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 DEPARTMENTCUSTOMER SERVICE DEPARTMENT
Tel: 0870 241 8180Tel:0870 600 9888
Fax: 01494 459775Fax: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
USER INSTRUCTIONS ........................................................................................................................................5
1 CONTROL PANEL...........................................................................................................................................5
2 HOW TO USE ..................................................................................................................................................6
9 HYDRAULIC DATA .......................................................................................................................................13
14.11INSTRUCTING THE END USER.......................................................................................................... 32
15 FITTING THE CASING .................................................................................................................................
16 SEQUENCE OF OPERATION...................................................................................................................... 34
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
1
18.2.4 Removing the ignition electrode............................................................................................................ 45
8.2.5Removing the fan.................................................................................................................................. 46
1
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
18.3.5 Removing the pump.............................................................................................................................. 49
18.3.6 Removing the pressure relief valve ..................................................................................................... 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
20.1 GENERAL REMARKS ............................................................................................................................. 54
20.2 CLEANING THE PRIMARY EXCHANGER ............................................................................................. 54
20.3 OPERATIONAL TEST ............................................................................................................................. 55
21 SHORT SPARES LIST ................................................................................................................................. 56
23 TECHNICAL DATA ....................................................................................................................................... 58
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.
4
1. Control Panel
USER INSTRUCTIONS
16
29
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 knoband temperature setting
30.- Central Heating control knob and temperature setting
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.
l
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
3
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,
26Power ON
OPENCLOSED
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
2.
is drawn, the secondary heat exchanger is kept warm
permanently.
When the boiler is operating in ‘comfortmode’ 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.
6
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
CH
•
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.
°
7
3
6
9
12
11
22
33
44
55
66
77
88
99
1010
1111
1212
1313
1414
1515
1616
1717
1818
1919
2020
2121
2222
2323
2424
99
66
1212
I
6. Setting the time clocks (continued)
6.1Setting the Mechanical Clock
Fig. 3
A
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.
C
B
8
6. Setting the time clocks (continued)
6.2Setting 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.
9
6. Setting the time clocks (continued)
Entering the switching times
ou have 20 memory Iocations available. Each switching time takes up one memory location.
Y
eep pressing the “Prog” button until a free memory location is shown in the display “– –:– –”.
K
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
1
2 3 4 5= Monday – Friday
1
7=Saturday – Sunday
6
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.
10
7. Description
10
2
3
8
20
22
21
12
6
INSTALLER INSTRUCTIONS
- Steel chassis complete with expansion vessel
1
9
7
4
5
42
1.
2.- Sealed chamber
3.- Burner and heat exchanger assembly
4.- Air / gas connection
- 24 V modulating fan
5.
6.- Gas valve
- Ignition electrode
7.
8.- Ionisation probe
- Ignitor
9.
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
13
16
Fig. 5
29
26
25
27
28
14
15
23
11
Fig. 6
30
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 knoband temperature
setting
30.- Central Heating control knob
temperature setting
31.- Menu button
32.- Reducing button
33.- Increasing button
34.- Setting button
and
17
18
19
Fig. 7
31
32
33
34
11
8. Dimensions
440
450 mini pour entretien
All dimensions in mm
96 (24 kW)
2
360 (30 kW)
afety valve C/H and condensate
IS
eating flow
J
H
K
D.H.W. outlet
L
Gas supply
M
Cold water inlet
N
Heating return
eight with packaging :
W
24 kW : 37 kg
30 kW : 40 kg
Minimum space required 450mm
Fig. 9
390 mm
12
NOTE:THE CLEARANCES STATED ABOVE ARE REQUIRED FOR SERVICING PURPOSES
9. Hydraulic data
20406080100 120140 160180200220 240
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1,8
1.9
2.0
260280
40°C
50°C
60°C
70°C
80°C
0
0.05
0
.1
0
.15
0
.2
0
.25
0.3
0.35
0
.4
0.45
0
200400600800100012001400
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.
v
aximum volume of expansion vessel: 6 litres.
M
ressure: 1 bar.
P
Pump Head Graph (15/50)
Pressure (bar)
The volume of the expansion vessel in a pressurised
ppliance varies according to:
a
- 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.
a
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
13
E
E
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.
i
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 7593:1992Treatment of water in domestic hot
water central heating systems
BS 5546:2000Installation of hot water supplies for
domestic purposes
BS 5440-1:2000 Flues
BS 5440-2:2000 Air Supply
BS 5449:1990Forced circulation hot water systems
BS 6798:2000Installation 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 7671:2001IEE Wiring Regulations
BS 4814:1990Specification for expansion vessels
BS 5482:1994Installation 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 opening300
B - Below gutters, solid pipes or drain pipes75
C - Below eaves200
D - From vertical drain pipes and soil pipes75
E - From internal or external corners300
F - Above ground on a public walkway or patio2100
G - From a surface facing a terminal2500
H - From a terminal facing a terminal2500
Vertically from a terminal in the same wall1500
-
I
J - Horizontally from a terminal in the same wall300
K - Horizontally from an opening window 300
Fixed by vertical flue terminal
-
L
NOT BE INSTALLED IN A PLACE LIKELY TO
NOTE:
T
HE
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. 813Domestic 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
14
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
E
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;
b
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.
c
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.
o
and must be inserted by at least 50mm
15
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.
m
iii) Terminating into a gully, below the grid level but above
the water level.
iv) Into a soakaway.
N
O
: If any condensate pipework is to be installed
TE
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.
b
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).
16
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.
M
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)
17
1
2
11. Installing the boiler (continued)
ig. 12
F
A
A
Fig. 13
P
P
Fig. 14
18
Fig. 15
5
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.
c
O
:SE
N
TE
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
T
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
/4
LITRE OF
BLES
A, B ANDC)
ig. 16
F
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
19
12.1 Fitting the coaxial flue (Ø 60/100 Horizontal)
CO
1X SI
NTENTS
LICONE
:
-R
I
NG
60mm)
(
O
1X ELBOW (90O)
2X WALLSE
X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100)
1
1X FLUECL
1X SC
REWS
x Seal
1
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
U
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.
s
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.
N
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
.
o
elbow
20
Seal
Clamp
Screws
ig. 19
F
Fig. 20
21
12.3 Fitting the Coaxial Flue (Ø 60 / 100 Vertical)
NOTE:
S
E
E PAGE
4
2
F
OR MAXIMUM AND MINIMUM FLUE RUNS
.
CONTENTS:
1X SILICONE O-RING (60mm)
1X CO
NICALADAPTOR
1X VE
RTICALFLUEKIT
X SC
3
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
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 5 metres, for each additional 90
Fig. 21.
o
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.
22
Fig. 21
Fig. 22
12. Connecting the flue (continued)
123.5141
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:
T
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;
3
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
C)
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
o
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
23
123.5
200
107
25
12. Connecting the flue (continued)
ø 100
60 mm
ig. 25
F
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
A
TABLE
B
TABLE
C
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 lengthMax. length
0.3 m5m
Min lengthMax. length
0.3 m10 m
0.3 m10 m
Min lengthMax. length
10 m
10 m
(30m air / 30m exhaust)
(30m air / 30m exhaust)
60 m
60 m
Fig. 26
Length
equivalency for
o
45
elbow
o
90
elbow
o
45
elbow
o
90
elbow
o
45
elbow
o
90
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.
24
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
25
13. Electrical connections
aking the Electrical Connections
M
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
R
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).
n
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.
9Auxiliary 230V Connector
10Actuators 230V
11Time Clock Connector (Internal)
12Room Thermostat Connector
13Remote Control
14Under Floor Heating Connector
15Not Used
Connector
6
Connector
Connector
8
97
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).
D
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
CONNECTOR 12 ON
PCB, SEE FIG. 31
CONNECTOR 12 ON
PCB, SEE FIG. 31
Fig. 30
27
13. Electrical connections (continued)
5
4
3
2
1
G
B
R
13.1Fitting 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);
a
NOTE: THE WIRES MAY BE TUCKED BEHIND THE ELECTRICAL COVER.
-Connect the clock wires as follows;
ME
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
28
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.
F
I
LLING THEHEATINGSYSTEM
emove the front casing panel and lower the control panel
R
:
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
F
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
5)
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.
A
TERTREATMENT
W
:
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;
g
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;
2.
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
29
14. Commissioning and testing (continued)
14.3 Adjusting the CO2
. Remove the casing panel as described in Section 18.1
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;
p
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.
4
5. Access the setting menu by pressing the and
keys for 5 seconds theicon 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).
f
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
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;
Q
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);
30
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.
h
To set up the external sensor, proceed as follows;
. Access the settings menu by pressing the and
1
buttons for five seconds;
. Press the button 5 times to access Menu 6;
2
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
;
D
9. Once the correct parameter has been set, press the
button again to confirm the selection .
Table D;
Table
TABLE D
CO
NVECTORRADIATOR
ST
EELRADIATOR
V
O
ERSIZEDSTEELRADIATOR
NDERFLOOR HEATING-CURVES 0.3TO0.5*
U
-CU
-CU
-CU
RVES
RVES
RVES
2.5T
1.5T
1T
3
O
2
O
1.2
O
*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;
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.
31
14. Commissioning and testing (continued)
14.10 Operational checks
. The system must be visually checked for soundness;
1
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
s
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;
s
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);
2
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
5
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
26
32
Fig. 38
1
Central Heating Output (kW)
24 kW
30 kW
0
123
4
56
789
10
Steps (Value P min - P max - Menu 4)
10
12
14
16
18
20
22
24
26
28
30
10
12.5
15
17.5
20
22.5
25
27.5
30
32.5
35
8
9.6
11.2
12.8
14.4
16
17.6
19.2
20.8
22.4
2
4
3
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);
A;
N
M
R
Fig. 39
A
Fig. 40
Fig. 41
33
16. Sequence of operation
16.1Central 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:
h
Central heating
ode ON
m
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.
N
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
34
16. Sequence of operation
16.2Domestic 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.
t
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.
35
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.
P.
3 a
nd
4.
Fig. 42
Fig. 43
DISPLAY
On/Off push buttonComfort button
Menu button- button
+ button
2nd digit
1st digit
Reset push button
Setting button
P
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
36
ACTIONCONFIGURATION
ISPLAY
D
5 ”
x times
once
Menu - 1 - Default register
Record of the last 10 faults
SectionDigit 1Digit 2Digit 3 and 4
Last fault occurred10code from 01 to 99
Last but one fault occurred11code from 01 to 99
...1...code from 01 to 99
Last fault occurred before the previous one19code from 01 to 99
ote --is displayed if no default is recorded
N
Menu - 2 - Boiler conditions
Indicates the conditions or the configuration of the boiler
Section Digit 1Digit 2Digit 3 and 4
Software version of display PCB20code from 01 to 99
x times
Software version of main PCB21code from 01 to 99
Flue type224 : Condensation
0 : no
Room thermostat is calling for heat23
1 : yes
0 : DHW
Theoretical position of the 3 way valve24
1 : CH
DHW flow temperature in °C25from 01 to 99
Hot water tank Temperature in °C26from 01 to 99
CH flow temperature in °C27from 01 to 99
C
CH return temperature in
Outside temperature
(Flashing when negative temperature)
°
28from 01 to 99
29from 01 to 99
37
CTION
A
once
ection
S
HW Comfort mode
D
ONFIGURATION
C
Menu - 3 - Boiler options
igit 1
D
30
igit 2
D
igit 3 and 4
D
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 action32
DHW flow switch delay
(time before DHW flow detection to
override pressure peak problem)
31
360 to 20 1/10 seconds
no
0 :
1 : yes
0 : central heating and
DHW comfort mode
1 : DHW comfort mode
2 : central heating
38
CTION
A
once
x times
ONFIGURATION
C
Menu - 4 - Boiler settings
SectionDigit 1Digit 2Digit 3 and 4
Stop pump after burner stops40
Pump speed41
no
0 :
1 : yes
0 : High speed
1 : Low speed
DISPLAY
setting
Factory
Pump post circulation duration42
43
Maximum Central Heating flow
temperature
Minimum Central Heating flow
temperature
CH anti-cycling delay48
CH maximum output (range rating)49
44
45
46
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
39
CTION
A
ONFIGURATION
C
Menu - 5 - Combustion rate control mode (test mode)
EffectDisplay
DISPLAY
once
once
x times
ombustion rate control mode OFF
C
Combustion rate control mode ONThe main exchanger temperature
appears on the display.
The digit - on the display shows the gas
utput level.
o
(Top = max, bottom = min).
Gas output settingTo 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.
40
CTION
A
ONFIGURATION
C
Menu - 6 - Automatic heating regulation
DISPLAY
once
x times
Section Digit 1 Digit 2Digit 3 and 4
Regulation on60
Heating setting in
utomatic/manual mode
a
Thermal Curve setting
(see table
Parallel Shift setting
(see table
D, page 30)
E, page 30)
61
62
63
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.
41
17. Adjustments and settings (continued)
H anti cycling delay setting :
C
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
1
2
3
witch to installer mode, press button
S
andfor 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
1
to
2
5 ”
x 3
or
3
x 8
42
4
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)
4
to
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).
c
IMPORTANT!
AFTER AN ANNUAL SERVICE, THE SERVICE INTERVAL RECORD (SECTION
25, PAGE 60) MUST BE COMPLETED.
18. Replacement of parts
A
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
43
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.
44
E
D
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
F
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).
c
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
G
Fig. 60
18.2.4 Removing the ignition electrode
Fig. 58
combustion chamber (Fig. 61);
Fig. 61Fig. 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. 63Fig. 64Fig. 65
3. Remove the electrode cable H from
the ignitor (Fig. 64);
H
4. Unscrew the 2 screws I on the
electrode (Fig. 65);
I
45
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. 66Fig. 67Fig. 68
3. Unscrew the two screws from the
enturi
v
valve (Fig. 67);
nd remove with the gas
J a
J
4. Unscrew the three screws K on the
ir/gas pipe and remove (Fig. 68);
a
5. Reassemble in reverse order.
K
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.
;
L
Fig. 70
Fig. 71
46
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
M f
rom the
emove the flow and return pipes
4.R
and the condense drain pipe from
he heat exchanger. (Fig. 75);
t
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. 74Fig. 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
N
Fig. 79
47
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
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.
Q1
Fig. 81
Fig. 82
Q2
P1
P2
Q4
Fig. 84
Q3
Fig. 80
P3
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;
48
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
R
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;
3.
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
e
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);
S2
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);
S3
Fig. 94
49
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;
a
5)
9
3. Reassemble in reverse order; take care to
nsure the valve is in the correct position;
e
;
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
F
ull the expansion vessel to remove it (see Fig. 94)
5.P
6. Reassemble in reverse order.
;
U
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).
50
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)
V
Fig. 97
18.4Access 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.
);
99
V
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);
W1
Fig. 99
4. Remove the two screws W3 from the front control panel
and lower the front control panel (see
Fig. 101);
W3
W2
Fig. 100
5. Remove all electrical connections from the display PCB
(see Fig. 102);
Fig. 101
Fig. 102
51
6. To remove the display PCB, remove the two screw
W4 and lift the PCB out (see Fig. 103);
7. Reassemble in reverse order;
W4
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.
W5
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
X
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.
52
OTE:THE
N
I
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
O
FAULT
ode
C
A
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
01
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
28
Fig. 107
53
19. Incorrect function (continued)
ault
F
The boiler doesn’t start
Red indicator alight
Noises in CH system
Radiators rise in temperature During
summer season
ause
C
No gas, no water or no electricity
Air in the gas pipePurge the air from the gas pipe
Room thermostat switched offTurn 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
S
Check gas, water and electrical
upplies, fuses…
s
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;
54
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.
e
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
N
ONCE THE BOILER HAS BEEN SERVICED IT IS NECESSARY TO
COMPLETE THE
61)
SERVICE INTERVAL RECORD (SECTION 25, PAGE
55
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
F
.
507
709
543
502
707
506
531
532
538
24
30
A
A
COMBI
COMBI
F
F
F
707
705
Manf. date
from to
.
200 FAN ASSEMBLY
204 TEMPERATURE PROBE 990686
231 GASKET D:129.461306030
400 GAS SECTION
401 GAS SECTION ASSY 61307584
GAS SECTION ASSY61310129
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 VALVE61312668
538 PUMP + AIR SEPARATOR 15/5061301964
This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.
59
24. Benchmark Commissioning Checklist
60
25. Service Interval Record
61
62
63
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:
A
•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
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