Ariston System A Installation, Servicing and Operating Instructions

Installation, Servicing and

Operating Instructions

Type C Boilers

SYSTEM A 24 MFFI G.C.N: 41-116-14

SYSTEM A 30 MFFI G.C.N: 41-116-15

LEAVE THESE INSTRUCTIONS

WITH THE END USER

Country of destination: GB/IE

These instructions are suitable for the SYSTEM 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 61), this provides a record of the commissioning of your boiler.

It contains important information about your particular installation that may be required by service engineers. 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 62).

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 Ariston Service 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 61) 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 61) and the appliance service history (Section 25, page 62).

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

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

CUSTOMER CARE

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

Advice on installation or servicing can also be obtained by contacting the Ariston Technical and Customer Service Departments on:

TECHNICAL DEPARTMENT		CUSTOMER SERVICE DEPARTMENT
Tel:	0870 241 8180	Tel:	0870 600 9888
Fax:	01494 459775	Fax:	01494 459775

GUARANTEE

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

CAUTION

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

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

All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in the Benchmark Commissioning Checklist (Section 24 - page 61). 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.

Contents

CUSTOMER CARE

			Page
Guarantee ............................................................................................................................................................			2
Statutory Requirements .......................................................................................................................................			2
Contents ...............................................................................................................................................................			3
INTRODUCTION ..................................................................................................................................................			4
USER’S INSTRUCTION .......................................................................................................................................			5
1	CONTROL PANEL...........................................................................................................................................		5
2	HOW TO USE .................................................................................................................................................		6
		Switching on and filling ..........................................................................................................................	6
		Time setting ............................................................................................................................................	6
		Heating ...................................................................................................................................................	6
		Burner ON................................................................................................................................................	6
		Stand by mode ........................................................................................................................................	6
		Switch OFF .............................................................................................................................................	6
		Anti-freeze and anti-sieze mode .............................................................................................................	7
3	MAINTENANCE ..............................................................................................................................................		7
4	GUARANTEE ..................................................................................................................................................		7
5	PRACTICAL INFORMATION...........................................................................................................................		7
6	SETTING THE TIME CLOCKS ........................................................................................................................		8
6.1		SETTING THE MECHANICAL CLOCK .....................................................................................................	8
6.2		SETTING THE DIGITAL CLOCK ...............................................................................................................	9
INSTALLERS’ INSTRUCTIONS.........................................................................................................................			11
7	DESCRIPTION...............................................................................................................................................		11
8	DIMENSIONS ................................................................................................................................................		12
9	HYDRAULIC DATA .......................................................................................................................................		13
10	INSTALLATION REQUIREMENTS................................................................................................................		14
11	INSTALLING THE BOILER............................................................................................................................		18
12	CONNECTING THE FLUE.............................................................................................................................		20
12.1		FITTING THE COAXIAL FLUE (Ø 60/100 HORIZONTAL) ...................................................................	21
12.2		FITTING THE 5” FLUE (Ø 80 / 125 HORIZONTAL/VERTICAL) ...........................................................	21
12.3		FITTING THE COAXIAL FLUE (Ø 60 / 100 VERTICAL) .......................................................................	23
12.4		FITTING THE TWIN PIPE FLUE (Ø80/80) ............................................................................................	24
13 ELECTRICAL CONNECTIONS .....................................................................................................................			27
13.1		FITTING THE MECHANICAL AND DIGITAL TIME CLOCKS ...............................................................	29
13.2		CONNECTING ZONE VALVES.............................................................................................................	30
14	COMMISSIONING AND TESTING ................................................................................................................		33
14.1		INITIAL PREPARATION ........................................................................................................................	33
14.2		INITIAL START-UP................................................................................................................................	33
14.3		ADJUSTING THE CO2...........................................................................................................................	34
14.4		GAS CONVERSION ..............................................................................................................................	34
14.5		ADJUSTING THE MAXIMUM HEATING POWER ................................................................................	34
14.6		FITTING THE EXTERNAL SENSOR.....................................................................................................	34
14.7		EXTERNAL SENSOR SET-UP..............................................................................................................	35
14.8		ADJUSTING THE PARALLEL SHIFT....................................................................................................	35
14.9		COMPLETION .......................................................................................................................................	35
14.10		OPERATIONAL CHECKS .....................................................................................................................	36
14.11		INSTRUCTING THE END USER...........................................................................................................	36
15	FITTING THE CASING ..................................................................................................................................		37
16	SEQUENCE OF OPERATION.......................................................................................................................		38
		CENTRAL HEATING MODE .................................................................................................................	38
17	ADJUSTMENTS AND SETTINGS .................................................................................................................		39

SERVICING INSTRUCTIONS
18 REPLACEMENT OF PARTS .........................................................................................................................		46
18.1	To Gain General Access........................................................................................................................	46
18.1.1	Removing the front panel.......................................................................................................................	46
18.1.2	Lowering the control panel.....................................................................................................................	46
18.2	Access to the Combustion Chamber .....................................................................................................	47
18.2.1	Removing the air/gas assembly.............................................................................................................	47
18.2.2	Removing the burner .............................................................................................................................	48
18.2.3	Removing the detection electrode .........................................................................................................	48
18.2.4	Removing the ignition electrode.............................................................................................................	48
18.2.5	Removing the fan...................................................................................................................................	49
18.2.6	Removing the gas valve.........................................................................................................................	49
18.2.7	Removing the heat exchanger ...............................................................................................................	50
18.2.8	Removing the spark generator...............................................................................................................	50
18.3	Access to the Water Circuit ...................................................................................................................	51
18.3.1	Drain down.............................................................................................................................................	51
18.3.2	Removing the Central Heating Return Body..........................................................................................	51
18.3.3	Removing the pump...............................................................................................................................	52
18.3.4	Removing the pressure relief valve ......................................................................................................	52
18.3.5	Removing the domestic expansion vessel.............................................................................................	53
18.3.6	Removing the overheat thermostat........................................................................................................	53
18.3.7	Removing the temperature sensors (NTC’s) .........................................................................................	53
18.3.8	Removing the pressure gauge...............................................................................................................	54
18.3.9	Removing the low water pressure switch ..............................................................................................	54
18.4	Access to the Control System................................................................................................................	54
18.4.1	Removing the PCB’s..............................................................................................................................	54
18.4.2	Removing the fuses ...............................................................................................................................	55
18.5	Connecting the External Sensor ............................................................................................................	55
19	ERROR CODES ....................................................................................................................................	56
20	INCORRECT OPERATION ..................................................................................................................	57
21	MAINTENANCE INSTRUCTIONS.........................................................................................................	58
21.1	General Remarks...................................................................................................................................	58
21.2	Cleaning the Primary Heat Exchanger ..................................................................................................	58
21.3	Operational Test ....................................................................................................................................	58
22	SHORT SPARES LIST ..........................................................................................................................	59
23	TECHNICAL DATA ................................................................................................................................	60
24	BENCHMARK COMMISSIONING CHECKLIST...................................................................................	61
25	SERVICE INTERVAL RECORD ............................................................................................................	62
	TERMS AND CONDITIONS OF GUARANTEE.....................................................................................	64

INTRODUCTION

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

The standard horizontal flue kit is suitable for lengths 300 mm minimum to 815 mm maximum (see pages 19 & 20) and includes an elbow adapter that can be rotated through 360° . The horizontal flue can extend up to 5 metres (Ø60/100) and 10 metres (Ø80/125) using 1 metre flue extension kits. 45° and 90° flue bends are also available as accessories, for more information on the fitting of the flue kits and the suitable flue runs, please refer to Section 12 Connecting the Flue (page 19).

USER’S INSTRUCTIONS

1. Control Panel

Fig 1	31	32	33	34

Control panel (Fig.1)		Connecting bracket
16.- Pressure Guage		Taps shown in Open position (Fig. 2)
25.- Display
26.- On/off push button and power on indicator light		39	: Gas service tap
28.- Reset push button and red indicator lockout light		41	: Central heating flow isolating valve
30.- Central Heating control knob	and temperature setting	42	: Central heating return isolating valve
31.- Menu key		43	& 44: Filling taps
32.- Reducing key		45	: Filling loop
33.- Increasing key
34.- Setting key

Fig. 2

2. How to Use

Switching on

1.Check that the pressure in the central heating system is above 0.7 bar and below 1.5 bar on the pressure gauge 16 (Fig. 1) should it be neccessary to re-pressurise the system, ensure the filling loop 45 (Fig. 2) is attached, open the filling taps 43 & 44 (Fig. 2), the pressure gauge will now start to rise, once the pressure reads 1.0 bar, close the filling taps and disconnect the filling loop, periodically check the pressure gauge for correct pressures.

2.Check that the gas service tap is opened at the gas meter and main power is on. Green indicator 26 (Fig. 1) lit.

3.Open the gas tap 39 (Fig.2).

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 attempt, (please refer to Section 20 Incorrect Operation, page 56).

OPEN CLOSED

Time setting

You can set the time by using the keys underneath the display.

Press the setting key for 5 seconds. The hour digits on the display will begin to flash. Set the correct time by using the or keys. To alter the minutes, press the setting key again, the minute digits will begin to flash. Set the correct time by using

the or keys, once the correct time has been set, press the setting key once more to accept the time.

Note: This is not a timer for Central Heating control.

To obtain heating

Turn the Central heating knob (30 Fig.1) between mini and maxi.

During the setting	flashes and displays the temperature the knob has been
set to.

The flashing will continue for a while after the setting and the display will then indicate one of the following :

-the heating temperature when the room thermostat is ON (Calling).

-the time when the room thermostat is OFF (Satisfied).

BURNER ON and output level

Burner operation is indicated by the symbol. The output of the burner is then indicated by the flame digits above the burner symbol.

Stand by mode

Turn the control knob 30 (Fig. 1) to the OFF position to deactivate the Central Heating. Leave the ON/OFF button (26 Fig. 1) On (green light).

During the stand by mode the display indicates the time, the anti-sieze and antifrost functions will remain active.

Switch OFF

Press the ON/OFF button (26 Fig.1) the green light will go out.

IMPORTANT: WHILE THE BOILER HAS BEEN SWITCHED OFF THE CENTRAL HEATING, ANTI-

FROST AND ANTI-SIEZE OPERATIONS WILL BECOME INACTIVE. THE BOILER IS STILL ALSO CONNECTED TO THE MAINS ELECTRICAL AND GAS SUPPLIES.

Room thermostat request pictogram

Flame digit

Burner ON

Anti-freeze and anti-sieze modes

Provided the ON/OFF button is on (green light), the water pressure is adequate and the boiler has not shut down due to an error, the anti-freeze and ant-sieze operations will remain active.

When the anti-freeze comes on, one of two codes will be displayed with the snowflake pictogram . The two possible codes are 05 (pump anti-freeze) or 06 (burner anti-freeze).

05 (Pump anti-freeze):

When the boiler senses a temperature of 8°C or lower, the pump will run for 2 minutes, the boiler will then check if the flow temperature is higher than 8°C. Should the temperature still be between 3°C and 8°C the above process will be repeated a maximum of 10 times, after this the burner will light and run until a temperature of 33°C is detected (see 06 Burner anti-freeze below).

06 (Burner anti-freeze):

When the boiler senses a temperature of 3°C or lower, the boiler will fire at minimum power until a temperature of 33°C is achieved, the pump will run for 2 minutes after the burner is switched off.

Anti-sieze mode

The anti-sieze mode will activate the pump for 1 minute everytime the boiler has been inactive for 23 hours.

Note: The anti-freeze and anti-sieze modes will be automatically overriden as soon as there is a demand for heaing from the room thermostat or cylinder thermostat.

The anti-freeze functions will only protect the boiler from freezing, to protect the Central Heating system it will be necessary to leave the boiler powered, the Central Heating knob turned on and the room thermostat set to its anti-frost setting (usually between 5°C and 10°C).

3. Maintenance

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 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 damp cloth, do not use any spray polishes or cleaners.

Precaution to avoid freezing

We recommend that 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 isolator)

• CH system

Choose one of the following solution :

-1) Drain the Central Heating system completely

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

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

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

• DHW system

Turn off the main cold water supply and drain the cylinder.

6.Setting the Time Clock

6.1Setting the Mechanical Clock

Fig. 4

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

Fig. 5

1. General layout

The mechanical clock covers a 24 hour period. Each tappet represents 15 minutes A (Fig. 5). An override switch is located on the clock B (Fig 5).

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. 5).

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

Set the selector switch B to the symbol to control the central heating by the clock. Set the selector switch B to «I» to select permanent operation or to «0» to turn the central heating off permanently.

6.Setting the Time Clock (continued)

6.3Setting the Digital Clock

		Manual switch
		Summer and
		winter time
	Reset	setting
	Reset
Enter		Enter
switching		the hours
times	.
	.
	g	h
	o
	r
	P	Week-
		Week-
		days
		flash

Imput	m	Enter
Imput		Enter
time		minutes
	Day
	Enter
	weekday/s

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.

6. Setting the Time Clock (continued)

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 be carried out by using the “Day” key.
When the day seIection is left bIank, the programmed switching 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. “18”. If all memory locations are occupied, the display “00” appears.

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 automatically 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 “ ” key pressed down for around 3 seconds. The switching time is now erased and the current time is displayed.

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.

Ariston System A Installation, Servicing and Operating Instructions

INSTALLER’S INSTRUCTIONS

7. Description

2	9
	9
3	7
3
8
20	4
22
21	5
	5
12
6	42
	42
13
	14
16
Fig. 6

1.- Steel chassis complete with expansion vessel

2.- Sealed chamber

3.- Burner and heat exchanger assembly

4.- Air / gas connection

5.- 24 V modulating fan

6.- Gas valve

7.- Ignition electrode

8.- Ionisation probe

9.- Ignitor

10.- Combustion products manifold

11.- Condense trap

12.- Silencer

13.- Electrical box

14.- Pump

16.- Pressure gauge

17.- Three way valve

18.- Automatic air separator and automatic vent

20.- Main exchanger return thermistor

21.- Main exchanger flow thermistor

22.- Overheat sensor

23.- Central heating pressure relief valve

24.- Condensate pipe

Fig. 7

25.- Display

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

28.- Reset push button and red indicator locking light

30.- Central Heating start button and temperature setting

31.- Menu key

32.- Reducing key

33.- Increasing key

34.- Setting key

Fig 8

8. Dimensions
All dimensions in mm	I	Safety valve C/H and condensate
	I	Safety valve C/H and condensate
	J	Heating flow
	K	Cylinder return
	L	Gas supply
	M	Cold water supply
	N	Heating return
		Weight with packaging :
		24 kW : 34 kg
		30 kW : 37 kg
		Minimum space required 450mm
296 (24 kW)
360 (30 kW)
		390 mm
		440
Fig. 9

NOTE: THE CLEARANCES STATED ABOVE ARE REQUIRED FOR SERVICING PURPOSES

9. Hydraulic data

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 vessel.

Maximum volume of expansion vessel: 6 litres.(24 kW)

6 litres.(30 kW)

Pressure: 1 bar.

The volume of the expansion vessel in a pressurised appliance varies according to:

-the average operating temperature in °C

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

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.

Central heating initial pressure when cold (in bar)

Pump Head Graph (15/50)

Pressure (bar)

flow rate (l/hr)

Pump Head Graph (15/60)

Pressure (bar)

flow rate (l/hr)	Fig. 10

System capacity chart

Fig. 11

System capacity (litres)

10. Installation Requirements

Reference Standards

In the United Kingdom, the installation and initial start up of the boiler must be by a CORGI Registered installer in accordance with the installation standards currently in 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 to the current ETCI rules for electrical installation.

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

C.O.S.H.H.

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

Codes of Practice

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

BS 7593:1992	Treatment of water in domestic hot
	water central heating systems
BS 5440-1:2000	Flues
BS 5440-2:2000	Air Supply
BS 5449:1990	Forced ciculation hot water systems
BS 6798:2000	Installation of gas fired hot water
	boilers of rated input not exceeding
	70kW
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.

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

I.S. 813

Domestic Gas Installations

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

Flue

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

The boiler must be installed so that the flue terminal is exposed to the free passage of external air at all times and must not be installed in a place likely to cause nuisance. It

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

Condensing boilers have a tendency to form a plume of water vapour from the 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.

The minimum acceptable clearances are shown below:


Fig. 12

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

NOTE: THE FLUE MUST NOT BE INSTALLED IN A PLACE LIKELY TO CAUSE 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.

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.

Electrical Supply

The appliance requires an earthed 230V - 50 Hz supply and must be in accordance with current I.E.E. regulations.

10. Installation Requirements (continued)

It must also be possible to be able to completely isolate the appliance electrically. Connection should be via a 3 amp fused double-pole isolating switch with a 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 pipework connected to the appliance should be of the same standard. If there is a possibility of the incoming mains pressure exceeding 6 bar, particularly at night, then a suitable pressure limiting valve must be fitted.

The boiler is designed to provide Central Heating on demand to a Central Heating system and to heat an Indirect Hot Water Storage Cylinder.

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. 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 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.

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

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

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

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 exchangers of those with a specific system water treatment.

IMPORTANT

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

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 Wiring Regulations.

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 2.5o and must be inserted by at least 50mm into a suitable acid resistant pipe - e.g. plastic waste or overflow pipe. The condensate discharge pipe must have a 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 above the invert of the stack). A trap giving a water seal of at least 75mm must be incorporated into the pipe run, there also must be an air 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 is down stream of the waste trap then an additional trap giving a minimum water seal of 75mm and an air break must be incorporated in the pipe run, as above.

10. Installation Requirements (continued)

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

iv)Into a soakaway.

NOTE: If any condensate pipework is to be installed externally then it should be kept to a minimum and be insulated with a waterproof insulation and have a continuous

fall. The total length of external pipe used should not exceed 3 metres.

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

1. Internal termination of condensate drainage pipe to internal stack

2.External termination of condensate drainage pipe via internal discharge branch

(e.g. sink waste) and condensate siphon

10.Installation Requirements (continued)

3.External termination of condensate drainage pipe via internal discharge

branch (e.g. sink waste - proprietary fitting)

4. External termination of condensate drainage pipe via condensate siphon

11. Installing the Boiler

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

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

-Hanging bracket

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

-Connection tails and valves

-Screws and washers

-Connection washers

-Installation, Servicing and Operating Instructions

-Air Inlet Header (for use with twin flue pipe)

-Guarantee Card

Method of positioning the boiler on the wall.

The paper template can be used to ensure the correct positioning of kitchen cabinets etc. It also details the commissioning instructions.

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

Drill and plug the wall and secure the hanging bracket using the screws provided. Remove the boiler from its packaging as shown in Fig. 13, unscrew the clamp locking bolt A and remove the casing (Fig. 14).

Place the boiler on the wall on the hanging bracket (Fig. 15).

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

Connecting the boiler to the system

-Remove the boiler casing as described in Section 18 (page 45).

-Push in the tabs “P” (Fig. 15) on either side of the boiler and pivot the electrical box forward to gain access to the valve connections

-Remove the caps and connect the valves to the boiler using the washers provided in the plastic bag. 2 x fibre washers for the C/H flow and return.

1 x rubber washer for gas connection

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 (page 32).

The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. The condensate pipe from the siphon (24 Fig. 7, page 11) should be connected to a drain as described in the relevant Brittish regulations.

Pay special attention to not bend the plastic condensate drain pipe in such a way as to cause the flow to be interrupted. Please use exclusively drain pipe material compatible with condensate products. (refer to BS 6798 : 2000)

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 trap (11 Fig. 7, page 11) must be filled with water. Before fitting the flue onto the boiler, pour 1/4 litre of water into the exhaust pipe as shown in Fig. 17 (page 19).

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

IMPORTANT!!

Use only the specific condensation flue kit supplied by MTS (GB) Limited.

11. Installing the Boiler (continued)

Fig. 13

Fig. 14

Fig. 15

Fig. 16

12. Connecting the Flue

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 concentric flue system.

NOTE: SEE PAGE 24 FOR MAXIMUM AND MINIMUM FLUE RUNS (TABLES A, B AND C)

IMPORTANT!!

BEFORE CONNECTING THE FLUE, ENSURE THAT 1/4 LITRE OF WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION TO FILL THE CONDENSATE TRAP (FIG. 17). SHOULD THE TRAP BE EMPTY THERE IS A TEMPORARY RISK OF FLUE GASSES ESCAPING INTO THE ROOM.

Fig. 17

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