Ariston microGENUS HE Installation and Servicing Manual

Installation and Servicing

Instructions

Type C Boilers

microGENUS HE 24 MFFI G.C.N:47-116-37 microGENUS HE 28 MFFI G.C.N:47-116-38 microGENUS HE 32 MFFI G.C.N:47-116-39

LEAVE THESE INSTRUCTIONS WITH THE END-USER

Countr

y of destination: GB / IE

TABLE OF CONTENTS

1. GENERAL INFORMATION PA

1.1 G

ENERAL INSTRUCTIONS PAGE.3

1.2 OVERALL VIEW PAGE.4

2. INSTALLATION PA

2.1 REFERENCE STANDARDS PAGE.5

2.2 SITING THE APPLIANCE PAGE.5 .3 O

VERALL DIMENSIONS PAGE.

2.4 CLEARANCES PAGE.6

2.5 MO

UNTING THEAPPLIANCE

PAGE.6

2.6 ELECTRICAL CONNECTION PAGE.7

2.7 GAS CONNECTION PAGE.8

2.8 W

ATER CONNECTION PAGE.8

2.8.1 CONDENSATE REMOVAL PAGE.10 12

2.9 F

UECONNECTION

2.9.1 FITTING THE COAXIAL FLUE

( 60/100 HORIZONTAL)PAGE.13

2.9.2 F

ITTING THE 5” FLUE

( 80/125 HORIZONTAL/VERTICAL)PAGE.14

2.9.3 F

TTING THECOAXIALFLUE

( 60/100 VERTICAL)PAGE.15

2.9.4 FITTING THE TWIN PIPE ( 80/80) PAGE.16

2.10 CONTROL PANEL PAGE.21

2.11 DIGITAL DISPLAY AND FAULT CODES PAGE.21

2.12 REMOVING THE FRONT PANEL PAGE. 22

2.13 ROOM THERMOSTAT / REMOTE CLOCK CONNECTION PAGE.22

2.14 FITTING THE DIGITAL CLOCK PAGE.23

2.15 SETTING THE MECHANICAL CLOCK PAGE.24

2.16 SETTING THE DIGITAL CLOCK PAGE.24

2.17 ELECTRICAL/SYSTEM DIAGRAMS PAGE.26

2.18 WATER CIRCUIT DIAGRAM PAGE.28

3. COMMISSIONING PAGE.29

3.1 INITIAL PREPARATION PAGE.29

3.2 INITIAL ST

3.3

PERA

-UP PAGE.

TIONAL

ADJUSTMENTS PAGE.

3.4 COMBUSTION ANALYSIS PAGE.32

3.5 PRODUCT OF COMBUSTION DISCHARGE MONITORING PAGE.32

3.6 COMFORT MODE PAGE.32

3.7 BOILER SAFETY SYSTEMS PAGE.33

3.8 DRAINING THE SYSTEM PAGE.34

3.9 COMPLETION PAGE.35

3.10 OPERATIONAL CHECKS PAGE.35

3.11 INSTRUCTING THE END USER PAGE.36

31 32

6.2.3 RE

.3 A

.3.1 R

MOVING THESIDEPANELS

CCESS TO THE COMBUSTION CHAMBER PAGE.

EMOVING THE COMBUSTION

PAGE.43

CHAMBER PAGE.44

6.3.2 RE

MOVING THEBURNER ANDJETS

PAGE.44

6.3.3 REMOVING THE ELECTRODES PAGE.44

6.3.4 R

EMOVING THE MAIN HEAT EXCHANGER PAGE.45

6.3.5 REMOVING THE AIR PRESSURE SWITCH PAGE.46

6.3.6 REMOVING THE FAN PAGE.47

6.3.7 RE

MOVING THEFLUE

SENSOR PAGE.

/CO

NDENSATE

6.3.8 REMOVING THE RECUPERATOR PAGE.48

6.3.9 REMOVING THE RECUPERATOR HOUSING PAGE.49

6.3.10 R

6.4 AC

EMOVING THE CONDENSATE TRAP PAGE.49

CESS TO THEGASVALV E

PAGE.50

6.4.1 REMOVING THE SPARK GENERATOR PAGE.50

6.4.2 R

EMOVING THE GAS VALVE PAGE.50

6.5 ACCESS TO THE WATER CIRCUIT PAGE.51

6.5.1 REMOVING THE D.H.W. (SECONDARY)

6.5.2 R

XCHANGER

EMOVING THE PUMP PRESSURE

PAGE.51

SWITCH PAGE.52

6.5.3 REMOVING THE SAFETY VALVE PAGE.52

6.5.4 REMOVING THE AUTOMATIC AIR VENT PAGE. 53

6.5.5 REMOVING THE PUMP PAGE. 53

6.5.6 R

6.5.7 R

6.5.8 R

EMO EMOVING THE EXPANSION VESSEL PAGE. 55 EMOVING THE OVERHEAT THERMOSTAT PAGE.55

PRESSURE GAUGE PAGE. 54

THE

VING

6.5.9 REMOVING THE C.H. TEMPERATURE SENSOR (N.T.C.) PAGE.56

6.5.10 REMO

VING

D.H.W.TEMPERA

TURE

THE

SENSOR (N.T.C.) PAGE. 56

6.5.11 REMOVING THE DIVERTER VALVE ACTUATOR PAGE.56

6.5.12 REMOVING THE D.H.W. FLOW SWITCH PAGE.

6.6 ACCESS TO THE CONTROL SYSTEM PAGE.57

6.6.1 CHECKING THE FUSES PAGE.57

6.6.2 R

6.6.3

EMO EMO

VING THE

THE

VING

.C.B. P

P TIME CLOCK PAGE.

7. FAULT FINDING PAGE.60

7.1 FAULT FINDING GUIDE (FLOW-CHARTS)PAGE.60

8. SHORT SPARE PARTS LIST PA

9. TECHNICAL INFORMATION PAGE.66

GAS ADJUSTMENTS

4.1

4.2

HANGING

DJUSTING

THE

TYPEOFGAS PAGE.

THE

GAS PRESSURES PAGE.

5. MAINTENANCE PA

PAGE.

37 37 37

6. SERVICING INSTRUCTIONS PAGE.42

6.1 REPLACEMENT OF PARTS PAGE.42

6.2 TO GAIN GENERAL ACCESS PAGE.42

VING VING

THE

ONT

THE

SEALED CHAMBER

PANEL PAGE.

6.2.1

6.2.2

EMO EMO

FRONT PANEL PAGE.43

10. BENCHMARK COMMISSIONING CHECKLIST

PAGE.68

11. SERVICE INTERVAL RECORD PAGE.69

1. GENERAL INFORMATION

This manual is an integral and essential part of the

roduct. It should be kept with the appliance so that it can

e consulted by the user and our authorised personnel.

Please carefully read the instructions and notices about the unit contained in this manual, as they provide important information regarding the safe installation, use and maintenance of the product.

For operating instructions please consult the separate End User Manual.

1.1 GENERAL INSTRUCTIONS

Read the instructions and recommendations in these Installation and Servicing Instructions carefully to ensure

roper installation, use and maintenance of the

p appliance.

eep this manual in a safe place.You may need it for your

K own reference while Servicing Technicians or your installer may need to consult it in the future.

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

This appliance 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.

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

Before connecting the appliance, check that the information shown on the data plate and the table in Section 9 comply with the electric, water and gas mains of the property.You will find the data plate on the inside of the left hand casing panel. The gas with which this appliance operates is also shown on the label at the bottom of the boiler.

must be used only for domestic use.

Do not install this appliance in a damp environment or

close to equipment which spray water or other liquids.

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

the appliance without supervision. If you smell gas in the room, do not turn on or off light

switches, use the telephone or any other object which might cause spar 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.

ou are going away for a long period of time, remember

If y to shut the mains gas tap or the gas cylinder valve.

Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch before cleaning the appliance or 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 or guarantee repairs contact MTS (GB) Limited.

ks.

iginal spare par

ts. For in-

23 22

21 20

1918171615

1.2 OVERALL VIEW

FIG. 1.0

LEGEND:

. Flue Manifold

2. Air Intake for Twin Pipe Flue Systems

3. Fan

4. Combustion Chamber Hood

. Main Heat Exchanger

6. Overheat Thermostat

. Central Heating Flow Temperature Probe

8. Combustion Chamber Insulation Panel

9. Burner

10. Detection Electrode

11. Ignition Electrodes

12. Motorised Valve

13. Condensate trap

14. Domestic Hot Water Temperature Probe

15. Low Water Pressure Switch

16. Secondary Heat Exchanger

17. Gas Valve

18. Spark Generator

19. Cold Water Inlet Filter

20. Pump (w/auto air vent)

21. Safety Valve

22. D.H.W. Flow Switch

23. Condensate Trap Tube

24. Combustion Chamber

25. Condensate Sensor

26. Latent Heat Collector

27. Air Pressure Switch

28. Combustion Analysis Test Point

2. INSTALLATION

2.1 RE

he technical information and instructions provided

erein below are intended for the installer / Servicing

FERENCESTANDARDS

Technician so that the unit may be installed and serviced correctly and safely.

n the United Kingdom the installation and initial start up

I of 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”, the current Building Regulations, reference should also be made to the current ETCI rules for electrical installation.

This appliance must be installed by a competent installer in accordance with current Gas Safety (installation & use) Regulations.

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).

2.2 SI

he appliance may be installed in any room or indoor

rea, although particular attention is drawn to the

TING THEAPPLIANCE

requirements of the current I.E.E. Wiring Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combined appliance in a room containing a bath or shower, the location of the boiler in a room containing a bath or shower should only be considered if there is no alternative.

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 so that it cannot be touched by a person using the bath or shower, specifically in accordance with current IEE Wiring Regulations.

The location must permit adequate space for servicing and air circulation around the appliance as indicated in Section 2.4. The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary. BS 6798-2000 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.

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 Br

itish

Standard Codes of Practice

BS 7593:1992 Treatment of water in domestic hot water

central heating systems

BS 5546:2000 Installation of hot water supplies for

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

of rated input not e BS 6891:1998 Installation of low pressure gas pipe up to

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

xceeding 70kW

and in the Republic of Ireland in accordance with the

wing Codes of Pr

ollo

actice:

The type C appliances (in which the combustion

cuit, air vent intake and combustion chamber are

cir air-tight with respect to the room in which the appliance is installed) can be installed in any type of room. However, as the appliance has many functioning components, pay particular attention when siting the appliance in room such as bedrooms as operating noise may be a nuisance.

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.

I.S.

813

Domestic Gas Installations

120

FIG. 2.1

2.3 OVERALL DIMENSIONS

GEND

A = Central Heating Flow (3/4” - 22mm Copper Tail) B = Domestic Hot Water Outlet (1/2” - 15mm Copper Tail) C D = Domestic Cold Water Inlet (1/2” - 15mm Copper Tail) E = Central Heating Return (3/4” - 22mm Copper Tail)

= Gas Inlet (3/4” - 15mm Copper Tail)

FIG. 2.2

2.4 CLEARANCES

In order to allow access to the interior of the boiler for maintenance purposes, the boiler must be installed in compliance with the minimum clearances indicated in

* Clearance for Servicing 25mm if behind a temporary

closure i.e. door.

2.5

After removing the boiler from its packaging, remove the template from the separate box containing the connection kit. NOTE: Pay particular attention to any test water that may spill from the appliance.

OUNTING

THE

APPLIANCE

FIG. 2.2

Place the template in the position the appliance is to be mounted and after ensuring it is hanging squarely, use it to mark the holes for the hanging bracket, connection kit and flue pipe(s) NB: For further information relating to the flue installation please refer to Section 2.9 FLUE CONNECTION. (If the appliance is to be fitted on a wall of combustible material, the wall must be protected by a sheet of fireproof material). If the appliance is to be fitted into a timber fr

uilding, guidance should be sought from the Institute of

Gas Engineers document

EF:

IGE/UP/7.

amed

2.5.1. Drill the wall and plug using those supplied with

85 mm

220 mm

he connections kit, position the hanging bracket and

t secure with the wall bolts supplied, assemble the

onnection kit and secure to the wall.

NOTE: I

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

.5.2. Position the appliance on the hanging bracket

nd connect the connection kit to the boiler connections.

a (see also Sections 2.7 Gas Connections, 2.8 Water Connections & F

. 2.3).

FIG. 2.3

2.6 EL

ECTRICALCONNECTION

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 in Section 9, where the maximum absorbed power is also indicated. Ensure that the connections for the live, neutral and earth wires correspond with the indications in the diagram (Fig. 2.4). The appliance electrical connections are situated on the PCB, see Section 2.17

TANT

IMPOR

In the event that the power supply cord must be changed, replace it with one with the same specifications. Note: The diagrams for the electrical system are indicated in Section 2.17.

FIG. 2.4

Warning, this appliance must be earthed.

ing to the appliance must be carried out by a

nal wir

Exter competent person and be in accordance with the current I.E.E. Regulations and applicable local regulations. The appliance is supplied with a fly-lead already connected, this must be connected to a 240v supply fused at 3A and must facilitate complete electrical isolation of the appliance, by the use of a fused double pole isolator having a contact separation of at least 3 mm in all poles or alternatively, by means of a 3 A fused three pin plug and unswitched, shuttered socket outlet both complying with BS 1363. The point of connection to the Electricity supply must be readily accessible and adjacent to the appliance unless the appliance is installed in a bathroom when this must be sited outside the bathroom (see Section 2.2).

Should external controls be required, the design of the external electrical circuits should be undertaken by a competent person, see Section 2.13 f

mation.

inf

or fur

ther

2.7 GAS CONNECTION

The local gas region contractor connects the gas meter to

he service pipe.

t If the gas supply for the boiler serves other appliances

nsure that an adequate supply is available both to the

e 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

maller size than the boiler inlet connection should not be

sed.

2.8 WA

FIG. 2.5

TERCONNECTIONS

VIEW OF THE BOILER CONNECTIONS

LEGEND:

A = Central Heating Flow B = Domestic Hot Water Outlet C = Gas Inlet D = Domestic Cold Water Inlet E = Central Heating Return F = Condensate discharge G = Drain valve H = Safety Valve Outlet

CENTRAL HEATING

Detailed recommendations are given in BS 6798:2000 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 b

uilt-in automatic air release v

alve, however it should be ensured as far as possible that the appliance heat exchanger is not a natur

al collecting point for air. Except where providing useful heat, pipes should be insulated to pre

ent heat loss and a

void freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

IG. 2.6

KT007A

BY-PASS:

The appliance includes an automatic by-pass valve, which protects the main heat e

xchanger in case of reduced or interrupted water circulation through the heating system, due to the closing of thermostatic valves or radiators.

SYSTEM DESIGN:

This boiler is suitable only for sealed systems.

DRAIN COCKS:

These must be located in accessible positions to permit the draining of the whole system and should be fitted at all low points. The taps must be at least 15mm nominal size and manufactured in accordance with BS 2870:1980.

FETYVALV EDISCHARGE

he discharge should terminate facing downward on the

exterior 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

r any other type of public access.

AIRRE

LEASEPOINTS

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 volume when the system is heated. It can accept up to 6 litres (1.3 gal) of expansion water. If the heating circuit has an unusually high water content, calculate the total expansion and add an additional sealed expansion vessel with adequate capacity. This should be located on the return pipe work as close as possible to the pump inlet.

MAINS WATER FEED - CENTRAL HEATING:

A method for initially filling the heating system is supplied with the connection kit. The filling loop is connected between the cold water inlet and the central heating flow connections, and incorporates a non-return valve. To operate the filling loop, it is necessary to open both quarter turn handles, once the required pressure has been achieved, close both handles and disconnect the hose in accordance with water byelaws. N

OTE: The

installer should ensure that there are no leaks as frequent filling of the heating system can lead to premature scaling of the main exchanger and failure of hydraulic components.

MESTICWATER

he domestic water must be in accordance with the

relevant recommendation of BS 5546:1990. Copper

ubing to BS EN 1057:1996 is recommended for water

t carrying pipe work and must be used for pipe work carrying drinking water, a scale reducer should also be used to reduce the risk of scale forming in the domestic

ide of the heat exchanger.

WATER TREATMENT

The boiler is equipped with a secondary heat exchanger (recuperator) made from stainless steel as well as the copper main 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. These include cleansers produced by Fernox and BetzDearborn, 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

VR003A

RESIDUALHEAD

THE

BOILER D T 20°C

FIG. 2.7

situation it is necessary to treat the water with an

ppropriate corrosion inhibitor.

- Any treatment of water by additives in the system for rost protection or for corrosion inhibition has to be

f absolutely suitable for all the metals used in the circuit. The use of a corrosion inhibitor in the system such as Fernox MB-1, BetzDeaborn Sentinel X100 or Fernox

ystem Inhibitor is recommended to prevent corrosion

sludge) damaging the boiler and systems;

(

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

check carefully that they are compatible with the metals used in the circuit. MTS suggests the use of suitable anti-freeze products such as Fernox ALPHI 11, which will prevent rust and incrustation taking place. 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

. If pipes of this kind are not used, keep the system separate by installing heat exchanger

s of those with a specific system

water treatment.

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

2.8.1 CONDENSATE REMIOVAL

CONDENSATEDISCHARGE:

1. Internal termination of condensate drainage pipe to internal stack

A flexible hose connected to the bottom of the boiler should be inser

NOTE:

THE CONDENSATE HOSE OUT OF THE BOTTOM OF THE BOILER

The condensate discharge hose from the boiler m

ted into a tundish (not supplied).

O REMOVE THE CASING TO PULL

NECESSAR

ust have a continuous fall of at least 2.5° and must be connected to a visible tundish and inserted by at least 50mm into a suitab

le acid resistant pipe with a nominal diameter of 32mm e.g. plastic waste pipe or overflow pipe. The condensate discharge pipe must have a continuous fall and preferably be installed and terminated

ent freezing.

within the b

uilding to pre

v The discharge pipe must be terminated in one of the following positions, allowing for a safe discharge:

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

above the invert of the stack). A trap giving a water seal of at least 75 mm m

ust be incorporated into the pipe run, there also must be an air break upstream of the trap i.e. tundish.

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).

ii) Connecting into the waste system of the building such

s a washing machine or sink trap. The connection

a must be upstream of the washing machine/sink (If the

onnection is down stream of the waste trap then an

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

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

the water level.

iv)Into a soakway.

NOTE: If any condensate pipe work is to be installed

externally, then it should be kept to a minimum and be insulated with a waterproof insulation and have a continuous fall.

Some examples of the type of condensate drains can be found in this section.

4. External termination of condensate drainage pipe via condensate siphon

2.9. CONNECTING THE FLUE

IMPORTANT!!

BEFORE CONNECTING THE FLUE, ENSURE THAT 1 LITRE OF WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION TO

FILL THE CONDENSATE TRAP E

MPTY THERE IS A TEMPORARY RISK OF FLUE GASSES

ESCAPING INTO THE ROOM.

2.8).

(

IG.

SHOULD THE TRAP BE

FIG. 2.8

FLUE SYSTEM

The provision for satisfactory flue termination must be made as described in BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outdoor air. The terminal must not discharge into another room or space such as an outhouse or lean-to. It is important that the position of the terminal allows a free passage of air across it at all times. The terminal should be located with due regard for the damage or discolouration that might occur on buildings in the vicinity, it must also be located in a place not likely to cause nuisance. In cold or humid weather water vapour may condense on leaving the flue terminal. The effect of such “steaming” must be considered. If the terminal is 2.1 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable stainless steel terminal guard must be fitted.

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

2.9.

FIG. 2.9

Ø 60/100 mm

TERMINAL POSITION mm

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

I - Vertically from a terminal in the same wall 1500 J - Horizontally from a terminal in the same wall 300 K - Horizontally from an opening window 300 L - Fixed by vertical flue terminal

2500

Fig. 2.10

Warning

118

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.

Important

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

Installation without extension

Installation with extension

2.9.1 FITTING THE COAXIAL FLUE (Ø 60 / 100 HORIZONTAL)

SEE PAGE 19 FOR MAX AND MIN FLUE RUNS

Level

Fig. 2.11

Level

Fig. 2.12

PART NO: 3318073

CONTENTS:

X SILICONE O-RING (60mm)

X ELBOW (90

1 2X WALL SEALS (INTERNAL & EXTERNAL) 1X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100) 2

X FLUE CLAMPS

4X SCREWS 2x Seals

)

Once the boiler has been positioned on the wall, insert the elbo

w into the sock

position. NOTE:

It is possible to rotate the elbow 360

et and rotate to the required

its vertical axis.

Using the flue clamps, seals and screws supplied (

Fig

2.13) secure the elbow to the boiler.

The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact X dimension of 823mm.

Measure the distance from the face of the external wall to the face of the flue elbow (X - Fig 2.10), this figure must now be subtracted from 815mm, you now have the total amount to be cut from the plain end of the flue.

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 2.13).

.g.

X = 555mm 823-555 = 268mm (Length to be cut from the plain end of the flue).

Seal

Clamp

Screws

Once cut to the required length, ensure that the flue is

ree from burrs and reassemble the flue. If fitting the

f flue from inside of the building attach the grey outer

all seal to the flue terminal and push the flue through

w the hole, once the wall seal has passed through the hole, pull the flue back into the elbow (ensuring that the flue seal is not dislodged) until the external wall seal is

lush with the wall, and that the flue is securely located

nto the elbow, finally secure the flue to the elbow with

i the clamp provided. Alternatively, the flue can be installed from outside of the building, the grey outer seal being fitted last.

Fig. 2.13

2.9.2 FITTING THE 5” FLUE (Ø 80 / 125 HORIZONTAL/VERTICAL)

SEE PAGE 19 FOR MAX AND

MIN

FLUE

RUNS

CONTENTS:

HORIZONTAL KIT - 3318095 3X SILICONE O-RINGS (60mm, 80mm & 125mm) 1X 90OELBOW (HORIZONTAL ONLY)

X ADAPTOR (60/100 - 80/125MM)

1 1X HORIZONTAL FLUE PIPE (INCLUDING TERMINAL)

(80/125mm) 2X WALL SEALS (INTERNAL & EXTERNAL) 2

X FLUE CLAMPS

2X SEALS 4X SCREWS

VERTICAL KIT - 3318080 (BLACK) / 3318081 (RED) 1X VERTICAL FLUE PIPE (INCL.TERMINAL) (80/125MM) 1X ADAPTOR (60/100 - 80/125) 1X SILICONE O-RING (60MM)

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

Fig. 2.14

Once the boiler has been positioned on the w necessary to insert the

Ø80/125 adaptor (FIG. 2.14)

all, it is

raised horizontal and vertical flue runs into the boiler flue

et (not supplied with flue kit - Par

sock

Push the adaptor onto the boilers flue connection, g the seals then add e

xtensions or elbo

t No 3318095

ws as required,

rease

secure the adaptor, using the clamp and screws provided.

o fit e

xtensions or elbo

ws it is first necessar

y 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.

efore proceeding to fit the flue, ensure that the

B maximum flue length has not been exceeded (See the

ables on Page 19) and that all elbows and bends have

t been taken into consideration, the maximum flue length is 10 metres, for each additional 90oelbow 1 metre must be subtracted from the total flue length, and for

ach 45

lue length

.5 metres must be subtracted from the total

the height of the vertical adaptor and a

( 45obend can be seen in Fig. 2.15 and a 90obend (raised horziontal only) in Fig. 2.16).

NOTE: DO NOT CUT THE VERTICAL FLUE KIT.

2.9.3. FITTING (Ø 60 / 100 VERTICAL)

Fig. 2.17

THECOAXIAL

FLUE

Fig. 2.15

Fig. 2.16

NOTE:SEE PAGE 19 FOR MAXIMUM AND MINIMUM FLUE

RUNS.

PART NO: 33108080 (BLACK) / 3318081 (RED)

ONTENTS:

C 1X SILICONE O-RING (60mm) 1X CONICAL ADAPTOR (60/100mm) 1

X VERTICAL FLUE KIT (80/125mm)

The vertical flue kit is supplied with a specially designed w either with a flat roof or a pitched roof.

Vertical flue kits useable lengths with the pitched

The 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 19) and that all elbows and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90oelbow 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. 2.18).

k the position of the flue hole in the ceiling and/or

Mar

eather proof terminal fitted, it can be used

Fig. 2.17.

Fig. 2.18

roof (see Fig. 2.16 for distance from the wall to the centre

f the flue).

ut a 120mm diameter hole through the ceiling and/or

C roof and fit the flashing plate to the roof.

DO NOT cut the vertical flue kit.

o connect the vertical flue kit directly to the boiler, place

T the vertical starter kit (Part No. 3318079) (see Fig. 2.17) 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.

2.9.4. FITTING THE TWIN PIPE (Ø80 / 80)

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.

NOTE:

PA GE

19 FOR

MAXIMUM AND MINIMUM FLUE RUNS

Where it is not possible to terminate the flue within the distance permitted for coaxial flues, the twin flue pipe can be used by 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, using one flue bracket per extension and avoiding low points. (MTS supply suitable clamps as Part No. 705778).

Fig. 2.18A

o utilise the e

xhaust manifold it is necessary to connect

the adaptor (Part No: 3318017) to the exhaust manifold and secure with the clamp (see FIG. 2.18A), add elbows or extensions as required.

To utilise the air intake it is necessary to:

Remove the ‘knockout’ of the air intake by cutting it with a suitable knife (FIG. 2.18B).

Insert the elbow/flue pipe into the air intake until it stops.

The twin flue pipes can be fitted with or without additional

lbows and need no clamps, simply ensure that the red o-

e ring is inserted in the female end of the flue pipe and push

he extension piece fully into the previous section of flue pipe

t or elbow, check that the o-ring is not dislodged when assembling the flue.

he twin flue pipes can be fitted with or without additional

lbows and need no clamps, simply ensure that the red o-

e 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 (greasing the seal will aid assembly).

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. 3318089). When running the twin flue pipe vertically.

Fig. 2.18B

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

When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals must be a minimum of 280 mm apart and the air intake

must not be sited above the exhaust

terminal (refer to Fig. 2.22). The air intake pipe can be run horizontally, however, the terminal and the final 1 metre of flue must be installed either horizontally or with a slight fall away from the boiler to avoid rain ingress.

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

The maximum permissible 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 length is 40 metres

, for runs with the terminals under

different atmospheric conditions (T

YPE 4) the maximum

YPE 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 40 metres.

The maximum length is reached by combining the total lengths of both the air intake and exhaust pipes. Therefore a maximum length of 40 metres for example, will allow a flue run of 20 metres for the air intake and 20 metres for the exhaust pipes, also for each 90oelbow 2.2 metres must be subtracted from the total length and for each 45oelbow

1.4 metres must be subtracted from the total flue length.

Some of the acceptab

le flue configurations are detailed on

page 20.

mation relating to flue r

or fur

ther inf

please contact the

echnical

Depar

uns not illustrated,

tment on 0870 241

8180.

ø 100

60 mm

In the event that the air intake and exhaust are run to the left, it will be necessary to reduce the height of the air

ntake by cutting 20mm from the base of the air intake

i elbow (see Fig. 2.19)

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 ø10 cm, this will then allow for easier assembly of the air intake elbow and the tube outside the wall (see Fig. 2.20).

Fig. 2.19

or coaxial systems, the maximum development value,

F mentioned in the table below also takes into account an

elbo 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 air intakes

and exhaust gas ducts.

2- If you need to insert elbows in the air intake and

exhaust gas ducts, you should consider for each one the equivalent length to be included in the calculation of developed length.

3- The exhaust gas duct should jut above the roof by at

least 0.5 m.

4- The intake and exhaust gas ducts in Type 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.

Fig. 2.20

The flue restr on the boiler. Please refer to the table on page 19 to determine whether it will be necessary to remove it.

o remove the restrictor it is simply necessary to lift the

T restrictor from the exhuast manifold (Fig. 2.20A)

ictor is factory fitted in the exhaust manifold

Fig. 2.20A

24 MFFI

Coaxial

Systems

ø 60/100

Coaxial

ystems

ø 80/125

Exhaust Type

Type 1

Type 2

Type 3

Type 1

ype 2

Type 3

Do not remove the

ø 40 mm

Restrictor

Between

500 mm - 1 m

Remove the

Restrictor

(Fig.2.20A)

Between 1 m - 4 m

aximum Flue

Length

Reduction 45

elbow (m)

4 m 0.5 m 1.0 m

0 m

Length

Reduction 90

elbow (m)

Twin Pipe

Systems

ø 80/80

28 MFFI

Coaxial

Systems

ø 60/100

Coaxial

Systems

ø 80/125

Twin Pipe

Systems

ø 80/80

Type 4

Type 5

Exhaust Type

Type 1

Type 2

Type 3

Type 1

Type 2

Type 3

Type 4

ype 5

Between

1m - 10 m

Between

1m - 10 m

Do not remove the

ø 41 mm

Restrictor

Between

500 mm - 1 m

TBC TBC 10 m TBC TBC

Between

1m - 10 m

een

Betw

1m - 10 m

Between

10 m - 40 m

Between

10 m - 40 m

Remove the

Restrictor

(Fig.2.20A)

Between 1 m - 4 m

Between

10 m - 40 m

Between

10 m - 40 m

40 m 1.4 m 2.2 m

Maxim

Length

um Flue

Length

Reduction 45

elbow (m)

4 m 0.5 m 1.0 m

40 m 1.4 m 2.2 m

Length

Reduction 90

elbow (m)

32 MFFI

Coaxial

Systems

ø 60/100

Coaxial

Systems

ø 80/125

Twin Pipe

Systems

ø 80/80

Exhaust

Type 1

Type 2

Type 3

Type 1

ype 2

Type 3

Type 4

Type 5

Do not remove the

Type

Restrictor

500 mm - 1 m

ø 43 mm

Between

Remove the

Restrictor

(Fig.2.20A)

Between 1 m - 4 m

Maximum Flue

Length

4 m 0.5 m 1.0 m

Length

Reduction 45

elbow (m)

Reduction 90

elbow (m)

TBC TBC 10 m TBC TBC

Between

1m - 10 m

Between

1m - 10 m

een

Betw

10 m - 40 m

een

Betw

10 m - 40 m

40 m 1.4 m 2.2 m

Length

TYPE 1

TYPE 2

TYPE 3

TYPE 4

TYPE 5

NOTE: DRAWINGS ARE INDICATIVE OF FLUEING OPTIONS ONLY.

FIG. 2.21

Fig. 2.22

R020A

* Warning the flue analysis mode must only be selected by a

qualified service engineer. See Section 3.4 for further instructions

FIG. 2.23

2.10 CONTROL PANEL

LEGEND:

On/Off Button

A B - Domestic Hot Water Temperature Adjustment C - Central Heating Temperature Adjustment D - Reset Button/Flue Test analysis mode* E - Comfort Mode Selector F - Summer Mode LED (Green)

Ignition/Overheat Lockout LED (Red)

G H - Central Heating (Winter Mode) LED (Green) I - Digital Display (Fault Code/Water Temperature) J - Time Clock K- Central Heating System Pressure Gauge

2.11 DIGITIAL DISPLAY AND FAULT CODES

DISPLAY CAUSE

AA 0011

AA 0033

No flame after safety time (7 seconds) The heating flow temperature exceeds 103oC

during operation Condensate Trap full of water

AA 7777

Condensate sensor short circuited Condensate sensor in open circuit

AA 7755 AA 9977 AA 9988 AA 9999

EE 0022

EE 0044

EE 0055

EE 0066

EE 0077

EE 0088

EE 0099

EE 2200

EE 2211

EE 3333

EE 3344

EE 9999

Problem with the flue stat Problem with the electronic monitoring Problem with the electronic monitoring

Problem with the electronic monitoring

Insufficient w Domestic hot w

ater pressure

ater temper open circuit Domestic hot w

ater temper short circuited Heating flo

w temper

ature probe in open circuit Heating flo

w temper

ature probe shor circuited Heating retur

n temper

circuit

Heating return temperature probe shor circuited

Flame detected with gas valve closed Error in the electrical connection (live and

neutral crossed) The air pressure switch is closed before the ignition sequence has begun The air pressure switch does not close when the fan runs More than 5 RESETS of the boiler in 15 minutes.

ature probe in

ature probe

ature probe in open

The Control Panel has a 3 digit display, during normal operation the display will show one of six things on the two right hand digits;

During Stand-by (no demand for Central Heating or D.H.W.)

on’ will be shown on the display and no LEDs will light.

‘

During a demand for Domestic Hot Water, the temperature of the outgoing hot water is displayed in oC (e.g. 38) and the summer mode LED will light (F - FIG. 2.23).

During a demand for Central Heating, the temperature of the central heating flow will be displayed in oC (e.g. 65) and the central heating mode LED will light (H - FIG.2.23).

ing the oper

Dur display will show ‘

ation of the flue analysis mode* the sc’.

Should a fault occur the display will show the fault code and one of two letters, for a non-volatile shutdown the letter ‘ the f

will be shown follow

A’

ault eg.

‘

A02’

ed b

and the red

y the tw

LED (

o digit code f

G - FIG.

2.23)will

light, a non-volatile shutdown will require the reset button (D - FIG. 2.23) to be pressed once before the boiler will attempt to relight, should the boiler lockout again, the

ised Service Engineer should be

assistance of an A

uthor

sought.

Should the boiler develop a fault that cannot be corrected by resetting the boiler, the letter ‘

E’ will be displayed

followed by a two digit code (e.g. E33) indicating a

olatile shutdown code, in the ev

ent of such a shutdo

the boiler will automatically resume oper

Should it not, the assistance

cause behind it is resolv

ised Ser

of an A

uthor

ed.

vice Engineer w

ould be required.

ation once the

wn,

A list of the fault codes can be found opposite.

2.12 REMOVING THE FRONT PANEL

In order to access the inside of the boiler, it is necessary to unscrew the fastening screws “A” of the control panel

ocated on the lower part of the panel itself.

he control panel moves downward and when pulled

T forward rotates on two lateral hinges. The panel stays in a horizontal position, which allows access to the inner parts of the boiler. To dismantle the front casing panel it is necessary to: 1 - Remove the two screws

- Move the front casing panel up and lift forward.

“B”;

2.13 ROOMTH

ERMOSTAT

MOTECLOCK

/ RE

CONNECTION

To connect a room thermostat, it is necessary to:

1. - Open the control panel as indicated in SECTION 2.12.

2.- Remove the screws “A1” from the reverse of the

control panel (picture 3).

3. - Insert the thermostat cable through the cable grommet and fasten it by means of the cable-clamp provided.

4. - Connect the thermostat wires to the terminal block

A2 (Picture 4) (Diagram A - Fig. 2.24).

5.- If a remote time clock is to be fitted, disconnect the integral time clock from the P.C.B.

6. - Using a volt-free switching time clock, connect the switching wires from the time clock following points 14 above

7. - If using an external time clock and room thermostat, these must be connected in series as Diagram C -

Fig. 2.24.

Note: Only a low voltage room thermostat capable of

(Diagram B - Fig. 2.24).

volt free switching must be used.

Factory fitted integral wiring must not be disturbed when wiring external controls.

Ensure high voltage and low voltage circuits are cabled separately to avoid induced voltage in the low voltage circuits.

FIG. 2.24

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