of condensate and clean if necessary;

8. Remove and clean the DHW flow switch;

9. Remove and clean the fan;

10. Remove and clean the electrodes with an emery cloth;

11. Remove and clean the burner;

12. Check and clean the primary heat exchanger as necessary;

13. Refill the boiler and check the following;

14. Check all electronic operation parameters are correct (see Section 3.6);

15. Check gas inlet pressure and correct working pressure;

16. Check the CO2(see Section 3.6.3) and adjust as necessary;

17. Check the gas rate;

18. Check the correct operations of the timeclock and room thermostat;

19. Check the DHW flow rates;

20. Advise the customer on the correct use of the appliance (clock setting and operation, repressurising etc.);

21. Complete the necessary paperwork, Service Interval Record (page 79, Section 12) and Annual Maintenance

Checklist.

11. BENCHMARK COMMISSIONING CHECKLIST

12. SERVICE INTERVAL RECORD

TERMS AND CONDITIONS OF GUARANTEE

Please read these terms and conditions which are in addition to any terms and conditions detailed in this book or any registration card supplied with your appliance.

A charge will be made to the owner of the appliance if:

∑ The reason for any service visit is as a direct result

of a failure to install the appliance in accordance with the manufacturer’s instructions.

∑ Your installer does not complete the necessary

commissioning process and procedure as detailed in the Installation and Operating Instructions.

∑ Your appliance is not serviced on or before the 12

month anniversary of installation - this only applies to appliances with a 2 and 5 year guarantee.

∑ Our service engineer calls as requested and the

failure is a non-manufacturing defect.

Failure to pay an invoice for any such occurence will be assumed by MTS that you accept that your appliance has not been installed correctly and understand that any

manufacturer’s guarantee has been withdrawn. On the 12 month anniversary of the appliance installation, you must have it serviced to continue any guarantee offered into the following year. Failure to do so will invalidate your guarantee and should an MTS engineer be required to attend and no proof of service documentation is made available, then MTS will charge.

As part of the commissioning process, it is a legal requirement to register all boiler installations or replacements with CORGI. Upon registration a “Certification Number” will be issued followed by a “Declaration of Safety” Certificate. MTS (GB) Ltd cannot be called upon to carry out any work under the manufacturer’s guarantee without proof of registration. The registration number must be quoted when requesting a service visit, and the “Declaration of Safety” Certficate subsequently shown to the service engineer. If the certificate is not made available, the engineer will not work on the appliance and a wasted call charge will be made.

If you have a problem with commissioning on installation, please contact our

099841832212 b - 03/2005

Technical Department on 0870 241 8180

Manufacturer: Merloni TermoSanitari SpA - Italy

Commercial subsidiary: MTS (GB) Limited, MTS Building, Hughenden Avenue, High Wycombe, Bucks HP13 5FT

MTS are continuously improving their products and therefore reserve the right to change specifications without prior notice and

accepts no liability for any errors or omission in the information contained in this document.

Ariston ACO 27 MFFI, ACO 32 MFFI, ACO 27 RFFI, ACO 32 RFFI Installation and Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual