Ariston TP 23, TP 30 Installation and Servicing Instructions

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Users Guide

Installation and Servicing Instructions

TP 23 - G.C. Number 47-116-32 TP 30 - G.C. Number 47-116-33

Manufacturered by Merloni TermoSanitari spa - Italy

Country of destination: GB - IE

TABLE OF CONTENTS

USERS GUIDE

1. GENERAL INFORMATION

2. OPERATING INSTRUCTIONS

3. BOILER SHUTDOWN SITUATIONS

4. TIME CLOCK

INSTALLATION AND SERVICING INSTRUCTIONS

5. GENERAL INFORMATION

5.1 General Instructions

5.2 Overall View

6. INSTALLATION

6.1 Reference Standards

6.2 Siting the Appliance

6.3 Overall Dimensions

6.4 Clearances

6.5 Mounting the Appliance

6.6 Electrical Connection

6.7 Gas Connection

6.8 Water Connections

6.9 Flue Connection

6.10 Control Panel

6.11 Removing the front panel

6.12 Fitting the Time Clock

6.13 Room Thermostat Connection

6.14 Electrical/System Diagrams

6.15 Water Circuit Diagram

7. COMMISSIONING

7.1 Initial Preparation

7.2 Initial Start up

7.3 Operational Adjustments

7.4 Combustion Analysis

7.5 Product of Combustion Discharge Monitoring

7.6 Boiler Safety Systems

7.7 Draining the System

7.8 Completion

7.9 Operational checks

7.10 Instructing the End User

8. GAS ADJUSTMENTS

8.1 Changing the Type of Gas

8.2 Adjusting the gas pressure

10. SERVICING INSTRUCTIONS

10.1 Replacement of Parts

10.2 To Gain General Access

10.2.1 Removing the Front Panel

10.2.2 Removing the Sealed Chamber Front Panel

10.2.3 Removing the Side Panels

10.3 Access to the Combustion Chamber

10.3.1 Removing the Combustion Cover

10.3.2 Removing the Burner and Jets

10.3.3 Removing the Electrodes

10.3.4 Removing the Main Heat Exchanger

10.3.5 Removing the Air Pressure Switch

10.3.6 Removing the Fan

10.4 Access to the Gas Valve

10.4.1 Removing the Spark Generator

10.4.2 Removing the Gas Valve

10.5 Access to the Water Circuit

10.5.1 Removing the D.H.W. (secondary) exchanger

10.5.2 Removing the Pump Pressure Switch

10.5.3 Removing the Safety Valve

10.5.4 Removing the Automatic Air Vent

10.5.5 Removing the Pump

10.5.6 Removing the Pressure Gauge

10.5.7 Removing the Expansion Vessel

10.5.8 Removing the Overheat Thermostat

10.5.9 Removing the Central Heating Temperature Sensor (N.T.C.)

10.5.10Removing the D.H.W.Temperature Sensor (N.T .C .)

10.5.11Removing the D.H.W. Flow Switch

10.5.12Removing the Divertor Valve Actuator

10.6 Access to the Control System

10.6.1 Checking the Fuses

10.6.2 Removing the Time Clock

10.6.3 Removing the P.C.B.

11. FAULT FINDING

11.1 Fault Finding Guide (Flow-chart)

12. SHORT SPARE PARTS LIST

9. MAINTENANCE

TECHNICAL INFORMATION

13.

DEFI HGK J

USERS GUIDE

1. General Information

This is a combined appliance for the production of central heating (C.H.) and domestic hot water (D.H.W.).This appliance must be used only for the purpose for which it is designed.The manufacturer declines all liability for damage caused by improper or negligent use. Do not allow children or inexperienced persons to use the appliance without supervision. If you smell gas in the room, do not turn on light switches, use the telephone or any other object which might cause sparks. Open doors and windows immediately to ventilate the room. Shut the gas mains tap (on the gas meter) or the valve of the gas cylinder and call your Gas Supplier immediately. If you are going away for a long period of time, remember to shut the mains gas tap or the gas cylinder valve.

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

Control Panel

LEGEND:

A - On/Off button B - Central heating temperature adjustment C - Domestic hot water temperature adjustment D - Heating system pressure gauge E - Time clock F - Central heating selector G - Central heating L.E.D. (green) H - Flue sensor L.E.D. (yellow) I - Ignition failure (lockout) and/or overheat reset button J - Overheat and/or ignition failure (lockout) L.E.D. (red)

K - ON/OFF L.E.D. (green

)

2. Operating Instructions

Installation, star t-up, adjustments and maintenance must be performed by a competent person only, in accordance with the current Gas Safety (Installation & Use) Regulations and the instructions provided. Improper installation may cause damage or injury to individuals, animals and personal property, for which the manufacturer will not be held liable. To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a competent person. If it is known or suspected that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.

To get the most out of your boiler, we have provided you with some useful advice on proper use and maintenance:

- Periodically check the system pressure using the pressure gauge “D”, make sure that the pressure is at 1.5 bar when the system is off and cool. If the pressure is below the minimum recommended value. Consult your installer for checking and refilling the system.

- The outer panels of the units case must only be cleaned with a damp cloth. Do not use abrasive cleaners. The control panel can be wiped with either a damp or dry cloth. Spray polishes must not be used on the control panel surface or knobs. Care must be taken in preventing any liquid entering the appliance.

- If the water is very hard, it is recommended that a water softener be added to the system so as to reduce the formation of limescale in the heat exchanger. This will ensure that the efficiency of the unit remains the same over time, reducing gas consumption and maintenance costs.

- If the boiler should be out of use for a prolonged period, it is recommended that the electrical power supply be disconnected and that the external gas cock be closed. If low temperatures are expected, the boiler and system pipe work should be drained in order to prevent frost damage.

- To improve comfort and take full advantage of the heat produced by the boiler, it is recommended that an external (room) thermostat be installed.

- It is good practice to clean and service the appliance and central heating system every year. Call an Authorised Service Centre.

Ignition Procedure

Press button “A”. The green L.E.D. “K” will illuminate indicating that the boiler is ready to operate. The centralised electronic control unit will ignite the burner, upon demand for either C.H. or D.H.W. If, after approximately 10 seconds, the burner has not ignited, the boiler safety devices will shut off the gas and the red L.E.D.“I” illuminates. To reset the ignition system, the reset “J” must be pressed and released. Should the boiler fail to ignite a second time, check that the external gas cock is open (see diagrams on the left). If the problem persists, contact a local Service Agent.

IMPORTANT!! Always wait 2 minutes before resetting each time.

3. Boiler Shutdown Situations

Winter and Summer Operating Modes

In the ‘winter operating mode’, the boiler will produce both Central Heating and Domestic Hot Water.In the ‘summer operating mode’, the boile r w i ll p ro du c e only domestic hot water. Press button “F” to select winter mode. The green LED “G” will illuminate.

Adjusting the Heating

It is possible to set the temperature of the heating system by adjusting the knob “B”. By positioning the indicator somewhere between MIN and MAX, a temperature may be obtained which varies from approximately 42˚C to about 82˚C.

External (Room) Thermostat Control

If an external (room) thermostat is installed, it is recommended that the temperature of the heating system be set by means of the knob “B”, leaving it at MAX position in order to obtain the best performance from the boiler and to allow the regulation of the external temperature to function efficiently.

Setting the Hot Water for Domestic Use

Both in the winter and summer mode, the temperature of the domestic hot water may be adjusted by rotating the knob “C”.A delivery temperature for the water may be selected between approx. 36˚C to 54˚C, depending on the flow rate of the water and the position of the knob between MIN and MAX settings. NOTE: Should the Domestic

Hot Water not be hot enough, it may be necessary to slow the flow rate from the hot water outlet being used.

Turning Off the Central Heating

To tur n off the Central Heating, press the Central Heating button “F”;the respective green LED “G” will go off. The boiler will stay in summer mode, only providing Domestic Hot Water

The boiler is equipped with safety devices that intervene in certain situations and shut it off.Most of these situations are communicated by means of the LED’s and at times the user may be able to remedy them.

Shutdown Due To Ignition Failure

In the event that the automatic ignition of the burner has failed, the red LED. “I” will illuminate. In order to reset the ignition, the button “J” must be pressed and released. Should the boiler fail to ignite a second time, check that the external gas cock is open. If the problem persists, contact a local Service Agent.

IMPORTANT!! Always wait 2 minutes before resetting each time.

Shutdown Due To Overheating

In the event that the safety limit is exceeded for the temperature of the water in the boilers exchanger, the thermostat shuts off the boiler and the red LED “I” illuminates. To remedy this situation, wait a few minutes to allow the exchanger to cool down, then press and release the reset button “J”. If this situation occurs frequently, contact a local Service Agent.

Temporary Shutdown Due To Defective Discharge of Exhaust Fumes

The boiler is fitted with safety devices, which in the event of a defective discharge of exhaust products, automatically interrupts the gas supply, thereby shutting off the boiler. The shut-off of the boiler is temporary and is indicated by the illumination of the yellow L.E.D.“H” for a period of about 15 minutes. Once this time period has passed and the discharge state of exhaust system has returned to normal, the boiler automatically turns back on.

IMPORTANT!

If this situation occurs frequently , contact a local Service Agent so that they may check that the exhaust fumes are being expelled correctly, that the flue is installed correctly and that the area is ventilated properly.

Turning Off the Boiler

To turn the boiler off, press the button “A”; the respective green LED “K” will go off.

3. Boiler Shutdown Situations

Shutdown Due To Insufficient Circulation

If the boiler is off, one possible cause for this state is an insuffi-

cient pressure of water in the system. Check the system pressure on the pressure gauge “D” and if it is less than 0.5 bar, re- pressurise the system as instructed by your installer, should you be unsure some basic instructions are provided hereafter;

Ensure that the filling loop hose is connected to the cold water inlet pipe and to either the Central Heating flow or return Open the handle/s or tap/s to allow water into the Central Heating system Once the needle on the pressure gauge reaches 1 Bar, close the handle/s or tap/s and disconnect the filling loop hose Should it still be unclear how to proceed, please consult your installer.

If the boiler does not start up again, contact a local Service Agent. If there are frequent drops in pressure within the system, have a plumber check the heating system for possible water leaks.

4.Time clock

UT011Ap

Note: the time clock is for central heating control only.

The time clock is provided with 96 switches , called riders, each of which covers a time interval of 15 minutes (four per hour). When a rider is switched from the inside (off setting) to the outside of the clock border (on setting), the circuit is closed (switch on) for a period of 15 minutes and then the boiler starts if the room thermostat (if installed) or the heating thermostat require heat (heating function on).

Anti-frost Device

The boiler is fitted with a device which, in the event that the water temperature falls below 8 temperature of 18˚C is attained. In the event that the water temperature falls below Hot Water and the burner fires and runs on minimum power until a temperature of 33˚C is attained. This device is only activated when the boiler is operating perf ectly and

- the system pressure is sufficient;

- the boiler is powered electrically;

- gas is being distributed.

˚C the pump activates and runs until a

˚C, the diverter valve switches to Domestic

EXAMPLE

To set the heating of your home in the time interval from 7.00 am to 9.30 am and from 7.00 pm to 10.00 pm every day:

- rotate the outer r ing of the clock in a clockwise direction until the correct time of day (24h) lines up with the arrow on the clock (at approx.2 o’clock position);

- under no circumstances should the minute hand be moved manually;

- make sure all the switches, i.e. the riders, are placed on the inside of the clock border;

- pull outward the riders for 7.00 am and 9.30 am, and then all riders between these two;

- repeat this for 7.00 pm and 10.00 pm. Other heating intervals may be set in the same way. The timer has approximately 150 hours of battery back up for power failure.

The clock is provided with a selector switch with three positions (see figure):

1.Position “I” CONSTANT: in this position, the clock circuit is always closed (switch on), therefore the boiler will constantly be on and will only shut off upon the request of the room thermostat (if installed) or the heating thermostat;

Position “O”HEATING OFF:in this position, the

UT014A

clock circuit is always open (switch off) and the boiler will therefore never ignite for heating;

UT014A

“Central” Position

PROGRAMMING ACTIVE: in this position, the programming set by the user is active.

UT014A

INSTALLATION AND SERVICING INSTRUCTIONS

5. GENERAL INFORMATION

5.1 General Instructions

This manual is an integ should be kept with the appliance so that it can be 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 Previous User Guide.

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

Keep this manual in a saf e place.Y ou ma y need it f or y our own reference while our Servicing Centre technicians or your installer may need to consult it in the future.

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

This appliance must be used only for the purpose for which it is designed. The man improper or negligent use.

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

Before connecting the appliance, check that the information sho with the electric, water and gas mains of the property.You will find the data plate on the reverse of the control panel. The gas with which this appliance operates is also shown on the label at the bottom of the boiler.

Do not install this appliance in a damp environment or close to equipment which spr

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

ance without supervision. If you smell gas in the room, do not turn on light switches, use

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

Always disconnect the appliance either by unplugging it from the mains or turning off the mains switch bef ance 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 A request the use of original spare parts. For in-guarantee repairs contact MTS (GB) Limited.

ufacturer declines all liability for damage caused by

wn on the data plate and the technical data section comply

ral and essential part of the product. It

ay water or other liquids.

y other object which might cause sparks.

ore cleaning the appli-

uthorised Servicing Centre and

Check the following at least once a year:

1 - Check the seals for the water connections; replace any

faulty seals. 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of com-

bustion by-products (see section 3.6) and cleaning of the

burner if needed. 5 - If called for by point.3, dismantling and cleaning of the com-

bustion

chamber. 6 - If called for by point.4, dismantling and cleaning of the burn-

er jets. 7 - Visual check of the primary heat exchanger:

- check for overheating in the blade assembly;

- clean the exhaust fan if needed.

8 - Adjustment of the flow rate of the gas: flow rate for lighting,

partial load and full load. 9 - Check of the heating safety systems:

- safety device for maximum temperature (overheat thermostat);

- safety device for maximum pressure (safety valve).

10- Check of the gas safety systems:

- safety device for lack of gas or flame ionisation (detection electrode);

- safety device for gas cock.

11- Check of the electrical connection (make sure it complies

with the instructions in the manual).

12- Check of domestic hot water production efficiency (flow rate

and temperature)

13- General check of the combustion by-products of the dis-

charge/ventilation system.

14- Check of the general performance of the unit.

OTE: THESE CHECKS ARE NOT EXHAUSTIVE, FURTHER HYDRAULIC,

MECHANICAL, ELECTRICAL AND OPERATIONAL CHECKS MAY BE REQUIRED AS NECESSARY

General Information

27 26

21 20

23 22

13 14

16 18 1917

5.2 Overall View

Fig. 5.0

Legend:

1. Flue connector

2. Air intake for twin pipe flue systems

3. Fan

4. Combustion chamber hood

5. Heat exchanger

6. Safety thermostat

7. Combustion chamber

8. Combustion chamber insulation panel

9. Detection electrode

10. Ignition electrodes

11. Pump pressure switch

12. Main circuit temperature probe

13. Safety valve (3 bar)

14. Domestic hot water temperature probe

15. Secondary exchanger

16. Gas valve

17. Spar k generator

18. Domestic hot water inlet filter

19. D.H.W. flow switch

20. Drain valve

21. Circulation pump with automatic air release valve

22. Motor ised diver ter valve

23. Automatic By-pass

24. Bur ner

25. Expansion vessel

26. Air pressure switch tube

27. Air pressure switch

28. Combustion analysis points

6. INSTALLATION

6.1 Reference Standards

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

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”, 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).

C.O.S.H.H.

Materials used in the manufacture of this appliance are non-hazardous and no special precautions are required when servicing. Installation should also comply with the following British Standard Codes of Practice

6.2 Siting the Appliance

The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, 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 6.4. The location must permit the provision of an adequate flue and termination. For unusual locations special procedures may be necessary. BS 6798-1987 gives detailed guidance on this aspect. A compartment used to enclose the appliance must be designed specifically for this purpose. No specific ventilation requirements are needed for the installation within a cupboard. This appliance is not suitable for outdoor installation.

The type C appliances (in which the combustion circuit, air vent intake and combustion chamber are air-tight with respect to the room in which the appliance is installed) can be installed in any type of room.

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

BS 7593:1992 Treatment of water in domestic hot water

central heating systems

BS 5546:1990 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 6798:1987 Installation of gas fired hot water boilers

of rated input not exceeding 60kW BS 6891:1989 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.

Installation

6.3 Overall Dimensions

FIG. 6.1

6.5 MOUNTING THE APPLIANCE

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

the appliance.

QT002A

Legend:

A = Central Heating Flow (3/4”) B = Domestic Hot Water Outlet (1/2”) C = Gas Inlet (3/4”) D = Domestic Cold Water Inlet (1/2”) E = Central Heating Return (3/4”)

6.4 Clearances

FIG. 6.2

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 FIG.6.2

DM001B

FIG. 6.3

Place the template in the position the appliance is to be mounted and after ensuring it is hanging squarely, use it to drill the holes for the hanging bracket and flue pipe(s) NB: For further information relating to the flue installation please refer to Section 6.9 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 framed building, guidance should be sought from the IGE document REF: IGE/UP/7.

Installation

6.7 Gas Connection

6.5.1. Drill the wall and plug using those supplied with the con-

nections kit, position the bracket and secure with the wall bolts supplied. Note: It is highly recommended that a spirit level be used to position the appliance to ensure that it is perfectly level.

6.5.2. Position the appliance on the hanging bracket and connect the isolating valves supplied in the connection kit as shown on the wall template (see also Sections 6.7 Gas Connections, 6.8 Water Connections & FIG. 6.3).

6.6 Electrical Connection

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 13, where the maximum absorbed power is also indicated.Make sure that the connections for the neutral and live wires correspond to the indications in the diagram.The appliance electrical connections are situated on the reverse of the control panel.

MPORTANT!

In the event that the pow er supply cord must be changed, replace it with one with the same specifications. Note: The diagrams for the electrical system are indicated in sec-

tion 6.13.

Warning, this appliance must be earthed.

External wiring to the appliance must be carried out by a 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 6.2).

Should external controls be required, the design of the external electrical circuits should be undertaken by a competent person, see section 6.12 for further information.

The local gas region contractor connects the gas meter to the service pipe. If the gas supply for the boiler serves other appliances ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time. Pipe work must be of an adequate size. Pipes of a smaller size than the boiler inlet connection should not be used.

6.8 Water Connections

View of the Boiler Connections

Fig. 6.4

Legend:

A = Centr B = Domestic Hot Water Outlet C = Gas Inlet D = Domestic Cold Water Inlet E = Central Heating Return F = Safety Valve Outlet G = Drain Valve

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 g r adient to ensure air is carried naturally to air release points and water flows naturally to drain taps. The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air. Except where providing useful heat, pipes should be insulated to prevent heat loss and avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

By-pass:

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

SYSTEM DESIGN:

This boiler is suitable for sealed systems only.

al Heating Flow

TE020E

Installation

FIG. 6.5

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.

Safety Valve Discharge:

The 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 or any other type of public access.

Air Release Points:

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

There must be no direct connection to the mains water supply even through a non-return valv e, without the approv al of the Local Water Authority, therefore a temporary method for initially filling the system and replacing lost water during servicing in accordance with current W ater Regulations and byla ws must be provided (FIG. 6.6).

Note: The installer should ensure that there are no leaks as fre-

quent filling of the heating system can lead to premature scaling of the main exchanger and failure of h ydraulic com-

ponents. Domestic Water: The domestic water must be in accordance with the relevant recommendation of BS 5546:1990. Copper tubing to BS EN 1057:1996 is recommended for water carrying pipe work and must be used for pipe work carrying drinking water, a scale reducer should also be used to reduce the risk of scale forming in the domestic side of the heat exchanger.

CENTRAL HEATING

Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance.

Residual Head of the Boiler

VR003A

∆

T=20°C

FIG. 6.6

Installation

6.9 Flue Connections

FLUE SYSTEM

The provision for satisfactory flue termination must be made in accordance with BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outside 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 and consideration must be given to adjacent boundaries. In cold or humid weather water vapour may condense on leaving the flue terminal. The effect of such “pluming”must be considered. If the terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be fitted. When ordering a terminal guard, quote the appliance model number. A suitable terminal guard is available from:

TOWER FLUE COMPONENTS Morle

y Road Tonbridge Kent TN9 1RA

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

IG. 6.7.

IMPORTANT! For all flue systems, a restrictor may need to be inserted into the exhaust manifold, the siz e of the restrictor and details of fitting requirements are shown in Table

6.1 (Page 18).

Ø 60/100 mm

FU003A

FIG. 6.7

ERMINALPOSITION

A - Directly below an openable window

or other opening300 B - Below gutters, solid pipes or drain pipes 75 C - Below eaves 200 D - Below balconies or car-port roof 200 E - From vertical drain pipes and soil pipes 150 F - From internal or external corners 300 G - Above ground or balcony level 300 H - From a surface facing a terminal 600

I - From a terminal facing a terminal 1200

J - From an opening in the car port

(e.g. door, window) into dwelling 1200 K - Vertically from a terminal in the same wall 1500 L - Horizontally from a terminal in the same wall 300

M - Hor izontally from an opening window 300 N - Fixed by vertical flue terminal

FU010ARev1

FIG. 6.8

Fitting the Coaxial Flue (Horizontal)

(For Telscopic Instructions see page 13 and for Vertical Flue and Twin Pipe Instr uctions see page 14)

CONTENTS: 1X SILICONE O-RING (60mm) 1X ELBOW (90O) 2X WALL SEALS (INTERNAL &EXTERNAL) 1X ALUMINIUM FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100) 2X FLUE CLAMPS 8X SCREWS 2X SEALS

Once the boiler has been positioned on the wall, insert the elbow into the socket (FIG 6.8) and rotate to the required position. NOTE:

It is possible to rotate the elbow 360oon its vertical axis. Using the flue clamps, seals and screws supplied (FIG 6.8)

secure the elbow to the boiler. The 1 metre horizontal flue kit (705958) supplied is suitable for an

exact X dimension of 823mm, and the 750mm horizontal flue kit (705785) is suitable for an exact X dimension of 573mm.

NOTE: THE FLUE MUST NOT TERMINATE IN A PLACE LIKELY TO CAUSE

NUISANCE

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

Installation

25 mm

face of the flue elbow (X - FIG 6.8), add 22 mm to this measurement, you now hav e the total length of flue required (including the terminal), this figure must now be subtracted from 860mm, you now have the total amount to be cut from the plain end of the flue.

Cut the flue to the required length ensuring that the distance between the inner and the outer flue is maintained (FIG 6.10).

e.g. X = 508mm + 22mm = 530mm

860 - 530 = 330mm (Length to be cut from the plain end

of the flue).

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

Fitting the Telescopic Flue Kit (Horizontal)

CONTENTS: 1X SILICONE O-RING (60mm) 1X ELBOW (90O) 2X WALL SEALS (INTERNAL &EXTERNAL) 1X ALUMINIUM FLUE PIPE INCLUDING TERMINAL (TELESCOPIC - 60/100) 2X FLUE CLAMPS 8X SCREWS 2X SEALS

FIG 6.9

The telscopic flue is suitable for use with an exact minimum X dimension of 270mm and an exact maximum X dimension

470mm.

IMPORTANT!! Do not extend the telescopic flue to an X dimension of more than 470mm. If longer lengths are required use extension pieces as necessary. Under no circumstances must the flue be cut.

The wall must then be made good around the flue (ensuring a fall of 1ois maintained away from the boiler to the flue terminal).

Once made good, place the inner (white) wall seal over the flue and push up to the wall, secure the flue to the elbow by using the clamp supplied.

For each additional 90oelbow 1 metre must be removed from the total flue length (maximum 4 metres including the 1st elbow). For each additional 45oelbow 0.5 metre must be subtracted from the total flue length (FIG 6.13).

Fitting the Coaxial Flue (Vertical)

(For Twin Pipe Instructions see page 14)

CONTENTS: 1X SILICONE O-RING (60mm) 1X ELBOW (90O) 2X WALL SEALS (INTERNAL & EXTERNAL) 1X ALUMINIUM FLUE PIPE INCLUDING TERMINAL (TELESCOPIC - 60/100) 2X FLUE CLAMPS 8X SCREWS 2X SEALS

FIG 6.11

FIG 6.10

WARNING

IT WILL BE NECESSARY TO CONSULT

TABLE

6.1 ON PAGE 18 TO

DETERMINE WHETHER THE FLUE RESTRICTOR IS REQUIRED IT NOT BE NEEDED THE RESTRICTOR WILL NEED TO BE REMOVED FROM THE FLUE GAS COLLAR

. SHOULD

(FIG. 6.11).

The vertical flue kit is supplied with a specially designed weather proof terminal fitted, it can be used either with a flat roof or a pitched roof. (see FIGS 6.12, 6.13).

FIG 6.12

Installation

The Vertical flue kits maximum and minimum useable lengths with both flat and pitched roof flashings are indicated in (Figs.

6.14 & 6.15).

Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded and that all elbows and bends have been taken into consideration, the maxim um 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 offset and height of 2

x 45ocan be seen in Fig. 6.16). Mark the position of the flue hole in the ceiling and/or roof (see

FIG. 6.14 for distance from wall to the centre of the flue).

Cut a 110mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof. Should it be necessary to cut the flue DO ar inlet tube, cut the aluminium exhaust flue 6mm longer than the outer white air tube when used at minimum length. DO NOT cut more that 250mm from the inner aluminium exhaust flue.

To connect the vertical flue kit directly to the boiler, place the adaptor (see FIG 6.12) (supplied with vertical flue kit) onto the exhaust manifold and secure with the clamp, 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.

NOT cut the outer white

FIG 6.13

NOTE:MAX LENGTH = a+a+a +

b+b = a+a+a+0.5+0.5 COMBINED LENGTH NOT

TO EXCEED 4m

Should extensions be required, they are available in 1 metre (Part No. 705786), 500mm (Part No. 705790) and 160mm lengths (Part No.705812), they must be connected directly to the boiler and secured with the clamp supplied before connecting the adaptor to allow the vertical flue kit to be fitted. In the event that extension pieces need to be shortened, they m the male end and it must be ensured that the distance between the inner and outer flue are kept (Fig. 6.10).

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.

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.

ust only be cut at

Fitting the Flue (Twin Pipe)

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.

FIG 6.14

Considerations necessary for twin flue installation; It is most important to avoid any possible condense formation

entering the appliance.

Installation

According to Table 6.1 (Page 18) decide if condensation will form within the flue. If yes, there are two options;

1) Where condense will form but can be negated with insulated flue, install the insulated flue with a fall of 5mm in every metre away from the boiler.

2) The exhaust flue will have a fall of 3 and a suitable trap will be fitted on the exhaust as close to the boiler as possible, condense will then be suitably disposed of .

Where the flue runs through cold spots, i.e. loft areas, condense is likely to be formed, therefore a fall back to the boiler and a trap is required. Always ensure that the flue is adequately supported, avoiding low points. (MTS supply suitable clamps as Part No.705778).

To utilise the air intake it is necessary to: Remove the ‘knoc k out’of the air intake by cutting it with a suitable

knife (FIG. 6.16). Insert the elbow/flue pipe into the air intake until it stops.

back to the boiler

FIG 6.15

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

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

It is not recommended that the pipe bridge be used for horizontal termination, however in the unlikely event that this proves to be a necessity it is extremely important that the entire flue has a fall of

back to the boiler, is suitably trapped and where the 60mm

3 inner flue of the concentric terminal connects to the pipe bridge, this point must be adequately sealed with silicone sealant to avoid condense leakage at this point.

Note: Vertical twin flue installations must have a trap on the

exhaust. MTS supply a suitable condense trap with float Part No. 705774 and recommend that this be used in the event that the flue may not form condense.

When siting the twin flue pipe horizontally, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals m imum of 500mm, the air intake must not be sited above the exhaust terminal (refer to FIG. 6.19). The air intake pipe can be run horizontally, however, the terminal and the final 1 metre of flue must be installed with a fall away from the boiler to avoid rain ingress.

ust be a minimum of 280 mm apart and a max-

WARNING

IT WILL BE NECESSARY TO CONSULT TABLE 6.1 ON PAGE

18 TO DETERMINE WHETHER THE FLUE RESTRICTOR IS

REQUIRED WILL NEED TO BE REMOVED FROM THE FLUE GAS COLLAR

. SHOULD IT NOT BE NEEDED, THE RESTRICTOR

(FIG. 6.11).

Minimum offset distance when using 2x 45obends

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.

FIG 6.16

Installation

For flue runs with the intake and exhaust pipes under the same atmospheric conditions (Type 4) the maximum length is 43 metres (80) and 28 metres (100), for runs with the terminals under different atmospheric conditions (Type 5) the exhaust terminal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the exhaust and air intake pipes are located on the same side of the building). For Type 5 also, the maximum permissible combined length is 40 metres (80) and 51 metres (100).

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 1.3 metres must be subtracted from the total length and for each 45oelbow 1 metre must be subtracted from the total flue length. Some of the acceptable flue configurations are detailed on below (FIG. 6.19).

For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 2418180.

FIG 6.17

FIG 6.16

FIG 6.18

Installation

EXHAUST

AIR INTAKE

AIR INTAKE MUST NOT BE

FITTED ABOVE THE EXHAUST

FIG. 6.19

Type 1

Type 4

Note: Drawings are indicative of flueing options only.

Type 2

Type 5

Type 3

FIG 6.20

Installation

TP 23

Coaxial

Systems

ø 60/100

Twin Pipe

Systems

ø 80/80

Exhaust

Type

TYPE 1 TYPE 2 TYPE 3

Exhaust

Type

TYPE 4

TYPE 5

Use the

ø 41 mm

Restrictor

Between

345 mm - 1 m

Use the

ø 43 mm

Restrictor

Up to 20 m

Up to 25 m

Do not use the

Restrictor

Between 1 m - 4 m

Do not use the

Restrictor

Between

20 m - 60 m

een

Betw

25 m - 59 m

Maximum

Flue

Length

4 m

Maximum

Flue

Length**

60 m

59 m

Risk of Condensation Forming

NOT APPLICABLE

T APPLICABLE

Risk of Condensation Forming With:

Standard T win Pipe

After:

3 m*

with a

ø 41 mm restrictor

3 m*

with a ø 41 mm restrictor

4 m*

with a

ø 41 mm restrictor

4 m*

with a ø 41 mm restrictor

Insulated Twin Pipe

After:

3 m*

with a

ø 41 mm restrictor

3 m*

with a ø 41 mm restrictor

Table 6.1

4 m*

with a

ø 41 mm restrictor

4 m*

with a ø 41 mm restrictor

TP 30

Coaxial

Systems

ø 60/100

Twin Pipe

Systems

ø 80/80

Exhaust

Type

TYPE 1 TYPE 2 TYPE 3

Exhaust

Type

TYPE 4

TYPE 5

Use the

ø 42 mm

Restrictor

Between

345 mm - 1 m

Use the

ø 42 mm

Restrictor

Up to 4 m

Up to 11.5 m

Do not use the

Restrictor

Between 1 m - 4 m

Do not use the

Restrictor

Between

4 m - 47 m

Between

5 m - 42 m

11.

Maximum

Flue

Length

4 m

Maximum

Flue

Length**

47 m

42 m

Risk of Condensation Forming

NOT APPLICABLE

Risk of Condensation Forming With:

Standard T win Pipe

After:

2 m*

with a

ø 42 mm restrictor

7.4 m*

with a ø 42 mm restrictor

7.5 m*

without a ø 42 mm restrictor

7.4 m*

without a

ø 42 mm restrictor

Insulated Twin Pipe

After:

2 m*

with a

ø 42 mm restrictor

7.4 m*

with a ø 42 mm restrictor

7.5 m*

without a

ø 42 mm restrictor

7.4 m*

without a

ø 42 mm restrictor

Where there is no risk of condense forming (and, therefore no requirement for a condense collector), ensure a

minimum fall of 5mm per metre away from the appliance.

** Maximum Length = combined length of air intake and exhaust pipes (less any equivalent lengths for elbows).

Note: Under some circumstances, condense may form at the exhaust terminal, special attention m

possible condense dripping from the terminal.

ust be paid with regard to

Installation

DEFI HGK J

6.10 Control Panel

LEGEND:

A - On/Off button B - Central heating temperature adjustment C - Domestic hot water temperature adjustment D - Heating system pressure gauge E - Time clock (knock out) F - Central heating selector G - Central heating L.E.D. (green) H - Flue sensor L.E.D. (yellow) I - Ignition failure (lockout) and/or overheat reset button J - Overheat and/or ignition failure (lockout) L.E.D. (red)

K - ON/OFF L.E.D. (green

)

To dismantle the front casing panel it is necessar y to: 1 - Remove the two screws “B”; 2 - Move the front casing panel up and lift forward.

6.11 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 located on the lower part of the panel itself The control panel moves downward and when pulled forward rotates on two lateral hinges. The panel stays in a semi-horizontal position, which allows access to the inner parts of the boiler. In order to increase the manoeuvering space, it is possible to raise the control panel and rotate it to a fully horizontal position.

Installation

3B4

6.12 Fitting the Time Clock

To fit the mechanical time clock supplied with the boiler, it is necessary to proceed as follows:

1) Remove the fastening screws ‘A’ from beneath the boiler;

2) Rotate the control panel forward, if necessary , it is possib le to lift the control panel up and rotate it to a fully horizontal position;

3) Using a suitable knife, remove the knock out ‘B’ for the time clock;

4) Insert the clock into the control panel;

5) Secure the clock in place using the four screw provided;

6) Remove the two screws ‘C’ and remove the cover to allow access to the Printed Circuit Board;

7) Plug the clock cable into the connector on the Printed Circuit Board and conect the cables to the clock as indicated in Fig.

6.21

Installation

GREY

BLACK

RED

GREY

BLACK

RED

MECHANICAL TIME CLOCK

DIGITAL TIME CLOCK

6.12 Fitting the Time Clock (continued)

FIG. 6.21

Installation

6.13 Room Thermostat Connection

To connect a room ther mostat, it is necessar y to:

1. - Open the control panel as indicated in SECTION 6.11.

2.- Remove the link “A” from the terminal block on the reverse

of the control panel.

3. - Insert the ther mostat cable through the cable grommet and

fasten it by means of the cable-clamp provided.

4. - Connect the thermostat wires to the terminal block

(Diagram A).

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 1-4 above

(Diagram B).

7. - If using an external time clock and room thermostat, these must

be connected in series as points 1-7 above (Diagram C).

Note: Only a low voltage room thermostat capable of volt

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

Important!! DO NOT install 240v wires and low voltage switching wires in the same cable/conduit, this may cause unwanted induced voltages in the low voltage switching system.

FIG. 6.22

Installation

FUSE

CN103

CN104

CN102

CN100

CN101

5 4 3

2 1

CN103

CN104

CN102

CN100

CN101

5 4 3

2 1

6.14 ELECTRICAL/SYSTEM DIAGRAMS

FIG. 6.23

A - Jumper:

1 - Don’t move (jumper is factory set in position B) 2 - Anti-cycling Device Adjustment for Heating

Position A = 0 mins Position B = 2 mins 3 - Don’t move (jumper is factory set in position B) 4 - Don’t move (jumper is factory set in position B) 5 - Fan/Pump over-run selector

Position A = OFF Position B = ON

B - Central Heating Temperature Adjustment C - Connector for Remote Control (Climate Manager) D - Domestic Hot Water Temperature Adjustment E - Soft-light Adjustment F - Maximum Heating Adjustment G - Time Clock Connector H - On/Off Switch I - Fume Sensor L.E.D. J - Central Heating Selector K - Ignition Failure (Lockout) L.E.D. L - On/Off L.E.D. M - Reset Button N - Central Heating L.E.D. O - Transformer P - Spark Generator I.C.

Q - Motor ised diverter valve Relay R - Gas Valve Relay S - Circulation Pump Relay T - Fan Relay A01 - Circulation Pump A02 - Fan A03 - Spark Generator Supply A04 - Gas Valve Supply A05 - Motorised diverter Valve A07 - Detection Electrode A08 - Main Circuit Temperature Probe A09 - Domestic Hot Water Temperature Probe A10 - D.H.W. Flow switch A11 - Pump Pressure Switch A12 - Modulator A13 - Air Pressure Switch A14 - Safety Thermostat A15 - External (Room) Thermostat

COLOURS: Gr - Grey Bl - Blue Bi - White Nr - Black Rs - Red Ro - Pink Mr - Brown

Installation

16 15

13 14

6.15 Water Circuit Diagram

FIG. 6.24

Legend:

1. Fan Heat Exchanger

3. Overheat Thermostat

4. Burner

5. Detection Electrode

6. Ignition Electrodes

7. Main Circuit Temperature Probe

8. Pressure Gauge

9. Low Water Pressure Switch

10. Safety Valve

11. Domestic Hot Water Temperature Probe

12. Secondar y Exchanger

13. Gas Valve

14. D.H.W. Flow Switch

15. D.H.W. inlet filter

16. Drain Valve

17. Motor ised Diverter Valve

18. Automatic By-pass

19. Circulation Pump with Automatic Air Release Valve

20. Expansion Vessel

21. Air Pressure Switch

A. Central Heating Flow B. Domestic Hot Water Outlet C. Gas Inlet D. Domestic Cold Water Inlet E. Central Heating Return

7. COMMISSIONING

7.1 Initial Preparation

Preliminary electrical system checks to ensure electrical safety must be carried out by a competent person i.e.polarity , earth continuity, resistance to earth and short circuit.

FILLING THE HEATING SYSTEM:

Lower the control panel and remove the case panels (see SECTION 6.11 for further information). Open the central heating flow and return cocks supplied with the connection kit (there are two isolation points on the return connection). Unscrew the cap on the automatic air release valve one full turn and leave open permanently. Close all air release valves on the central heating system. Gradually open valve(s) at the filling point (filling-loop) connection to the central heating system until water is heard to flow, do not open fully. Open each air release tap starting with the lowest point and close them only when clear water, free of air, is visible.

Purge the air from the pump by unscrewing the pump plug anticlockwise, also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free.

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

Filling of the D.H.W. System:

Close all hot water draw-off taps. Open the cold water inlet cock supplied with the connection kit. Open slowly each draw-off tap and close them only when clear water, free of bubbles, is visible.

7.2 Initial Start-up

THE CHECKS TO BE RUN BEFORE INITIAL START-UP ARE AS FOLLOWS:

1. Make sure that:

-the screw on the automatic air valv e has been loosened when the system is full;

- If the water pressure in the system is below 1 bar, bring it up to the appropriate level;

-Ensure that the gas cock is closed;

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

- Supply power to the boiler by pushing the On/Off button “A” (see FIG. 6.16) - the L.E.D.“K” will illuminate.Then push the button “F” in for central heating - the L.E.D.“G” will illuminate.This will start the circulation pump.After 7 seconds, the boiler will signal a shutdown due to ignition failure.Leave the boiler as it is until all of the air has been bled from the system.

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

-Repeat the procedure for bleeding the radiators of air;

-Open the taps for a brief period;

-Check the system pressure and, if it has dropped, open the filling loop again to bring the pressure back up to 1 bar.

2. Make sure that all gate valves are open;

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

4. Press the reset button “I” for the lighting system; the spar k will light the main burner.If the burner does not light the first time, wait 1 minute and repeat the procedure.

5. Check the minimum and maximum burner pressure values; adjust if needed using the values indicated in the table in SECTION 4.

Gas Supply:

Inspect the entire installation including the gas meter, test for tightness and purge the supply as described in BS 6891:1988. Open the gas cock (supplied with the connection kit) to the appliance and check the gas connections on the appliance for leaks.

When the installation and filling are completed, flush the system while cold, refill, turn on the Central Heating system (Section

7.2) and run it until the temperature has reached the boiler operating temperature.The system must then be immediately flushed through. The flushing procedure must be in line with BS 7593:1992 code of practice for treatment of water in domestic hot water central heating systems. During this operation, we highly recommend the use of a central heating flushing detergent (Fernox Superfloc or equivalent), whose function is to dissolve any foreign matter that may be in the system.

Substances different from these could create serious problems to the pump or other components.

The use of an inhibitor in the system such as Fernox MB-1 or equivalent is strongly recommended to prevent corrosion (sludge) damaging the boiler and system.

Failure to carry out this procedure may invalidate the appliance warranty.

7.3 Operational Adjustments

To access the areas in which adjustments are made, it is necessary to open the control panel, as indicated in Section 6.11, then remove the rear inspection cover by unscrewing the two screws. Access is thereby provided to the P.C.B .and to the following components:

1. The power supply cable connector;

2. The fuses;

3. The soft-light potentiometer the setting for which can range

from the minimum thermal power to the maximum;

4. The maximum thermal heating power potentiometer

adjustable by the minimum to maximum power (already calibrated in the factory to 70% of the maximum thermal power);

5. The jumper for adjusting the ignition delay (anti-cycling) fea-

ture, which can be set from 0 to 2 minutes (set in the factory at two minutes);

Fan/Pump Over-run (Electrical Diagram). When the jumper is set to position A the Fan and Pump over-run is activated. (The jumper is factory set in position B)

7. The time clock connector.

Commissioning

7.4 Combustion Analysis

The flue connector has two apertures, readings can be taken for the temperature of the combustion by-products and of the combustion air, as well as of the concentrations of O To access these intakes it is necessary to unscrew the front screw and remove the metal plate with sealing gasket. It is possible to activate the flue test mode (maximum output) by pressing and holding the RESET button “I” for 10 seconds, the yello

w L.E.D.“H” will light. tion after 5 minutes.The boiler can be returned to normal operation sooner by switching the boiler off and on again.

The boiler will return to normal opera-

and CO2, etc.

FU008A

7.5 Product of Combustion Discharge

Monitoring

In the boiler, it is possible to monitor the correct operation of the flue exhaust/air intake, checking for a loss of general pressure in the system.Through the use of a differential manometer connected to the test points of the combustion chamber, it is possible to detect the P of operation of the air pressure switch. The value detected should not be less than 0.55 mbar (TP 23) -

0.90 mbar (TP 30) under conditions of maximum thermal power in order for the boiler to function properly and without interruption.

7.6 Boiler Safety Systems

The boiler is fitted with the following devices (see SECTION 6.10 for references).

1 - Ignition Failure:

This indicates ignition failure when a flame is not detected within 7 seconds of starting an ignition sequence.The L.E.D. “I” will illuminate to signal the shutdown status. The system can be reset by pressing and releasing the button “J” after checking to make sure that the gas cock is open.

2 - Insufficient System Pressure:

In the event of insufficient water pressure in the heating system, a safety device will shutdown the boiler. Check the system pressure on the pressure gauge “D” and if it is less than 0.4 bar refill the system to 1.5 bar. Once the system pressure is at the correct level the boiler will reset automatically.

3 - Overheating:

This control shuts off the boiler in the case where the primary circuit reaches a temperature in excess of 105°C. The red L.E.D.“I” will illuminate to signal this shutdown status. The system can be reset by waiting a few minutes for the primary exchanger to cool down and then by pressing and releasing the “J” button.

4. Anti-frost device:

The boiler is fitted with a device which, in the event that the water temperature falls below 8 runs until a temperature of 18˚C is attained. In the event that the water temperature falls below switches to Domestic Hot Water and the burner fires and runs on minimum power until a temperature of 33˚C is attained. This device is only activated when the boiler is operating perfectly and

- the system pressure is sufficient;

- the boiler is powered electrically;

- gas is being distributed.

6. Exhaust Discharge Anomaly Shutdown:

The boiler is fitted with safety devices, which in the event of defective discharge of e xhaust products, automatically interrupts the gas supply, thereby shutting off the boiler. The shutdown of the boiler is temporary and is indicated by the illumination of the yellow L.E.D.“E” for a period of about 15 minutes. Once this time period has passed and the discharge state of exhaust fumes has returned to normal, the boiler automatically turns back on.

7. Pump Protection:

To prevent the pump from seizing the boiler will activate the pump for 20 seconds every 21 hours after it’s last operation.

˚C the pump activates and

˚C, the diverter valve

FU009A

Commissioning

7.7 Draining the System

Draining the Heating System

The heating system must be drained as follows:

- Turn off the boiler;

- Attach a hose pipe and open the drain valve;

- Drain the system at the lowest points (where present).When

the heating system is unused for an extended period of time, it is recommended that you add antifreeze with an ethylene glycol base to the water in the heating pipe work and radiators if the ambient temperature drops below 0°C during the winter. This makes repeated draining of the entire system unnecessary.

Draining the Domestic Hot Water System

Whenever there is the danger of the temperature dropping below the freezing point, the domestic hot water system must be drained as follows:

- Turn off the general water valve for the household plumbing

system;

- Turn on all the hot and cold water taps;

- Empty the remaining water from the lowest points in the sys-

tem (where present).

7.8 Completion

7.10 Instructing The End User

1. Hand over the copy of the End User Instructions supplied with the appliance, together with these instructions, and explain how to use the timeclock and room thermostat if fitted.

2. Show the End User how to switch the appliance off quickly, and indicate the position of the electric supply isolator.

3. Inform the End User of the location of all drains, isolating valves and air vents.

4. Explain how to turn the appliance off for both short and long periods and advise on the precautions necessary to prevent damage in the event that the appliance is inoperative when freezing conditions occur.

5. Finally advise the End User that, for continued safe and efficient operation, the appliance must be serviced by a competent person at least once a year.

For the Republic of Ireland it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in the current edtion of I.S.813. In addition it is necessary to complete the Log Book.

7.9 Operational Checks

1. The flue system must be visibly checked for soundness.

2. Run the Central Heating and manipulate the Central Heating temperature control knob to check the gas pressures at high and low fire with a pressure guage/manometer, and adjust if necessary.

3. Range rate the thermal power for Central Heating, as detailed in SECTION 8.2

4. Run the Domestic Hot Water, manipulate the Domestic Hot

Water temperature control knob to check the gas pressures at high and low fire with a pressure guage/ manometer, and adjust if necessary.

5. Balance the Central Heating system until all return temper-

atures are correct and equal.

6. Turn ON/OFF button OFF, disconnect the pressure Gauge,

retighten screw and re-light boiler.

7. Re-examine Central Heating, Domestic Hot Water and Cold

Water supplies for soundness.

8. Check the appearance of the gas flame to assess the ade-

quacy of the combustion air supply.

9. If external controls have been disconnected, reconnect and

test.

10. Refit boiler casing.

8. GAS ADJUSTMENTS

Model CATEGORY II2H3+ Methane Gas

G20

Lower Wobbe Index (15°C;1013mbar)

TP 23 TP 30

TP 23 Main Burner: n. 14 jets (ø) mm

TP 30 Main Burner: n. 14 jets (ø) mm

MJ/m3h Nominal Delivery Pressure mbar Minimum Delivery Pressure mbar

Consumption (15°C; 1013mbar) m3/h Consumption (15°C; 1013mbar) Kg/h Gas Burner Pressure max - min mbar

45.67 20 20

1.25

2.80

----

11.3 - 2.0

1.35

3.49

---

11.5 - 2.2

8.1 Changing the Type of Gas

The boiler can be converted to use either methane (natural) gas (G20) or L.P.G. (G30

- G31) by an Authorised Service Centre.

The operations that must be performed are the following:

1. Replace the jets on the main burner (see table in section 8);

2. Adjust the maximum and minimum thermal capacity values for the boiler

(see table in section 8 and 8.2 Adjusting the Gas Pressures);

3. Adjust the maximum thermal power setting;

4. Adjust the soft-light feature (see table below for recommended pressure);

5. Adjust the ignition delay feature for the heating system by adjusting the jumper 2 as shown in Section. 6.13 (can be set from 0 to 2 mins.).

CATEGORY

II2H3+

Recommended

Soft-light Pressure

(mbar)

Model

Microcombi

TP 23 5 12 12

TP 30 4.5 12 12

8.2 Adjusting the Gas Pressures

Setting the minimum and the maximum power of the boiler

1. Check that the supply pressure and dynamic pressure to the

gas v

2. To do this, loosen the screw “A”.

3. To check the pressure supplied by the gas valve to the burner,

4. Push the On/Off button to “ON” position -green light- and

alve is a minimum of 20 mbar for natural gas.

Fit the pipe of the pressure gauge to the inlet pressure connection of the gas valve “B” and check for the correct standing pressure correct working pressure. When you have completed this operation, replace the screw “A” securely into its housing to seal off the gas (check for tightness).

loosen the scre pressure outlet test point of the gas valve “D”. Disconnect the compensation pipe “D1” either from the gas v

alve or from the sealed chamber.

ensure that the hot water temperature control knob is set to maximum.

urn on the boiler by running a hot water tap. Adjust the 10mm nut “E” on the modureg to set the maximum gas pressure wise to decrease the pressure until the required pressure is achieved (see TABLE A page 28).

Liquid Butane Gas

G30

80.58 29 28

0.72

----

2.09

28.1 - 5.0

0.80

---

2.60

26.8 - 5.3

Methane Gas

G20

, then operate the appliance and check for the

w “C”.Fit the pipe of the pressure gauge to the

, turn the nut clockwise to increase and anti clock-

Butane Gas

Liquid Propane Gas

35.6 - 6.8

34 - 6.5

Liquid

Propane Gas

G30

G31

80.58 37 36

0.72

----

2.06

0.80

---

2.56

Liquid

G31

Gas Adjustments

5. To set the minimum power, disconnect a supply terminal “F1”

from the modureg and adjust screw “F” (ensure that the 10mm n increase the pressure and anti-clockwise to decrease the pressure (displayed on the pressure gauge) corresponding to the minimum power (see TABLE

6. When you have completed the above operations, turn off the hot w on the gas valve, reconnect the compensation pipe and replace the cap on the screw of the modureg.

Setting the maximum heating circuit power

7. To set the maximum heating circuit power, push the On/Off

utton to the “ON” position -green light- and push the Heating button and set the time cloc “ON” position -green light. Tur n the knob of the heating thermostat cloc

8. Remove the inspection panel of the P.C.B. and fit a small cross-head scre below). Turn clockwise to increase the pressure or counterclockwise to reduce the pressure. Adjust the setting to the required heating pressure value (displayed on the pressure gauge), as indicated in the charts shown on pages 28.

9. Turn off the boiler by placing the main switch to the "OFF" position.

Setting the pressure for soft-light ignition.

Disconnect the detection electrode connection close to the P.C.B. (F Start the boiler and during the ignition sequence adjust the left hand potentiometer until the gas pressure reads the required gas pressure (see the table on pag Once the gas pressure is set turn off the boiler and re-connect the detection electrode to the P.C.B. NB.: It may be necessary to reset the flame failure reset a number of times during this operation.

ut is held in position). Turn the screw clockwise to

A page 28).

ater tap, reconnect the supply terminal to the modureg

k and any external controls to the

kwise to maximum.

wdriver in to the right hand potentiometer (see

IG. 6.13).

e 28).

10. Remove the pipe from the test point and tighten the scre w “C”

to the pressure test point in order to seal off the gas

11. Carefully check the pressure test points for gas leaks (valve

inlet and outlet).

IMPORTANT!

Whenev tions, always check for leaks using a leak detection fluid.

er you disassemble and reassemble the gas connec-

Soft - Light

Adjustment

Max Heating

Adjustment

Gas Adjustments

TP 23 MFFI

2.80

10.3

2.0

1.16

2.09 Kg/h

0.87 Kg/h

28.1 mbar

5.0 mbar

28 mbar

14 x 0.7214 x 1.25

2.06 Kg/h

0.85 Kg/h

35.6 mbar

6.8 mbar

37 mbar

14 x 0.72

TP 30 MFFI

3.49

11.5

2.2

1.48

2.60 Kg/h

1.10 Kg/h

26.8 mbar

5.3 mbar

28 mbar

14 x 0.8014 x 1.35

2.56 Kg/h

1.09 Kg/h

34.0 mbar

6.5 mbar

37 mbar

14 x 0.80

model 23 model 30

TABLE A

Regulating the heating power for natural gas (G20)

CG010A

Regulating the heating power for propane gas (G31)

Regulating the heating power for butane gas (G30)

CG011A

9. MAINTENANCE

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

1 - Check the seals for the water connections;replace any

faulty seals 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of

combustion by-products (see section 3.6) and cleaning of

the burner if needed. 5 - If called for by point.3, dismantling and cleaning of the

combustion

chamber. 6 - If called for by point.4, dismantling and cleaning of the

burner jets. 7 - Visual check of the primary heat exchanger:

- check for overheating in the blade assembly;

- clean the exhaust fan if needed.

8 - Adjustment of the flow rate of the gas: flow rate for lighting,

partial load and full load. 9 - Check of the heating safety systems:

- safety device for maximum temperature (overheat thermostat);

- safety device for maximum pressure (safety valve).

10- Check of the gas safety systems:

- safety device for lack of gas or flame ionisation (detection electrode);

- safety device for gas cock.

11- Check of the electrical connection (make sure it complies

with the instructions in the manual).

12- Check of domestic hot water production efficiency (flow

rate and temperature)

13- General check of the combustion by-products of the dis-

charge/ventilation system.

14- Check of the general performance of the unit.

10. SERVICING INSTRUCTIONS

To ensure efficient safe operation, it is recommended that the boiler is serviced annually by a competent person.

Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool.

Before and after servicing, a combustion analysis should be made via the flue sampling point (please refer to SECTION 3.4 for further details).

After servicing, preliminary electrical system checks must be carried out to ensure electrical safety (i.e. polarity, earth continuity, resistance to earth and shor t circuit).

10.1 Replacement of Parts

The life of individual components vary and they will need servicing or replacing as and when faults develop. The fault finding sequence chart in SECTION 7 will help to locate which component is the cause of any malfunction, and instructions for removal, inspection and replacement of the individual parts are given in the following pages.

10.2 To Gain General Access

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

FIG. 10.3

2. The control panel moves downward and when pulled forward, rotates on two lateral hinges; the panel stays in a semi-horizontal position, which allows access to the inner parts of the boiler (FIG. 10.2);

3. In order to increase the manoeuvring space, it is possible to raise the control panel and rotate it to a fully horizontal position (FIG. 10.3);

4. Remove the screws “B”from the front panel bottom lip (FIG. 10.4);

5. Lift the front panel up and forward from the raised screws at the the top of the casing (FIG.10.5).

FIG. 10.4

10.2.1 Removing the front panel

1. Loosen the fastening screws “A” of the control panel located

on the lower part of the panel itself. (FIG. 10.1);

FIG. 10.1

FIG. 10.2

FIG. 10.5

Servicing Instructions

10.2.2 Removing the sealed chamber front cover

1. Remove the screws “C”(FIG. 10.6);

2. Lift the sealed chamber front cover from the locating pins

(FIG. 10.7).

FIG. 10.6

FIG. 10.7

10.2.3 Removing the side panels

1. Remove the four screws “D” for each side panel (FIG.10.8);

2. Pull the panel away from the boiler at the base, then lift the

panel up and remove from the boiler (FIG.10.9).

FIG. 10.8

FIG. 10.9

Servicing Instructions

10.3 Access to the Combustion Chamber

10.3.1 Removing the combustion cover

1. Remove the screws “E”(FIG. 10.10);

2. Lift off the combustion cover.

10.3.2 Removing the burner and jets

1. Remove the screws “F”from the burner (FIG. 10.11);

2. Remove the burner (FIG. 10.12);

3. Disconnect the electrodes (see SECTION 10.3.3);

4. Remove the jets using a No.7 socket spanner;

5. Replace in reverse order.

FIG. 10.11

FIG. 10.10

10.3.3 Removing the electrodes

Before carrying out this procedure, unscrew and slide the burner forward (see previous section).

1. Remove rubber gasket “G” (FIG. 10.13);

2. To remove the detection electrode disconnect the cable at its

connection point close to the P.C.B. (FIG. 10.14);

3. Remove screw “H” (FIG. 10.15);

4. Gently slide the electrode downward (FIG. 10.16).

FIG. 10.13

FIG. 10.14

FIG. 10.15

Fig. 10.12

FIG. 10.16

To replace, repeat the steps in reverse order, paying particular attention to the following: a - Centre the electrode in the

positioning hole carefully, otherwise the electrode may break;

b - Ensure that the left hand and

right hand electrodes are located the correct way round (facing each other), to give the correct spark gap;

c - Check that the cables have

been connected correctly;

d - Check that the rubber gasket

seals the cable/ electrode connection point completely.

Servicing Instructions

10.3.4 Removing the main heat exchanger

1. Drain the boiler of water;

2. Remove the side panels (see 10.2.3)

3. Remove the overheat thermostat sensor “I”(FIG. 10.17);

4. Remove the clip “J” (FIG. 10.18);

5. Remove the “U” clip “K” (FIG. 10.19);

7. Pull down the pipe (FIG.10.20);

4. Pull it straight out (FIG.10.21).

Fig. 10.17

FIG. 10.18

FIG. 10.21

10.3.5 Removing the air pressure switch

1. Disconnect the electrical connections “L” and silicone pipes

“M” from their connection points (FIG. 10.22);

2. Remove screws “N” on the top of the sealed chamber (FIG.

10.23);

3. Lift out the air pressure switch (FIG.10.24);

4. Unscrew to remove the switch from the plate.

FIG. 10.19

FIG. 10.20

FIG. 10.22

FIG. 10.23

FIG. 10.24

Servicing Instructions

10.3.6 Removing the fan

1. Disconnect electrical connections “O” and silicone pipe “P”

(FIG.10.25);

2. Remove screw “Q” and remove the fan collar clamp “R” (FIG.

10.26);

3. Remove screws “S” (FIG. 10.27);

4. Remove fan and mounting plate (FIG. 10.28).

FIG. 10.25

FIG. 10.26

10.4 Access to the Gas Valve

10.4.1. Removing the spark generator

1. Disconnect ignition leads “T”by pulling upward

(FIG. 10.29);

2. Remove the screw “U” (FIG. 10.30);

3. Remove the spark generator by pulling forward from the gas

valve (FIG.10.31).

FIG. 10.29

FIG. 10.27

FIG. 10.28

FIG. 10.30

FIG. 10.31

Servicing Instructions

10.4.2 Removing the gas valve

Important! Before removing the gas valve, ensure the gas sup-

ply is turned off.

1. Disconnect all the cables from the solenoid and modureg;

2. Remove the spark generator (see previous section);

3. Release the nuts “V” (FIG. 10.32);

4. Remove the screws “W”from the bottom of the gas valve (FIG.

10.33);

5. Remove the gas valve (FIG.10.34).

FIG. 10.32

10.5 Access to the Water Circuit

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

10.5.1 Removing the D.H.W. (secondary) exchanger

1. Remove the screws “X” (FIG 10.35);

2. Disconnect the cable “Y” (FIG 10.36);

3. Push the exchanger towards the rear of the boiler, and

lift upwards and remove out of the front of the boiler (FIG 10.37-10.38);

4. Before replacing the exchanger ensure that the O-rings are in good condition and replace if necessary.

FIG. 10.35

FIG. 10.33

FIG. 10.34

FIG. 10.36

FIG. 10.37

FIG. 10.38

10.5.2 Removing the pump pressure switch

1.Remove the pump pressure switch electrical connections “Z”

(FIG10.39);

2. Unscrew the pump pressure switch by nut (FIG10.40);

3.Remove the pump pressure switch .

FIG. 10.39

using

a spanner on the

10.5.3 Removing the safety valve

1. Disconnect the discharge pipe work from below the boiler;

2. Unscrew and remove the valve “A1” (FIG. 10.41).

FIG. 10.41

10.5.4 Removing the automatic air vent

1. Remove the U-clip “B1” (FIG. 10.42);

2. Unscrew valve top and remove valve complete with float

(FIG 10.43).

FIG. 10.40

FIG. 10.42

FIG. 10.43

Servicing Instructions

10.5.5 Removing the pump

1. Remove the electrical connection “ C1”(FIG. 10.44);

2. Remove the allen screw “D1” (FIG. 10.45);

3. Remove the pump (FIG.10.46).

FIG. 10.44

10.5.6 Removing the pressure gauge

1. Remove the U-clip “E1” (FIG. 10.47)

2. Push the pressure gauge through the control panel from the

rear (FIG. 10.48).

FIG. 10.47

FIG. 10.48

FIG. 10.45

FIG. 10.46

Servicing Instructions

10.5.7 Removing the expansion vessel

1. Release nuts “F1” and remove the gas pipe (FIG. 10.49);

2. Release nut “G1” (FIG. 10.50);

3. Remove back-nut “H1” (FIG. 10.51);

4. Remove the expansion vessel (FIG. 10.2).

FIG. 10.49

FIG. 10.50

FIG. 10.51

10.5.8 Removing the overheat thermostat

1. Disconnect the ov erheat thermostat electrical connections “I1”

(FIG. 10.53);

2. Then remove the thermostat from its mounting by releasing the securing clip (FIG. 10.54 /10.55).

FIG. 10.53

FIG. 10.54

FIG. 10.55

FIG. 10.52

10.5.9 Removing the heating temperature

sensor (N.T.C.)

1. Pull off the electrical connector and unscrew the sensor probe

using a suitable spanner (FIG. 10.56).

FIG. 10.56

Servicing Instructions

10.5.10 Removing the D.H.W. temperature sensor (N.T.C.)

1. Pull off the electrical connector and unscrew the sensor probe

using a suitable spanner (FIG. 10.57).

FIG. 10.57

10.5.11 Removing the D.H.W. flow switch

1. Unplug the electrical connector “J1” (FIG. 10.58);

2. Unscrew the screws “K1” (FIG. 10.59);

3. Remove the D.H.W. flow switch.

6.5.12 Removing the divertor valve actuator

1. Unplug the electrical connector “L1” (FIG. 6.60);

2. Release the retaining clip “M1” and remove the divertor

valve actuator (FIG.6.61).

FIG. 6.60

FIG. 10.58

FIG. 10.59

FIG. 6.61

Servicing Instructions

10.6 Access to the Control System

Important! Isolate the electrical supply to the boiler before accessing the control panel.

10.6.1 Checking the fuses

1. Remove the inspection cover on the reverse of the control

panel (FIG. 10.62);

2. Remove the fuses (FIG. 10.63).

FIG. 10.56

10.6.2 Removing the P.C.B.

1. Isolate electricity;

2. Remove the inspection cover from the reverse of the control

panel;

3. Unplug all electrical connections from the P.C.B.

4. Remove the screws “N1”(FIG. 10.64);

5. Separate the facia panel from the rear of the control panel ;

6. Remove the screws “O1”and remove the P.C.B.

(FIG. 10.65).

FIG. 10.64

FIG. 10.63

FIG. 6.65

11. FAULT FINDING

11.1 Fault Finding Guide (Flow-charts)

These fault finding guides are not exhaustive. However, it is possible to detect and correct many defects by using the standard fault finding diagrams described in this chapter, ensure these guides are carried out in the set order.

To ensure that the external controls do not interfere with the fault finding, disconnect the wires from the terminal block on the rear of the control panel and provide a solid link between the terminals.

Fault Finding

0.55mbar (23kW)

0.90mbar (30kW)

0.55mbar (23kW)

0.90mbar (30kW)

Fault Finding

12. SHORT SPARE PARTS LIST

118

119

120

301 302 303

304

14 15

16 17

39 40 41

43 44

111

110

34 35 36 373029 3331 32

101

100

116

115

112

117

113

125

126

124

6268 646667

123

52 51

121

104

107

103

108

104

106

105

103

102

114

282524 26 27

17 45

18 19

109

122

Short Spares Parts List

Key Part Number Description

16 65101294 PCB 28 995903 Pump Pressure Switch 32 997088 Safety Valve (3 Bar) 35 65101390 Pressure Gauge 36 995948 D.H.W. Flow Switch 40 997147 3 Way Valve Motor 45 996615 Pump Motor 46 996123 Gasket (Pump Motor) 49 995865 Auto Air Vent 59 65100716 Air pressure Switch 75 65100719 Fan 80 996065 Overheat Thermostat 81 65100521 Clip (Overheat Stat) 82 65100297 Cable (Time Clock) 83 999599 Time Clock 86 65100693 Ignition Electrode (RH) 87 65100694 Ignition Electrode (LH) 88 65100692 Detection Electrode 89 990685 Secondary Exchanger (30 kW) 89 995945 Secondary Exchanger (23 kW)

94 998458 Temperature Probe 113 573520 Gasket (3/4”) 114 997089 Gas Valve (SIT 845 SIGMA) 115 65100514 Spark Generator 122 61010017 Main Exchanger (23 kW) 122 61011136 Main Exchanger (30 kW)

Fault Finding

13.TECHNICAL INFORMATION

CE Certification Heat Input max/min kW Heat Output max/min kW Efficiency of Nominal Heat Input % Efficiency at 30% of Nominal Heat Input % Heat Loss to the Casing (∆T=50°C) % Flue Heat Loss with Burner Operating % Flue Heat Loss with Burner Off % Max Discharge of Products of Combustion (G20) Kg/h Residual Discharge Head mbar

Consumption at Nominal Capacity(G2 0) m Gas Consumption after 10 Minutes* m

(15°C, 1013 mbar) (G30-G31) Kg/h Temp. of exhaust fumes at nominal capacity °C

Content %

O CO Content ppm Minimum Ambient Temperature °C Head Loss on Water Side (max) (∆T=20°C) mbar Residual Head of System bar Heating Temperature max/min °C Domestic Hot Water Temperature (approx) max/min °C D.H.W. Flow Rate ∆T=35°C l/min D.H.W. Minimum Flow Rate l/min Pressure of Domestic Hot Water max/min bar Expansion Vessel Capacity l Expansion Vessel Pre-load Pressure bar Maximum Water Content of System l Maximum Heating Pressure bar Nominal Pressure Natural Gas (G20) mbar

LPG (G30-G31) mbar Electrical Supply V/Hz Power Consumption W Protection Grade of Electrical System IP Internal Fuse Rating Weight Kg

TP 23 MFFI

0694BO0090

25.6/11.0

24.8/9.7

92.9

91.1

1.0

6.1

0.4

49.5

0.96

2.72

0.32/0.39

2.02/2.00 123

7.2

7.5

51.9 +5

200

0.25

82/42 56/36

9.7

2.6

8/0.2

6 1

130

30-37

230 / 50

110

X4D

FAST 2 AT

TP 30 MFFI

0694BO0090

36.6/15.5

30.6/12.1

83.4

80.9

1.7

5.7

0.4

63.73

1.6

3.49

0.41

2.60/2.56

121.2

7.19

7.8 53 +5

200

0.25 82/38 56/36

12.5

2.5

8/0.2

7 1

130

28-37

230/50

148

X4D

FAST 2 AT

G.C. Number 47-116-32 47-116-33

*Calculated at 70% maximum output

Manufacturer: Merloni T ermoSanitari S.p.A.

echnical Service Hot Line: 0870 241 8180

Customer Service Help Desk: 0870 241 8174

0 99 84 1869 000

Ariston TP 23, TP 30 Installation and Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual