Ariston CLAS HE 24, CLAS HE 30, CLAS HE 38 Installation and Servicing Instructions

Installation and Servicing Instructions

CLAS HE

Gas ired condensing wall hung combination boilers

G.C.N : 47-116-51 (24 kW)

G.C.N : 47-116-52 (30 kW)

G.C.N : 47-116-53 (38 kW)

CLAS HE 24

CLAS HE 30

CLAS HE 38

Country of destination GB, IE

The code of practice for the installation, commissioning & servicing of central heating systems

overview

INDEX
Overview
General Information.................................................................................................	3
Advice for the Installer.............................................................................................	4
CE Labelling.................................................................................................................	4
Data Plate Symbols...................................................................................................	4
Safety Regulations ....................................................................................................	5
Product description
Control Panel...............................................................................................................	6
Display...........................................................................................................................	6
Overall View.................................................................................................................	7
Overall Dimension ....................................................................................................	7
Minimum Clearances ...............................................................................................	7
Technical Information..............................................................................................	8
Installation
Reference Standards ................................................................................................	9
Installing the Boiler................................................................................................	1
Gas Connection.......................................................................................................	13
Water Connection ..................................................................................................	13
Instructions for Opening the Casing and Performing an
Internal Inspection.................................................................................................	13
Connecting the Flue..............................................................................................	15
Fitting the Coaxial Flue (Ø 60/100 Horizontal).............................................	16
Fitting the 5” Flue (Ø 80/1 5 Horizontal / Vertical).....................................	17
Fitting the Coaxial Flue (Ø 60/100 Vertical)...................................................	18
Fitting the Twin Pipe (Ø 80/80)..........................................................................	19
Electrical Connections..........................................................................................	3
Peripheral Unit Connection................................................................................	3
Room Thermostat Connection ..........................................................................	4
Outdoor Sensor Connection ..............................................................................	4
Electrical Diagram ..................................................................................................	5
Commissioning
Initial Preparation...................................................................................................	6
Electricity Supply....................................................................................................	6
Filling the Heating System ..................................................................................	6
Filling of the DHW System...................................................................................	6
Gas Supply ................................................................................................................	6
Water Treatment .....................................................................................................	6
First Igniton Operation.........................................................................................	7
Ignition procedure.................................................................................................	8
Test Function and Combustion Analysis........................................................	30
AUTO Function ........................................................................................................	31
Boiler Protection Devices
Boiler Protection Devices ....................................................................................	3
Anti-Frost Device ....................................................................................................	3
Table summarising error codes.........................................................................	3
Settings - Adjustment - Problem Identiication Menus
Accessing the Menus ............................................................................................	33
Maintenance
General Comments................................................................................................	41
General Access ........................................................................................................	4
Electrical Unit...........................................................................................................	43
Hydraulic Unit..........................................................................................................	45
Main Heat Exchanger............................................................................................	53
Burner Unit ...............................................................................................................	54
Fan Unit......................................................................................................................	57
Gas Valve....................................................................................................................	58
Annual Maintenance.............................................................................................	59
Spare Parts Short List ............................................................................................	60
Benchmark Commissioning Checklist ............................................................	61
Benchmark Service Interval Record.................................................................	6

overview

These instructions are suitable for CLAS HE boilers : Do not forget the Log Book!

MTS supports Benchmark, the heating industry code to ensure the correct installation, commissioning and servicing of domestic central heating systems.

To The Householder

Make sure you have a completed Log Book for your boiler. This provides a record of the commissioning of your boiler.

It contains important information about your particular installation that may be required by service engineers. The Log Book will also provide contact details for the installer should you need guidance in the use of this appliance or if there are any problems.

As with your car, your boiler will work more reliably and eiciently if regularly serviced. We recommend an annual service check. The service history of the appliance will be recorded on the Log Book.

In the unlikely event of any problems with your boiler or system you should irst contact your installer. If your installer cannot resolve the problem he should telephone our national service helpline.

A charge may be made if MTS Service is called out to resolve a non-product related fault. Your statutory rights are not afected.

To The Installer

As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the Householder. Please ensure that your customer is aware of the importance of keeping the Log Book safe as a record of the installation and the appliance service history.

Please ensure that your customer is aware of the correct operation of the system, boiler and controls.

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

CUSTOMER CARE

MTS, as a leading manufacturer of domestic and commercial water heating appliances is committed to providing high quality products and a high quality after sales service.

Advice on installation or servicing can also be obtained by contacting the MTS Technical and Customer Service Departments at High Wycombe.

TECHNICAL DEPARTMENT		CUSTOMER SERVICE DEPARTMENT
Tel:	0870 41 8180	Tel:	0870 600 9888
Fax:	01494 459775	Fax:	01494 459775

GUARANTEE

The manufacturer’s guarantee is for years from the date of purchase. The guarantee is invalidated if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us in providing you with an eicient after sales service, please return the guarantee registration card enclosed with the boiler without delay.

CAUTION

In the United Kingdom, installation, start-up, adjustments and maintenance, must be performed by a competent person only, in accordance with the current Gas Safety (Installation & Use) Regulations and the instructions provided.

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

All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI direct on:- [phone].

Improper installation may cause damage or injury to individuals, animals and personal property for which the manufacturer will not be held liable. To ensure eicient and safe operation it is recommended that the boiler is serviced annually by a competent person.

If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.

This instruction booklet is especially designed for appliances installed in the UK and the Republic of Ireland

3

overview

Advice for the installer

The installation and irst ignition of the boiler must be performed by qualiied personnel in compliance with current national regulations regarding installation, and in conformity with any requirements established by local authorities and public health organisations.

After the boiler has been installed, the installer must ensure that the end user receives the declaration of conformity and the operating manual, and should provide all necessary information as to how the boiler and the safety devices should be handled.

This appliance is designed to produce hot water for domestic use.

It should be connected to a heating system and a distribution network for domestic hot water, both of which must be compatible with its performance and power levels.

The use of the appliance for purposes other than those speciied is strictly forbidden.The manufacturer cannot be held responsible for any damage caused by improper, incorrect and unreasonable use of the appliance or by the failure to comply with the instructions given in this manual.

Installation, maintenance and all other interventions must be carried out in full conformity with the governing legal regulations and the instructions provided by the manufacturer. Incorrect installation can harm persons, animals and possessions; the manufacturing company shall not be held responsible for any damage caused as a result. The boiler is delivered in a carton. Once you have removed all the packaging, make sure the appliance is intact and that no parts are missing. If this is not the case, please contact your supplier.

Keep all packaging material (clips, plastic bags, polystyrene foam, etc.) out of reach of children as it may present a potential hazard.

In the event of a fault and/or malfunction, turn the appliance of, turn of the gas cock and do not attempt to repair it yourself. Contact a qualiied professional instead.

Before any maintenance or repair work is performed on the boiler, make sure you have disconnected it from the electricity supply by switching the external bipolar switch to the “OFF” position and removing the fuse.

All repairs, which should only be performed using original spare parts, should be carried out by a qualiied professional. Failure to comply with the above instructions could compromise the safety of the appliance and invalidate all liability on the part of the manufacturer.

In the event of any maintenance or other structural work in the immediate vicinity of the ducts or lue gas exhaust devices and their accessories, switch the appliance of by switching the external bipolar switch to the “OFF” position and shutting of the gas control valve. When the work has been completed, ask a qualiied technician to check the eiciency of the ducting and the devices.

Turn the boiler of and turn the external switch “OFF” to clean the exterior parts of the appliance.

Clean using a cloth dampened with soapy water. Do not use aggressive detergents, insecticides or toxic products. If the appliance is used in full compliance with current legislation, it will operate in a safe, environmentally-friendly and cost-eicient manner.

If using kits or optional extras, make sure they are authentic.

CE labelling

The CE mark guarantees that the appliance conforms to the following directives:

-90/396/CEE

relating to gas appliances

-89/336/CEE

relating to electromagnetic compatibility

-92/42/CEE

relating to energy eiciency

-73/23/CEE

relating to electrical safety

Symbols used on the data plate

MIN MAX

Key:

1.Brand

. Manufacturer

3.Boiler model - code

4.Serial number - certiication number

5.Destination country - gas category

6.Gas setting

7.Boiler type

8.Electrical data

9.Maximum domestic hot water pressure

10.Maximum heating pressure

11.NOx class

1 . Eiciency

13.Max - min heat input

14.Max - min heat output

15.Max/min operating room temperature

16.Max. central heating temperature

17.Gases which may be used

4

overview

Safety regulations

Key to symbols:

Failure to comply with this warning implies the risk of personal injury, in some circumstances even fatal

Failure to comply with this warning implies the risk of damage, in some circumstances even serious, to property, plants or animals.

Install the appliance on a solid wall which is not subject to vibration.

Noisiness during operation.

When drilling holes in the wall for installation purposes, take care not to damage any electrical wiring or existing piping.

Electrocution caused by contact with live wires. Explosions, ires or intoxication caused by gas leaking from damaged piping. Damage to existing installations. Flooding caused by water leaking from damaged piping.

Perform all electrical connections using wires which have a suitable section.

Fire caused by overheating due to electrical current passing through undersized cables.

Protect all connection pipes and wires in order to prevent them from being damaged.

Electrocution caused by contact with live wires. Explosions, ires or intoxication caused by gas leaking from damaged piping. Flooding caused by water leaking from damaged piping.

Make sure the installation site and any systems to which the appliance must be connected comply with the applicable norms in force.

Electrocution caused by contact with live wires which have been installed incorrectly. Damage to the appliance

caused by improper operating conditions.

Use suitable manual tools and equipment (make sure in particular that the tool is not worn out and that its handle is ixed properly); use them correctly and make sure they do not fall from a height. Replace them once you have inished using them.

Personal injury from the falling splinters or fragments, inhalation of dust, shocks, cuts, pricks and abrasions.

Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions.

Use electrical equipment suitable for its intended use (in particular, make sure that the power supply cable and plug are intact and that the parts featuring rotary or reciprocating motions are fastened correctly); use this equipment correctly; do not obstruct passageways with the power supply cable, make sure no equipment could fall from a height. Disconnect it and replace it safely after use.

Personal injury caused by falling splinters or fragments, inhalation of dust, knocks, cuts, puncture wounds, abrasions, noise and vibration. Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions.

Make sure any portable ladders are positioned securely, that they are suitably strong and that the steps are intact and not slippery and do not wobble when someone climbs them. Ensure someone provides supervision at all times.

Personal injury caused by falling from a height or cuts (stepladders shutting accidentally).

Make sure any rolling ladders are positioned securely, that they are suitably strong, that the steps are intact

and not slippery and that the ladders are itted with handrails on either side of the ladder and parapets on the landing.

Personal injury caused by falling from a height.

During all work carried out at a certain height (generally with a diference in height of more than two metres), make sure that parapets are used to surround the work area or that individual harnesses are used to prevent falls. The space where any accidental fall may occur should be free from dangerous obstacles, and any impact upon falling should be cushioned by semi-rigid or deformable surfaces.

Personal injury caused by falling from a height.

Make sure the workplace has suitable hygiene and sanitary conditions in terms of lighting, ventilation and solidity of the structures.

Personal injury caused by knocks, stumbling etc.

Protect the appliance and all areas in the vicinity of the work place using suitable material.

Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions.

Handle the appliance with suitable protection and with care.

Damage to the appliance or surrounding objects from shocks, knocks, incisions and squashing.

During all work procedures, wear individual protective clothing and equipment.

Personal injury caused by electrocution, falling splinters or fragments, inhalation of dust, shocks, cuts, puncture

wounds, abrasions, noise and vibration.

Place all debris and equipment in such a way as to make movement easy and safe, avoiding the formation of any piles which could yield or collapse.

Damage to the appliance or surrounding objects from shocks, knocks, incisions and squashing.

All operations inside the appliance must be performed with the necessary caution in order to avoid abrupt contact with sharp parts.

Personal injury caused by cuts, puncture wounds and abrasions.

Reset all the safety and control functions afected by any work performed on the appliance and make sure they operate correctly before restarting the appliance.

Explosions, ires or intoxication caused by gas leaks or an incorrect lue gas exhaust. Damage or shutdown of the appliance caused by out-of-control operation.

Before handling, empty all components that may contain hot water, carrying out any bleeding if necessary.

Personal injury caused by burns.

Descale the components, in accordance with the instructions provided on the safety data sheet of the product used, airing the room, wearing protective clothing, avoid mixing diferent products, and protect the appliance and surrounding objects.

Personal injury caused by acidic substances coming into contact with skin or eyes; inhaling or swallowing harmful chemical agents. Damage to the appliance or surrounding objects due to corrosion caused by acidic substances.

If you detect a smell of burning or smoke, keep clear of the appliance, disconnect it from the electricity supply, open all windows and contact the technician.

Personal injury caused by burns, smoke inhalation, intoxication.

5

product description

Control panel

1

2

3

4

5

6

7

8

Legend :

1. Display

. RESET button

3.Red indicator locking light

4.Orange indicator COMFORT fonction

5.Pressure gauge

6.Heating temperature regulation knob

7.button _

8.MENU/OK button (Programming key)

9.ESC button

10.button +

						17
						16
						15
						14
	2	1	24			13
				23
	3
	4	12		22
	5
				21
6				I	20	12
8	9				18
7					19
	9	6		17
	10			16
	11			15
	12	13	14
						11

10

9

11. Domestic Hot Water adjustment knob

1 . Time clock

13.ON/OFF button

14.Blue indicator burner ON

15.Yellow indicator AUTO fonction

16.AUTO button (To active Thermoregulation)

17.COMFORT button

6

product description

Overall view

1
	25
2		1.	lue connector
	24	. air pressure switch
		3.	burner
3		4.	detection Electrode
		5.	overheat thermostat
		6.	C.H. Return temperature probe
	23	7.	C.H. Flow temperature probe
4	22	8.	gas valve
		9.	secondary heat exchanger
		10.	D.H.W. temperature probe
	21	11.	siphon
		1 . C.H. pressure relief valve
5		13.	electrical box
6
7	20	15.	C.H. circuit ilter
		16.	D.H.W. Flow switch
8		17.	circulation Pump with air release valve
	19	18.	diverter valve
	18
		19.	switch On-Of
9		0.	silencer
10	17	1.	modulating Fan
11		. ignition electrodes
	16	3.	ignitor
12
	15	4.	thermal fuse
		5.	combustion Analysis Test Point
13

Overall Dimensions

		200				200			24/30/38
		120			120							180

770

				28	150
65	67	67	65

A. Central Heating Flow

B. Domestic Hot Water Outlet

C. Gas Inlet

D. Domestic Cold Water Inlet

E. Central Heating Return

25

770

Minimum clearances

In order to allow easy access to the boiler for maintenance operations, The boiler must be installed in accordance with the clearances stated below.

300	50	50
450
		300

7

product description

Technical Data

GENERAL NOTE

POWER SPECIFICATIONS

EMISSIONS

DOMESTIC HOT WATER ELECTRICAL HEATING CIRCUIT CIRCUIT

Model			24 kW	30 kW	38 kW
CE Certiication (pin)				0085BR0347
Boiler type			B 3-C13-C33-C43-C53-C83
Max/min nominal caloriic low rate (Pci)	Qn	KW	,0/5,5
				8,0/6,5	31,0/7,5
Max/min nominal caloriic low rate (Pcs)	Qn	KW	4,4/6,1	31,1/7,	34,4/8,3
Domestic hot water max/min nominal caloriic low rate (Pci)	Qn	KW	5,0/5,5	30,0/6,5	38,0/7,5
Domestic hot water max/min nominal caloriic low rate (Pcs)	Qn	KW	7,8/6,1	33,3/7,	4 , /8,3
Max/min power output (80°C-60°C)	Pn	KW	1,6/5,	7,4/6,	30,3/7,3
Max/min power output (50°C-30°C)	Pn	KW	3,5/6,0	30,0/6,9	33,1/8,0
Domestic hot water max/min power output	Pn	KW	5,0/5,0	30,0/6,0	38,9/7,1
Combustion eiciency (of lue gas)		%	97,9	97,9	98,0
Nominal caloriic low rate eiciency (60/80°C) Hi/Hs		%	98,0/88,	98,0/88,	97,6/87,9
Nominal caloriic low rate eiciency (30/50°C) (condensation) Hi/Hs		%	107,0/96,4	107,0/96,4	106,7/96,1
Eiciency at 30% at 30°C (condensation) Hi/Hs		%	108,0/97,3	108,0/97,3	109,1/98,
Eiciency at 30% at 47°C Hi/Hs		%	101,0/90,9	98, /88,4	103,1/9 ,8
Minimum caloriic low rate eiciency (60/80°C) Hi/Hs		%	95,0/85,5	95,6/86,1	96,8/87,
Eiciency rating (dir. 9 /4 /EEC)		stars	****	****	****
Sedbuk class		class	A / 90,3	A / 90,3	A / 90,1
Loss when stopped (∆T = 50°C)		%	0,	0,1	0,1
Loss of burner gas when operating		%	,1	,1	,0
Available air pressure		Pa	137	141	13
NoX class		class	5	5	5
Flue gas temperature (G 0) (80°C-60°C)		°C	63	63	63
CO content (G 0) (80°C-60°C)		%	9,0	9,0	9,6
CO content (0%O ) (80°C-60°C)		ppm	< 100	< 100	< 1 5
O content (G 0) (80°C-60°C)		%	4,5	4,5	3,5
Maximum lue gas low (G 0) (80°C-60°C)		Kg/h	41,	49,4	59,
Excess air (80°C-60°C)		%	7	7	0
Expansion chamber inlation pressure		bar	1	1	1
Maximum heating pressure		bar	3	3	3
Expansion chamber capacity		L	6,5	6,5	6,5
Maximum water capacity with in the appliance (75°C-35°C)		L	100/300	100/300	100/300
Min/max heating temperature (high temperature range)		°C	35/8	35/8	35/8
Min/max heating temperature (low temperature range)		°C	0/45	0/45	0/45
Domestic hot water max/min temperature		°C	36/60	36/60	36/60
Speciic low rate of domestic hot water (∆T=30°C)		l/mn	1 ,0	15,0	18,
Quantity of hot water ∆T= 5°C		l/mn	14,4	18,0	1,8
Quantity of hot water ∆T=35°C		l/mn	10,3	1 ,9	15,6
Hot water comfort rating (EN13 03)		stars	***	***	***
Hot water minimum low rate		l/mn	<	<	<
Domestic hot water max/min pressure		bar	7/0,3	7/0,3	7/0,3
Power supply frequency/voltage		V/Hz	30/50	30/50	30/50
Total electrical power absorbed		W	114	115	150
Minimum ambient temperature for use		°C	+5	+5	+5
Protection level for the electrical appliance		PI	X5D	X5D	X5D
Weight		kg	3	35	35,5
Dimension (L x H x D)		mm	440/8 0/385	440/8 0/455	440/8 0/455

8

installation

Reference Standards

In the United Kingdom, the installation and initial start-up of the boiler must be by a CORGI registered installer in accordance with the installation standards currently in efect, 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” and the current Building Regulations, reference should also be made to the current ETCI rules for electrical installation.

The installation of this appliance must be in accordance with the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the by-laws of the local

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

C.O.S.H.H.

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

Codes of Practive

Installation should also comply with the following British Standards Code of Practice:

BS 7593:1992	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 cicrulation hot water systems
BS 6798:2000	Installation of gas ired hot water boilers
	of rated input not exceeding 70kW
BS 6891:1989	Installation of low pressure gas pipes up to
	28mm
BS 7671:2001	IEE Wiring Regulations
BS 4814:1990	Speciication for expansion vessels
BS 5482:1994	Installation of L.P.G.

and in the Republic of Ireland in accordancce with the following codes of practice:

I.S. 813

Domestic Gas Installations

Avoid installing the boiler where the air inlet can be polluted by checmical products such as chlorine (swimming pool area), or ammonia (hair dresser), or alkalin products (launderette).

Flue

Detailed information on lue assembly can be found in the “Connecting the Flue” section.

The boiler must be installed so that the lue terminal is exposed to the free passage of external air at all times and must not

be installed in a place likely to cause nuisance. It must not be allowed to discharge into another room or space such as an outhouse or closed lean-to.

Condensing boilers have a tendency to form a plume of water vapour from the lue terminal due to the low temperature of the lue gasses. The terminal should therefore be located with due regard for the damage or discolouration that may occur to

building within the vicinity and consideration must also be given to adjacent boundaries, openable windows should also be taken into consideration when siting the lue.

The minimum acceptable clearances are shown below:

- A Directly below an opening, window, etc							300 mm
- B Horizontally to an opening, window, etc							300 mm
- C Below gutters, soils pipes or drain pipes							75 mm
- D Below eaves							00 mm
- E From vertical drain pipe or soil pipe							75 mm
- F From internal or external corner							300 mm
- G Above ground, roof or balcony level							300 mm
- H From a surface facing the terminal							500 mm
- I From a terminal facing a terminal							500 mm
- J Vertically from a terminal on the same wall							1500 mm
- K Horizontally from an terminal on the same wall							300 mm
- L Fixed by vertical lue terminal

NOTE: THE FLUE MUST NOT BE INSTALLED IN A PLACE LIKELY TO CAUSE A NUISANCE AND POSITIONED TO ENSURE THAT PRODUCTS OF COMBUSTION DO NOT DISCHARGE ACROSS A BOUNDARY

It may be necessary to protect the terminal with a guard, if this is the case it will be necessary to purchase a stainless steel terminal guard. Reference should be made to the Building Regulations for guidance.

Ventilation

The room in which the boiler is installed does not require speciic ventilation. If the boiler is installed in a cupboard or compartment ventillation is not required for cooling purposes.

Gas Supply

The gas installation and tightness testing must be in accordance with the requirements of BS6891. Ensure that the pipe size is adequate for demand including other gas appliances on the same supply.

Electrical Supply

The appliance requires an earthed 30V - 50 Hz supply and must be in accordance with current I.E.E. regulations. It must also be possible to be able to completely isolate the appliance electrically. Connection should be via a 3 amp douple pole fused isolating switch with contact separation of at least 3mm on both poles. Alternatively, a fused 3 Amp, 3 pin plug and unswitched socket may be used, provided it is not used in a room containing a bath or shower, it. It shoild only supply the appliance.

9

installation

Water Supply

The boiler is suitable for sealed systems only. The maximum working pressure for the appliance is 6 bar. All ittings and pipework for the appliance should be of the same standard. If there is a possibility of the incoming mains pressure exceeding 6 bar, particularly at night, then a suitable pressure limiting valve must be itted.

The boiler is designed to provide hot water on demand to multiple outlets within the property. If there is a requirement for greater demands, for example if the boiler has several bathrooms and cloakrooms, a vented or unvented hot water storage system may be used.

Showers

Any shower valves used with the appliance should be of a thermostatic or pressure balanced type. Refer to the shower manufacturer for performance guidance and suitability.

Flushing and Water Treatment

The boiler is equipped with a stainless steel heat exchanger.

The detailed recommendations for water treatment are given in BS 7593:199 (Treatment of water in domestic hot water central heating systems); the following notes are givent for general guidance;

If the boiler is installed on an existing system, any unsuitable additives must be removed.

Under no circumstances should the boiler be ired before the system has been thoroughly lushed; the lushing procedure must be in line with BS 7593:199 .

We highly recommend the use of a lushing detergent appropriate for the metals used in the circuit. These include cleansers produced by Fernox BetzDearbon, whose function is to disolve any foreign matter that may be in the system;

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

The formation of scale strongly compromises the eiciency of the thermic exchanger because small areas of scale cause a high increase of the temperature of the metallic walls and therefore add to the thermal stress of the heat exchanger.

Demineralised water is more aggressive so in this situation it is necessary to treat the water with an appropriate corrosion inhibitor.

Any treatment of water by additives in the system for frost protection or for corrosion inhibition has to be absolutely suitable for all metals used in the circuit.

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

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

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

Preiodically check the pH balance of the water/anti-freeze mixture of the boiler circuit and replace it when the amount measured is out of the range stipulated by the manufacturer (7 < pH < 8).

DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE

In under-loor 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 47 6/47 9. If pipes of this kind are not used, keep the system separate by installing heat exchangers of those with a speciic system water treatment.

IMPORTANT

Failire to carry out the water treatment procedure will invalidate the appliance guarantee.

System Controls

The boiler is electrically controlled and is suitable for most modern electronic time and temperature controls. The addition of such external controls can be beneicial to the eicient operation of the system. The boiler connections for external contols are 1 V DC and so only controls of 1 V DC that have voltage free contacts should be used. (page 4).

MTS supply a range of wired and wireless system controls. Contact your supplier for more details.

Location

The boiler can be installed on any suitable internal wall (suitable sound prooing may be required when installing onto a stud partition wall). Provision must be made to allow for the correct routing of the lue and siting of the terminal to allow the safe and eicient removal of the lue products. A compartment or cupbaord may be used provided that it has been built or modiied for this purpose. It is not necessary to

provide permanent ventillation for cooling purposes. Detailed recommendations are given in BS 5440 Part . If it is proposed that it is to be installed in a timber framed building then reference should be made to British Gas Document DM , IGE/ UP/7 or advice sought from CORGI.

Where a room sealed appliance is installed in a room containing a bath or shower, the appliance and any electrical switch or appliance control, utilising mains electricity should be situated speciically in accordance with current IEE Wiring Regulations.

For unusual locations, special procedures may be necessary. BS 6798:2000 gives detailed guidance on this aspect.

Codensate Discharge

The condensate discharge hose from the boiler must have a continuous fall of .5o and must be inserted by at least 50mm into a suitable acid resistant pipe - e.g. plastic waste or overlow pipe. The condensate discharge pipe must have a minimum diameter of mm, must have a continuous fall and preferably be installed and terminated to prevent freezing.

The discharge pipe must be terminated in a suitable position:

i)Connecting into an internal soil stack (at least 450mm above the invert of the stack). A trap giving a water seal of at least 75mm must be incorporated into the pipe run, there also must be an air beak upstream of the trap.

10

installation

ii)Connecting into the waste system of the building such as a washing maching or sink trap. The connection must be

upstream of the washing machine/sink. If the connection is down stream of if the waste trap then an additional trap

giving a minimum water seal of 75mm and an air break must be incorporated in the pipe run, as above.

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

iv)Into a soakaway

Note: If any condensate pipework is to be installed externally then it should be kept to a minimum and be insulated with a waterproof insulation and have a continuous fall. The total length of external pipe used should not exceed 3 metres.

Some examples of the type of condensate terminations can be found below.

1. Internal termination of codensate drainage pipe to internal stack.

. External terminaton 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 itting).

4. External termination of condensate drainage pipe via condensate siphon

11

installation

Installing the Boiler

Please check that you are familiar with the installation requirement before commencing work (pages 7 - 11).

The installation accessories described in the following list are included in the boiler packaging:

-Hanging bracket

-A paper template (showing the dimensions of the boiler with 5 mm side clearances)

-Connection valves (Compression)

-Screws and washers

-Filling loop

-Installation, Servicing and Operating Instructions

-Flue gasket

Method of positioning the boiler on the wall

The paper template can be used to ensure the correct positioning of kitchen cabinets etc.

The paper template has to be ixed to the wall and used to locate the position of the hanging bracket and the centre for the lue hole.

Drill and plug the wall and secure the hanging bracket using the screws provided. Remove the boiler from it’s packaging and remove the front casing panel.

Place the boiler on the hanging bracket.

NOTE: THE APPLIANCE MUST NOT BE FITTED ON A COMBUSTIBLE WALL SURFACE.

Connecting the Boiler to the System

-Remove the boiler casing as described on page 13;

-Remove the caps and connect the valves to the boiler using the washers provided;

-4 x ibre washers for the CH low and return, cold water inlet and hot water outlet connections;

Safety Valve Discharge and Condense Outlet

The pressure relief valve tube is made of copper. It should terminate below the boiler safely outside the premises. Care should be taken that it does not terminate over an entrance or window or where a discharge of heated water could endanger occupants or passers by.

Fill the central heating and DHW system and bleed air from the system as described in the Commissioning instructions (page6).

The system should be carefully checked for leaks, as frequent reilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. The pipe from the trap should be connected to a drain as described in the relevant regulations.

Pay special attention not to bend the condensate silicone drain pipe is such a way as to interrupt the low. Please only use drain pipe material compatible with condensate products (refer to BS 6798: 000).

The condensate low can reach litres/hour because of the acidity of the condensate products (Ph close to ), take care before operation.

See page 11 for condensate discharge possibiities.

Note: Connections viewed from behind boiler

A

A

-remove the screws A from the transport bar

-dispose of the transport bar and reassemble the ixing screws.

1

installation

Gas connection

Make sure, using the labels on the packaging and the data plate on the appliance itself, that the boiler is in the correct country and that the gas category for which the boiler was designed corresponds to one of the categories available in the country where it will be used.

The gas supply piping must be created and measured out in compliance with speciic legal requirements and in accordance with the maximum power of the boiler; you should also make sure that the shut-of valve is the right size and that it is connected correctly.

Check that the supplied gas corresponds to the type of gas for which the boiler was designed (see the data plate located on the appliance itself).

It is also important to check that the pressure of the gas (methane or LPG) you will be using to feed the boiler is suitable, because if it is insuicient the power may be reduced, causing inconvenience for the user.

Water connection

The illustration shows the connections for the water and gas attachments of the boiler. See valves coniguration on page 13. Check that the maximum water mains pressure does not exceed 6 bar; if it does, a pressure reducing valve must be installed.

For the measuring of the pipes and of the heating bodies in the heating system, the residual head value should be calculated as a function of the requested low rate, in accordance with the values shown in the circulation pump graph.

Instructions for opening the casing and performing an internal inspection

Before performing any work on the boiler, irst disconnect it from the electrical power supply using the external bipolar switch removing the fuse and shutting of the gas valve.

To access the inside of the boiler, the following is necessary: 1. Remove the casing by unhooking it from the control panel (a)

. Loosen the two screws on the front casing (b), pull it forwards and unhook it from the upper pins (c)

3.Lower the control panel (d)

4.Unhook the two clips on the combustion chamber panel and lift of (e).

(a)

(b)

(c)

(d)

E

D

	F	C
	B	H	(e)
	A
	I

A. Central heating Flow	E. Central Heating Return
B. Domestic Hot Water Outlet	F. Safety Valve Discharge
C. Gas Inlet	H. Drain Valve
D. Domestic Cold Water Inlet	I. Drain condensate

13

installation

To calculate the size of the heating installation, refer to the "Available pressure" graph below.

Graph representing the available circulation pump pressure

T20oC
mbar
500
450
400
350									30-38 kW
									30-35 kW
300
250					24 kW
200
150
100
50
0
0	100	200	300	400	500	600	700	800	900	1000	1100	1200
												l/h

Before the irst time the equipment is used, the trap must be illed with water. To do this, add approximately 1/4 litre of water via the lue outlet before itting the lue system, or unscrew the cap on the trap positioned underneath the boiler, ill it with water and reit it

Warning! insuicient water in the trap can temporarily cause the lue gas to be expelled into the surrounding ambient air

G

E

D

C

F

B H

Underloor heating

For appliances with underloor heating, it a safety thermostat onto the underloor heating outlet. For the electrical connection of the thermostat see the section on “Electrical connections - page 4”.

If the outlet temperature is too high, the boiler will stop both domestic hot water and the heating production and the error code 1 16 “loor thermostat contact open” will appear on the display. The boiler will restart when the thermostat is closed during automatic resetting.

If the thermostat cannot be installed, the underloor heating equipment must be protected by a thermostatic valve, or by a by-pass to prevent the loor from reaching too high a temperature.

Water circuit diagram
1
2			22
3
4			21
5			20
6
			19
7			18
8			17
9
10			16
11			15
12			14
			13
A	B	C	D E

1.	Manual air vent		1 .	Condensate trap
.	Overheat thermostat		14.	C.H. circuit ilter
3.	Burner		15.	D.H.W. Flow switch
4.	Detection electrode		16.	diverter valve
5.	C.H. low	temperature	17.	water pressure sensor
	probe		18.	circulation Pump
6.	C.H. return temperature		19.	expansion vessel
	probe		0.	modulating Fan
7.	Secondary	heat ex-	1.	ignition electrodes
	changer		.	thermal fuse

8.C.H. pressure relief valve

9.D.H.W. temperature probe

10.By-pass

11.Drain valve

14

installation

Connecting the Flue

Flue System

The provision for satisfactory lue termination must be made as described in BS 5440-1.

The appliance must be installed so that the lue 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 lue terminal.

The efect of such “steaming” must be considered.

If the terminal is less than metres above a balcony, above ground or above a lat roof to which people have access, then a suitable stainless steel terminal guard must be itted.

The minimum acceptable spacing from the terminal to obstructions and ventilation openings are speciied in Fig. 1.

Fig. 1

- A Directly below an opening, window, etc	300 mm
- B Horizontally to an opening, window, etc	300 mm
- C Below gutters, soils pipes or drain pipes	75 mm
- D Below eaves	00 mm
- E From vertical drain pipe or soil pipe	75 mm
- F From internal or external corner	300 mm
- G Above ground, roof or balcony level	300 mm
- H From a surface facing the terminal	500 mm
- I From a terminal facing a terminal	500 mm
- J Vertically from a terminal on the same wall	1500 mm
- K Horizontally from an terminal on the same wall	300 mm
- L Fixed by vertical lue terminal

See4 table on page 1

See table

180118 mm

118 MM

Fig.

15

installation

Warning

The exhaust gas ducts must not be in contact with or close to inlammable material and must not pass through building structures or walls made of inlammable material.

When replacing an old appliance, the lue system must be changed.

Important

Ensure that the lue is not blocked.

Ensure that the lue is supported and assembled in accordance with these instructions.

Installation without extension

Level

118

150 mm

Fig. 3

Installation with extension

slope

Level

* pente

150 mm

slope*5pentemm5 mmperparmetremè

Fitting the Coaxial Flue

(Ø 60 / 100 Horizontal)

Contents:

1x Silicone O-Ring (60mm)

1x Elbow (90°)

x Wall Seals (Internal & External)

1x Flue Pipe including Terminal (1 metre - 60/100)x Flue Clamps

4x Screws

x Seals

Once the boiler has been positioned on the wall, it the rubber lue seal into the internal lue turret (see diagram opposite),

insert the elbow into the socket and rotate to the required position. note: It is possible to rotate the elbow 360° on its vertical axis.

Using the lue clamp, seals and screws supplied (Fig 4) secure the elbow to the boiler.

The 1 metre horizontal lue kit (3318073) supplied is suitable for an exact X dimension of 753mm.

Measure the distance from the face of the external wall to the face of the lue elbow (X - Fig ), this igure must now be subtracted from 753mm, you now have the total amount to be cut from the plain end of the lue.

Draw a circle around the outer lue and cut the lue to the required length taking care not to cut the inner lue, next cut the inner lue ensuring that the length between the inner and outer lue is maintained. (Fig 4).

e.g.

X = 555mm

753-555 = 198mm (Length to be cut from the plain end of the lue).

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

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

Note: See table for maximum and minimum lue runs.

16

installation

Clamp

Screws

Seal

Fig. 4

Fitting the 5” Flue

(Ø 80 / 1 5 Horizontal/vertical)

180 mm

Fig. 5

Once the boiler has been positioned on the wall, it is necessary to insert the Ø80/1 5 adaptor (Fig. 5) for both horizontal and vertical lue runs into the boiler lue socket (not supplied with lue kit - Part No 3318095).

Push the adaptor onto the boilers lue connection, grease the seals then add extensions or elbows as required, secure the adaptor, using the clamp and screws provided.

To it extensions or elbows it is irst necessary to ensure that the lip seal is itted correctly into the inner lue, once veriied, it is simply necessary to push them together, no clamps are necessary to secure the lue components.

Before proceeding to it the lue, ensure that the maximum lue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the maximum lue length is 10 metres, for each additional 90° elbow 1

metre must be subtracted from the total lue length, and for each 45° 0.5 metres must be subtracted from the total lue length (the height of the vertical adaptor and a 45° bend can be seen in Fig.6 and a 90° bend in Fig. 7).

Note: DO NOT cut the vertical lue kit.

Fig. 6

Fig. 7

17

installation

Fitting the Coaxial Flue

(Ø 60 / 100 Vertical)

180 mm

Fig. 7

Fig. 8

Note: See table for maximum and minimum lue runs.

Contents:

1x Silicone O-Ring (60mm)

1x Conical Adaptor (60/100mm)

1x Vertical Flue Kit (80/1 5mm)

3x Screws

The vertical lue kit is supplied with a specially designed weather proof terminal itted, it can be used either with a lat roof or a pitched roof.

The Vertical lue kits useable lengths with the pitched roof lashings are indicated in Fig. 7.

Before proceeding to it the lue, ensure that the maximum lue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the

maximum lue length is see table, for each additional 90° elbow 1 metre must be subtracted from the total lue length, and for each 45° 0.5 metres must be subtracted from the total lue length (the height of the vertical adaptor and a 45° bend can be seen in Fig. 8).

Mark the position of the lue hole in the ceiling and/or roof (see Fig. 7 for distance from wall to the centre of the lue).

Cut a 130mm diameter hole through the ceiling and/or roof and it the lashing plate to the roof.

DO NOT cut the vertical lue kit.

To connect the vertical lue kit directly to the boiler, place the vertical starter kit (Part No. 3318079) (see Fig. 7) onto the exhaust manifold and secure with the clamp, it 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 it connection), the vertical lue kit must then be inserted through the roof lashing, this will ensure that the correct clearance above the roof is provided as the terminal is a ixed 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 lue kit to be itted. 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 lue remain lush.

When utilising the vertical lue system, action must be taken to ensure that the lue is supported adequately to prevent the weight being transferred to the appliance lue connection by using 1 lue bracket per extension.

When the lue passes through a ceiling or wooden loor, there must be an air gap of 5mm between any part of the lue system and any combustible material. The use of a ceiling plate will facilitate this. Also when the lue passes from one room to another a ire stop must be itted to prevent the passage of smoke or ire, irrespective of the structural material through which the lue passes.

18

installation

Fitting the Twin Pipe (Ø80 / 80)

Note: See table for maximum and minimum lue runs.

Where it is not possible to terminate the lue within the distance permitted for coaxial lues, the twin lue pipe can be used by itting a special adaptor to the lue connector and using the aperture for the air intake located on top of the combustion chamber.

Always ensure that the lue is adequately supported, using one lue 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 of the top of the appliance

) Assemble the lange 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 lue pipes can be itted with or without additional elbows and need no clamps, simply ensure that the red o-ring is inserted in the female end of the lue pipe and push the extension piece fully into the previous section of lue pipe or elbow, check that the o-ring is not dislodged when assembling the lue (greasing the seal will aid assembly).

Twin pipe can also be converted back to Coaxial lue to enable vertical termination with a coaxial kit by using the pipe bridge (Twin - Coaxial Adaptor - Part No. 3318089). When running the twin lue pipe vertically.

It is not possible to terminate concentrically horizontally. Termination is only possible with separate air and exhaust terminals.

When siting the twin lue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals must be a minimum of 80 mm apart and the air intake must not be sited above the exhaust terminal (refer to Fig. 10). The air intake pipe can be run horizontally, however, the terminal and the inal 1 metre of lue 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 lue length for twin lue is dependent on the type of run used (see table on page 1).

For further information relating to lue runs not illustrated, please contact the Technical Department on 0870 41 8180.

19

installation
	120	180
195	105
		Fig. 9

AIR INTAKE MUST NOT BE

FITTED ABOVE THE EXHAUST

							AIR INTAKE	EXHAUST

AIR INTAKE

Fig. 10

For coaxial systems, the maximum development value, mentioned in the table below also takes into account an elbow.

For twin lue 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 lue pipes for the air intakes and

exhaust gas ducts.

- If you need to insert elbows in the air intake and exhaust gas ducts, you should consider for each one the equivalent length to be included in the calculation of developed length.

3- The exhaust gas duct should jut above the roof by at least 0.5 m. 4- The intake and exhaust gas ducts in Type C13 + C53 must be installed on the same wall, or where the exhaust is vertical and the air intake horizontal, the terminals must be on the same

side of the building.

0