Ariston ACO 35 Installation and Servicing Instructions

Country of destination: GB/IE

Installation and Servicing Instructions Type C Boilers

ACO 35 MFFIG.C.N: 47-116-35

LEAVE THESE INSTRUCTIONS WITH THE END USER

SERIES

TABLE OF CONTENTS

1. GENERAL INFORMATION

1.1. GENERAL INFORMATION 3

1.2. T

ECHNICAL INFORMATION 4

1.3. O

VERALL VIEW 6

2. INSTALLATION

2.1. REFERENCE STANDARDS 7

2.2. S

ITING THE APPLIANCE 7

2.3. O

VERALL DIMENSIONS 8

2.4. M

INIMUM CLEARANCES 8

2.5. M

OUNTING THE APPLIANCE 9

2.6. E

LECTRICAL CONNECTION 9

2.7. G

AS CONNECTION 9

2.8. W

ATE R CONNECTIONS 10

2.9. F

LUE CONNECTIONS 13

2.9.1 F

ITTING THE COAXIAL FLUE

(Ø 60 / 100 HORIZONTAL)14

2.9.2 F

ITTING THE 5” FLUE

(Ø 80 / 125 Horizontal/Vertical) 15

2.9.3 F

ITTING THE COAXIAL FLUE

(Ø 60 / 100 VERTICAL) 16

2.9.4 F

ITTING THE TWIN PIPE (Ø80 / 80) 17

2.10. F

ITTING THE MECHANICAL/DIGITAL

TIME CLOCK 20

2.11. S

ETTING THE MECHANICAL TIME CLOCK 22

2.11.1. S

ETTING THE DIGITAL TIME CLOCK 22

2.12. A

CCESSORY CONNECTION 24

2.13. E

LECTRICAL DIAGRAM 26

2.14. W

ATE R CIRCUIT DIAGRAM 28

3. COMMISSIONING

3.1. INITIAL PREPARATION 30

3.2. R

EMOVING THE CASING 32

3.3. C

ONTROL PANEL 33

3.4. I

NITIAL START-UP 35

3.5. D

ISPLAY: MESSAGES SHOWN DURING

NORMAL OPERATION 36

3.6. O

PERATING PARAMETERS 37

3.6.1. R

EGULATION MENU TABLE 37

3.6.2. S

ETTINGS DISPLAY 43

3.6.3. G

AS REGULATION CHECK 44

3.6.4. I

GNITION DELAY ADJUSTMENT 45

3.6.5. A

DJUSTING THE MAXIMUM HEATING

POWER 45

3.6.6. S

OFT LIGHT ADJUSTMENT 45

3.7. C

HANGING THE TYPE OF GAS 45

3.8. A

DJUSTING THE DOMESTIC HOT

WATER FLOW RAT E 45

3.9. B

ALANCING THE CENTRAL

HEATING SYSTEM 45

3.10. B

OILER SAFETY SYSTEMS 46

3.11. C

OMPLETION 47

3.12. D

RAINING 47

4. ZONE VALVES 48

5. SEQUENCE OF OPERATION 51

5.1 CENTRAL HEATING MODE 51

5.2 D

OMESTIC HOT WATE R MODE 51

6. MAINTENANCE 52

6.1. GENERAL REMARKS 52

6.2. C

LEANING THE PRIMARY EXCHANGER 52

6.3. C

LEANING THE CONDENSATE TRAP 52

6.4. O

PERATIONAL TEST 52

7. SERVICING INSTRUCTIONS 53

7.1. REPLACEMENT OF PARTS 53

7.2. T

O GAIN GENERAL ACCESS 53

7.3. A

CCESS TO THE COMBUSTION

CHAMBER 54

7.3.1. R

EMOVING THE FAN 54

7.3.2. R

EMOVING THE AIR PRESSURE SWITCH 55

7.3.3. R

EMOVING THE BURNER 55

7.3.4. R

EMOVING THE ELECTRODES 56

7.3.5. R

EMOVING THE HEAT EXCHANGER 56

7.3.6. R

EMOVING THE CONDENSATE

TRAP (TUBE)58

7.3.7. R

EMOVING THE CONDENSATE TRAP 58

7.4. A

CCESS TO THE GAS VALVE 59

7.4.1. R

EMOVING THE GAS VALVE 59

7.4.2. R

EMOVING THE SPARK GENERATOR 60

7.5. A

CCESS TO THE WATER CIRCUIT 60

7.5.1. R

EMOVING THE D.H.W.

ECONDARY) EXCHANGER 60

7.5.2. R

EMOVING THE SAFETY VALVE 61

7.5.3. R

EMOVING THE AUTOMATIC AIR VENT 61

7.5.4. R

EMOVING THE DIVERTER VALVE

ACTUATOR 62

7.5.5. R

EMOVING THE DHW FLOW SWITCH

(MFFI ONLY)62

7.5.6. R

EMOVING THE PUMP 62

7.5.7. R

EMOVING THE PRESSURE GAUGE 63

7.5.8. R

EMOVING THE EXPANSION VESSEL 64

7.5.9. R

EMOVING THE D.H.W. TEMPERATURE

PROBE (N.T.C. - MFFI ONLY)64

7.5.10. R

EMOVING THE C.H. FLOW

TEMPERATURE PROBE (N.T.C.) 65

7.5.11. R

EMOVING THE C.H. RETURN

TEMPERATURE PROBE (N.T.C.) 65

7.6. A

CCESS TO THE CONTROL SYSTEM 66

7.6.1. C

HECKING THE FUSES 66

7.6.2. R

EMOVING THE PRINTED CIRCUIT

BOARDS 66

7.6.3. R

EMOVING 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

11. BENCHMARK COMMISSIONING CHECKLIST 78

12. SERVICE INTERVAL RECORD 79

PAGE PAGE

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.

1. GENERAL INFORMATION

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 35 MFFI is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.) and is designed 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 inside of the casing. 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.

1.1. GENERAL INFORMATION

Name CE Certification Flue Type

Heat Input max (Domestic Hot Water) kW Heat Input max/min (Central Heating) kW Heat Output max/min (Central Heating) kW Heat Output max/min (Domestic Hot Water) 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 (∆T=50°C) % Flue Heat Loss with Burner Operating %

General Info

Energy Performance

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

2 Content %

CO Content ppm Nox Class

Emissions

Head Loss on Water Side (max) (∆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 Heating Temperature max/min (Low Temperature) °C

Central Heating

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

Domestic Hot Water

Nominal Pressure Natural Gas (G20) mbar Consumption at Nominal Capacity(G20) m3/h Gas Consumption after 10 Minutes* m

Gas

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

ACO 35 MFFI

1312BQ4461

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

44.6 62

9.4

3.8

109

5 (70 mg/kW/h)

200

0.2

0.7 3 7

130 82 / 46 75 / 25

56 / 36

18.84

13.5

2.5

6 / 0.2

3.17

0.37

3 4

230/50

145

24D

2A Fast Fuse

310/450/750

47-116-35

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

Max. Condensate produced l/h PH of condensate PH

1.2. TECHNICAL INFORMATION

37.2

33.3 / 7.4

29.4 / 6.5

33.3 / 7.4

88.2

94.6

92.5

97.4

87.3

A / 90.2

0.4

1.7

LEGEND:

1. Air Release Valve

2. Main Heat Exchanger (Stainless Steel)

3. Detection Electrode

4. Central Heating Flow Temperature Probe

5. Overheat Thermostat

6. Central Heating Return Temperature Probe

7. Air / Gas Mixer

8. Gas Valve

9. P.C.B. Box

10. Diverter Valve

11. Condensate Discharge

12. Condensate Trap

13. Low Water Pressure Switch

14. Domestic Hot Water Temperature Probe

1.3. OVERALL VIEW

FIG. 1.0

15. Secondary Heat Exchanger

16. Domestic Hot Water Flow Switch

17. Circulation Pump with Automatic Air Release Valve

18. Safety Valve (3 bar)

19. Automatic By-pass

20. Fan

21. Ignition Electrode

22. Silencer

23. Spark Generator

24. Expansion Vessel

25. Combustion Analysis Test Point

26. Flue Connector

26 25

5 6

11 1312 14 15 16

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 byelaws of the local water authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635 “Electricity at work regulations 1989” and in the Republic of Ireland with the current edition of I.S. 813, the Local Building Regulations (IE).

C.O.S.H.H.

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

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

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

2. INSTALLATION

2.1. REFERENCE STANDARDS

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 6891:2005 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.

I.S. 813 Domestic Gas Installations

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.

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.

2.3. OVERALL DIMENSIONS

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.

2.4. MINIMUM CLEARANCES

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) SV outlet = 1/2” Female BSP (Not Shown)

FIG. 2.0

FIG. 2.1

IG. 2.2

After removing the boiler from its packaging, remove the template from the separate box containing the connection kit. N

OTE: 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 F

LUE CONNECTION. (If the appliance is to be

fitted on a wall of combustible material, the wall must

be protected by a sheet of fireproof material). If the appliance is to be fitted into a timber framed building, guidance should be sought from the Institute of Gas Engineers document REF: IGE/UP/7.

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. N

OTE: 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 & F

IG. 2.4).

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.

2.5.

MOUNTING THE APPLIANCE

785

310

450

130 130

225 225

143

750 35

93 65

67 67 65 93

100

120

water gas

323

310

2.8. WATER CONNECTIONS

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 G = Condensate trap F = Safety valve discharge

Central Heating

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

IPEWORK

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.

YSTEMDESIGN

This boiler is suitable only for sealed systems.

RAINCOCKS

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.

VIEW OF THE BOILER CONNECTIONS

FIG. 2.4

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 those indicated in Fig.2.3). The appliance electrical connections are situated inside the electrical box (see Section 2.12).

MPORTANT

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. 2.3

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.

Note: The diagrams for the electrical system are indicated in Sections 2.12 and 2.13 (pages 22-24).

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 for further information.

RESIDUAL HEAD OF THE BOILER∆T20°C

FIG. 2.5

AFETYVALVEDISCHARGE

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.

ONDENSATEDISCHARGE

A flexible hose is supplied for connection to the condensate discharge point H (Fig. 2.4). The condensate discharge hose 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 tundish / 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.

OTE: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 seen on this page.

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).

1. Internal termination of condensate drainage pipe to internal stack

800

700

600

500

400

[mbar]

300

200

100

0 200 400 600 800 1000 1200 1400 1600

[l/h]

4. External termination of condensate drainage pipe via condensate siphon

AIRR

ELEASEPOINTS

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.

AINSWATE RFEED

- C

ENTRALHEATING

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.

ILLING

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 regulations. N

OTE: 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.

OMESTICWATE R

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.

NDERFLOORHEATINGSYSTEMS

In the event of an under floor heating system, fit a safety thermostat on the boiler flow (instructions for wiring the thermostat to connection SP on the PCB can be found in 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 “E08” would be displayed; boiler operation resumes 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.

WATER TREATMENT

The boiler is equipped with a stainless steel heat exchanger.

The detailed recommendations for water treatment are given in BS 7593:1992 (Treatment of water in domestic hot water central heating systems); the following notes are given for general guidance;

If the boiler is installed on an existing system, any unsuitable 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 circuit. These include cleansers produced by Fernox and BetzDearborn, 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.

The use of a corrosion inhibitor in the system such as Fernox MB-1, BetzDeaborn Sentinel X100 or Fernox System Inhibitor is recommended to prevent corrosion (sludge) damaging the boiler and system;

If anti-freeze substances are to be used in the system, check carefully that they are compatible with the metals used in the circuit.

MTS suggests the use of suitable anti-freeze products such as Fernox ALPHI 11, which will prevent rust and incrustation taking place.

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 systems metal parts (metal piping, boiler, etc), through the formation of oxides and bacterial agents.

To prevent this problem, it is necessary to use pipes with an “oxygen-proof barrier”, in accordance with standards DIN 4726/4729. If pipes of this kind are not used, keep the

system separate by installing heat exchanger

s of those

with a specific system water treatment.

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

Ø 60/100 mm

Fig. 2.9

FIG. 2.9

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

LUESYSTEM

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.

120 mm

Warning

The exhaust gas ducts must not be in contact with or close to inflammable material and must not pass through building structures or walls made of inflammable material. When replacing an old appliance, the flue system must be changed.

Important

Ensure that the flue is not blocked. Ensure that the flue is supported and assembled in accordance with these instructions.

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

Installation without extension

Installation with extension

Fig. 2.10

Fig. 2.11

Level

ONTENTS

XSILICONE

O-R

ING

(60mm)

1XE

LBOW

(90O)

2XW

ALLSEALS(INTERNAL&EXTERNAL

)

XFLUEPIPE INCLUDINGTERMINAL

METRE

- 60/100)

1XF

LUECLAMP

1XS

CREWS

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 360

on 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.

120

* slope

150 mm

150 mm

* slope 5 mm per metre

Fig. 2.12

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

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

OTE: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 (F

IG. 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.

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

elbow 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. 2.14 and a 90

bend in Fig. 2.15).

OTE: DO NOT CUT THE VERTICAL FLUE KIT.

Screws

Clamp

Seal

Fig. 2.13

Fig. 2.14

Fig. 2.15

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

ONTENTS

XSILICONE

O-R

ING

(60mm)

XCONICALADAPTOR

(60/100mm)

1XV

ERTICALFLUEKIT

(80/125mm)

XSCREWS

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 90

elbow 1 metre must be subtracted from the

total flue length, and for each 45

0.5 metres must be

subtracted from the total flue length (the height of the

vertical adaptor and a 45

bend can be seen in Fig. 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).

Cut a 120mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof.

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

must

only be cut at the male end and it must

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.

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.

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

Fig. 2.16

Fig. 2.17

2.9.4. FITTING THE TWIN PIPE (Ø80 / 80)

NOTE:SEE PAGE 19 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 must

be a minimum of 280 mm apart and the air

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 (T

YPE 4) the maximum length is

38 metres (27kW) and 48 metres (32kW), for runs with the terminals under different atmospheric conditions (T

YPE 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 T

YPE

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 90

elbow 2.2 metres must be

subtracted from the total length and for each 45

elbow 1.4

metres must be subtracted from the total flue length.

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.

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. 2.19

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)

Coaxial

Systems

Twin Pipe

Systems

Exhaust Type

Type 1 Type 1

Types 2 & 3

Type 4

Type 5

Maximum Extension

Exhaust/Air

(m)

4 (Horizontal)

16 (Horizontal)

4 (Vertical)

16 (Vertical)

(Air Intake & Exhaust

Equal Lengths (27

and 27 metres)

1+56 (Air Intake 1

Metre and Exhaust 56

Metres)

Diameter

of Pipes

(mm)

Ø 60/100 Ø 80/125

Ø 80/80

Reduction

(m)

0.5

0.25

Reduction

(m)

1 1

0.5

ø 100

60 mm

Fig. 2.20

NOTE: DRAWINGS ARE INDICATIVE OF FLUEING OPTIONS ONLY.

TYPE 1

TYPE 5

TYPE 4

TYPE 3

TYPE 2

Fig. 2.19

AIR INTAKE MUST NOT BE

FITTED ABOVE THE EXHAUST

AIR INTAKE

EXHAUST

AIR INTAKE

FIG. 2.22

FIG. 2.21

FIG. 2.23

DIGITAL

MECHANICAL

FIG. 2.20

2.10. FITTING THE MECHANICAL / DIGITAL CLOCK

The ACO MFFI 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

2. Open the control panel (see fig. 2.20);

3. Unplug the electrical connection from the PCB and unscrew the four screws (Fig. 2.21);

4. Remove the time clock (Fig. 2.22).

5. Connect the wires supplied with the clock to the digital time clock as shown in Fig. 2.23;

6. Reassemble in reverse order.

OTE:THE MECHANICAL CLOCK HAS FOUR WIRES, THEREFORE THE

HARNESS WILL REQUIRE CHANGING ALSO

2.11. SETTING THE MECHANICAL TIME CLOCK

2.11.1. SETTING THE DIGITALTIME CLOCK

Fig. 2.24

1. General layout

The mechanical clock covers a 24 hour period. Each tappet represents 15 minutes A (Fig. 2.25). An override switch is

located on the clock B (Fig 2.25).

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. 2.25).

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.

Fig. 2.25

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.

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

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

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

Manual Override Switch “ ”

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

Reading the programmed switching times

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

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

Changing the programmed switching times

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

Notes on storing switching times:

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

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

Deleting individual switching times

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

AM / PM time display

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

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.

IMPORTANT!!

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

FIG. 2.27

IG. 2.26

In order to gain access to the external control connections, it is first necessary to remove the casing (as shown in Section 3.2 page 39) then proceed as follows:

1. Remove the cover of the main PCB box (Fig 2.26).

2. Access can now be gained to the following connectors (see Section 2.13 - page 24): CN10 - Safety thermostat for underfloor heating (SP) CN 9 - Room Thermostat (TA) CN 11 - Time clock CN 6 - Interface PCB (

FIG. 2.28)

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. 2.27 - 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. 2.27 - Diagram B).

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

these must be connected in series as points A-D above (Fig. 2.27 - Diagram C).

OTE:ENSURE LOW VOLTAGE AND HIGH VOLTAGE CIRCUITS ARE

CABLED SEPARATELY TO AVOID INDUCED VOLTAGES IN THE LOW

VOLTAGE CIRCUITS

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