Ariston TP 23, TP 30 Installation and Servicing Instructions
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.
2
A
B
C
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.
D
K
A
I
IMPORTANT!! Always wait 2 minutes before
resetting each time.
3
J
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.
G
F
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.
B
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
G
F
C
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.
I
J
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.
I
J
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.
K
A
4
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.
D
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
3
˚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;
2.
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
3.
“Central” Position
PROGRAMMING ACTIVE:
in this position, the programming set by the user
is active.
5
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,
N
MECHANICAL, ELECTRICAL AND OPERATIONAL CHECKS MAY BE
REQUIRED AS NECESSARY
.
6
General Information
27
26
25
21
20
24
23
22
9
10
8
13
14
12
15
6
5
4
3
2
1
28
16 18 1917
11
7
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
7
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.
8
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.
9
F
G
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!
I
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
10
Installation
E
A
B
D
C
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
11
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
T
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
mm
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
12
Installation
25 mm
25 mm
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
13
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.
14
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.
o
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
o
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
15
Loading...