Installation and servicing instructions MODEL :
Type C with Sealed Combustion Chamber
G.C. NUMBER: 4711605
Produced by Merloni TermoSanitari spa - Italy
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER
Sect. | Subject | Page | Sect. | Subject | Page |
---|---|---|---|---|---|
No. | • | No. | 0 | ||
1 | GENERAL INFORMATION | 6.15 | Gas modulator cartridge | 26 | |
1.1 | Overall view | 2 | 6.16 | Gas modulator coil | 27 |
1.2 | Technical data | 3 | 6.17 | On-off operator coils | 27 |
1.3 | Available pump head | 4 | 6.18 | Gas valve | 27 |
1.4 | Flue pipes optional extras | 4 | 6.19 | Removing the fan | 28 |
1.5 | Design principles and operating | 6.20 | Air pressure switch | 28 | |
sequence | 4 | 6.21 | Main heat exchanger | 29 | |
6.22 | Automatic air purger | 29 | |||
2 | GENERAL REQUIREMENTS | 6.23 | Pump | 30 | |
2.1 | Related documents | 6 | 6.24 | Pump pressure switch | 30 |
2.2 | Location of appliance | 6 | 6.25 | Main circuit flow switch | 30 |
2.3 | Flue system | 6 | 6.26 | Temperature pressure gauge | 31 |
2.4 | Gas supply | 6 | 6.27 | Removing divertor valve | 31 |
2.5 | Air supply | 7 | 6.28 | Secondary exchanger | 31 |
2.6 | Water circulation | 7 | 6.29 | Expansion vessel | 32 |
2.7 | Domestic water | 8 | 6.30 | Safety valve | 32 |
2.8 | Electrical supply | 8 | 0.00 | 02 | |
• | 7 | FAULT FINDING | |||
3 | INSTALLATION | 71 | Total check system | 33 | |
3.1 | Deliverv | 9 | 79 | Special defects | 33 |
3.2 | Measurements for installing the | Ū | 791 | Water leaks | 33 |
0.12 | appliance | 9 | 7.2.1 | Difficulty in lighting the burner | 22 |
3,3 | Unpacking the boiler | 10 |
7.2.2
799 |
Incorrect compustion | 24 |
3.4 | Positioning of the boiler | 10 |
7.2.9
79A |
24 | |
3.5 | Mounting the flue exhaust pipes | 11 | 70 | Installation of the TCS | 34 |
3.6 | Flue terminal quard | 12 | 7.3 | Foult finding | 34 |
37 | Electrical connections | 12 | 7.4 | Fault finding without the utilization | 34 |
9.7 | Electrical connections | 15 | 1.3 | of the total sheek system | 40 |
A | COMMISSIONING | 7 2 4 | of the total check system | 48 | |
્યાન | 15 | 7.3.1 | Appliance completely shut down | 48 | |
-r.1
A D |
Gas supply installation | 15 | 1.3.2 | Appliance doesn't attempt to ignite | 10 |
~r.≤
⊿ Q |
Filling the d h w eveter | 15 | the burner ( no sparks ) | 49 | |
Initial filling of the system | 15 | 1.5.3 | Appliance ignition frequently fails | ||
47.47
A E |
Sotting the system pressure | 15 | with consequent lockout (red light | ||
44.C)
A R |
Setting the bailer | 10 | on the reset push button ) | 50 | |
43.0
1/7 |
Checking the full serveres server | 10 | 1.5.4 | Fault on "not water-space heating" | |
43.
1
A 10 |
Checking the full sequence control | 16 | switching | 51 | |
4.0 | resting the d.n.w. system flow | 16 | |||
- | 8 | ELECTRIC DIAGRAMS | |||
9 | 8.1 | Electrical connection | 52 | ||
5.1 | General | 17 | 8.2 | Functional flow connection | 53 |
9.Z | Recommended routine maintenance | 1/ | |||
0 | 9 | SHORT SPARE PARTS LIST | 54 | ||
6 | SERVICING INSTRUCTIONS | ||||
6.1 | Replacement of parts | 18 | ٩ | Control panel | |
6.2 | To gain access | 18 | ٩ | Residual head of circulator | |
6.3 | To drain the main circuit of the boiler | 19 | ٩ | Regulating heating power for | |
6.4 | To drain the d.h.w. circuit of the boile | r 19 | Natural Gas (G20) | ||
6.5 | Setting gas pressure | 20 | Regulating heating power for | ||
6.6 | Overheat thermostat | 22 | Butane Gas (G30) | ||
6.7 | Removing ignition electrodes | 22 | ٩ | Regulating heating power for | |
6.8 | Removing flame sensor | 23 | Propane Gas (G31) | ||
6.9 | Removing d.h.w. thermostat | 24 | |||
6.10 | Boiler thermostat | 24 | |||
6.11 | EMC filter (radio interferance surpres | sor) | |||
25 | |||||
6.12 | Microswitches on divertor valve | 25 | |||
6.13 | Burner and injectors | 25 | |||
6.14 | Insulation panel | 26 |
Read the instructions and recommendations in this owner's manual carefully to ensure proper installation, use and maintenance of the appliance.
Keep this owner's manual in a safe place.
You may need it for your own reference while our Servicing Centre technicians or your installer may need to consult it in the future.
This appliance is designed to produce hot water. It must be connected to a central heating system or to hot water mains system suited to its specifications and capacity.
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.
BEFORE CONNECTING the appliance check that the information shown on the data plate and the table on pages 4-5 comply with the electric, water and gas mains of your home.
You will find the data plate on 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 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 ( on the gas meter ) or the valve of the gas cylinder and call your Gas Supplier immediately. If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.
ALWAYS DISCONNECT the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the appliance or carriyng out maintenance.
off the appliance and turn off the gas tap. Do not tamper with the appliance.
For repairs, call your local Authorized Servicing Centre and request the use of original spare parts.
For in guarantee repairs contact MTS (GB) LIMITED
NEVER block the ventilation outlet of the compartment in which the boiler is installed with rags or paper.
CHECK the following at least once a year:
The CHALLENGER 80 E is a combined central heating (c.h.w.) and domestic hot water (d.h.w.) appliance. It is produced as a room sealed category appliance. It is suitable for wall mounting applications only.
It is suitable for sealed systems only.
• | |||
---|---|---|---|
Heating input | max | 25.6 kW | 87364 Btu/h |
Heating input | min | 11.0 kW | 37539 Btu/h |
Heating output | max | 23.1 kW | 78832 Btu/h |
Heating output | min | 8.8 kW | 30031 Btu/h |
CENTRAL HEATING | |||
Operating temperature | max | 85 °C | |
Operating temperature | min | 45 °C | |
Working pressure | max | 2.5 bar | 36.25 p.s.i. |
Water content | 2.7 lts | 0.6 gals. | |
Built-in expansion vessel - Total ca | pacity | 7 lts | 1.53 gals. |
Built-in expansion vessel - Pre-cha | 1 bar | 14.5 p.s.i. | |
Available head at 1000 lts./h ( 220 | gals./h) | 2.50 m w.g. | 98.42 ins w.g |
Temp. difference for flow and return | n | 20 °C | |
Flow rate of water through the app | liance | 1000 lts./h | 219.3 gals./h |
Max permissible cold water capacity v
expansion vessel (1) |
without additional | 70 lts./h | 15.3 gals./h |
DOMESTIC HOT WATER | |||
Working pressure | max | 6 bar | 87 p.s.i. |
Working pressure | min | 0.2 bar | 2.9 p.s.i. |
Water content | 0.30 lts | 0.08 gals. | |
Flow rate | min | 2.4 Its./min | 0.5 gals./min |
Flow rate | 30 °C rise | 11.0 lts.min | 2.4 gals./min |
Flow rate | 35 °C rise | 9.5 lts./min | 2.1 gals./min |
Flow rate | 40 °C rise | 8.3 lts./min | 1.8 gals./min |
COMPONENT DETAILS | |||
---|---|---|---|
Gas control valve | SIT 8 | 37 TANDEM | |
Burner | osferic steel - POLIDORO | ||
ELECTRICAL DATA | |||
Electrical supply | 230 V~ | ||
Frequency | 50 Hz | ||
Power consumption | 150 W | ||
Internal fuse rating | 2 A | ||
CONNECTIONS | |||
Gas connection | 15 mm o.d. | ||
C.h. flow | 22 mm o.d. | ||
C.h. return | 22 mm o.d. | ||
D.c.w. inlet | 15 mm o.d. | ||
D.h.w. outlet | 15 mm o.d. | ||
Safety discharge pipe | 15 mm o.d. | ||
FLUE PIPES SPECIFICATIONS | |||
Outer diameters | Flue exhaust pipe | 60 mm | 2.36 ins |
Outer diameters | Air intake pipe | 100 mm | 3.93 ins |
Standard length | 1000 mm | 39.38 ins | |
Maximun length (2) | 3000 mm | 118.1 ins | |
OTHER SPECIFICATIONS | |||
Height | 796 mm | 31.34 ins | |
Width | 456 mm | 17.95 ins | |
Depth | 370 mm | 14.57 ins | |
Dry weight | 46 Kg | 101.4 lb |
GAS REQUIREMENTS | NATURAL GAS (G20) | BUTANE GAS (G30) | PROPANE GAS (G31) | ||||
---|---|---|---|---|---|---|---|
Gas rate | max | 2.7 m 3 /h | 96.0 ft 3 /h | 0.8 m 3 /h | 28.2 ft 3 /h | 1.0 m 3 /h | 36.5 ft 3 /h |
Gas rate | min | 1.1 m³/h | 38.8 ft 3 /h | 0.3 m 3 /h | 10.6 ft 3 /h | 0.4 m 3 /h | 14.7 ft 3 /h |
Inlet pressure | 20 mbar | 7.8 in w.g. | 28 mbar | 10.9 in w.g. | 37 mbar | 14.4 in w.g. | |
Burner pressure ( Natural gas ) | max | 12.3 mbar | 4.8 in w.g. | 28 mbar | 10.9 in w.g. | 37 mbar | 14.4 in w.g. |
Burner pressure ( Natural gas ) | min | 2.0 mbar | 0.8 in w.g. | 5.1 mbar | 2.0 in w.g. | 7.0 mbar | 2.7 in w.g. |
Burner injectors | 13 x 1.25 | 13 x 0.72 | 13 x 0.72 |
(1) If required, an external expansion vessel can be fitted
(2) Using one or more horizontally elongated flue pipes kits (see sect. 1.4)
The curve at pag.57 shows the water pressure (head) available to the central heating (c.h.) circuit as a function of flow; the load loss of the appliance has already been subtracted.
For a full report about flue pipe optional extras, please consult the flue pipe accessories !
The basic purpose of a boiler is to generate heat through the combustion of gas and to direct the heat through a water circuit.
A combination-type appliance allows the heat to be used either for heating the environment or for heating hot water for domestic use.
This is an internal water circuit in the appliance which passes through the main heat exchanger and absorbs heat directly from the combustion of gas. The water in this circuit is the same water that is circulated by the pump and flows through the c.h. system.
The direction of the water in the main water circuit can be changed by a divertor valve. The main water circuit is connected to the c.h. circuit during operation with the c.h. system (see fig. 1.2)
When d.h.w. is required, the main water circuit is directed through the d.h.w. heat exchanger via the divertor valve (see fig. 1.3).
fig. 1.3
If the flow rate in the main water circuit is insufficient, the flow switch on main water circuit disconnects the supply to the full sequence control p.c.b.
In this case the boiler is turned off in order to prevent damage.
An overheat thermostat disconnects the two ON-OFF operators on the gas valve; as a result, the burner is shut down and the shut down warning light will appear.
A safety valve is provided to relieve excess pressure from the main circuit.
The appliance is equipped with a safety system (venturi device and air pressure switch) which detects the velocity of the exhaust flues.
If the air pressure switch does not detect the correct velocity, the burner will shut down.
The function switch must be set on position III . The water in the main circuit is sent to the c.h. system when the divertor valve is in the c.h. position. In this configuration, the divertor is in the normal position and the d.h.w. heat exchanger circuit is cut out. The appliance is controlled by an electronic thermostat; water delivery temperature can be adjusted from 35° C to 85° C.
When heat is required a command starts the fan, which switches the air pressure switch.
After the air pressure switch has been switched, the combustion chamber is purged of any residual unburned gasses for a few seconds. Next, the lighting cycle begins with a spark from the ignition electrode; at the same time, electrical power is fed to the two ON-OFF operators on the gas valve.
If the flame detection electrode does not sense the flame within 10 seconds from the beginning of the cycle, the full sequence control p.c.b. interrupts the lighting cycle, the electric spark is shut off and the power is disconnected from the two ON-OFF operators on the gas valve; as a result, the burner is shut down.
At this point, the shut down warning light appears and the reset push-button must be pressed to restart the lighting cycle.
If the detection electrode senses flame within 10 seconds from the beginning of the cycle, the full sequence control p.c.b. interrupts the electrical sparks and holds the burner alight
At the same time, the temperature of the heating circuit is measured by the main circuit temperature probe and this temperature is compared with the value set on the c.h. temperature adjustment (III).
After lighting has been accomplished, the flow from the gas valve is determined by the electronic regulation p.c.b. :
-When the temperature of the circuit heating water (c.h.w.) is 5°C (or more) under the preset temperature, the appliance will supply its maximum preset power. -When the temperature of the circuit heating water (c.h.w.) is just few degrees under (<5°C) the preset temperature, the appliance will supply its minimum preset power (that corresponds to 35% of the maximum rated power).
When the function switch is set on position ¬ the c.h. adjustment system is deactivated, the divertor valve is actuated and the shutter closes water delivery to the d.h.w. heat exchanger. When d.h.w. is drawn from the d.h.w. system, the appliance operates in the same way as when the function switch set on position III .
This appliance must be installed by a
competent installer in accordance with the 1984 Gas Safety ( installation & use ) Regulations (as amended)
The installation of this appliance must be in accordance with the relevant requirements of the 1984 Gas Safety
(installation & use) Begulations, the Local Building Regulations, the current I.E.E. Wiring Regulations, the by laws of the local water undertaking and in Scotland in accordance with the Building Standards (Scotland) Regulation, Health and safety document n° 635 " Electricity at work regs 1989 "
Installation should also comply with the following British Standard Codes of Practice:
Low pressure | ||
pipes | BS 6891 | 1988 |
Boilers of rated input | ||
not exceeding 60 kW | BS 6798 | 1987 |
Forced circulation hot | ||
water system | BS 5449 | 1990 |
Installation of gas hot water | ſ | |
supplies for domestic purpo | oses | |
( 2 nd family gases) | BS 5546 | 1990 |
Flues | BS 5540-1 | 1990 |
Air supply | BS 5540-2 | 1989 |
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 Regualtions, 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
Where a room-sealed appliance is installed in a room containing a bath or shower, 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.
The location must permit adequate space for servicing and air circulation around the appliance (see fig. 3.1-a and 3.1a ).
The location must permit the provision of an adequate flue and termination.
For unusual locations special procedures may be necessarv.
BS 6798-1987 gives detailed guidance on this aspect.
A compartment used to enclose the appliance must be designed specifically for this purpose.
This appliance is not suitable for outdoor installation.
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 an 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 at all times
The terminal should be located with due regard for the damage or discoloration that might occur on buildings in the vicinity
In cold and/or humid weather water vapour may condense on leaving the flue terminal.
The effect of such " steaming " must be considered The minimum accetable spacing from the terminal to obstructions and ventilation openings are specified in fig 21
mm
The gas meter is connected to the service pipe by the local gas region contractor.
If the gas supply for the boiler serves other appliance ensure that an adequate supply is available both to the boiler and the other appliance when they are in use at the same time
Pipework must be of an adequate size. Pipes of a small size than the boiler inlet connection should not be used. Installation pipes should be fitted in accordance with BS 6891-1988 and the complete installation should be tested for soundness
The room in which the boiler is installed does not require a purpose provided air vent.
If installed in a cupboard or compartement, ventilation is required for cooling.
Recommendations for air supply are detailed in BS 5440-2:
the following notes are for general guidance:
the minimum effective area requirement is
230.4 cm2 / 34.9 in2 at high level
230.4 cm2 / 34.9 in2 at low level
The figures quotes relate to the ventilation requirement if the ventilation is into a room. If the ventilation is to the outside then the above sizes can be halved.
Detailed recommendations are given in BS 6798-1987 and BS 5449-1 1990; the following notes are given for general guidance.
Copper tubing to BS 2871-1 1977 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.
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.
The installation of a by-pass is essential if all of the radiators are to be fitted with thermostatic radiator valves. The suggested method of installation is shown in the diagram below, in figure 2.3.
This boiler is suitable only for sealed systems. A typical lay-out is illustrated in fig. 2.3.
These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870-1980.
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 accomodate the increase of water volume when the
It can accept up to 7 lts (1.5 gals) of expansion water If the heating circuit has an unusually high water content. calculate the total expansion and add additional cooled expansion vessel with adequate capacity
No direct connection to the mains water supply even through a non return valve, may be made without the approval of the Local Water Authority
A method for initially filling the system and replacing water lost during servicing must be provided and it must comply with local water authority regulations. A possible method is shown in fig. 2.4
The installer should ensure that no leaks exist as frequent filling of the sytem could cause premature scaling of the heat exchanger.
The domestic water must be in accordance with the relevant recommendations of BS 5546. Copper tubing to BS 2871-1 is recommended for water carrying pipework and must be used for pipework carrying drinking water
External wiring to the appliance must be carried out by a gualified technician and be in accordance with the current LE F. Regulations and applicable local regulations
More over this appliance is supplied for connection to a 230 V~ 50 Hz supply.
The supply must be fused at 3 A.
The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance by the use of a fused double pole isolator having a contact separation of the 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 bathroom when this must be sited outside the bathroom
fig. 2.4
There will be 3 items:
To allow easy access to the interior of the boiler for maintenance work ensure that at least the minimum dimensions shown in the drawing are used
To allow easy access to the interior of the boiler for maintenance work, keep to the minimum dimensions shown in the drawing
fig 31
TOP VIEW
(see fig. 3.2).
All of the boiler packaging ( carton and polystyrene )is fully recyclable.
All packaging must be properly and thoroughly disposed of, as some components (i.e. : polythene, staples etc.) could prove to be dangerous to young children.
(see fig. 3.3).
During the drilling of hole for the flue air intake, ensure that its diameter is bigger than the pipe that will
be fitted.
This is to ensure that the pipe can be removed if required.
The sealant between the pipe and the wall is assured by internal and external flance (see figure below ).
Flue kit contains the following (see fig. 3.4):
If your particular installation requires you to shorten the flue, see the following instructions for cutting measures.
N.B. : When shortening the flue pipe, cut the external 100 diam. pipe and the internal 60 diam. pipe, keeping the
If you need to extend the flue or change its direction, optional kits are available.
All measures are in millimetres unless otherwise specified.
Both pipes must be cut on the side facing the elbow.
1 - Minimun flue length 'S' 500 mm (see fig. 3.5) 2 - Maximum flue length 'S' 3000 mm
Where flue lengths between 500 mm and 1000 mm are required, diaphragm '11' must be installed (see fig.3.4). For flue lengths up to 1000 mm only the standard flue kit is required.
For flue lengths above 1000 mm and up to 3000 mm additional extension kits will be required.
For flue lengths above 1000 mm the diaphragm '11' must not be installed.
For a full list of flue pipe optional extras, please consult the flue pipe accessories !
1- Fit the 100 diam. gasket into the housing at the top
6- Use the clamp to fix the elbow and external 100 diam.
pipe together.
Where the lowest part of the terminal is less than 2 m (6.5 ft) above the level of any ground, balcony, flat roof or place to which any person has access then a suitable terminal guard must be fitted. A suitable guard is available from:
TOWER FLUE COMPONENTS Morley Road Tonbridge Kent TN19 1RA
When ordering the guard, quote appliance model number. The guard should be fitted centrally over the terminal.
WARNING - THIS APPLIANCE MUST BE EARTHED
The appliance is delivered with a flexible cable for electrical supply. The cable allows the electrical connection as detailed in sect. 2.8.
Electrical connection of a room thermostat (see fig.3.12) 1- Fit the cables of the room thermostat into the silicone cable holders on the manifold of the frame (1) and on the back fold of the instrument panel (2):
2- "Remove the top lid of the junction block "A" (see fig. 3.13). Remove the terminal strip of the room thermostat/time clock "B" - this will help you fit the cables more easily".
When a room thermostat is used it must be of a type which can only be opened by using a tool.
Preliminary electrical system checks to ensure electrical safety must be carried out by a qualifed electrician.
I.e. polarity, earth continuity, resistance to earth and short circuit. If a fault has occurred on the appliance the fault finding procedure should be followed as specified under the servicing section of this document.
1 Open central heating flow and return cocks as indicated in fig. 4.3;
turn and leave open permanently;
pump plug as indicated in fig. 4.4;
When the installation and filling are completed turn on the central heating system (sect. 4.5) and run it until the temperature has reached the boiler operating temperature. The system must then be immediately flushed through.
The flushing procedure must be in line with BS7593:1992 treatment of Water in Domestic Hot Water Central Heating Systems.
During this operation, we highly recommend the use of a central heating flushing detergent, whose function is to dissolve any foreign matter which may be in the system i.e. Fernox Superfloc or equivalent.
We also recommend the use of an inhibitor in the system such as Fernox MB1 Universal or equivalent.
The actual reading should ideally be 1.5 bar (see fig. 4.5).
Set the time clock to manual (1) - if fitted.
If external controls are fitted e.g. Timeclock, room thermostat ensure that they " call for heat ".
With the burner on high flame, close the gas cock turning the screw in a clockwise direction (see fig. 4.7):
After several seconds, the shut-down warning light wil appear.
To reset the boiler, depress the reset push button "C' marked with the symbol b (see fig. 4.6).
4.3 TESTING THE D.H.W. SYSTEM FLOW
1 Turn the function switch as indicated and check the switching flow rate that should be at minimun 2.5 lts/min (0.66 gals/min);(see fig. 4.8)
To ensure efficient safe operation of the appliance it is nocessant to carry out routine maintenance at regular intonyala
The frequency of servicing will depend upon the particular. installation conditions and the use of the boiler, but in general, once a vear should be adequate.
The following notes apply to the appliance but it should be remembered that attention must be also paid to the central heating and domestic hot water circuits with special attention to radiator valves: thermostats clocks leaking hot water tans etc.
Before starting any servicing work switch-off the electrical supply or disconnect the plug at the main isolating switch and socket ( if a switch is used remove the fuse
After any service on electrical components carry out a preliminary electrical checks: in particular: earth continuity: polarity: earthing resistance
The following procedures should be carried out at least once a vear.
tight. To check the exhaust gas, remove the screw indicated in fig. 5.1 and connect the analyser to the flue gas sampling point.
Cloan or replace if necessary
9 Inspect the main heat exchanger for any deposits of soot If cleaning is necessary place a cloth over the burner to catch debris and clean the main heat exchanger using a soft brush
Do not use brushes with metallic bristles:
The life of individual components varies and they will need servicing as and when faults develop.
The fault finding sequence chart in chapter 7 will serve 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. These operations also require the removal of the casing.
The casing is fixed to the boiler frame by screws (see fig.6.1):
oving the sealed chamber cover
To remove the cover, remove screw A (see fig.6.2). Pull cover forward. When replacing cover ensure that the sillcone seal is in good condition. If not replace the seal.
Setting the minimum and the maximum power of the boiler (see fig.6.7)
gas.
3) To check the pressure supplied by the gas valve, remove the screw "A". Fit the pipe of the pressure gauge to the pressure outlet of the gas valve. Disconnect the compensation pipe either from the gas valve or from the sealed chamber (see fig.6.7 a-
b)
4) Set the ON/OFF switch to position <I> and the "sum mer/winter" switch to winter position III - ... To set the maximum power, turn on the hot water tap and allow hot water tap to run at a rate of about 8 litres/minute so that the main burner turns on. Adjust screw "D" on the solenoid to set the pressure valve ( displayed on the pressure gauge ) correspon ding to the maximum power ( see table sect.1.2 ).
5) To set the minimum power, disconnect a supply terminal and adjust screw "C".
Turn the screw clockwise to increase the pressure and counter-clockwise to decrease the pressure ( displayed on the pressure gauge ) corresponding to the minimum power ( see table sect.1.2 ).
6) When you have completed the above operations, turn off the hot water tap, re-connect the supply terminal to the sole- noid on the gas valve and replace the cap on the screws of the solenoid.
Setting the maximum heating circuit power (see fig. 6.8) 1) To set the maximum heating circuit power, place the ON/OFF switch to position <I> and the "summer/winter" switch to winter position III . Turn the knob of the heating thermostat clockwise to maximum:
Turn on the boiler by placing the main switch to position "I" and sparks will come on.
Check the gas pressure on the pressure gauge which must be about 50 mm H2O.
NATURAL GAS (G20) | BUTANE GAS (G30) | PROPANE GAS (G31) | |
---|---|---|---|
Recommended pressure for
slow ignition |
5 mbar - 1.95 in w.g. | 18 mbar - 7.0 in w.g. | 19 mbar - 7.4 in w.g. |
If it is necessary adjust the slow ignition. Fit a cross-head screw driver into the hole marked "REGULATION OF SLOW BURNER IGNITION" on the electronic P.C.B., throught the potentiometer.
Whenever you disassemble and reassemble the gas connections, always check for leaks using a soap and water solution.
1 Ensure electricity is switched off at main isolator:
2 Remove cap "A" (see fig. 6.10);
3 Remove the securing nut "B" (see fig. 6.11);
4 Lower control panel (sect. 6.2) and remove electrical connectors "C" (see fig. 6.12);
3 Remove screws "A" using a POZI-DRIVE No.2 start screw-driver( see fig. 6.14 );
4 Slide the plate "B" and disconnect the cables pulling them downwards (see fig. 6.15);
5 Remove screws "C" using a PHILLIPS No.2 star tip screwdriver ( see fig. 6.16 ):
6 Slide the electrodes gently downwards (see fig. 6.17); To mount, repeat the steps in reverse order, paying particular attention to the following:
a Centre the second support hole which you will find between the connections, otherwise the electrode may break (see fig. 6.18);
b Check that the cables have in fact been connected, since friction and interference are often misleading;
c Check that the transparent silicone pipe covers the cable-electrode connection point adequately (see fig. 6.20);
(Detection electrode)
When you reassemble the part, follow the steps in reverse order ensuring that you centre the second support hole between the connection, otherwise the electrode may break.
3 Disconnect the electric wires (see fig. 6.23);
7 You will need a 14 mm open ended to rotate the
coupling which is part of the thermostat (see fig. 6.25). Do not loose the thermostat gasket!!
To re-install follow the steps in reverse order.
screw-driver ( see fig. 6.27 );
5 Remove the clamps which joins the capillary of the ther
mostat to the other cables;
6 Remove the proper spring and then the bulb*
( see fig. 6.28 );
Follow the steps in reverse order to reassemble, but be especially careful with the electrical connections because it is very easy to make a mistake
3 Remove nut "A" by a "14 mm" open ended spanner ( see fig. 6.29 ):
3 Remove retention clip A (see fig. 6.31);
4 Remove the 4 screws "A" using a PHILLIPS No.2 star tip screw-driver ( see fig. 6.33 );
5 Remove the CONNECTION unit (see fig. 6.34);
6 Remove the nozzles using a No.7 socket spanner. Keep the washers ( see fig. 6.35 ):
Reassemble in reverse order.
NOTE: When you are replacing the nozzles to convert the appliance for use with a different type of gas, remember to replace the existing data plate ( under the instrument panel ) by the plate supplied in the modification kit ( see fig. 6.36 ).
To replace the front insulation panel (see fig. 6.37)
1 To remove the combustion chamber cover (sect. 6.2 hold the panel firmly and pull downwards. No other tool is required.
3 Turn the protection cap "A" and remove it from the adjustment control. Use a flat-edge screw driver to
4 With a 14 mm spanner turn the cartridge "B" counter-clockwise (see fig. 6.40);
sect.6.16;
Ensure that the silicone seal is in good order. If necessary replace the seal.
5 Remove screws which fix the air pressure switch to its support plate by a n°2 star tip screw driver (see fig.6.51)
REASSEMBLE IN REVERSE ORDER
Every type of A.P. switch has its own screws. Different screws could compromise their normal operating.
4 To remove the front panel of the flue hood, unscrew the 3 screws "A" using a POZI-DRIVE No.2 star tip screwdriver ( see fig. 6.52 );
5 Remove the front panel of the hood "B" (see fig. 6.53);
6 Release nuts "C" (see fig. 6.54);
7 Lift the exchanger in order to release the attachments from their housing (see fig. 6.55);
Reassemble in reverse order.
3 Release nuts "B" using a 36 mm open ended (see fig.6.58);
4 Disconnect electrical connections (see fig. 6.59, 6.60, 6.61).
3 Remove pump pressure switch using a 17mm open ended ( see fig.6.63 );
fig. 6.66 );
downwards ( see fig. 6.67 );
8 Reassemble in reverse order.
If there is not adequate clearence the boiler must be removed from the wall before the removal procedure can be carried out.
The TOTAL CHECK SYSTEM ( which will be referred to as "TCS" ) is designed to locate faults quickly and easily. The TCS tests GOVE2-CAME and CAME/ES type electronic PCBs ( see fig.7.1 ).
This device makes it possible to check the proper functioning of the electronic PCBs and components these control, it is connected to the PCB via the cable which you will see is folded back inside the TCS.
The TCS indicates:
- The actual state of the boiler;
- The eventual fault.
The informations given by the TCS are as follows ( see fig.7.2 ):
- the actual state of the boiler according to the following
numbers:
Note: During the operation of the TCS, faults may be signaled by the red LED and a letter in the display for short periods ( one second or less ), this is normal and does not signify these faults.
There are special defects that can not been indicated by the TCS; these defects are treated in the following sections:
Make sure that the surfaces which come into contact with the gaskets are free from dirt, roughness or deformation. Then substitute the gasket (both O-rings and flat gaskets).
This may be caused by leaks from the d.h.w. over-pressurizing the heating circuit.
In this case remove the d.h.w. heat exchanger and replace it.
If the leak only occurs when the appliance is operating, empty the main water circuit and check the pressure applied to expansion vessel (1.2 bar).
Make sure that input and output pressures on the gas valve are set to the correct values.
Also, make sure that no pressure variations are being caused by a malfunctioning component (defective pressure reducers or regulator; dirty gas filters; other gas consuming equipment installed on the same gas line, etc.).
Make sure that the ignition electrodes are positioned correctly. Make sure that injectors are clean.
Make sure that the gas modulator has been set correctly and make sure that the following elements are clean:
Make sure that the exhaust flue does not return to the appliance through the air intake duct.
Make sure that the flue terminal on the exhaust system has been installed in the correct position (see sect 3.4). If extension flue have been used in the exhaust duct, make sure that these flue have been inserted correctly.
Please ensure that flue length does not exceed the maximum allowed ( consult special manual ).
Type c boiler installation instructions for air and flue exhaust pipes.
If gas is detected in the installation area, use a soap solution or a specific leak-detection product to make sure that all the gas connectors in the system are perfectly sealed.
Check for leaks when the appliance is shut down and during operation.
If exhaust fumes are detected in the installation area, make sure that the exhaust duct has been built to the exact
specifications prescribed. Also, check the exhaust duct for leaks and make sure that it is clean. Make sure that all exhaust duct-work conforms to current technical standards.
1 Remove the boiler casing and lower the control panel as described in paragraph 6.2;
2 To remove the electronic PCB from its clamp, lift and then rotate it then remove the cover of pcb (fig.7.3);
3 Remove the cover at the back in order to release the cable of the TCS.
You will see that there are two connectors: a black one
and a grey one (see fig.7.4).
Connect the grey connector to the electronic PCB (see fig.7.5).
With the boiler switch set to ON, once you have made above connections, all the LEDs will light up and number 8 will flash on the display for one second; it means that the TCS is ready for use.
The TCS gives information as to whether the boile faulty or is running properly.
According to the signals of the TCS, some verificati must be made and then the faults can be removed.
Follows the fault flow chart and the relative verificati according to the TCS state.
If the TCS is not available or is damaged, please foll the sequence as described at par. 7.5.
(letter "A" appears at the end of the autodiagnosis if ventilation is faulty.)
Supply voltage ( 230 VAC -10% ÷ +15% ) should be indicated by terminals of the fan Set the tester to VAC
Verify that C and NC connectors of the air pressure switch are closed, measuring the resistance between them that must be zero. Set the tester to Ohm.
Verify that the connector B is properly fitted to the PCB terminal and that the cables are not damaged
Verify that the No.2 siliconic transparent static pressure tubes are free of dust or condensation and that also the "venturi" is not blocked
Do as follows:
the reset switch
- 38 -
Verify that C and NO connectors of the air pressure switch are closed, measuring the resistence between them that must be zero.
Set the tester to Ohm.
Verify the flue pipes and the terminal as follows:
The check can be done visually.
Verify that the resistence between the two pin is infinity. Set the tester to Ohm.
(letter "E" appears during the autodiagnostic if there is a supervised flame before opening the gas valve )
Verify the distance of the terminal of the detection electrode to the burner; it can be from 5 to 7 mm (see Fig. Ref.11-a). Set the tester to DC (µA).
The tester should be connected in series with the detection circuit ( see Fig. Ref.11-b ).
The value of detection current without flame must be lower than 0.5 µA.
- 42 -
Verify that the distance between the terminal of the ignition electrodes and the burner is about 5 mm
Install a manometer in the outlet pressure intake of the gas valve.
Remove the detection electrode and activate an ignition cycle.
As ignition is attempted measure the gas pressure. Verify that this value is according to the installation booklet.
Supply voltage should be indicated when power is supplied to the operators.
Take measurements with the device reset from shutdown.
Set the tester to VAC.
Disconnect the terminals of the overheat thermostat and measure the resistance that must be zero. If not the thermostat is open. Set tester to Ohm
Verify visually that sparks are on the burner and distance is according to ref.12.
To check the coil in the on-off operators, disconnect the winding from its circuit and measure the resistance; it must be not infinity.
Note : This state is a fault only if it remains indefinitely, even when central heating is called.
Disconnect the terminals of the thermostat and make measurements of the resistance; it must be zero when the temperature of the bulb is lower than the preset valve. Set tester to Ohm.
Disconnect the terminals of the thermostat and make measurements of the resistance that must be zero. Set tester to Ohm.
Ref.20 Try to reset the overheat thermostat.
Disconnect the terminals of the flow switch and take measurements of the resistance that must be zero.
Measure first that supply voltage is supplied to the pump. Set the tester to VAC
Then measure the resistance of the windings of the pump it must be not lower than 190 Ω.
Set tester to Ohm.
Note: This state is faulty only if it remains indefinitely even when central heating or hot water are expected
Measure the voltage between the pink and the red cable on the terminal of the switch. The value must be zero. Set tester to VAC.
Measure the resistance between the terminals of the clock and /or the room thermostat. The value must be zero. Set the tester to Ohm.
The utilization of TCS is the more efficient way to single out a defect, because its message let only a restricted area to be checked.
But in the case of TCS not availability, it is possible to detect and remove the eventual defect utilizing the standard fault finding diagrams described in this chapter.
The checking modes referred to are the same as with utilization of TCS.
INITIAL CONDITIONS:
- The main switch is on position "ON" (neon light):
INITIAL CONDITIONS:
- 49 -
INITIAL CONDITIONS:
INITIAL CONDITIONS:
CASE A : The appliance operates in the central heating mode only and not in hot water mode.
CASE B : The appliance operates in the hot water mode only and not in central heating mode.
COLOUR BI =Blue Red =Red Brw =Brown Blk =Black Gry =Grev =Violet Wht =White Pnk =Pink Orng =Orange Yll/Grn =Yellow/Green Wht/Blk =White/Black Wht/Red
Key
no. |
G.C. part
no. |
Description | No. |
ARISTON
Part No. |
---|---|---|---|---|
1 | 379250 | Expansion vessel | 1 1 | 564492 |
11 | 164225 | 3/4" gasket | 8 | 573520 |
15 | 164229 | 1/2" gasket | 6 | 573528 |
16 | 379079 | Automatic air release valve | 1 | 564254 |
17 | 164230 | 1" gasket | 2 | 569387 |
18 | 379975 | Pump | 1 | 570590 |
22 | 379080 | Pump pressure switch | 1 | 570605 |
25 | 164307 | P.C.B. | 1 | 921080 |
26 | 379817 | Overheat thermostat | 1 | 573805 |
30 | 379818 | Temperature - pressure gauge | 1 | 573586 |
32 | 379824 | Wired reset button | 1 | 560171 |
42 | 379825 | Fan | 1 | 569431 |
44 | 164242 | Collar for venturi device | 1 | 569434 |
45 | 164243 | Venturi device | 1 | 569435 |
47 | Air pressure switch | 1 | 571651 | |
56 | 164253 | Back combustion chamber insulation panel | 1 | 573723 |
57 | 164254 | Front combustion chamber insulation panel | 1 | 573721 |
62 | 164259 | Side combustion chamber insulation panel | 1 | 573720 |
64 | 164261 | 1/4" gasket | 9 | 569390 |
66 | 379979 | Right ignition eletrode | 1 | 569560 |
67 | 379980 | Left ignition eletrode | 1 | 569561 |
68a | Burner jet 1,25ø | 13* | 570248 | |
68b | Burner jet 0,72ø | 13* | 570251 | |
69 | 379981 | Detection electrode | 1 | 573441 |
72 | 379976 | Gas valve SIT TANDEM | 1 | 570732 |
80 | 379829 | Main circuit flow switch | 1 | 570742 |
81 | D.h.w. exchanger | 1 | 571785 | |
82 | 379821 | Divertor valve (without microswitches) | 1 | 560166 |
84 | Flow switch micro square | 1 | 569172 | |
91 | 164277 | Main heat exchanger | 1 | 569487 |
93a | 379820 | Main burner natural gas | 1 | 570588 |
93b | Main burner LPG | 1 | 570823 | |
99 | 164282 | 3/8" gasket | 2 | 573521 |
103 | 164286 | Cable clamper | 2 | 570561 |
201 | 164302 | Fast fuse 2AT | 2 | 950030 |
202 | 164303 | Gas modulator cartridge | 1 | 573745 |
203 | 379978 | Safety valve | 1 | 569292 |
- | - | |||
REGULATING HEATING POWER FOR NATURAL GAS (G20)
REGULATING HEATING POWER FOR BUTANE GAS (G30)