Ariston COMBI A 24 MFFI, COMBI A 30 MFFI User Manual

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Installation, Servicing and Operating Instructions

Type C Boilers

COMBI A 24 MFFI G.C.N: 47-116-44 COMBI A 30 MFFI G.C.N: 47-116-45

LEAVE THESE INSTRUCTIONS WITH THE END USER

Country of destination: GB/IE

These instructions are suitable for the COMBI A boilers :

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

To The Householder

Make sure that your installer completes Section 24 of this manual (page 60) .

commissioning of your boiler.

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

As with your car, your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service check. The service history of the appliance must be recorded in Section 25 of this manual (page 61).

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

A charge may be made if MTS (GB) Limited is called out to resolve a non-product related fault.

Your statutory rights are not affected.

To The Installer

As part of the commissioning of this appliance it is necessary to complete Section 24 of this manual (page 60) and give this manual to the Householder. Please ensure that your customer is aware of the importance of keeping this manual safe as a record of the installation (Section 24, page 60) and the appliance service history (Section 25, page 61).

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

This provides a record of the

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

CUSTOMER CARE

The MTS Group 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 Ariston Technical and Customer Service Departments on:

TECHNICAL DEPARTMENT CUSTOMER SERVICE DEPARTMENT

Tel: 0870 241 8180 Tel: 0870 600 9888

Fax: 01494 459775 Fax: 01494 459775

GUARANTEE

The manufacturer’s guarantee is for 2 years from the date of purchase. The guarantee is invalidated if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler without delay.

CAUTION

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

In the Republic of Ireland, the installation and initial start up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building 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 must be recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI direct on:- (01256) 372300.

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

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

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

Contents

CUSTOMER CARE

Guarantee ............................................................................................................................................................2

Statutory Requirements .......................................................................................................................................2

Contents ...............................................................................................................................................................3

INTRODUCTION ..................................................................................................................................................4

USER INSTRUCTIONS ........................................................................................................................................5

1 CONTROL PANEL...........................................................................................................................................5

2 HOW TO USE ..................................................................................................................................................6

3 MAINTENANCE ...............................................................................................................................................7

4 GUARANTEE...................................................................................................................................................7

5 PRACTICAL INFORMATION...........................................................................................................................7

6 SETTING THE TIME CLOCKS ........................................................................................................................8

6.1 SETTING THE MECHANICAL CLOCK ...................................................................................................8

6.2 SETTING THE DIGITAL CLOCK.............................................................................................................9

INSTALLERS’ INSTRUCTIONS.........................................................................................................................11

7 DESCRIPTION...............................................................................................................................................11

8 DIMENSIONS ................................................................................................................................................12

9 HYDRAULIC DATA .......................................................................................................................................13

10 INSTALLATION REQUIREMENTS................................................................................................................14

11 INSTALLING THE BOILER............................................................................................................................17

12 CONNECTING THE FLUE.............................................................................................................................19

12.1 FITTING THE COAXIAL FLUE (Ø 60 / 100 HORIZONTAL) ................................................................ 20

12.2 FITTING THE 5” FLUE (Ø 80 / 125 HORIZONTAL/VERTICAL) .......................................................... 20

....................................................................................... 22

12.3 FITTING THE

12.4 FITTING THE TWIN FLUE (

13 ELECTRICAL CONNECTIONS .................................................................................................................... 26

13.1 FITTING THE MECHANICAL AND DIGITAL TIME CLOCKS ............................................................. 28

14 COMMISSIONING AND TESTING ...............................................................................................................

14.1 INITIAL PREPARATION ....................................................................................................................... 29

14.2 INITIAL START-UP............................................................................................................................... 29

14.3 ADJUSTING THE CO2 ......................................................................................................................... 30

14.4 GAS CONVERSION ............................................................................................................................. 30

14.5 ADJUSTING THE MAXIMUM HEATING POWER ............................................................................... 30

14.6 FITTING THE EXTERNAL SENSOR

14.7 EXTERNAL SENSOR SET-UP............................................................................................................. 31

14.8 SETTING THE PARALLEL SHIFT........................................................................................................ 31

14.9 COMPLETION

14.10 OPERATIONAL CHECKS .................................................................................................................... 32

14.11 INSTRUCTING THE END USER.......................................................................................................... 32

15 FITTING THE CASING .................................................................................................................................

16 SEQUENCE OF OPERATION...................................................................................................................... 34

16.1 CENTRAL HEATING MODE ................................................................................................................ 34

16.2 DOMESTIC HOT WATER MODE......................................................................................................... 35

17 ADJUSTMENTS AND SETTINGS

VERTICAL FLUE (

......................................................................................................................................

Ø 60 / 100

80 / 80) ................................................................................................ 23

.................................................................................................... 30

................................................................................................................ 36

)

Page

SERVICING INSTRUCTIONS

18 REPLACEMENT OF PARTS ........................................................................................................................ 43

18.1 TO GAIN GENERAL ACCESS ................................................................................................................ 43

18.1.1 Removing the front panel...................................................................................................................... 43

18.1.2 Lowering the control panel.................................................................................................................... 43

18.2 ACCESS TO THE COMBUSTION CHAMBER ........................................................................................ 44

18.2.1 Removing the combustion chamber front panel ................................................................................... 44

18.2.2 Removing the burner ............................................................................................................................ 45

8.2.3Removing the detection electrode ........................................................................................................ 45

18.2.4 Removing the ignition electrode............................................................................................................ 45

8.2.5Removing the fan.................................................................................................................................. 46

18.2.6 Removing the gas valve........................................................................................................................ 46

18.2.7 Removing the heat exchanger .............................................................................................................. 47

18.2.8 Removing the spark generator.............................................................................................................. 47

18.3 ACCESS TO THE WATER CIRCUIT ...................................................................................................... 48

18.3.1 Drain down............................................................................................................................................ 48

18.3.2 Removing the 3 way valve.................................................................................................................... 48

18.3.3 Removing the float of the flow switch ................................................................................................... 48

18.3.4 Removing the secondary heat exchanger

............................................................................................ 49

18.3.5 Removing the pump.............................................................................................................................. 49

18.3.6 Removing the pressure relief valve ..................................................................................................... 50

18.3.7 Removing the domestic expansion vessel

............................................................................................ 50

18.3.8 Removing the overheat thermostat....................................................................................................... 50

18.3.9 Removing the temperature sensors (NTC’s) ........................................................................................ 50

18.3.10 Removing the pressure gauge.............................................................................................................. 50

18.3.11 Removing the DHW flow switch............................................................................................................ 51

18.4 ACCESS TO THE CONTROL SYSTEM.................................................................................................. 51

18.4.1 Removing the PCB’s............................................................................................................................. 51

18.4.2 Removing the fuses .............................................................................................................................. 52

18.5 CONNECTING THE EXTERNAL SENSOR ............................................................................................ 52

19 INCORRECT FUNCTION ............................................................................................................................. 53

20 MAINTENANCE INSTRUCTIONS ................................................................................................................ 54

20.1 GENERAL REMARKS ............................................................................................................................. 54

20.2 CLEANING THE PRIMARY EXCHANGER ............................................................................................. 54

20.3 OPERATIONAL TEST ............................................................................................................................. 55

21 SHORT SPARES LIST ................................................................................................................................. 56

22 NOTES

.......................................................................................................................................................... 57

23 TECHNICAL DATA ....................................................................................................................................... 58

24 BENCHMARK COMMISSIONING CHECKLIST ........................................................................................... 60

25 SERVICE INTERVAL RECORD ................................................................................................................... 61

TERMS AND CONDITIONS OF GUARANTEE ............................................................................................ 64

INTRODUCTION

The COMBI A is a fully automatic, wall mounted, low water content condensing combination boiler. It is a room sealed, fan assisted, appliance providing central heating and mains pressure domestic hot water on demand. It has electronic ignition and is suitable for all modern electrical control systems. The boiler is designed for sealed systems only and a circulating pump, expansion vessel together with a pressure gauge and safety valve are included within the boiler.

The COMBI Arange of boilers are domestic gas boilers and intended for domestic use only.

1. Control Panel

USER INSTRUCTIONS

Fig. 1

Control panel (Fig. 1)

16.- Pressure gauge

25.- Display

26.- On/off push button and power on indicator light

27.- Yellow indicator - Comfort button

28.- Reset push button and red indicator lock-out light

29.- DHW control knob and temperature setting

30.- Central Heating control knob and temperature setting

31.- Menu button

32.- Reducing button

33.- Increasing button

34.- Setting button

Connecting bracket

Taps shown in Open position (Fig. 2)

39.- Gas Service Tap

40.- Water Service Tap

41.- Central Heating Flow Isolating Valve

42.- Central Heating Return Isolating Valve 43 & 44.- Filling Taps

45.- Filling Loop

Fig. 2

2. How to Use

Switching on and filling instructions

1. Check the pressure in the central heating system is above 0.7 bar and below 1.5 bar with the pressure gauge 16 (fig.1),

should it be necessary to re-pressurise the system,ensure the filling loop the pressure gauge will now start to rise, once the pressure reads 1.0 bar, close the filling taps and disconnect the filling

oop.

2. Check that the gas service tap is opened at the gas meter and the main power is on. Green indicator fig.2).

. Open the gas tap

39(

4. The boiler is now ready to use.

NOTE: If the boiler is left off for a long time, some air in the gas pipe can hinder the first lighting

attempts. (please refer to Section 19 Incorrect Function, page 53)

Time setting

You can set the time by using the keys underneath the display. Press the setting button for more than 5 seconds, the hours will begin to flash. You can now set the correct hour by using the + and - keys. Pressing the setting button again will make the minutes flash. You can set the minutes by using the + or - buttons. Pressing the setting button once more will store the set time.

NOTE:THIS IS NOT A TIMER FOR CH CONTROL

45 (fig. 2) is attached, open the filling taps 43 & 44,

26 Power ON

OPEN CLOSED

DHW mode

Turn the control knob 29 between min and max. During the adjustment, flashes. The flashing goes on for a while after the adjustment, then the display indicates the time.

When DHW is drawn, the display indicates the following:

Comfort mode

To activate the comfort mode it is necessary to press the comfort button, this will be indicated by a yellow light. The comfort mode has priority over any other heating request. There are two settings for the comfort mode (they can be adjusted in the parameters menu, see Section 17

Adjustments and Settings):

1. As soon as DHW is drawn, the secondary heat exchanger is kept warm for 30 mins. As soon as DHW

is drawn, the secondary heat exchanger is kept warm

permanently.

When the boiler is operating in ‘comfort mode’ the display indicates the following:

Heating mode

Turn the control knob 30 between min and max. During the adjustment flashes. The flashing goes on for a while after the adjustment, the display will then indicate:

- the central heating flow temperature if the room thermostat is calling for heat.

- the time if the room thermostat is OFF.

comfort

BURNER ON and output level

The flame digits will increase or decrease depending on the output.

Room thermostat request

symbol

Flame digit

Burner ON

Stand-by mode

Turn the control knobs 29 and 30 to the OFF position to deactivate the DHW and Heating. Leave the ON/OFF button On with the green light on.

uring the stand-by mode the display indicates the time, anti-seizing and anti-

D freezing will be active, see below.

Switch OFF

Press the ON/OFF button.

During this mode the boiler will not operate, but is still connected to the mains.

Anti-freezing mode

urn the control knobs 29and 30toOFFto switch off the heating and hot water

T functions. Leave the On/Off button on with the green light on. When the anti-freeze comes on, the corresponding code is displayed with the snowflake pictogram .

The two possible codes are 05 (anti-freeze - pump only) or 06 (anti-freeze burner).

When this mode is active, the circulating pump operates for one

05: minute and the diverter valve switches every 23 hours. Caution: in this mode, the room thermostat anti-freeze function is inoperative.

Boiler anti-freeze function: the pump starts at 8°C

the burner starts at 3°C

3. Maintenance

Your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service check. The service history of the appliance will be marked in the Service Interval Record (Section 25, page 61).

4. Guarantee

The manufacturer`s guarantee is for 2 years from the date of purchase. The guarantee is voidable if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler without delay.

5. Practical Information

Cleaning the casing and control panel

Should it be necessary to clean the casing and control panel. do so only with a soft damp cloth, do not use any spray polishes or cleaners.

Precaution to avoid freezing

We recommend you contact your installer or local service centre for further advice on the actions to be taken to avoid the system freezing (Should the boiler be turned off at the mains electrical isolator).

DHW system

•

Turn off the main cold water supply and drain the boiler :

- Open a hot water tap

- Unscrew the cold water inlet tail

system

•

Choose one of the following solutions :

- 1) Drain completely the Central Heating system

- 2) Protect the Central Heating system with anti freeze chemical products and verify the concentration periodically C)

- 3) Leave the Heating mode switched on and set the room thermostat to anti-freeze mode (between 5 and 10

- 4) Leave your boiler in stand by mode, the anti-freeze device will switch on the pump and the burner if necessary.

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424

1212

6. Setting the time clocks (continued)

6.1 Setting the Mechanical Clock

Fig. 3

Fig. 4

1. General layout The mechanical clock covers a 24 hour period. Each tappet represents 15 minutes A (Fig. 4). An override switch is located on

B (Fig 4).

symbol to control the central heating by the clock. Put the switch

B to «I» to select

the clock

2. To set the time

To set the time of day, grasp the outer edge of the dial and turn slowly clockwise until the correct time is lined up with the arrow

C (Fig. 4).

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

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

4. For operation

Put the selector switch B to the permanent operation or to «0» to turn the central heating off permanently.

6. Setting the time clocks (continued)

6.2 Setting the Digital Clock

Operating the time switch

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

Preparing for Operation

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

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

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

Enter current time and weekday

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

1 = “Monday”..............7 = Sunday

- Release the “ ” button.

6. Setting the time clocks (continued)

Entering the switching times

ou have 20 memory Iocations available. Each switching time takes up one memory location.

eep pressing the “Prog” button until a free memory location is shown in the display “– –:– –”.

rogramme ON or OFF with the “ ” button:

P “ ”= OFF; “ ”= ON Enter the hour using “h” Enter the minutes using “m” If a switching command is to be carried out every day (1 2 3 4 5 6 7) then store using the “ ” button, otherwise select the day(s) it is to be carried out by using the “Day” button. When the day seIection is left bIank, the programmed switching instruction operates at the same time every day

2 3 4 5 6 = Monday – Saturday

2 3 4 5 = Monday – Friday

7 =Saturday – Sunday

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

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

Manual Override Switch “ ”

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

Reading the programmed switching times

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

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

Changing the programmed switching times

Press the “Prog” button repeatedly until the switching time you want to change is displayed. You can now enter the new data.

Entering the switching times”.

See “

Notes on storing switching times:

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

In addition, a complete switching command is stored pressed. The time switch then enters the automatic operating mode and displays the current time again.

Deleting individual switching times

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

00” appears.

automatically after around 90 seconds provided no other button is

18”. If all memory

AM / PM time display

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

7. Description

21 12

INSTALLER INSTRUCTIONS

- Steel chassis complete with expansion vessel

2.- Sealed chamber

3.- Burner and heat exchanger assembly

4.- Air / gas connection

- 24 V modulating fan

6.- Gas valve

- Ignition electrode

8.- Ionisation probe

- Ignitor

10.- Combustion products manifold

11.- Condense trap

12.- Silencer

- Electrical box

13.

14.- Pump

15.- Secondary heat exchanger

16.- Pressure gauge

17.- Three way valve

18.- Automatic air vent 19 - Domestic hot water flow switch

20.- Primary flow thermistor

21.- Primary return thermistor

22.- Overheat sensor

23.- Central heating pressure relief valve

Fig. 5

Fig. 6

25.- Display

On/off push button and power on

26.-

indicator light

27.- Yellow indicator - Comfort button

28.- Reset push button and red indicator

lock-out light

29.- DHW control knob and temperature

setting

30.- Central Heating control knob

temperature setting

31.- Menu button

32.- Reducing button

33.- Increasing button

34.- Setting button

and

Fig. 7

8. Dimensions

440

450 mini pour entretien

All dimensions in mm

96 (24 kW)

2 360 (30 kW)

afety valve C/H and condensate

I S

eating flow

D.H.W. outlet

Gas supply

Cold water inlet

Heating return

eight with packaging :

24 kW : 37 kg 30 kW : 40 kg

Minimum space required 450mm

Fig. 9

390 mm

NOTE:THE CLEARANCES STATED ABOVE ARE REQUIRED FOR SERVICING PURPOSES

9. Hydraulic data

20 40 60 80 100 120 140 160 180 200 220 240

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1,8

1.9

2.0

260 280

40°C

50°C

60°C

70°C

80°C

0.05

.15

.25

0.3

0.35

0.45

200 400 600 800 1000 1200 1400

The boiler is fitted with an automatic by-pass as standard.

The graphs (Fig. 10) show the development of the pressure available in relation to flow (on exit from the boiler).

To ensure correct operation, the minimum flow of the appliance must be 300 l/h. (Thermostatic taps closed).

Capacity of the installation.

The water heater is fitted with a pressurised expansion

essel.

aximum volume of expansion vessel: 6 litres.

ressure: 1 bar.

Pump Head Graph (15/50)

Pressure (bar)

The volume of the expansion vessel in a pressurised

ppliance varies according to:

- the average operating temperature in °C

- the static height, which is the difference in metres between the highest point of the appliance and the expansion vessel

xis.

The minimum cold filling pressure of the appliance is 0.8 bar

recommended pressure between 1.0 and 1.5 bar).

(

The pressure of the expansion vessel should always be greater than the static height (in metres) divided by 10.

flow rate (l/hr)

Pump Head Graph (15/60)

Pressure (bar)

flow rate (l/hr)

System capacity chart

Central heating initial pressure when cold (in bar)

System capacity (litres)

Fig. 10

Fig. 11

10. Installation requirements

Reference Standards

n the United Kingdom, the installation and initial start up of

I the boiler must be by a CORGI Registered installer in accordance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI.

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

nstallation.

he installation of this appliance must be in accordance with

T the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the by-laws of the local water authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635, “Electricity at Work Regulations 1989” and in the Republic of Ireland with the current edition of I.S. 813 and the Local Building Regulations (IE).

For detailed information on the installation of Condensing boilers, reference should be made to the

ODPM Guide to the Condensing Boiler Assesment Procedure for Dwellings

exposed to the free passage of external air at all times and

ust not be installed in a place likely to cause nuisance. It

m must not be allowed to discharge into another room or space such as an outhouse or closed lean-to.

Condensing boilers have a tendency to form a plume of water vapour from the flue terminal due to the low temperature of the flue gasses. The terminal should therefore be located with due regard for the damage or discolouration that might occur to buildings in the vicinity and consideration must also be given to adjacent boundaries, openable windows should also be taken into consideration when siting the flue.

Fig. 11

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 Practice

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

BS 7593:1992 Treatment of water in domestic hot

water central heating systems

BS 5546:2000 Installation of hot water supplies for

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

boilers of rated input not exceeding

70kW BS 6891:2000

Installation of low pressure gas pipe up

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

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

The minimum acceptable clearances are shown below:

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

Vertically from a terminal in the same wall 1500

I J - Horizontally from a terminal in the same wall 300 K - Horizontally from an opening window 300

Fixed by vertical flue terminal

NOT BE INSTALLED IN A PLACE LIKELY TO

NOTE:

CAUSE

MUST

FLUE

A NUISANCE

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.

I.S. 813 Domestic Gas Installations

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

Flue

Detailed information on flue assembly can be found in Section 12 “Connecting the flue”

The boiler must be installed so that the flue terminal is

Ventilation

The room in which the boiler is installed does not require specific ventilation. If it is installed in a cupboard or compartment

permanent ventilation is not required for cooling purposes.

Gas Supply

The gas installation and soundness testing must be in accordance with the requirements of BS 6891. Ensure that the pipe size is adequate for demand including other gas appliances on the same supply.

10. Installation requirements (continued)

lectrical Supply

All electrical work carried out must be in accordance with all

urrent local Building Regulations and British Standards.

c The appliance requires an earthed 230V - 50 Hz supply and

ust be in accordance with current I.E.E. It must also be

m possible to be able to completely isolate the appliance

lectrically. Connection should be via a 3 amp fused double-

e pole isolating switch with contact separation of at least 3 mm 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 should only supply the appliance.

The boiler is suitable for sealed systems only. The maximum working pressure for the appliance is 6 bar. All fittings and

ipework connected to the appliance should be of the same

p standard. If there is a possibility of the incoming mains pressure exceeding 6 bar, particularly at night, then a suitable pressure limiting valve must be fitted. The boiler is designed to provide hot water on demand to multiple outlets within the property. If there is a requirement for greater demands, for example if the property has several bathrooms and cloakrooms, a vented or unvented hot water storage system may be used.

Showers

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

Flushing and Water Treatment

The boiler is equipped with a stainless steel heat exchanger.

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

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

Under no circumstances should the boiler be fired before the system has been thoroughly flushed; the flushing procedure must be in line with BS7593:1992.

We highly recommend the use of a flushing detergent appropriate for the metals used in the circuit, whose function is to dissolve any foreign matter that may be in the system.

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

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

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

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

he use of a corrosion inhibitor in the system is

T recommended to prevent corrosion (sludge) damaging the

oiler and system;

f anti-freeze substances are to be used in the system, check

I carefully that they are compatible with the metals used in the

ircuit.

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

Periodically check the pH of the water/anti-freeze mixture of the boiler circuit and replace it when the amount measured is out of the range stipulated by the manufacturer ( 7 < pH < 8). DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE

In under-floor systems, the use of plastic pipes without protection against penetration of oxygen through the walls can cause corrosion of the systems metal parts (metal piping, boiler, etc), through the formation of oxides and bacterial agents.

To prevent this problem, it is necessary to use pipes with an “oxygen-proof barrier”, in accordance with standards DIN 4726/4729

system separate by installing heat exchangers of those with a specific system water treatment.

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

System Controls

The boiler is electrically controlled and is suitable for most modern electronic time and temperature controls. The addition of such external controls can be beneficial to the efficient operation of the system, please refer to local Building Regulations for further advice. The boiler connections for external controls are 12V DC and so only controls of 12V DC that have voltage free contacts should be used. (Section 13 Electrical Connections - page 26).

Location

The boiler can be installed on any suitable internal wall. Provision must be made to allow the correct routing of the flue and siting of the terminal to allow the safe and efficient removal of the flue products. A compartment or cupboard may be used provided that it has been purpose-built or modified for the purpose. It is not necessary to provide permanent ventilation for cooling purposes. Detailed recommendations are given in BS 5440 pt 2. If it is proposed that it is installed in a timber framed building then reference should be made to British Gas Document DM2, or advice sought from CORGI.

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

For unusual locations, special procedures may be necessary.

BS 6798:2000 gives detailed guidance on this aspect.

Condensate Discharge

The condensate discharge hose from the boiler must have a continuous fall of 2.5 into a suitable acid resistant pipe - e.g. plastic waste or

. If pipes of this kind are not used, keep the

Wiring Regulations.

and must be inserted by at least 50mm

10. Installation requirements (continued)

verflow pipe. The condensate discharge pipe must have a

o minimum diameter of 22mm, must have a continuous fall and preferably be installed and terminated to prevent freezing. The discharge pipe must be terminated in a suitable position:

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

bove the invert of the stack). A trap giving a water seal

a of at least 75mm must be incorporated into the pipe run, there also must be an air break upstream of the trap.

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

a washing machine or sink trap. The connection must be upstream of the washing machine/sink. If the connection

s down stream of the waste trap then an additional trap

i giving a minimum water seal of 75mm and an air break

1. Internal termination of condensate drainage pipe to internal stack

ust 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.

: If any condensate pipework is to be installed

xternally then it should be kept to a minimum and be

e 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

e found below.

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

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

4. External termination of condensate drainage pipe via condensate siphon

11. Installing the boiler

Please check that you are familiar with the installation requirements before commencing work (Section 10).

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 tails and valves

- Screws and washers

- Connection washers

- Installation, Servicing and Operating Instructions

ethod of positioning the boiler on the wall.

The paper template can be used to ensure the correct positioning of kitchen cabinets etc. It also details the commissioning instructions. The paper template has to be fixed to the wall and used to locate the position of the hanging bracket and the centre for the flue

ole.

h Drill and plug the wall and secure the hanging bracket using the screws provided. Remove the boiler from its packaging as shown in Fig. 16 and unscrew the two clamp locking bolts Place the boiler on the wall on the hanging bracket (Fig. 14).

NOTE: TH

Connecting the boiler to the system

- Remove the boiler casing as described in Section 18.

- Push in the tabs “

- Remove the caps and connect the boiler to the taps using the washers provided in the plastic bag.

E APPLIANCE MUST NOT BE FITTED ON A COMBUSTIBLE WALL SURFACE

P” (Fig. 14) on either side of the boiler and pivot the electrical box forward to gain access to the valve

connections

4 x fibre washers for the C/H flow and return, hot water outlet and cold water inlet connections 1 x rubber washer for gas connection

A and remove the casing (Fig. 13).

Safety valve discharge

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 Section 14. The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. The pipe from the condense trap (11 Fig. 5) should be connected to a drain as described in the relevant British regulations. Pay special attention to not bend the condensate silicone drain pipe such as the flow will be interrupted. Please use exclusively drain pipe material compatible with condensate products. (refer to The condensate flow can reach 2 litres / hour; because of the acidity of the condensate products (Ph close to 2), take care before operation.

Fitting the Horizontal Flue Attention ! Before starting the boiler, the condensate trap (11 Fig. 5) must be filled with water. Before fitting the flue l onto the boiler, pour 1/4 litre of water in the exhaust pipe as shown in Fig. 16.

Instructions on fitting the flue can be found in Section 12.

IMPORTANT!!

Use only the specific condensation flue kit supplied by MTS.

BS 6798 : 2000)

11. Installing the boiler (continued)

ig. 12

Fig. 13

Fig. 14

Fig. 15

12. Connecting the Flue

118

The boiler should only be installed with a flue system supplied by MTS (GB) Limited. These kits are supplied separately to the appliance in order to respond to different installation solutions. For more information with regard to the inlet/outlet accessories consult the accessory catalogue. The boiler is supplied ready for connection to a

oncentric flue system.

:SE

IMPORTANT!!

BEFORE CONNECTING THE FLUE, ENSURE THAT 1

WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION TO FILL THE CONDENSATE TRAP (FIG. 16). SHOULD THE

RAP BE EMPTY THERE IS A TEMPORARY RISK OF FLUE

GASSES ESCAPING INTO THE ROOM

E PAGE

24 F

OR MAXIMUM AND MINIMUM FLUE RUNS

(TA

LITRE OF

BLES

A, B ANDC)

ig. 16

Warning

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

Ø 60/100 mm

Fig. 17

Installation without extension

Important

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

Level

Installation with extension

Fig. 18

Level

12.1 Fitting the coaxial flue (Ø 60/100 Horizontal)

CO 1X SI

NTENTS

LICONE

-R

60mm)

(

O 1X ELBOW (90O) 2X WALLSE

X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100)

1 1X FLUECL 1X SC

REWS

x Seal

Once the boiler has been positioned on the wall, insert the elbow into the socket and rotate to the required position. N

ALS

AMP

(IN

TERNAL

&EX

TERNAL

)

: It is

OTE

possible to rotate the elbow 360oon its vertical axis.

sing the flue clamp, seals and screws supplied

The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact

Measure the distance from the face of the external wall to the face of the flue elbow

ubtracted from 815mm, you now have the total amount to be cut from the plain end of the flue.

Fig 19)secure the elbow to the boiler.

(

X dimension of 815mm.

(X - Fig 17), this figure must now be

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

(Fig 19).

e.g.

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

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

12.2 Fitting the 5” Flue (Ø 80 / 125 Horizontal/vertical)

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

OTE:SEE PAGE 24 FOR MAXIMUM AND MINIMUM FLUE RUNS.

Once the boiler has been positioned on the wall, for horizontal flue runs insert the Ø60/100 elbow into the boiler, and connect the elbow to the Ø80/125 adaptor, for vertival flue runs it is necessary to insert the Ø80/125 adaptor (Fig.20) (not supplied with flue kit

Part No 3318095) into the boiler flue socket.

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

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

Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables on Page 24) and that all elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90 1 metre must be subtracted from the total flue length, and for each 45o0.5 metres must be subtracted from the total flue length.

KIT

NOTE: DO

NOT

CUT

THE

VERTICAL

FLUE

elbow

Seal

Clamp

Screws

ig. 19

Fig. 20

12.3 Fitting the Coaxial Flue (Ø 60 / 100 Vertical)

NOTE:

E PAGE

OR MAXIMUM AND MINIMUM FLUE RUNS

CONTENTS: 1X SILICONE O-RING (60mm) 1X CO

NICALADAPTOR

1X VE

RTICALFLUEKIT

X SC

REWS

(60/100mm)

(80/125mm)

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

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

Fig. 21.

elbow

1 metre must be subtracted from the total flue length, and for each 45o0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45obend can be seen in Fig. 22).

Mark the position of the flue hole in the ceiling and/or roof (see

Fig. 21 for distance from wall to the centre of the flue).

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

DO NOT cut the vertical flue kit.

To connect the vertical flue kit directly to the boiler, place the vertical starter kit

(Part No. 3318079) (see Figs. 21 & 22) onto the

exhaust manifold and secure with the clamp, fit the vertical adaptor onto the vertical starter kit (note: there is no need to use a clamp to secure this as it is a push fit connection), the vertical flue kit must then be inserted through the roof flashing, this will ensure that the correct clearance above the roof is provided as the terminal is a fixed height.

Should extensions be required, they are available in 1 metre

(Part No. 3318077), 500mm (Part No. 3318078) and 160mm

lengths, they must be connected directly to the vertical starter kit before connecting the adaptor to allow the vertical flue kit to be fitted. In the event that extension pieces need to be shortened, they must only be cut at the male end and it must be ensured that the inner and outer flue remain flush.

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

When the flue passes through a ceiling or wooden floor, there must be an air gap of 25mm between any part of the flue system and any combustible material. The use of a ceiling plate will facilitate this. Also when the flue passes from one room to another a fire stop must be fitted to prevent the passage of smoke or fire, irrespective of the structural material through which the flue passes.

Fig. 21

Fig. 22

12. Connecting the flue (continued)

123.5 141

230 MIN *

200

132

12.4 Fitting the twin pipe (Ø80/80)

NOTE:SE

here it is not possible to terminate the flue within the distance permitted for coaxial flues, the twin flue pipe can be used by

W fitting a special adaptor to the flue connector and using the aperture for the air intake located on top of the combustion chamber.

Always ensure that the flue is adequately supported, avoiding low points. (MTS supply suitable clamps as Part No. 705778).

o utilise the air intake it is necessary to:

1) Take the air intake cover off;

2) Assemble the flange on the header supplied with the boiler; ) Insert the restrictor if necessary, on the tube or the elbow;

4) Insert the header on the tube or the elbow up until the lower stop

you do not have to use the washer);

(

5) Insert the elbow/header in the boiler air intake hole and fasten it with screws;

The twin flue pipes can be fitted with or without additional elbows and need no clamps, simply ensure that the red o-ring is inserted in the female end of the flue pipe and push the extension piece fully into the previous section of flue pipe or elbow, check that the o-ring is not dislodged when assembling the flue.

Twin pipe can also be converted back to Coaxial flue to enable vertical termination with a coaxial kit by using the pipe bridge (Twin - Coaxial Adaptor - Part No. 705767). When running the twin flue pipe vertically.

It is not recommended that the pipe bridge be used for horizontal termination, however in the unlikely event that this proves to be a necessity it is extremely important that the entire flue has a fall of 5mm in every metre back to the boiler, and where the 60mm inner flue of the concentric terminal connects to the pipe bridge, this point must be adequately sealed with silicone sealant to avoid condense leakage at this point.

E PAGE

24 F

OR MAXIMUM AND MINIMUM FLUE RUNS

(TA

BLE

When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals

27). The air intake pipe can be run horizontally, however, the terminal and the final 1 metre of flue must be installed with a fall

away from the boiler to avoid rain ingress.

It is also strongly recommended that the air intake pipe run be constructed of insulated pipe to prevent condense forming on the outside of the tube.

The maximum permissible flue length for twin flue is dependent on the type of run used.

For flue runs with the intake and exhaust pipes under the same atmospheric conditions (T metres (24kW and 30kW), for runs with the terminals under different atmospheric conditions (TYPE 5) the exhaust terminal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the exhaust and air intake pipes are located on the same side of the building). For TYPE 5 also, the maximum permissible combined length is 60 metres (24kW and 30kW).

The maximum length is reached by combining the total lengths of both the air intake and exhaust pipes. Therefore a maximum length of 60 metres for example, will allow a flue run of 30 metres for the air intake and 30 metres for the exhaust pipes, also

for each 90 from the total flue length.

Some of the acceptable flue configurations are detailed on page 25.

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

must be a minimum of 280 mm apart and the air intake must not be sited above the exhaust terminal (refer to Fig.

YPE 4) the maximum length is 60

elbow 2.2 metres must be subtracted from the total length and for each 45oelbow 1.4 metres must be subtracted

Fig. 23

Fig. 24

123.5

200

107

12. Connecting the flue (continued)

ø 100

60 mm

ig. 25

In the event that twin flue pipes are used, and the boiler has a side clearance of less than 60mm from the wall, it is necessary to cut a larger diameter hole for the flue pipe, this should be ø100 mm, this will then allow for easier assembly of the air intake elbow and the tube outside the wall (see Fig. 26).

TABLE

Concentric outlet

60/100

24 , 30 and 35 kW

(Type 1, Type 2, Type 3)

Concentric outlet

80/125

24 , 30 and 35 kW

(Type 1)

24 , 30 and 35 kW

(Type 2, Type 3)

Twin flue outlet

24 , 30 and 35 kW

Type 4

80/80

Type 5

80/80

Min length Max. length

0.3 m 5m

Min length Max. length

0.3 m 10 m

Min length Max. length

10 m

(30m air / 30m exhaust)

60 m

Fig. 26

Length

equivalency for

elbow

0.5 m

1 m

0.5 m

1 m

1.4 m

2.2 m

For coaxial systems, the maximum development value, mentioned in the table above also takes into account an elbow. For twin flue systems the maximum development value, mentioned in the table includes the exhaust gas/air intake terminal.

Type 5 outlets should respect the following instructions: 1- Use the same ø 80 mm flue pipes for the gas intakes and exhaust gas ducts. 2- If you need to insert elbows in the gas intake and exhaust gas ducts, you should consider for each one the equivalent length to be included in the calculation of developed length. 3- The exhaust gas duct should jut above the roof by at least 0.5 m. 4- The intake and exhaust gas ducts in Type 5 must be installed on the same wall, or where the exhaust is vertical and the air intake horizontal, the terminals must be on the same side of the building.

12. Connecting the flue (continued)

TYPE 1

TYPE 4

NOTE: DRAWINGS

TYPE 2

TYPE 5

ARE INDICATIVE OF FLUEING OPTIONS ONLY

TYPE 3

Fig. 27

13. Electrical connections

aking the Electrical Connections

Lower the electrical box to gain access to the elec-

Fig. 28) on

rical connections. Push in the tabs

t either side of the boiler and pivot the box forward.

emove the PCB cover (see Section 18.4 - page

51). Connect the live neutral and earth wires to

the main cable.

oom thermostats or other external control, they

R can be connected in place of the link on the termi-

al block (Diagram A - Fig. 30).

ote: Use only controls designed for voltage free

N switching or 24V supply. Do not connect to a 230V supply, and do not run 230v cables alongside the low voltage cables.

ll necessary settings for room thermostat opera-

A tions are described in Section 17 ADJUSTMENTS AND SETTINGS.

P (

Fig. 28

Fig. 29

LEGEND

1 NTC 2 Display Connectors 3 EEPROM 4 24V 5 Fan Connector 6 Flame Detection Connector 7 Fuses 2A

Connectors

Key

Supply

230V (X2)

8 230V

9 Auxiliary 230V Connector 10 Actuators 230V 11 Time Clock Connector (Internal) 12 Room Thermostat Connector 13 Remote Control 14 Under Floor Heating Connector 15 Not Used

Connector

13. Electrical connections (continued)

- If a remote time clock is to be fitted, using a volt-free switching time clock, remove the link wire and connect the switching wires from the time clock following points above (see also

If using an external time clock and room thermostat, remove the link wire and connect in series as above (see also

iagram C Fig. 30).

Live and Neutral connections to operate the clock motor must be taken from a suitable source.

Diagram B Fig. 30).

Connector fitting instructions, please refer to those provided with the clock or page 28 of this manual.

11 (Fig. 30), is used by the mechanical time clock supplied with the boiler or for the optional digital programmer, for

CONNECTOR 12 ON PCB, SEE FIG. 31

Fig. 30

13. Electrical connections (continued)

13.1 Fitting the Digital Programmer

The boiler is supplied with a factory fitted mechanical time clock, to

it the optional digital programmer it is necessary to proceed as

f follows; (this should only be carried out by a competent engineer)

- Isolate the electrical supply to the appliance; Remove the front panel as described in Section 18.1.1;

- Remove the mechanical clock on the right hand side (Fig. 31)

nd pull out the 4 wires (Fig. 32);

NOTE: THE WIRES MAY BE TUCKED BEHIND THE ELECTRICAL COVER.

- Connect the clock wires as follows;

CHANICALMODEL

Red Wire - Contact 1

lack Wire - Contact 2

B Black Wire - Contact 3 Grey Wire - Contact 5

NOTE: TH

Red Wire - Contact 1 Black Wire - Contact 2 Grey Wire - Contact 3

NOTE: SE

- Push the clock back into the panel and refit the casing

E TWO BLACK WIRES ONCONTACTS

DIGITAL MODEL (Fig. 34)

CONDBLACKWIRE

panel (Fig. 35).

Fig. 33

(Fig. 33)

IS NOT CONNECTED.

2 & 3 C

AN BE REVERSED

Fig. 31

Fig. 32

Fig. 34

Fig. 35

14. Commissioning and testing

14.1 Initial preparation

MTS (GB) Limited support the initiative. In Sections 24 and 25 (pages 60 and 61) of this manual the

Commissioning Checklist and Service Interval Record can be found. It is important that this is completed in the presence of your customer, they are shown how to use it, and it is signed by them. Please instruct your customer that

hey must have this manual with them whenever they contact

t a service engineer or us.

Preliminary electrical system checks to ensure electrical

afety must be carried out by a competent person i.e.

s polarity, earth continuity, resistance to earth and short circuit.

LLING THEHEATINGSYSTEM

emove the front casing panel and lower the control panel

as described in Section 18.1 (page 43). Open the central heating flow and return cocks supplied with the connection kit; Unscrew the cap on the automatic air release valve one full turn and leave open permanently; Close all air release valves on the central heating system; Gradually open the valves at the filling point (filling loop)

until water is heard to flow, do not open fully; Open each air release tap starting with the lowest point and close them only when clear water free of air is visible;

Purge the air from the pump by unscrewing the pump plug anti-clockwise, also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free;

Refit the pump plug; Continue filling the system until at least 1.5 bar registers on the pressure gauge; Inspect the system for water soundness and remedy any leaks discovered.

OF THE

ILLING

DHW SYSTEM: Close all hot water draw off taps; Open the cold water inlet cock supplied with the connection kit; Slowly open each draw off tap and close them only when clear water, free of bubbles, is visible.

AS SUPPLY:

G Inspect the entire installation including the gas meter and test for soundness. The entire installation should be in accordance with the relevant standards. In GB

this is BS

6891 and in IE this is the current edition of I.S.813.

The connection on the the appliance is a 15mm copper tail located at the rear of the gas service cock (

39 Fig. 2 - page

If the gas supply serves other appliances, ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time.

Pipe work must be of an adequate size. Pipes of less than 22mm should not be used.

Open the gas cock (supplied with the connection kit) to the appliance and check the gas connection on the appliance for leaks.

TERTREATMENT

The boiler is equipped with a stainless steel heat exchanger.

The detailed recommendations for water treatment are given

n BS 7593:1992 (Treatment of water in domestic hot water

i central heating systems); the following notes are given for

eneral guidance;

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

nder no circumstances should the boiler be fired before the

U system has been thoroughly flushed; the flushing procedure must be in line with BS7593:1992.

Firstly fill the central heating system with the power off, and flush through cold, fill the central heating system again, adding a flushing detergent, run the boiler on central heating until it reaches its operating temperature and flush the system, refill the system with a suitable corrosion inhibitor,

NOTE:FA

RESULT IN THE WARRANTY BECOMING VOID.

ILURE TO CARRY OUT THE FLUSHING PROCEDURE WILL

14.2 Initial start-up

The checks to be run before initial start-up are as follows:

1. Make sure that:

- The screw on the automatic air valve has been loosened when the system is full;

- If the water pressure in the system is below 1.0 bar, bring it up to the appropriate level;

- Ensure that the gas cock is closed;

- Make sure that the electrical connection has been made properly and that the earth wire is connected to an efficient earthing system;

- Supply power to the boiler by pushing the on/off button 26 (Fig. 1) the green led indicator light will illuminate;

- Turn the central heating control knob maximum and switch the time clock (if fitted) to constant and turn up the room thermostat;

- After 7 seconds, the boiler will signal a shutdown due to ignition failure. Leave the boiler as it is until all the air has been bled from the system;

- Loosen the cap on the head of the pump to eliminate any air pockets;

- Repeat the procedure for bleeding the radiators of air; Open the hot water taps for a short period;

Check the system pressure and, if it has dropped, open

the filling loop again to bring the pressure back up to 1.0 bar;

Make sure that all radiator valves are open;

3. Turn on the gas cock and check the seals on the connections with any approved soap solution and eliminate any leaks;

4. Press the reset button

28 (Fig. 1) the boiler will re-attempt

ignition. If the burner does not light the first time, wait 1 minute and repeat the procedure;

5. Check the minimum and maximum CO rates;- Adjust if necessary as indicated in Section 14.3

(page 30).

29 (Fig. 1) to

2 values and gas

14. Commissioning and testing (continued)

14.3 Adjusting the CO2

. Remove the casing panel as described in Section 18.1

(page 43);

2. Connect a manometer to the inlet test nipple on the gas valve, turn on a hot tap and ensure the inlet working

ressure is 20mbar. If correct proceed as follows;

3. Turn on the combustion analyser, remove the combustion

est point plug

t into the test point;

. Turn on a hot tap and ensure that the boiler is firing.

5. Access the setting menu by pressing the and keys for 5 seconds the icon will be shown in the display;

6. Press the menu button four times to access Menu 5 and press the setting button once to switch the output

of the boiler to maximum (two digits will be flashing indicating the temperature of the boiler). There will be a cursor at the top of the display indicating the boiler is at maximum output. If the cursor is at the bottom of the display (indicating minimum output) press the button the change to maximum output;

7. If necessary adjust the screw on the gas valve (Fig. 37) to set the CO (LPG);

8. Press the setting button once to set the combustion control rate mode to minimum, and, if necessary, adjust the screw on the gas valve to set the CO2 to 8.9% +/-

0.2% (NG) or 9.7% +/- 0.2% (LPG);

9. Press the setting button again to set the combustion rate control mode to maximum and if necessary adjust the screw on the gas valve to set the CO

0.2% (NG) or 9.2% +/- 0.2% (LPG);

10. Reassemble in reverse order.

Fig. 36) and insert the analyser probe

Q (

2 to 8.9% +/- 0.2% (NG) or 9.7% +/- 0.2%

2 to 8.9% +/-

14.4 Gas Conversion

To convert from Natural Gas (G20) to LPG (G31), it is

ecessary to insert a diaphragm and restrictor between the

n gas valve and air/gas arm.

Once the conversion has been made, the CO need to be checked as described in Section 14.3, for LPG the CO2 reading should be 10% +/- 0.2% with the front case

itted).

To convert from LPG (G31) to Natural Gas (G20), it is necessary to remove the diaphragm and restrictor from between the gas valve and air/gas arm. Once the conversion has been made, the CO need to be checked as described in Section 14.3, for NG the

2 reading should be 9.2% +/- 0.2% (with the front case

CO fitted).

2 setting will

Adjustment screw

Test nipple

Fig. 37

Fig. 36

14.5 Range rating the maximum heating power

To adjust the maximum heating power it is necessary to access the settings menu by pressing the and buttons together for five seconds, and proceed as follows;

1. Press the menu button 3 times to access Menu 4;

2. Press the button to access Menu 4.9;

3. The value is adjustable between 0 and 10, 0 being the minimum output and 10 being the maximum, please refer to the chart on page 33 (Fig. 40) for the required setting;

4. The maximum central heating output can now be adjusted by pressing the setting button ;

5. To exit the setting mode, do not press any buttons for 1 minute, the boiler will automatically exit the Setting Menu.

14.6 Fitting the external sensor

The external sensor should be fitted 1.5 meters above the floor on a North to North West facing wall, out of direct sunlight.

To connect the external sensor, it is first necessary to remove the casing panel as described in Section 18 (page

42);

Remove the PCB cover as described in Section 18.4 and connect the external sensor as described in Section 18.5 (page 50).

14.7 External sensor set-up (where fitted)

When using an outdoor sensor, the microprocessorcontrolled PCB will select the most suitable flow

emperature, taking into account the external temperature

t and the type of system. The microprocessor is capable of

oing this because it is possible to establish a link between

d the external temperature and the flow temperature of the

entral Heating system water. This link translates into a

C “thermal curve”. The type of curve should be chosen in correspondence with the planned temperature of the system and the nature of the

eat loss present in the building.

To set up the external sensor, proceed as follows;

. Access the settings menu by pressing the and

buttons for five seconds;

. Press the button 5 times to access Menu 6;

3. Press the button, the 3rd and 4th digits will flash;

4. Press the or buttons to change from 1 (sensor not

fitted ) to 0 (sensor fitted) and press the button again

to select the change;

5. Select the thermal curve required from

6. Press the or buttons to change to Menu 6.2;

7. To adjust the thermal curve, press the button, the 3rd

and 4th digits will begin to flash;

8. Press the or buttons to select the parameter that

best meets your temperature requirement shown in

;

9. Once the correct parameter has been set, press the

button again to confirm the selection .

Table D;

Table

TABLE D

NVECTORRADIATOR

EELRADIATOR

ERSIZEDSTEELRADIATOR

NDERFLOOR HEATING -CURVES 0.3 TO 0.5*

-CU

RVES

2.5 T

1.5 T 1 T

1.2

*WHERE CURVE 0.3 OR 0.5 ARE SELECTED, A SYSTEM SAFETY

THERMOSTAT MUST BE CONNECTED TO THE MAIN

PCB TERMINAL 14

(SEE FIG. 29, PAGE 26).

NOTE: DO NOT FIT THE EXTERNAL SENSOR IN THE

EVENT THAT THE BOILER IS BEING USED TO

HEAT AN INDIRECT HOT WATER STORAGE

CYLINDER

14.8 Setting the parallel shift

In the event that the thermal curve set is giving too high or too low a temperature, there are two options, you can either alter the thermal curve as described in Section 14.7 or adjust the parallel shift of the curve.

To adjust the parallel shift, proceed as follows:

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

2. Press the button 5 times to access Menu 6; Press the or buttons to access Menu 6.3;

4. Press the button, the 3rd and 4th digits will flash;

5. Press the or buttons to adjust the parallel shift up and down in steps of 1 between 0 and 20 (see

Table E).

14.9 Completion

For the Republic of Ireland it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813. In addition it is necessary to complete the Commissioning Checklist in Section 24 of this manual (Page

60).

TABLE E

As part of the commissioning process, it is a legal requirement to register all boiler installations or replacements with CORGI.

14. Commissioning and testing (continued)

14.10 Operational checks

. The system must be visually checked for soundness;

2. Fill the condensate trap with water, by pouring 1/

litre of water into the exhaust flue connector (see Fig. 38). N.B. In the event of a prolonged period of

ystem shutdown, the condensate trap should be

illed before any renewed use. A shortage of water

f in the trap could possibly lead to a temporary leakage of fumes into the air, until it refills itself;

3. Ensure that the flue is fitted correctly;

4. Allow the central heating system to warm up and adjust

he central heating temperature control knob 30(Fig.1),

t check the burner modulates between the high and low

ettings;

5. Range rate the thermal power for central heating as

detailed in Section 14.5. To adjust the maximum heating power it is necessary to follow the steps in Section 14.5 Menu 4 (page 30). and adjust in relation to the chart on Page 33 (Fig. 39);

6. Check the gas rate;

7. Record the finding in the Benchmark Commissioning

Checklist (Section 24, Page 60);

14.11 Instructing the end user

1. Hand over these instructions and explain how to use the ime clock and room thermostat and explain how to

t register the guarantee;

2. Show the end user how to switch the appliance off

uickly, and indicate the position of the electric supply

q isolator;

3. Inform the end user of the location of all drains, isolating

valves and air vents;

4. Explain how to turn the appliance off for both short and

long periods and advise on the precautions necessary to prevent damage in the event that the appliance is inoperative when freezing conditions occur;

. Instruct the end user on the correct procedure for

checking and refilling the boiler;

6. Finally advise the end user that, for continued safe and

efficient operation, the appliance must be serviced by a competent person at least once a year and the service logged in the Service Interval Record (Section 25, Page

61).

8. Run the domestic hot water and adjust to the correct water flow rate, adjust the domestic hot water temperature control knob modulates between the high and low settings;

9. Balance the central heating system until all return temperatures are correct and equal;

10. Turn the boiler off by pressing the On/Off button (Fig.1) to OFF, disconnect the gas pressure gauge, retighten the screw and relight the boiler;

11. Re-examine the central heating, domestic hot water and old water supplies for soundness;

12. If external controls have been disconnected, reconnect and test;

13. Refit the boiler casing.

29 (Fig.1) to ensure the burner

Fig. 38

Central Heating Output (kW)

24 kW

30 kW

123

789

Steps (Value P min - P max - Menu 4)

12.5

17.5

22.5

27.5

32.5

9.6

11.2

12.8

14.4

17.6

19.2

20.8

22.4

5 kW

14. Commissioning and testing (continued)

15. Fitting the casing

Fitting the casing

Remove the protective film on the casing;

- Locate the lower clips into the slots in the chassis;

- Engage hooks

- Close the panel mounting clamps (Fig. 41);

- Screw in the clamp locking bolt

Note: it is essential to refit the locking bolt A

N on the casing in notches R on the side panels M (Fig. 40);

Fig. 39

Fig. 40

Fig. 41

16. Sequence of operation

16.1 Central Heating Mode

Activation of the time clock and/or room thermostat starts the boiler. The display panel indicates the flow temperatures in central

eating as illustrated below:

Central heating

ode ON

oom thermostat

R contact ON

ith the boiler in rest, the diverter valve is in the domestic hot water position, activation of the central heating changes the

W position of the motorised valve head, moving the diverter valve into the central heating position.

The start of the pump is delayed for 7 seconds to allow the movement of the diverter valve. The PCB checks the pressure of the primary circuit, if the pressure measured is 0.8 bar or lower, the boiler will lockout after 40 seconds. The error code appear on the LCD and the pump will stop.

If the pressure measured is above 0.8 bar, the boiler ignition sequence will begin.

At first, the fan starts and the speed increases to the required ignition speed (3460 rpm), once this speed has been achieved, the safety coil of the gas valve is supplied with 230V DC, after 8 seconds the boiler checks that the burner has lit, if the boiler does not sense that the burner has lit, the error code relight two more times (20 seconds between each attempt). After this, should the boiler still not sense a flame, error code appear on the LCD.

Should the boiler detect that the burner has lit, the boiler continues to regulate as follows.

E04 will appear on the display, should this error occur, the boiler will attempt to

E02 will

A03 will

The NTC fitted on the outlet of the primary circuit exchanger is the only NTC to adjust the heat output of the boiler according to the adjustable setting point. This point is adjustable from 25°C to 85°C by the user. This NTC relays information to the PCB, which in turn modulates the burner by adjusting the speed of the fan.

When the NTC senses that the set temperature has been achieved (+ 4°C to the temperature set by the user), the burner will go out. To avoid excessive burner lighting, an anti-cycle timer can be set between 0 to 7 minutes in menu Adjustments and Settings).

The speed of the pump can be set at two levels. The PCB controls the speed of the circulation pump depending on the speed set in menu modulate between high and low speed depending on the ∆T between the inlet and the outlet. If the ∆T is greater than 20°C the pump will run on high speed and if the ∆T is less than 20°C the pump will run on low speed.

4 line 41. Setting 410 will cause the pump to operate continually at high speed, and setting 411 will cause the pump to

OTE:THE DEFAULT SETTING FOR THE PUMP IS HIGH SPEED.

4 line 48 (see Section 17

16. Sequence of operation

16.2 Domestic Hot Water Mode

The Domestic Hot Water (DHW) production always has priority over the Central Heating (CH) mode.

When a hot tap is turned on, the DHW flow switch is activated. The minimum DHW flow rate is 2 l/min. If the diverter valve is in

he CH position it will motor into the DHW position and the boiler will start.

The LCD will show that the boiler is working in hot water mode as below:

The appliance follows the same operating logic as described in Section 16.1 Central Heating Mode.

In domestic hot water mode NTC1 limits the maximum temperature of the primary heating circuit to 78°C during DHW production, re-ignition will occur at 74°C. The domestic hot water temperature is limited to 64°C, re-ignition will occur at 62°C.

The NTC

The DHW setting is adjustable from 40°C to 60°C by the user.

The PCB compares the values of the DHW NTC with the setting of the DHW control knob. If the temperature of the DHW NTC is 4°C greater than the temperature set on the DHW control knob, the burner will go off, it will restart when the temperature of the DHW NTC is less than + 2°C of the temperature set on the DHW control knob.

at the end of the plate heat exchanger is the only NTC used for the regulation according to the DHW setting.

17. Adjustments and settings

The boiler is delivered with pre-set values described

n menus

i All settings must only be changed by the installer or

qualified person. To gain access to the setting

a buttons please, open the front control panel cover

(Fig. 42) and follow the instructions below.

3 a

Fig. 42

Fig. 43

DISPLAY

On/Off push button Comfort button

Menu button - button

+ button

2nd digit

1st digit

Reset push button

Setting button

3rd digit

4th digit

Pressing the, comfort, reset, menu, +, -, or setting buttons will make the display light. The light will go out 30 seconds after the

last button has been pressed.

To gain access to the setting menus press the and buttons together for 5 seconds. (Fig. 43). Menu 1 is displayed on

the 1st digit.

Changing the menu :

Press the Menu button (Fig. 43). The menu number is displayed for 3 seconds. Press the menu button again to change

to the next Section.

Setting a parameter in a section :

Press the or button to change from between sections.

Note : When you arrive at the last section of a menu, pressing the button will change to the the 1st section. When you

are at the first section, pressing the button will change to the last section of the menu.

Changing section in a menu (available only for menu 3 and 4) :

Press the setting button

button to select the correct value then press the setting button to select this modification and to exit the setting mode. The

3rd and 4th digit stop flashing.

to enter the modification mode, The 3rd and 4th digits will be flashing, press the or

Recalling the basic configuration :

Select menu 3 or 4 then press the and

to indicate that the operation is completed.

buttons together for more than 5 seconds. The digits will flash

CM for a while

Clearing Menu 1 (default register) :

Select menu 1 then press the and

indicate that the operation is completed.

Note : To exit from setting mode, leave the boiler for approx. 1 minute, the display will switch back to user mode.

buttons together for more than 5 seconds. The digits will flash

CM for a while to

ACTION CONFIGURATION

ISPLAY

5 ”

x times

once

Menu - 1 - Default register

Record of the last 10 faults

Section Digit 1 Digit 2 Digit 3 and 4

Last fault occurred 1 0 code from 01 to 99

Last but one fault occurred 1 1 code from 01 to 99

... 1 ... code from 01 to 99

Last fault occurred before the previous one 1 9 code from 01 to 99

ote --is displayed if no default is recorded

Menu - 2 - Boiler conditions

Indicates the conditions or the configuration of the boiler

Section Digit 1 Digit 2 Digit 3 and 4

Software version of display PCB 2 0 code from 01 to 99

x times

Software version of main PCB 2 1 code from 01 to 99

Flue type 2 2 4 : Condensation

0 : no

Room thermostat is calling for heat 2 3

1 : yes

0 : DHW

Theoretical position of the 3 way valve 2 4

1 : CH

DHW flow temperature in °C 2 5 from 01 to 99

Hot water tank Temperature in °C 2 6 from 01 to 99

CH flow temperature in °C 2 7 from 01 to 99

CH return temperature in

Outside temperature (Flashing when negative temperature)

2 8 from 01 to 99

2 9 from 01 to 99

CTION

once

ection

HW Comfort mode

ONFIGURATION

Menu - 3 - Boiler options

igit 1

3 0

igit 2

igit 3 and 4

0 : permanent

1 : 30 mins

DISPLAY

setting

Factory

x times

DHW thermostatic kit fitted to boiler? (limits DHW temp to 60°C)

Internal time clock action 3 2

DHW flow switch delay

(time before DHW flow detection to override pressure peak problem)

3 1

3 6 0 to 20 1/10 seconds

0 :

1 : yes

0 : central heating and

DHW comfort mode

1 : DHW comfort mode

2 : central heating

CTION

once

x times

ONFIGURATION

Menu - 4 - Boiler settings

Section Digit 1 Digit 2 Digit 3 and 4

Stop pump after burner stops 4 0

Pump speed 4 1

0 :

1 : yes

0 : High speed

1 : Low speed

DISPLAY

setting

Factory

Pump post circulation duration 4 2

4 3

Maximum Central Heating flow temperature

Minimum Central Heating flow temperature

CH anti-cycling delay 4 8

CH maximum output (range rating) 4 9

4 4

4 5

4 6

0 to 5 min by step

0.5 min

50° to 80°

by steps of 1°

25° to 50°

by steps of 1°

0 to 7 min by step

0.5 min

Value from 0 to 10

Pmin & Pmax general

CTION

ONFIGURATION

Menu - 5 - Combustion rate control mode (test mode)

Effect Display

DISPLAY

once

x times

ombustion rate control mode OFF

Combustion rate control mode ON The main exchanger temperature

appears on the display. The digit - on the display shows the gas

utput level.

o (Top = max, bottom = min).

Gas output setting To modify the gas output use the + and -

buttons.

To cancel the combustion rate control mode press the “Menu” button.

The combustion rate control mode will be inactive when :

- boiler is in stand-by mode

- room thermostat is not calling for heat

- boiler in lockout mode

- after the default settings have been restored or if the main supply fails (power cut)

- if the operator exits the 5th menu

- after 5 minutes if no buttons are pressed

Note : As soon as the combustion rate control mode is active, the Central Heating and Domestic Hot Water

control knobs become inactive.

CTION

ONFIGURATION

Menu - 6 - Automatic heating regulation

DISPLAY

once

x times

Section Digit 1 Digit 2 Digit 3 and 4

Regulation on 6 0

Heating setting in

utomatic/manual mode

Thermal Curve setting (see table

Parallel Shift setting (see table

D, page 30)

E, page 30)

6 1

6 2

6 3

0 : External sensor fitted

1 : External sensor not fitted

0 : External sensor not fitted

1 : External sensor fitted

0.3

0.5 1

1.2

1.5 2

2.5 3

from 0 to 20

by steps of 1

setting

Factory

In the event of connection of the external sensor, you must:

1. Activate the external sensor (menu 6.0)

2. Activate the external sensor automatic adjustment (menu 6.1)

3. Program the thermal curve (menu 6.2*)

4. Program the parallel shift (menu 6.3*)

*SEE SECTIONS 14.7 AND 14.8 (PAGE 31) FOR DETAILED INSTRUCTIONS ON SETTING THE THERMAL CURVE AND PARALLEL SHIFT.

17. Adjustments and settings (continued)

H anti cycling delay setting :

If you would like to change the setting of CH anti cycling delay, if you want 3 min, proceed as follows: (NOTE : THE FACTORY SETTING IS 2 MIN 30 SECONDS AND THE FOLLOWING EXPLANATION REFER TO MENU 4 SECTION 8)

Display

witch to installer mode, press button

and for 5 seconds, the

display shows :

default in the default register.

Press 3 times on menu button

gain access to menu

shows :

Change to section 8 (CH anti cycling

delay), press on button 8 times,

the display shows :

setting 2 min 30 seconds)

4 = menu 4

8 = section 8

2.5 = 2.5 min (2 min 30 seconds)

10=0 if there is no

4, the display

40=0 or 40=1

48=2.5 (factory

5 ”

x 3

x 8

Press the setting button one

time, the 3rd and 4th digits flash

together,

change the CH anti cycling delay, the

display shows :

48=3.0 press the setting button

to confirm the value. The display

stops flashing.

Setting procedure is finished.

To exit from setting mode, leave the

boiler for approx. 1 minute then the

PCB will switch back to user mode.

After programming please close the

front control panel cover

page

Then press the

36)

P (Fig. 43

SERVICING INSTRUCTIONS

To ensure efficient safe operation, it is recommended that the

oiler is serviced annually by a competent person, refer to

b Section 20 (page 54) for the Servicing Schedule.

Before starting any servicing work, ensure both the gas and

lectrical supplies to the boiler are isolated and the boiler is

e cool.

Before and after servicing, a combustion analysis should be made via the flue sampling point.

After servicing, preliminary electrical system checks must be carried out to ensure electrical safety (i.e. polarity, earth

ontinuity, resistance to earth and short circuit).

IMPORTANT! AFTER AN ANNUAL SERVICE, THE SERVICE INTERVAL RECORD (SECTION 25, PAGE 60) MUST BE COMPLETED.

18. Replacement of parts

The life of individual components vary and they will need servicing or replacing as and when faults develop. The fault finding sequence chart in 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.

Section 19 will help to locate

18.1 To Gain General Access

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

18.1.1 Removing the front panel :

1. Remove the security screw and unlock the two case

locking catches A (see Figs. 44 & 45);

2. Remove the front panel from the rest of the casing (see Fig. 46)

18.1.2 Lowering the control panel :

1. Remove the front panel;

2. Unlock the two clamps locking and pivot the electrical

box downward

(see Fig. 47).

Fig. 44

Fig. 45

Fig. 46

Fig. 47

18.2 Access to the Combustion Chamber

18.2.1 Removing the air gas assembly

olate the gas supply to the boiler;

1.Is

2. Carry out step 18.1.1;

3. Remove the silencer (Fig. 48);

isconnect the detection electrode

4.D

cable (Fig. 49);

emove the earth cable from the

5.R

ignition electrode (Fig. 50), and remove the ignition electrode cable from the ignitor (Fig. 51)

Fig. 48

6. Unplug the gas valve and fan connectors (Figs. 52 and 53);

Fig. 52

7. Unscrew the 6 nuts D on the

combustion chamber (Fig. 54);

8. Unscrew the gas valve nut E

(Fig. 55);

Fig. 49

Fig. 53

Fig. 50

Fig. 51

9. Remove the air gas assembly and combustion chamber front (Fig. 56);

10. Reassemble in reverse order.

Fig. 54

Fig. 55

Fig. 56

18.2.2 Removing the burner

1. Carry out step 18.1.1 and 18.2.1;

emove the 3 screws

2.R

air/gas manifold (Fig. 57)

F f

;

rom the

3. Slide the burner out from the ront, taking care not to damage the

f insulation (Fig. 58);

4. Reassemble in reverse order and hecking all seals are undamaged

c and the burner is positioned

orrectly (Fig. 59).

Fig. 57

18.2.3 Removing the detection electrode

1. Carry out step 18.1.1;

2. Remove the 2 screws G from the

electrode manifold (Fig. 60);

3. Pull the electrode from the

Fig. 60

18.2.4 Removing the ignition electrode

Fig. 58

combustion chamber (Fig. 61);

Fig. 61 Fig. 62

Fig. 59

4. Disconnect the detection electrode

cable (Fig. 62).

5. Reassemble in reverse order.

1. Carry out step 18.1.1;

2. Remove the earth cable from the

electrode (Fig. 63);

Fig. 63 Fig. 64 Fig. 65

3. Remove the electrode cable H from

the ignitor (Fig. 64);

4. Unscrew the 2 screws I on the

electrode (Fig. 65);

18.2.5 Removing the fan

1. Carry out step 18.1.1;

emove the air gas manifiold as in

2.R

18.2.1 (Fig. 66);

Fig. 66 Fig. 67 Fig. 68

3. Unscrew the two screws from the enturi

v valve (Fig. 67);

nd remove with the gas

J a

4. Unscrew the three screws K on the

ir/gas pipe and remove (Fig. 68);

5. Reassemble in reverse order.

18.2.6 Removing the gas valve

1. Carry out step 18.1.1;

2. Remove the air gas manifiold as in

18.2.1 (Fig. 69);

3. Unscrew the three screws L on the

air/gas pipe and remove (Fig. 70);

4. Unscrew the three screws holding the gas valve on the venturi (Fig.

71);

Fig. 69

5. Remove the gas valve from the venturi. (Fig. 72)

6. Reassemble in reverse order;

7. The gas valve settings will need to

be adjusted (see Section 14.3 page

28);

8. Reinstate the gas supply and test for tightness on reassembly.

;

Fig. 70

Fig. 71

Fig. 72

18.2.7 Removing the heat exchanger

1. Carry out step 18.1.1;

emove the air gas manifiold as in

2.R

18.2.1 (Fig. 73)

;

nscrew the three bolts

3.U

main heat exchanger (Fig. 74);

M f

rom the

emove the flow and return pipes

4.R

and the condense drain pipe from

he heat exchanger. (Fig. 75);

Fig. 73

5. Remove the heat exchanger from the boiler by sliding out. (Fig. 76);

6. Reassemble in reverse order.

Fig. 76

18.2.8 Removing the spark generator

1. Carry out step 18.1.1;

2. Disconnect the earth cable from the

ignition electrode. (Fig. 77);

Fig. 74 Fig. 75

3. Disconnect the ignition electrode, live, neutral and earth cables from the ignitor. (Fig. 78);

4. Remove the two screws N from the

ignitor and remove (Fig. 79);

5. Reassemble in reverse order.

Fig. 77

Fig. 78

Fig. 79

18.3 Access to the Water Circuit

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

18.3.1 Drain down

DHW : close the DHW inlet tap and open a tap on the installation / CH : Close the flow and return isolating valve and

open the pressure relief valve.

8.3.2 Removing the 3 way valve

1. Carry out step 18.1.1 and 18.1.2;

2. Disconnect the wire from the 3 way valve;

emove the clip “P2”and the 3 way valve motor (see Figs. 80 and 81)

3.R

4. Unscrew the two screws “P3” (Fig. 85) and remove the 4 clips “Q1* - Q4”

(see Figs. 82 to 84);

5. Remove the 3 way valve body by pulling it toward you (see Fig. 86); eassemble in reverse order;

6.R

;

See the paragraph

18.3.1 before removing the clips.

Fig. 81

Fig. 82

Fig. 84

Fig. 80

Fig. 83

Fig. 86

18.3.3 Removing the float of the flow switch

1. Remove the clip “Q1” fixing the brass connector (see Fig. 82);

2. Disconnect the connecting pipe;

3. Pull down the brass connector and catch simultaneously the

float (see Figs. 87 &

4. Reassemble in reverse order;

88);

Fig. 85

Fig. 87

Fig. 88

18.3.4 Removing the secondary heat exchanger

1. Carry out step 18.1.1 and 18.1.2;

2. Remove the 3 way valve motor as in step 18.3.2;

isconnect the expansion vessel pipe.

3.D

Fig. 89

18.3.5 Removing the pump

1. Carry out step 18.1.1;

2. Lower the electrical box cover as in step 18.1.2;

Remove the PCB cover;

4. Remove the pump plug from the control board and earth

plug from earth socket (see Fig. 91)

4. Unscrew the two fixing screws R and pull the heat

xchanger toward you

5. Reassemble in reverse order; he heat exchanger is so designed that it cannot be

T remounted incorrectly;

5. Unscrew the pump nut (see Fig. 92);

see Figs. 89 & 90)

(

;

Fig. 90

6. Remove the clip S2 on the pump volute (see Fig. 93);

Fig. 93

Fig. 91

Fig. 92

7. Pull the pump toward you and remove the clip S3 securing

the pressure gauge

8. Reassemble in reverse order.

(see Fig. 94);

Fig. 94

18.3.6 Removing the pressure relief valve

arry out step 18.1.1 and 18.3.1

1.C

2. Remove the clip securing the valve (see Fig.

nd pull it toward you;

3. Reassemble in reverse order; take care to nsure the valve is in the correct position;

;

18.3.7 Removing the expansion vessel

1. Carry out step 18.3.1;

2. Isolate the gas supply and disconnect all pipe

connections;

3. Remove the boiler from the wall

4. Unscrew the nut U (see Fig. 93);

ig. 95

ull the expansion vessel to remove it (see Fig. 94)

5.P

6. Reassemble in reverse order.

;

Fig. 93

18.3.8 Removing the overheat thermostat

1. Remove the casing as in step 18.1.1;

2. Pull off the thermostat connections. Then

remove the thermostat from the pipe by releasing it’s securing clip (see Fig. 95).

Fig. 94

18.3.9 Removing the temperature sensors (N.T.C’s)

1. Remove the casing as in step 18.1.1;

2. Pull off the NTC connections. Then remove

the NTC from the pipe by releasing it’s securing clip

(see Fig. 96).

Fig. 95

Fig. 96

18.3.10 Removing the pressure gauge

18.3.11 Removing the pressure switch

1. Carry out steps 18.1.1 and 18.3.1;

emove the pressure gauge by releasing the two clips

2.R

and pulling the pressure gauge out. (see Fig. 97)

Fig. 97

18.4 Access to the Control System

18.4.1 Removing the P.C.B.s

1. Carry out steps 18.1.1 and 18.1.2;

2. Remove the screw W1 from the electrical box (see Fig.

);

1. Remove the casing as in step 18.1.1 and drain down as in step 18.3.1;

2. Pull off the connections. Then remove the pressure switch by releasing it’s securing clip (see Fig. 98).

Fig. 98

3. Release the three clips W2 and remove the electrical box cover (see Fig. 100);

Fig. 99

4. Remove the two screws W3 from the front control panel

and lower the front control panel (see

Fig. 101);

Fig. 100

5. Remove all electrical connections from the display PCB (see Fig. 102);

Fig. 101

Fig. 102

6. To remove the display PCB, remove the two screw

W4 and lift the PCB out (see Fig. 103);

7. Reassemble in reverse order;

Fig. 103

8. To remove the main PCB disconnect all electrical

connections and remove the two screws W5 (see Fig.

);

104

Fit the correct EEPROM supplied with the replacement PCB;

9. Reassemble in reverse order.

Fig. 104

18.4.2 Removing the fuses

1. Carry out step 18.4.1;

2. Remove the fuses “X” (see Fig. 105)

3. Reassemble in reverse order.

NOTE:FUSE RATING = 2AMP FAST FUSE

Fig. 105

18.5 Connecting the external sensor

1. Access the main PCB as in step 18.4.1;

2. Install the interface PCB supplied in the external

sensot kit on the main PCB

3. Connect the wires between the external sensor and the interface PCB* (see Fig. 106).

* ENSURE THAT THE WIRES FOR THE EXTERNAL SENSOR

ARE CONNECTED TO THE TERMINALS INDICATED IN

110.

(see Fig. 106);

Fig. 106

FIG.

OTE:THE

MPORTANT!!

WIRES ARE NOT POLARITY SENSITIVE

DO NOT FIT THE EXTERNAL SENSOR IN THE EVENT THAT

THE BOILER IS BEING USED TO HEAT AN INDIRECT HOT

WATER

STORAGE

CYLINDER

19. Incorrect function

In case of problem, or when the boiler has displayed an error code, the display flashes 2 digits. Please refer to the table below to diagnose the fault.

For faults 01 and 03, press the reset button 28.

verheating lock out

FAULT

ode

A 03

A 36

A 37

A 39

A 40

A 41

E 02

E 04

E 05

E 06

E 07

E 08

E 09

E 10

E 11

E 12

E 13

E 14

E 15

E 16

E 18

E 20

E 22

E 23

E 29

E30

E33

E 37

E 38

Fault description

Overheat lock out

No flame after safety time

Flue pipe too high temperature

CPU fault

MCU fault 1

MCU fault 2

Fan error

Pump protect

No flame detection

Anti freezing system, pump on

Anti freezing system, pump and burner on

No water circulation in primary circuit

No water in the primary circuit

DHW sensor open circuit

DHW sensor short circuit

Flow sensor open circuit

Flow sensor short circuit

Return sensor open circuit

Return sensor short circuit

Outdoor sensor open circuit (if fitted)

Outdoor sensor short circuit (if fitted)

Flame lift

Flame detect with gas valve off

Fault air pressure switch

Low fan speed

Room thermostat open circuit

Room thermostat short circuit

Floor heating thermostat open circuit (if fitted)

Communication problem with the main PCB

Reset button pressed 5 times in 15 minutes

A appears on the display, the boiler is locked and the reset button illuminates (28). To reset the boiler

Fig. 107

19. Incorrect function (continued)

ault

The boiler doesn’t start

Red indicator alight

Noises in CH system

Radiators rise in temperature During summer season

ause

No gas, no water or no electricity

Air in the gas pipe Purge the air from the gas pipe

Room thermostat switched off Turn the room thermostat up

Overheat lockout (A01) No flame after safety time (A03)

o flame detected (E04)

N Flame lift (E18)

Air presence in CH system or insufficient pressure

Gravity effect in the CH system

Diverter valve sticking

olution

Check gas, water and electrical

upplies, fuses…

Wait for a few minutes Press the reset button 28 (Fig. 107) the red led goes out and the boiler attempts to

e-light.

r If the red indicator lights too frequently, please call your local service centre.

Purge the system of air (Section 14.2, page 29) and increase the system pressure (Section 2, page 6)

Close the heating flow isolating valve (41 Fig. 2, page 5). Don’t forget to open it again before starting the heating.

Remove and Clean

If these solutions do not cure the fault, call a qualified professional

20. Maintenance

20.1 General remarks

It is recommended that the following inspections be carried out on the boiler at least once a year;

1. Check the seals in the water group, and if necessary, replace the gasket and restore the seal to perfect working order;

2. Check the seals in the gas group, and if necessary replace the gaskets and restore the seal to perfect working order;

3. Visually check the overall condition of the boiler;

4. Visually check the combustion, and if necessary, disassemble and clean the burner;

Following inspection 3, disassemble and clean the

5. combustion chamber as necessary;

6. Following inspection 4, disassemble and clean the injector, if necessary;

11. Check the correct operation of the low pressure switch;

12. Check the diverter valve movement;

13. Check the correct operation of the gas group safety devices:

- absence of gas or flame safety device (ionisation);

Check that the electrical connections are correct (as

14. described in Section 13, page 26 Fig 29);

15. Check the efficiency of the production of domestic hot water (test the flow rate and temperature rise);

16. Carry out a general inspection of the boiler;

Check the flue and termination point;

17.

18. Remove any oxide from the detection electrode by using an emery cloth.

7. Clean the primary heat exchanger. (see Section 20.2);

8. Check and adjust the CO Section 14.3);

9. Check the correct operation of the heating safety devices:

- Overheat thermostat

10. Check the correct operation of the flow switches;

2 emissions as necessary (see

20.2 Cleaning the primary exchanger

Cleaning the exhaust side

Remove the air gas assembly (Section 18.2.1). Check that the exhaust passages are free, if there are deposits present, clean the exchanger with compressed air or wash with water or a vinegar based detergent.

20. Maintenance Instructions (continued)

Cleaning the water side

Use detergents that dissolve CaCO3. Leave to act for a short time and then rinse.

Make sure that the detergent does not remain inside the

xchanger.

20.3 Operational test

Unscrew the lower part of the condensate trap and clean it. Fill it with water and replace.

After carrying out the maintenance operation, fill the heating circuit to a pressure of approximately 1.5 bar and release the air from the system. Also fill the domestic hot water system.

- Place the boiler in operation.

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

- Check the settings, seals and the correct functioning of the system for expelling the products of combustion and drawing combustion air.

- Check the settings and correct operation of all the control, regulation and monitoring components.

- Check that the burner ignites properly and carry out a visual check of the burner flame.

- Check that the 3 bar safety valve is operating correctly.

- Check the operation of the time control and room thermostat (if fitted).

OTE:THESE CHECKS ARE NOT EXHAUSTIVE

ONCE THE BOILER HAS BEEN SERVICED IT IS NECESSARY TO

COMPLETE THE

61)

SERVICE INTERVAL RECORD (SECTION 25, PAGE

21. Short spares list

231

101

110

204

401

DescriptionKey N°

100 HEAT EXCHANGER

101 HEAT EXCHANGER 24KW 61313760

HEAT EXCHANGER 30KW 61313763

G.C N°

Manf. Pt. N°

407

554

537

589

Type

507

709

543

502

707

506

531

532

538

COMBI

707

705

Manf. date

from to

200 FAN ASSEMBLY

204 TEMPERATURE PROBE 990686 231 GASKET D:129.4 61306030

400 GAS SECTION

401 GAS SECTION ASSY 61307584

GAS SECTION ASSY 61310129

407 FAN ASSY 61314434

500 HYDRAULIC BLOCK

502 MOTOR - THREE-WAY VALVE 61302483 506 VALVE KIT 61311597 507 OVERHEAT THERMOSTAT 100 531 AIR SEPARATOR HEAD ASSEMBLY 61304608 532 GASKET KIT 61304618 537 PRESSURE RELIEF VALVE 61312668 538 PUMP + AIR SEPARATOR 15/50 61301964

PUMP + AIR SEPARATOR 15/60 61303461

543 FLOW SWITCH SENSOR 61311745 554

PRESSURE SENSOR 0.8B 61310364

589 WATER/WATER HEAT EXCHANGER 61302409

WATER/WATER HEAT EXCHANGER 61314111

700 ELECTRICAL BOX

705 PRESSURE GAUGE 61313561 707 PRINTED CIRCUIT BOARD 65102353

PRINTED CIRCUIT BOARD ADJUST. 61312782 PRINTED CIRCUIT BOARD CONNECT. 61314958

709 IGNITER 61002105-20

61010572

22. Notes

23. Technical data

Model COMBI A 24 MFFI

E certificate

Performance category ****

NoX class 5

Category II2H3P

entral Heating input (min/max) kW

Central Heating output (min/max) 80°C/60°C kW 7 to 24

Central Heating output (max) 50°C/30°C kW 26

omestic Hot Water input (max) kW

Domestic Hot Water output (max) kW 24

SEDBUK rating / SAP efficiency Band / % A / 90.0

Nominal gas flow rate (15 °C-1013 mbar) min max

Central Heating & DHW flow rate Qn kW 7.5 25

G 20 (NG H -Lacq) 34.02 MJ/m3under 20 mbar Vr m3/h 0.79 2.65

G 31 (Propane) 46.4 MJ/kg 37 under mbar Vr kg/h 0.58 1.94

Membrane Diameter (mm)/marking

G 20 mm without

G 31 (propane) mm 4.4

312-BP-4083

.5 to 25

Adjustable heating outlet temperature: °C 25 to 85

Central heating minimum flow rate I/h 300

Central heating circuit maximum pressure Pw max bar

Central heating expansion vessel capacity L 6

Expansion vessel inflation pressure bar 0.7

Adjustable hot water temperature °C 40 to 70

Minimum DHW ignition flow rate l/min. 2

DHW specific flow rate (∆T: 35oC) I/min.

DHW start minimum pressure

Maximum pressure of DHW circuit Pw max bar

DHW expansion vessel L without

Electric voltage 230 volt, single phase - 50 Hz

Electrical input power W 150

Electrical protection IPX 4D

Fresh air flow rate required for combustion

Mass flow rate for combustion products g/s 10.9

Fume temperature (60-80) °C 79

Fume temperature (30-50) °C 60

CO2 G20 % 9.5

CO2 G31 % 10

Dimensions

Weight kg 37

Flue duct type C13 C33 C43 C53

Maximum Flue Length (Ø 60/100) m

Maximum Flue Length (Ø 80/125) m 10

Maximum Flue Length (

Ø 80/80) m

Pw min

Height / Width / Depth (mm)

bar

h. 29

2.5

9.8

0.5

720 / 390 / 296

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

odel

CE certificate 1312-BP-4084

erformance category

NoX class 5

Category II2H3P

Central Heating input (min/max) kW 9.4 to 30

Central Heating output (min/max) 80°C/60°C kW 9 to 29

Central Heating output (max) 50°C/30°C kW 32

Domestic Hot Water input (max) kW 30

omestic Hot Water output (max) kW

SEDBUK rating / SAP efficiency Band / % A / 90.2

Nominal gas flow rate (15 °C-1013 mbar) min max

Central Heating & DHW flow rate Qn kW 9.4 30

G 20 (NG H -Lacq) 34.02 MJ/m3under 20 mbar Vr m3/h 0.99 3.17

G 31 (Propane) 46.4 MJ/kg 37 under mbar Vr kg/h 0.73 2.33

Membrane Diameter (mm)/marking

G 20 mm Not Used

G 31 (propane) mm 4.8

OMBI A 30 MFFI

***

Adjustable heating outlet temperature: °C 25 to 85

Central heating minimum flow rate I/h 300

Central heating circuit maximum pressure Pw max bar 2.5

Central heating expansion vessel capacity L 6

Expansion vessel inflation pressure bar 0.7

Adjustable hot water temperature °C 40 to 70

DHW ignition flow rate l/min. 2

DHW specific flow rate (∆T: 30 K) D I/min. 15.0

DHW start minimum pressure Pw min bar 0.5

Maximum pressure of DHW circuit Pw max

DHW expansion vessel

Electric voltage 230 volt, single phase - 50 Hz

Electrical input power W 150

Electrical protection IPX 4D

Fresh air flow rate required for combustion V m3h. 36

Mass flow rate for combustion products 13.5

Fume temperature (60-80)

Fume temperature (30-50)

CO2 G20 % 9.2

CO2 G31 % 10

Dimensions Height / Width / Depth (mm) 720 / 390 / 360

Weight kg 40

Flue duct type C13 C33 C43 C53

Maximum Flue Length (Ø 60/100) m

Maximum Flue Length (Ø 80/125) m

Maximum Flue Length (Ø 80/80) m

bar

none

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

24. Benchmark Commissioning Checklist

25. Service Interval Record

TERMS AND CONDITIONS OF GUARANTEE

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

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

• The reason for any service visit is as a direct result of a failure to install the appliance in accordance with the manufacturer’s instructions.

• Your installer does not complete the necessary commissioning process and procedure as detailed in the Installation and Operating Instructions.

• Your appliance is not serviced on or before the 12 month anniversary of installation - this only applies to appliances with a 2 and 5 year guarantee.

• Our service engineer calls as requested and the failure is a non-manufacturing defect.

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

On the 12 month anniversary of the appliance installation, you must have it serviced to continue any guarantee offered into the following year. Failure to do

illinvalidate your guarantee and should an MTS

o w

s engineer be required to attend and no proof of service documentation is made available, then MTS

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

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

will charge.

099841832212 b - 03/2005

Technical Department on 0870 241 8180

Please remove the completed boiler

commissioning checklist sticker from the

front of the boiler and place in this box

for customer reference

Commercial subsidiary: MTS

Manufacturer: MTS SA - France

(GB) Limited,

Building, Hughenden Avenue, High Wycombe, Bucks HP13 5FT

MTS

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

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

Ariston COMBI A 24 MFFI, COMBI A 30 MFFI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual