Ariston GENUS 30 Plus Installation and Servicing Manual

End User, Installation &

D a y

Servicing Instructions Type C Boilers

G.C.N: 47-116-28

LEAVE THESE INSTRUCTIONS WITH THE END USER

TABLE OF CONTENTS

. General Information

2. Control Panel

3. How to Use

. Anti-Frost Device

5. Maintenance

6. Trouble Shooting

7. Filling Instructions

8. Time Clock

8.1

8.2 Setting the Digital Clock

9.1 Overall View

Setting the Mechanical Clock

General Information for the Installer

10. Installation

10.1 Delivery

10.2 Reference Standards

10.3 Siting the Appliance

10.4 Clearances

10.5 Overall View

10.6 Mounting the Appliance

10.7 Electrical Connection

10.8 Gas Connection

10.9 Water Connections

16. Gas Adjustments

16.1 Changing the Type of Gas

17. Maintenance

18. Servicing Instructions

18.1 Replacement of Parts

18.2 To Gain General Access

18.2.1 Removing the front panel

18.2.2 Removing the control panel

18.3 Access to the Control System

8.3.1 Removing the main PCB

18.3.2 Removing the display PCB

18.3.3 Removing the fuses

18.3.4 Removing the programmer

18.4 Access to the Sealed Chamber

18.4.1 Removing the sealed chamber front panel

18.4.2 Removing the combustion chamber front panel

18.4.3 Removing the burner

18.4.4 Removing the electrodes

18.4.5 Removing the burner manifold

18.4.6 Removing the main exchanger

18.4.7 Removing the air pressure switch

18.4.8 Removing the fan

18.5 Access to the Gas Valve

18.5.1 Removing the spark generator

18.5.2 Removing the gas valve

11. Connecting the Flue

11.1 Flue Connections

11.2 Fitting the Coaxial Flue (Ø 60/100 mm Horizontal)

11.3 Fitting the Telescopic Flue (Ø 60/100 mm Horizontal)

11.4

11.5

Fitting the Coaxial Flue (Ø 60/100 mm - Vertical) Fitting the Twin Pipe (Ø 80/80 mm)

12. Electrical Connections

13. Electrical System Diagrams

14.

15.

15.1

15.2 Completion

15.3 Removal and Fitting of the Case - Servicing

15.4 Control Panel

15.5 Initial Start-Up

15.6 Sequence of Operation

15.7 Operational

15.8 Combustion Analysis

15.9 Boiler Safety Systems

Water Circuit Diagrams

Commissioning

Initial Preparation

Adjustments

18.6 Access to the Water Circuit

18.6.1

18.6.2 Removing the display PCB

18.6.3 Removing the heating return filter

18.6.4 Removing the by-pass

18.6.5 Removing the pressure relief valve (3 bar)

18.6.6 Removing the pressure relief valve (6 bar)

18.6.7

18.6.8

18.6.9 Removing the expansion vessel

18.6.10 Removing the overheat thermostat

18.6.11 Removing the heating temperature sensor

18.6.12 Removing the tank temperature sensor

18.6.13 Removing the DHW flow switch

18.6.14

18.6.15

18.6.16 Removing the tank

19.

Drain down

Removing the temperature & valve (7 bar) Removing the pump

Removing the DHW Removing the flow limiter

expansion vessel

Fault Finding Guide

pressure relief

20. Short Spares List

21. Technical Information

Dear Customer,

Thank you for choosing an ARISTON boiler.

We guarantee that your boiler is a reliable and technically sound product.

The following Instructions provide detailed instructions and recommendations for proper installation, use and maintenance.

Remember to keep this manual in a safe place for future reference e.g. by the gas meter.

Your local MTS Servicing Centre is at your complete disposal for all requirements.

TS (GB) Limited

The guarantee on this appliance is valid

for 24 months from the first day of

Repairs to the electric, hydraulic or gas circuits may be carried out only by your local authorised MTS Servicing Centre.

installation.

CAUTION 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. 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 or suspected that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.

Every attempt has been made to avoid

errors of any kind in this instruction

manual, the Management invites

customers to inform of any

inaccuracies which they may find. This

will help to improve our service.

IMPORTANT

Please read this manual carefully.

Please ensure this manual is kept with the appliance so that they can be used by the end-user, installer or our authorised engineer.

1. GENERAL

FF ON

1 2 3 4 1

2 3 4

Day

INFORMATION

MTS (GB) Limited support the initiative. Your installer will give you, and show you how to use, a Log Book which will give you important information about your boiler and heating system. Please

ave this Log Book to hand whenever you contact a service engineer or

h us.

All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI direct on :- (01256) 372300.

This is a combined appliance for the production of central heating (C.H.)

ust be used only

nd domestic hot water (D.H.W.). This appliance

or the purpose for which it is designed. The manufacturer declines all

liability for damage caused by improper or negligent use. Do not allow children or inexperienced persons to use the appliance without supervision. If you smell gas in the room,

do not turn on or off light switches, use the telephone or any other object which might cause sparks. Open doors and windows immediately to ventilate the room. Shut the gas mains tap (on the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately. If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.

2. CONTROL PANEL

Before any intervention within the boiler it is first necessary to cut off the electrical power supply by turning the external switch to the off position.

Legend:

25 - Selector Knob :

Central Heating and Hot Water Hot Water Only

O Stand-by

Central Heating Only 26 - D.H.W. temperature control knob 27 - C.H. temperature control knob 28 - Heating temperature indicator and diagnostic

indicator 29 - Green indicator - Power ON 30 - Orange indicator - Burner ON 31 - Red indicator - Lock out / flame failure 32 - Reset button 33 - Pressure gauge

Time clock (digital model shown)

34 -

3. HOW TO USE

FF ON

1 2 3 4 1

2 3 4

Day

FIG. 3.1 FIG. 3.2

GAS COCK CLOSED

GAS COCK OPEN

Switching on

1. Check that the pressure in the heating system is adequate, i.e. the pressure gauge

33 shows 1 bar

minimum and 1.5 bar maximum.

2. Check that the gas service tap

Figs. 3.1 and 3.2)and that the mains power is on,

(

he green indicator

he boiler is now ready to use.

39 (Fig. 3.3) is opened

ill light.

Note : If the boiler has been turned off for some time,

the presence of air in the gas pipe may result in a lockout.

To obtain hot water only

Turn the selector switch 25to the « » position, the

reen LED

ndicate that the burner is alight.

ill light; the orange LED30will light to

29w

- To adjust the temperature of the domestic hot water,

it is necessary to rotate the control knob

26 «» clockwise to increase and anti-clockwise to decrease the temperature until the desired temperature is achieved.

NOTE

On initial start-up, if the boiler has been switched off for any period of time or when the storage tank is emptied of hot water, it will be necessary for the storage tank to be heated before hot water can be drawn. It will also be necessary for occasional reheating of the storage tank to maintain the temperature set on the hot water control knob

26 (this will happen automaticall as long as the boiler is powered, operating normally and the selector switch 25 is set to one of the hot water positions or

To obtain central heating and domestic hot water

green LED

29 will lightt; the orange LED 30 will light to

25 to the « » position, the

Turn the selector switch

indicate that the burner is alight.

- Upon a demand for domestic hot water the operation of the central heating will be interrupted until the hot water tank has been reheated to the set temperature.

- The control knob

27 « » allows you to adjust the water temperature in the central heating circuit according to seasonal requirements.

- Turn the control knob

27:

- Clockwise in cold weather

- Anti-clockwise in mild weather (by turning the knob fully anti-clockwise, the Central Heating will switch off).

FIG. 3.3

- The LEDs

28 will display the temperature of the

water in the central heating circuit.

- Furthermore, your home must be fitted with a room thermostat, ensure it is set to the desired indoor temperature.

- The orange LED

30 will light each time the burner

operates.

To obtain central heating only

- Turn the selector switch 25 to the « » position, the green LED 29 will light.

- Ensure that the time clock is on (see S

hermostat is calling for heat.

- The control knob

27 « » allows you to adjust the water

ECTION 8), and that the room

temperature in the central heating circuit according to seasonal requirements.

- Turn the control knob

27:

- Clockwise in cold weather

- Anti-clockwise in mild weather (by turning the knob too far, the Central Heating will switch off). The LEDs

entral heating circuit.

ill display the temperature of the water in the

- Furthermore, your home must be fitted with a room thermostat, set it to the desired indoor temperature.

The orange LED

ill light each time the burner operates.

30w

Stopping the central heating

- Turn the selector switch 25 to the “ ” position. In this state the boiler will only produce domestic hot water, alternatively, you can turn the time clock off or turn the room thermostat down.

Stand-by mode

- Turn the selector switch 25 to the «O » position, the green LED 29 will remain alight. The appliance will remain in stand-by mode unless the anti-frost device is activated.

Turn off the appliance*

- Turn the selector switch 25 to the «O» position

- Turn off the external power supply to the boiler.

4. ANTI-FROST DEVICE

MAINTENANCE

* NOTE: IN THIS STATE THE APPLIANCES ANTI-FROST DEVICE IS INACTIVE

The boiler is fitted with a device, which in the event that the water temperature falls below 8 temperature of 18 temperature falls below 3 Hot Water and the burner fires on minimum power until a temperature of 33

C is attained.

C the pump activates and runs until a

C is attained. In the event that the water

C, the diverter valve switches to Domestic

This device is only activated when the boiler is operating perfectly and

the system pressure is sufficient;

- the boiler is powered electrically;

- gas is available.

Schedule an annual maintenance check-up for the boiler with a CORGI registered Service Engineeer in the UK and with a competent person as described in I.S.813 for IE.

Correct maintenance always results in savings in the cost of running the system.

6. TROUBLE

OFF ON

1 2 3 4 1

2 3 4

Day

SHOOTING

FIG. 6.1

Incorrect functions are signalled by the diagnostic indicator LED

31 display flashing. Contact your local

authorised Servicing Centre (unless a low water fault is

ndicated, in which case refer to Section 7 for filling

i instructions).

7. FILLING INSTRUCTIONS

A method for initially filling the system and replacing lost water during servicing and initial filling (in accordance with current Water Regulations), is provided as an integral part of the connection kit (see Fig. 7.1).

To fill the system and replace lost water it is necessary to proceed as follows:

- Switch off the power to the boiler;

- Ensure that the flexible hose is connected to both the cold water inlet connection and the C.H. flow connection;

- Open the black lever on the valve for the C.H. return connection and slowly open the black handle on the valve for the cold water inlet until water is heard passing through the valves;

- Once the pressure gauge

33 (Fig. 6.1) reads between 1 and 1.5 bar close the levers on both the cold water connection and the C.H. return connection

- Switch the power to the boiler back on.

NOTE: THE FLEXIBLE HOSE MUST BE REMOVED ONCE THE

SYSTEM HAS BEEN FILLED

FIG. 7.1

8. TIME CLOCK

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424

1212

8.1 Setting the Mechanical Clock

. General layout

he mechanical clock covers a 24 hour period. Each tappet represents

T 15 minutes A (Fig. 4). An override switch is located on the clock B (Fig

8.1)

. To set the time

To set the time of day, grasp the outer edge of the dial and turn slowly

lockwise until the correct time is lined up with the arrow

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

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

4. For operation

Put the selector switch B to the symbol to control the central heating by the clock. Put the switch «

0» to turn the central heating off permanently.

B to «I» to select permanent operation or to

(Fig. 8.1)

FIG. 8.1

Day

Manual switch

Summer and winter time setting

Reset

nter

weekday/s

Enter the hours

Week- days flash

Enter minutes

Enter

switching

times

Imput

time

utomatic Manual Continuous

Operation Operation Operation

The switching If the current You can only times corres- switching mode is return to automatic pond to the changed manually, mode from the program the next switching continuously-ON entered. time will be and continuously-  carried out auto- OFF switching  matically again modes by  according to the pressing the " "  entered switching key.  program.

= ON = ON = Continuously ON

= OFF = OFF = Continuously OFF

8.2 Setting the Digital Clock

Operating the time switch

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

Preparing for Operation

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

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

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

Enter current time and weekday

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

1 = “Monday”..............7 = Sunday

- Release the “ ” key.

Entering the switching times

You have 20 memory Iocations available. Each switching time takes up one memory location. Keep pressing the “Prog” key until a free memory location is shown in the display “– –:– –”.

Programme ON or OFF with the “ ” key:

“ ”= OFF; “ ”= ON Enter the hour using “h” Enter the minutes using “m” If a switching command is to be carried out every day (1 2 3 4 5 6

7) then store using the “ ” key, otherwise select the day(s) it is to e carried out by using the “Day” key.

hen the day seIection is left bIank, the programmed switching

W instruction operates at the same time every day 1 2 3 4 5 6 = Monday – Saturday 1 2 3 4 5 = Monday – Friday 6 7 =Saturday – Sunday

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

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

Manual Override Switch “ ”

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

Reading the programmed switching times

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

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

Changing the programmed switching times

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

Entering the switching times”.

“

Notes on storing switching times:

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

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

Deleting individual switching times

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

00” appears.

” key pressed down for around 3 seconds. The

18”. If all memory locations are

automatically

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.

9. GENERAL INFORMATION FOR THE INSTALLER

Read the instructions and recommendations in these Installation and Servicing Instructions carefully to ensure proper installation, use and maintenance of the appliance.

Keep this manual in a safe place. You may need it for your own reference while Servicing Technicians or your installer may need to consult it in the future.

This is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.).

his appliance

esigned.

d The manufacturer declines all liability for damage caused by improper or negligent use.

No asbestos or other hazardous materials have been used in the fabrication of this product.

Before connecting the appliance, check that the information shown on the data plate and the Technical Information (Section 21) comply with the electric, water and gas mains of the property. You will find the data plate on the reverse of the control panel.

Do not install this appliance in a damp environment or close to equipment which spray water or other liquids.

Do not place objects on the appliance. Do not allow children or inexperienced persons to use the appliance

without supervision.

If you smell gas in the room, the telephone or any other object which might cause sparks. Open doors and windows immediately to ventilate the room. Shut the gas mains tap (at or adjacent to the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately. If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.

ust be used onlyfor the purpose for which it is

do not turn on or off light switches, use

Always disconnect the appliance either by unplugging it from the

mains or turning off the mains switch before cleaning the appliance or carrying out maintenance.

In the case of faults or failure, switch off the appliance and turn off the gas tap. Do not tamper with the appliance. For repairs, call your local Authorised Servicing Agent and request the use of original spare parts. For in-guarantee repairs contact MTS (GB) Limited.

Check the following at least once a year: 1 - Check the seal of water connections, replacing the gaskets if

necessary. Check the seal of the gas connections, replacing the gaskets if

2 -

necessary.

3 - Check the general condition of the appliance and of the

combustion chamber visually.

4 - Visual check of the combustion: clean burners if necessary. 5 - With reference to point 3, dismantle and clean the combustion

chamber if necessary.

6 - With reference to point 4, dismantle and clean the injectors if

necessary.

7 - Visual check of the primary heat exchanger:

Day

- check for overheating of the exchangers fins;

- clean the exhaust side of the exchanger and fan if necessary. Regulate the gas pressure, ignition pressure, partial flame, maximum

8 -

flame.

9 - Check proper operation of the heating safety system:

- maximum safety temperature;

- maximum safety pressure.

10 - Check the proper operation of the gas safety system:

- gas or flame safety device;

- gas valve safety device. Check that the electrical connections have been made in compliance

11-

it h the instructions shown in the Installation Instructions.

12 - Check the efficiency of the hot water supply (flow and temperature). 13 - Check pressure in the Domestic Expansion Vessel and top up as

necessary.

14 - Check manually by turning the test knob the Temperature & Pressure

Relief Valve.

15 - Check manually by turning the test knob the Expansion Relief Valve. 16 - Check discharge pipes from both the central heating and domestic hot

water for obstructions.

17 - Check general operation of the appliance. 18 - Check the exhaust system for the combustion products. 19 - Check all unvented domestic hot water controls and systems

9.1 OVERALL VIEW

1. - Steel chassis

2. - Expansion vessel (primary)

3. - Fan

4. - Main heat exchanger made of copper

5. - Sealed chamber

6. - Stainless steel multi-gas burner

assembly comprising :

• removable burner manifold

• two ignition electrodes

• one flame detection electrode

7. - Gas section comprising :

• two safety valves

• one modulating valve

8. - Automatic air vent

9. - Stainless steel domestic hot water tank

10. - Pump

11. - Electrical box

12. - Igniter

13. - Overheating safety device

14. - Air pressure switch

15. - Tank thermistor

16. - Heating flow thermistor

17. - Heating return thermistor

18. -Three way valve

19. - Indirect coil

20. - DHW activator

21. - Hot water control thermistor

22. - DHW expansion vessel

23. - Programmer

24. - Safety valve T&P K. - Flue kit fixing point (refer to Section 11)

NOTE: These checks are not exhaustive

14 21 19

4 5

10. INSTALLATION

The technical information and instructions provided herein below are intended for the installer / Servicing Technician so that the unit may be installed and serviced correctly and safely.

10.1 Delivery

10.2 Reference Standards

There will be two items: 1 - The fully assembled boiler 2 - A separately boxed connection kit

WATER REGULATIONS

In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999, for Scotland, The Water Bylaws 2000, Scotland. The

enus 30 Plus is an approved product under the Water Regulations.

To comply with the Water Regulations, your attention is drawn to The Water Regulations guide published by the Water Regulations Advisory Scheme (WRAS) gives full details of the requirements.

In IE, the requirements given in the current edition of I.S.813 and the current Building Regulations must be followed.

BUILDING REGULATIONS

These are a statutory document and take priority over all other regulations and recommendations. The installation of an unvented hot water storage cylinder is classified as a "Controlled Service" and Regulation G3 applies. To meet the requirements of the Regulation, installation of an unvented system should be undertaken by a "competent installer".

All installations of unvented hot water storage systems having a capacity of more than 15 litres should be notified to the relevant Local Authority by means of Building Notice or by the submission of full plans. It is important to note that it is a criminal offence to install an unvented hot water storage system without notifying the Local Authority.

The installation of this appliance must be in accordance with the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the bylaws of the local water authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635 “Electricity at work regulations 1989” and in the Republic of Ireland with the current edition of I.S. 813, the Local Building Regulations (IE).

C.O.S.H.H.

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

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

BS 7593 Treatment of water in domestic hot water

central heating systems

BS 5546 Installation of hot water supplies for

domestic purposes BS 5440-1 Flues BS 5440-2 Air supply BS 5449 Forced circulation hot water systems BS 6798

BS 6891 Installation of low pressure gas pipe up to

BS 7671 BS 7074 Specification for expansion vessels BS 5482 Installation of L.P.G.

Installation of gas fired hot water boilers

of rated input not exceeding 60kW

28mm

IEE wiring regulations

10.3 Siting the Appliance

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

I.S. 813 Domestic Gas Installations

The following BS Standards give valuable information;

S 5546 Installation of hot water supplies for

omestic purposes

S 5449 Forced circulation hot water systems

B BS 7074 Specification for expansion vessels BS 7593 Treatment of water in domestic hot water

central heating systems

WARNING!!

The addition of anything that may interfere with the normal operation of the appliance without express written permission of the manufacturer or his agent could invalidate the warranty. In GB this could also infringe the

REGULATIONS

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

The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, and in the Republic of Ireland, the current edition of I.S.813, with respect to the installation of the combined appliance in a room containing a bath or shower. The location of the boiler in a room containing a bath or shower should only be considered if there is no alternative.

GAS SAFETY (Installation and Use)

Where a room-sealed appliance is installed in a room containing a bath or shower reference should be made to the relevant requirements.

In GB this is the current I..E.E. WIRING REGULATIONS and BUILDING REGULATIONS. In IE reference should be made to the current edition of I.S.813 and the current ETCI rules.

If the boiler is to be sited into a timber framed building, reference must be made to the current edition of the Institution of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing).

The location must permit adequate space for servicing and air circulation around the appliance as indicated in Section 10.4. The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary. BS 6798-1987 gives detailed guidance on this aspect. A compartment used to enclose the appliance must be designed specifically for this purpose. No specific ventilation requirements are needed for the installation within a cupboard.

This appliance is not suitable for outdoor installation.

925

500

950

470

195

54 145



188

135

172 54

317

280

595

450mm minimum for  servicing purposes

180

The type C appliances (in which the combustion circuit, air vent intake and combustion chamber are air-tight with respect to the room in which the appliance is

nstalled) can be installed in any type of room.

Secondary ventilation is not required with this boiler. The boiler must be installed on a solid, non-combustible, permanent wall to prevent access from the rear.

10.4 Clearances

10.5 Overall Dimensions

Legend:

= Gas service tap

39 40 = Heating return 41 = Heating flow 42 = Water service tap 43 = Tank hot water flow 38 = Water tank

discharge valve

44 = Central heating

discharge valve

In order to allow for access to the interior of the boiler for

aintenance purposes, the boiler must be fitted with a

learance of 450mm in front 400mm below the boiler and

c 200mm above the boiler, and installed in compliance with the clearance requirements indicated in

Fig. 10.1.

FIG. 10.1

10.6 Mounting the Appliance

40 41

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

OTE: Pay particular attention to any test water that may

kit. N

pill from the appliance.

Place the template in the position the appliance is to be mounted and after ensuring it is hanging squarely, use it to

flue pipe(s) installation please refer to S

NB: For further information relating to the flue

ECTION 11 FLUE CONNECTION.(If

drill the holes for the hanging bracket, connection kit and

the appliance is to be fitted on a wall of combustible

ustbe protected by a sheet of fireproof

aterial, the wall

aterial).

If the appliance is to be fitted into a timber framed building, guidance should be sought from the Institute of Gas Engineers document R

: IGE/UP/7.

Legend: 39

= Gas service tap

40 = Heating return 41 = Heating flow 42 = Water service tap 43 = Tank hot water flow 38 = Water tank valve 44 = Heating valve

10.7 Electrical Connection

FIG. 10.2

10.6.1.

Drill the wall and plug using those supplied with the connections kit, position the hanging bracket and secure with the wall bolts supplied, assemble the connection kit and secure to the wall.

NOTE: It is highly recommended that a spirit level be used to position the appliance to ensure that it is perfectly level.

10.6.2. Position the appliance on the hanging bracket and connect the connection kit to the boiler connections. (see also Sections 10.8 Gas Connections, 10.9 Water Connections & F

IG.10.2).

For safety purposes, have a competent person carefully check the electrical system in the property, as the manufacturer will not be held liable for damage caused by the failure to earth the appliance properly or by anomalies in the supply of power. Make sure that the residential electrical system is adequate for the maximum power absorbed by the unit, which is indicated on the rating plate. In addition, check that the section of cabling is appropriate for the power absorbed by the boiler.

The boiler operates with alternating current, as indicated in the Technical Information table (Section 21), where the maximum absorbed power is also indicated. Make sure that the connections for the neutral and live wires correspond to the indications in the diagram. The appliance electrical connections are situated on the reverse of the control panel (see the Servicing Instructions Section 18 for further information).

FIG. 10.3

Important!

In the event that the power supply cord must be changed, replace it with one with the same specifications. Make the connections to the terminal board located within the control panel, as follows:

- The yellow-green wire should be connected to the terminal marked with the earth symbol; make sure to re-use the ferrule mounted on the other supply cord;

- The blue wire should be connected to the terminal marked “N”;

- The brown wire should be connected to the terminal marked “L”. Note: The diagrams for the electrical system are indicated in Section 13.

Warning, this appliance must be earthed.

External wiring must be correctly earthed, polarised and in accordance with relevant regulations / rules. In GB this is the current I.E.E. WIRING REGULATIONS. In IE reference should be made to the current edition of the ETCI rules. This boiler is supplied for connection to a 220 - 240 V~50 Hz supply.

The supply must be fused at 3 A.

The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance, by the use of a fused

ouble pole isolator having a contact separation of at least 3 mm in

ll poles or alternatively, by

a and unswitched shuttered socket outlet both complying with BS

1363.

The point of connection to the Electricity supply must be readily accessible and adjacent to the appliance unless the appliance is installed in a bathroom when this must be sited outside the bathroom.

eans of a 3 A fused three pin plug

10.8 Gas Connection

10.9 Water Connections

The local gas region contractor connects the gas meter to the service pipe.

The gas installation should be in accordance with the relevant standards. In GB this is BS6891 and in IE this is the current edition of I.S.813.

The connection the the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 10.2).

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

Pipe work must be of an adequate size. Pipes of a smaller size than the boiler inlet connection should not be used.

Central Heating

Detailed recommendations are given in BS 6798:1987 and BS

5449-1:1990, the following notes are given for general guidance.

Pipe Work:

Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing should be either with capillary soldered or compression fittings. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps. The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air. Except where providing useful heat, pipes should be insulated to prevent heat loss and avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

By-pass:

The appliance includes an automatic by-pass valve, which protects the main heat exchanger in case of reduced or interrupted water circulation through the heating system, due to the closing of thermostatic valves or cock-type valves within the system.

System Design:

This boiler is suitable only for sealed systems.

Drain Cocks:

These must be located in accessible positions to permit the

raining of the whole system. The taps must be at least 15mm

d nominal size an manufactured in accordance with BS 2870:1980.

Safety Valve Discharge (Primary Water):

he discharge should terminate facing downwards on the exterior

T of the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, but in an easily visible position, and not cause damage to electrical components and wiring. The discharge must not be over an entrance or a window or any other type of public access.

Mains Water Feed - Central Heating:

There must be no direct connection to the mains water supply

ven through a non-return valve, without the approval of the Local

e Water Authority, and must be in accordance with water supply regulations. Your attention is drawn to, for GB: Guidance G24.2 and recommendation R24.2 of the water regulations guide and for IE: the current edition of I.S.813.

Filling:

A temporary method for initially filling the system and replacing lost water during servicing and initial filling (complying to current water regulations and byelaws) is provided. The flexible hose must be removed once the system has been filled.

Domestic Hot Water

Storage Discharge Pipe Work

1) The tundish must be installed directly below the discharge outlet connection of the boiler. The tundish must also be in a position visible to the occupants, and positioned away from any electrical devices. The discharge pipe from the tundish should terminate outside in a safe place where there is no risk to persons in the vicinity of the discharge and to be of metal.

2) Discharge pipes from the temperature & pressure relief and expansion relief valve are joined together within the appliance.

3) The pipe diameter must be at least one pipe size larger than the nominal outlet size of the safety device unless it's total equivalent hydraulic resistance exceeds that of a straight pipe 9m long. i.e. Discharge pipes between 9m and 18m equivalent resistance length should be at least 2 sizes larger than the nominal outlet size of the safety device. Between 18m and 27m at least 3 sizes larger, and so on. Bends must be taken into account in calculating the flow resistance. See fig. 10.4 (page 18) and Table 1 (page 19).

4) The discharge pipe must have a vertical section of pipe at least 300m in length, below the tundish before any elbows or bends in the pipework.

5) The discharge pipe must be installed with a continuous fall.

6) The discharge must be visible at both the tundish and the final point of discharge, but where this is not possible or practically difficult; there should be clear visibility at one or other of these locations. Examples of acceptance are: i) Ideally below a fixed grating and above the water seal in a trapped gully. ii) Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. These are acceptable providing that where children may play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility.

iii) Discharges at high level; I.e. into a metal hopper and metal down

500 mm Max.

00 mm

Min.

Temperature & pressure r

elief valve

Metal discharge pipe (D1) from t

emperature & pressure relief valve.

to tundish.

Metal discharge pipe (D2) from tundish w

ith continuous fall. See Table 2 and worked

example.

Tundish

ixed grating

Trapped gulley

Discharge below f

ixed grating. (see page 6 for a

lternative points

of discharge).

pipe with the end of the discharge pipe clearly visible (tundish visible or not).

r onto a roof capable of withstanding high temperature discharges of

O water 3m from any plastic guttering systems that would take such a discharge (tundish visible). iv) Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily.

Fig.10.4

The single common discharge pipe should be at least one pipe size large

than the largest individual discharge pipe to be connected. If unvented hot water storage systems are installed where discharges from safety devices may not be apparent I.e. in dwellings occupied by the blind, infirm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place. Note: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

Warning

The outlet from the temperature & pressure relief valve must not be used for any other purpose. The temperature & pressure relief valve must not be removed in any circumstances. Any of the above will totally invalidate the warranty.

Note

The discharge from the central heating and domestic hot water systems may be joined together after the tundish.

Air Release Points:

These must be fitted at all high points where air naturally collects and must be sited to facilitate complete filling of the system. The appliance has an integral sealed expansion vessel to accommodate the increase of water value when the system is heated.

It can accept up to 7l (1.5 gal) of expansion water. If the heating circuit

Valve outlet size Minimum size of

discharge pipe D1*

Minimum size of

discharge pipe D2*

from tundish

Maximum

resistance allowed,

expressed as a

length of pipe (i.e.

no elbow or bends)

Resistance created

by each elbow or

bend

G 1/2 15 mm 22 mm

28 mm 35 mm

Up to 9 m Up to 18 m Up to 27 m

0.8 m

1.0 m

1.4 m

G 3/4 22 mm 28 mm

35 mm 42 mm

Up to 9 m Up to 18 m Up to 27 m

1.0 m

1.4 m

1.7 m

G 1 28 mm 35 mm

42 mm 54 mm

Up to 9 m Up to 18 m Up to 27 m

1.4 m

1.7 m

2.3 m

has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity.

omestic Water:

The domestic water must be in accordance with the relevant recommendation of BS 5546:1990. Copper tubing to BS EN 1057:1996 is recommended for water carrying pipe work and must be used for pipe work carrying drinking water. The domestic hot water temperature should be be adjusted to trip at 60˚C. This temperature will prevent the formation of limescale in hard water areas.

ote: This appliance is capable of producing domestic hot water of

p to 70˚C. For extra security against scalding a thermostatic

u blending valve may be installed on the domestic hot water outlet.

Secondary Return:

he secondary return connection can be used as an option. A Non

Return Valve (not supplied) must be fitted to prevent back flow and a Bronze Pump will be needed in conjunction with a Pipe Thermostat to circulate the hot water (neither of which are supplied).

Table 1. Sizing of copper discharge pipe “D2” for

common temperature valve outlet sizes.

Worked Example:

The example below is for a G 1/2 Temperature & Pressure Relief valve with a discharge pipe (D2) having 4 no. elbows and length of 7m from the Tundish to the point of discharge.From Table 1 Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from G 1/2 T & P valve is 9m. Subtract the resistance for 4 no. 22mm elbows at 0.8m each = 3.2m. Therefore the maximum permitted length equates to: 5.8m.

As 5.8m is less than the actual length of 7m therefore calculate the next largest size. Maximum resistance allowed for a straight length of 28mm pipe (D2) from G 1/2 T & P valve equates to: 18m. Subtract the resistance for 4 no. 28mm elbow at 1.0m each = 4m. Therefore the maximum permitted length equates to: 14m As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

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