C&M Minima HE, Minima HE 24 NAT, Minima HE 30 NAT, Minima HE 35 NAT Installation, Servicing And Operating Instructions

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Page 1

CONDENSING WALL HUNG COMBINATION BOILER

Heating and Instantaneous Domestic Hot Water - Fanned Flue system

MMiinniimmaa HHEE

Installation, Servicing and Operating Instructions

Manufacturers N° Model Type Gas Council N°

3650007.31 Minima HE 24 Nat 47 - 980 - 33

3650008.31

3650009.31

Country of destination

Minima HE 30 Nat 47 - 980 - 34

Minima HE 35 Nat

47 - 980 - 35

Page 2

These instructions are suitable for the Minima HE boilers :

Do not forget the Log Book!

Chaffoteaux & Maury supports Benchmark, the heating industry code to ensure the correct installation, commissioning and servicing of domestic central heating systems.

To The Householder

ake sure that your installer completes Section 24 of this manual (page 60) .

commissioning of your boiler.

It contains important information about your particular installation that may be required by service engineers. It will also provide contact details for the installer should you need guidance in the use of this appliance or if there are any problems.

As with your car, your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service check. The service history of the appliance must be recorded in Section 25 of this manual (page 61).

In the unlikely event of any problems with your boiler or system you should first contact your installer. If your installer cannot resolve the problem he should telephone our national service helpline.

A charge may be made if Chaffoteaux & Maury Service is called out to resolve a non-product related fault.

Your statutory rights are not affected.

To The Installer

As part of the commissioning of this appliance it is necessary to complete Section 24 of this manual (page 60) and give this manual to the Householder. Please ensure that your customer is aware of the importance of keeping this manual safe as a record of the installation (Section 24, page 60) and the appliance service history (Section 25, page 61).

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

his provides a record of the

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

CUSTOMER CARE

Chaffoteaux & Maury, as a leading manufacturer of domestic and commercial water heating appliances is committed to providing high quality products and a high quality after sales service.

Advice on installation or servicing can also be obtained by contacting the Chaffoteaux Technical and Customer Service Departments at High Wycombe.

TECHNICAL DEPARTMENT CUSTOMER SERVICE DEPARTMENT

Tel: 0870 241 8180 Tel: 0870 600 9888

Fax: 01494 459775 Fax: 01494 459775

GUARANTEE

The manufacturer`s guarantee is for 24 months from the date of purchase. The guarantee is voidable if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer and if the appliance is not serviced in accordance with manufacturers instructions and the Service Interval Record (Section 25, page 60) is not completed after the first year. To assist us in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler without delay.

CAUTION

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

Use) Regulations and the instructions provided.

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

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

Improper installation may cause damage or injury to individuals, animals and personal property for which the manufacturer will not be held liable. To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a competent person.

If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.

This instruction booklet is especially designed for appliances installed in the UK and the Republic of Ireland

Page 3

Contents

CUSTOMER CARE

Guarantee ............................................................................................................................................................2

Statutory Requirements .......................................................................................................................................2

Contents ...............................................................................................................................................................3

INTRODUCTION ..................................................................................................................................................4

USER INSTRUCTIONS ........................................................................................................................................5

1 CONTROL PANEL...........................................................................................................................................5

2 HOW TO USE ..................................................................................................................................................6

3 MAINTENANCE ...............................................................................................................................................7

4 GUARANTEE...................................................................................................................................................7

5 PRACTICAL INFORMATION...........................................................................................................................7

6 FITTING AND SETTING THE TIME CLOCK...................................................................................................8

6.1 FITTING THE MECHANICAL AND DIGITAL CLOCKS ..........................................................................8

6.2 SETTING THE MECHANICAL CLOCK ...................................................................................................9

6.1 SETTING THE DIGITAL CLOCK...........................................................................................................10

INSTALLERS’ INSTRUCTIONS.........................................................................................................................12

Page

7 DESCRIPTION...............................................................................................................................................12

8 DIMENSIONS ................................................................................................................................................13

9 HYDRAULIC DATA .......................................................................................................................................13

10 INSTALLATION REQUIREMENTS................................................................................................................14

11 INSTALLING THE BOILER............................................................................................................................17

12 CONNECTING THE FLUE.............................................................................................................................19

12.1 FITTING THE COAXIAL FLUE (Ø 60 / 100 HORIZONTAL) ................................................................ 20

12.2 FITTING THE 5”

12.3 FITTING THE

12.4 FITTING THE TWIN FLUE (Ø 80 / 80) ................................................................................................ 23

13 ELECTRICAL CONNECTIONS .................................................................................................................... 26

14 COMMISSIONING AND TESTING ...............................................................................................................

14.1 INITIAL PREPARATION ....................................................................................................................... 28

14.2 INITIAL START-UP............................................................................................................................... 28

14.3 ADJUSTING THE CO2 ......................................................................................................................... 29

14.4 GAS CONVERSION ............................................................................................................................. 29

14.5 ADJUSTING THE MAXIMUM HEATING POWER ............................................................................... 29

14.6 FITTING THE EXTERNAL SENSOR

14.7 EXTERNAL SENSOR SET-UP............................................................................................................. 29

14.8 ADJUSTING THE PARALLEL SHIFT................................................................................................... 30

14.9 COMPLETION

14.10 OPERATIONAL CHECKS .................................................................................................................... 30

14.11 INSTRUCTING THE END USER.......................................................................................................... 30

15 FITTING THE CASING .................................................................................................................................

16 SEQUENCE OF OPERATION...................................................................................................................... 32

16.1 CENTRAL HEATING MODE ................................................................................................................ 32

16.2 DOMESTIC HOT WATER MODE......................................................................................................... 33

17 ADJUSTMENTS AND SETTINGS

FLUE

VERTICAL FLUE (

......................................................................................................................................

Ø 60 / 100)....................................................................................... 22

.................................................................................................... 29

................................................................................................................ 34

Ø 80 / 125 HORIZONTAL/VERTICAL

(

) .......................................................... 20

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SERVICING INSTRUCTIONS

18 REPLACEMENT OF PARTS ........................................................................................................................ 41

18.1 To Gain General Access....................................................................................................................... 41

18.1.1 Removing the front panel...................................................................................................................... 41

18.1.2 Lowering the control panel.................................................................................................................... 41

18.2 Access to the Combustion Chamber .................................................................................................... 42

18.2.1 Removing the combustion chamber front panel ................................................................................... 42

18.2.2 Removing the burner ............................................................................................................................ 43

8.2.3Removing the detection electrode ........................................................................................................ 43

18.2.4 Removing the ignition electrode............................................................................................................ 43

8.2.5Removing the fan.................................................................................................................................. 44

18.2.6 Removing the gas valve........................................................................................................................ 44

18.2.7 Removing the heat exchanger .............................................................................................................. 45

18.2.8 Removing the spark generator.............................................................................................................. 45

18.3 ACCESS TO THE WATER CIRCUIT ................................................................................................... 46

18.3.1 Drain down............................................................................................................................................ 46

18.3.2 Removing the 3 way valve.................................................................................................................... 46

18.3.3 Removing the float of the flow switch ................................................................................................... 46

18.3.4 Removing the secondary heat exchanger

18.3.5 Removing the pump.............................................................................................................................. 47

18.3.6 Removing the pressure relief valve ..................................................................................................... 48

18.3.7 Removing the domestic expansion vessel

18.3.8 Removing the overheat thermostat....................................................................................................... 48

18.3.9 Removing the temperature sensors (NTC’s) ........................................................................................ 48

18.3.10 Removing the pressure gauge.............................................................................................................. 49

18.3.11 Removing the DHW flow switch............................................................................................................ 49

18.4 ACCESS TO THE CONTROL SYSTEM .............................................................................................. 49

18.4.1 Removing the PCB’s............................................................................................................................. 49

18.4.2 Removing the fuses .............................................................................................................................. 50

18.5 CONNECTING THE EXTERNAL SENSOR ......................................................................................... 50

19 INCORRECT FUNCTION ............................................................................................................................. 51

20 MAINTENANCE INSTRUCTIONS ................................................................................................................ 52

20.1 GENERAL REMARKS.......................................................................................................................... 52

20.2 CLEANING THE PRIMARY EXCHANGER .......................................................................................... 52

20.3 OPERATIONAL TEST .......................................................................................................................... 53

21 SHORT SPARES LIST ................................................................................................................................. 54

22 NOTES

23 TECHNICAL DATA ....................................................................................................................................... 56

24 BENCHMARK COMMISSIONING CHECKLIST ........................................................................................... 59

25 SERVICE INTERVAL RECORD ................................................................................................................... 60

.......................................................................................................................................................... 55

............................................................................................ 47

............................................................................................ 48

INTRODUCTION

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

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1. Control panel

USER INSTRUCTIONS

Fig. 1

Control panel (Fig. 1)

25.- Display

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

27.- Yellow indicator - Comfort button

28.- Reset push button and red indicator lock-out light

29.- DHW control knob and temperature setting

30.- Central Heating control knob and temperature setting

31.- Menu key

32.- Reducing key

33.- Increasing key

34.- Setting key

Connecting bracket

Taps shown in Open position (Fig. 2)

39 : Gas service tap

40 : Water service tap

41 : Central heating flow isolating valve

42 : Central heating return isolating valve

43 & 44: Filling taps

45 : Filling loop

Fig. 2

Page 6

2. How to use

Switching on and filling instructions

1. Check the pressure in the central heating system is above 0.7 bar and below 1.5 bar with the pressure gauge 16 (fig.1),

should it be neccessary to re-pressurise the system,ensure the filling loop 44, the pressure gauge will now start to rise, once the pressure reads 1.0 bar, close the filling taps and disconnect the filling

oop.

2. Check that the gas service tap is opened at the gas meter and the main power is on. Green indicator fig.2).

. Open the gas tap

4. The boiler is now ready to use.

NOTE: If the boiler is left off for a long time, some air in the gas pipe can hinder the first lighting

attempts. (please refer to Section 19 Incorrect Function, page 47)

Time setting

You can set the time by using the keys underneath the display. By pressing the setting key for more than 5 seconds the hours willl begin to flash. You can now set the correct hour by using the + and - keys. By pressing the setting key will make the minutes flash. You can set the minutes by using the + or - keys. Pressing the setting key once more will store the set time.

NOTE:THIS IS NOT A TIMER FOR CH CONTROL

39(

45 (fig. 2) is attached, open the filling taps 43 &

26 Power ON

OPEN CLOSED

DHW mode

Turn the control knob 29 between min and max. During the adjustment, flashes. The flashing goes on for a while after the adjustment, then the display indicates the time.

When DHW is drawn, the display indicates the following:

Comfort mode

To activate the comfort mode it is necessary to press the comfort button, this will be indicated by a yellow light. The comfort mode has priority over any other heating request. There are two settings for the comfort mode (they can be adjusted in the parameters menu, see Section 17

1. As soon as DHW is drawn, the secondary heat exchanger is kept warm for 30 mins. As soon as DHW

2. permanently.

When the boiler is operating in ‘comfort mode’ the display indicates the following:

Heating mode

Turn the control knob 30 between min and max. During the adjustment flashes. The flashing goes on for a while after the adjustment, the display will then indicate:

- the central heating flow temperature if the room thermostat is calling for heat.

- the time if the room thermostat is OFF.

is drawn, the secondary heat exchanger is kept warm

Adjustments and Settings):

comfort

BURNER ON and output level

The flame digits will increase or decrease depending on the output.

Room thermostat request

symbol

Flame digit

Burner ON

Page 7

Stand-by mode

Turn the control knobs 29 and 30 to the OFF position to deactivate the DHW and Heating. Leave the ON/OFF button On with the green light on.

uring the stand-by mode the display indicates the time, anti-seizing and anti-

D freezing will be active.

Switch OFF

Press the button ON/OFF.

During this mode the boiler will not operate, but is still connected to the mains.

Anti-freezing mode

urn the control knobs 29and 30 to OFFto switch off the heating and hot water

T functions. Leave the On/Off button on with the green light on. When the anti-freeze comes on, the corresponding code is displayed with the snowflake pictogram .

The two possible codes are 05 (anti-freeze - pump only) or 06 (anti-freeze burner).

When this mode is active, the circulating pump operates for one

05: minute and the diverter valve switches every 23 hours. Caution: in this mode, the room thermostat anti-freeze function is inoperative.

Boiler anti-freeze function: the pump starts at 8°C

the burner starts at 3°C

3. Maintenance

As with your car, your boiler will work more reliably and efficiently if regularly serviced. We recommend an annual service check. The service history of the appliance will be marked in the Log Book.

4. Guarantee

5. Practical information

Cleaning the casing and control panel

Should it be necessary to clean the casing and control panel. do so only with a soft damp cloth, do not use any spray polishes or cleaners.

Precaution to avoid freezing

We recommend you contact your installer or local service centre for further advice on the actions to be taken to avoid the system freezing.

DHW system

•

Turn off the main cold water supply and drain the boiler :

- Open a hot water tap

- Unscrew the cold water inlet tail

system

•

Chose one of the following solutions :

- 1) Drain completely the Central Heating system

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

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

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

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6. Fitting and setting the time clock

6.1 Fitting the mechanical and digital time clocks

To fit the integral time clock it is necessary to proceed as

ollows;

- Isolate the electical supply to the appliance;

- Remove the front panel as described in Section 18.1.1; Remove the plastic cover on the right hand side (Fig. 3)

and pull out the 4 wires (Fig. 4); Connect the time clock wires as follows;

CHANICALMODEL

Red Wire - Contact 1

lack Wire - Contact 2

B Black Wire - Contact 3

rey Wire - Contact 5

NOTE: TH

Red Wire - Contact 1 Black Wire - Contact 2 Grey Wire - Contact 3

NOTE:SECOND BLACK WIRE IS NOT CONNECTED.

- Push the clock back into the panel and refit the casing

E TWO BLACK WIRES ONCONTACTS

GITALMODEL

panel (Fig. 7).

Fig. 5

(Fig. 5)

(Fig. 6)

2 & 3 C

AN BE REVERSED

Fig. 3

Fig. 4

Fig. 6

Fig. 7

Page 9

1010

1111

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

2424

1212

6. Fitting and setting the time clock (continued)

6.2 Setting the mechanical clock

Fig. 8

Fig. 9

1. General layout The mechanical clock covers a 24 hour period. Each tappet represents 15 minutes A (Fig. 9). An override switch is located on

B (Fig 9).

symbol to control the central heating by the clock. Put the switch

B to «I» to select

the clock

2. To set the time

To set the time of day, grasp the outer edge of the dial and turn slowly clockwise until the correct time is lined up with the arrow

C (Fig. 4).

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

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

4. For operation

Put the selector switch B to the permanent operation or to «0» to turn the central heating off permanently.

Page 10

Day

anual switch

Summer and w

inter time

etting

eset

Enter

weekday/s

nter

he hours

Week- d

ays

lash

nter

inutes

nter

witching

times

mput

ime

6. Fitting and setting the time clock (continued)

6.3 Setting the Digital Clock

Operating the time switch

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

Preparing for Operation

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

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

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

Enter current time and weekday

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

1 = “Monday”..............7 = Sunday

- Release the “ ” key.

Page 11

6. Fitting and setting the time clock (continued)

Entering the switching times

ou have 20 memory Iocations available. Each switching time takes up one memory location.

eep pressing the “Prog” key until a free memory location is shown in the display “– –:– –”.

rogramme ON or OFF with the “ ” key:

P “ ”= OFF; “ ”= ON Enter the hour using “h” Enter the minutes using “m” If a switching command is to be carried out every day (1 2 3 4 5 6 7) then store using the “ ” key, otherwise select the day(s) it is to be carried out by using the “Day” key. When the day seIection is left bIank, the programmed switching instruction operates at the same time every day

2 3 4 5 6 = Monday – Saturday

2 3 4 5 = Monday – Friday

7 =Saturday – Sunday

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

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

Manual Override Switch “ ”

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

Reading the programmed switching times

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

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

Changing the programmed switching times

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

Entering the switching times”.

point “

Notes on storing switching times:

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

In addition, a complete switching command is stored The time switch then enters the automatic operating mode and displays the current time again.

Deleting individual switching times

Press the “Prog” key repeatedly until the switching time you wish to delete is shown in the display. Then set to “– –” using the “h” or “m” key and keep the “ ” key pressed down for around 3 seconds. The switching time is now erased and the current time is displayed.

00” appears.

automatically after around 90 seconds provided no other key is pressed.

18”. If all memory

AM / PM time display

If you press the “+/-1h” and “h” keys at the same time, the time display switches into the AM/PM mode.

Page 12

7. Description

21 12

INSTALLER INSTRUCTIONS

- Steel chassis complete with expansion vessel

2.- Sealed chamber

3.- Burner and heat exchanger assembly

4.- Air / gas connection

- 24 V modulating fan

6.- Gas valve

- Ignition electrode

8.- Ionisation probe

- Ignitor

10.- Combustion products manifold

11.- Siphon

12.- Silencer

- Electrical box

13.

14.- Pump

15.- Secondary heat exchanger

16.- Pressure gauge

17.- Three way valve

18.- Automatic air vent 19 - Domestic hot water flowswitch

20.- Main exchanger inlet thermistor

21.- Main exchanger outlet thermistor

22.- Overheat sensor

23.- Central heating pressure relief valve

Fig. 10

Fig. 11

25.- Display

On/off push button and power on

26.-

indicator light

27.- Yellow indicator - Comfort button

28.- Reset push button and red indicator

locking light

29.- DHW control knob and temperature

setting

30.- Central Heating control knob

temperature setting

31.- Menu key

32.- Reducing key

33.- Increasing key

34.- Setting key

and

Fig. 12

Page 13

8. Dimensions

440

450 mini pour entretien

54 54 54 54

JKLMN

296

720

691,5

121,5

172,5

4,7

20 40 60

80 100 120

140 160 180 200 220 240

1,0

1,1

1,2

1,3

1,4

1,5

1,6

1,7

1,8

1,9

2,0

Capacité maximale de l'installation (en litres)

260

Pression à froid pour le circuit chauffage (en bar)

280

40°C

50°C

60°C

70°C

80°C

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

200 400 600 800 1000 1200 1400

Fig. 13

296 (24 kW) 360 (30/35 kW)

All dimensions in mm

afety valve C/H and condensate

I S

Heating flow

D.H.W. outlet

Gas supply

Cold water inlet

Heating return

With packaging :

24 kW : 37 kg 30 kW : 40 kg 35 kW : 41 kg

minimum space required 450

390

9. Hydraulic data

Pump Head Graph (15/50)

Pressure (bar)

flow rate (l/hr)

Pump Head Graph (15/60)

The boiler is fitted with an automatic by-pass as standard.

The graph (Fig. 9) shows the developmentof the pressure available in relation to flow (on exit from the boiler ∆T 20°C).

To ensure correct operation, the minimum flow of the appliance must be 300 l/h. (Thermostatic taps closed).

Capacity of the installation.

The water heater is fitted with a pressurised expansion vessel.

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

7 litres.(30 / 35 kW)

Pressure: 1 bar.

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

- the average operating temperature in °C

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

The minimum cold filling pressure of the appliance is 1 bar (recommended pressure between 1.2 and 1.7 bar).

The pressure of the expansion vessel should always be greater than the static height (in metres) divided by 10.

Pressure (bar)

flow rate (l/hr)

Central heating initial pressure when cold (in bar)

System capacity chart

Fig. 14

C litre

Page 14

10. Installation requirements

Reference Standards

In the United Kingdom, the installation and initial start up of the boiler must be by a CORGI Registered installer in accordance with the installation standards curently 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

ccordance with the current edition of I.S.813 “Domestic Gas

a Installations” and the current Building Regulations, reference should also be made the the current ETCI rules for electrical installation.

The installation of this appliance must be

n accordance with the relevant

i requirements of the Local Building

egulations, the current I.E.E. Wiring

R Regulations, the by-laws of the local water authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635, “Elelectricity at Work Regulations 1989” and in the Republic of Ireland with the current edition of I.S. 813 and the Local Building Regulations (IE).

must not be installed in a place likely to cause nuisance. It must not be allowed to discharge into another room or space such as an outhouse or closed lean-to.

Condensing boilers have a tendency to form a plume of water vapour from the flue terminal due to the low temperature of the flue gasses. The terminal should therefore be located with due regard for the damage or discolouration that might occur to buildings in the vicinity and consideration must also be given to

djacent boundaries, openable windows should also be taken

a into consideration when siting the flue. The minimum acceptable clearances are shown below:

Fig. 15

C.O.S.H.H.

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

Codes of Practice

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

BS 7593:1992 Treatment of water in domestic hot

water central heating systems

BS 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 ciculation hot water systems BS 6798:2000 Installation of gas fired hot water

boilers of rated input not exceeding

70kW 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.

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

I.S. 813 Domestic Gas Installations

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

- Vertically from a terminal in the same wall 1500

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

NOT BE INSTALLED UNDER A CAR PORT

FLUE

MUST

NOTE:

ROOF OR IN A PLACE LIKELY TO CAUSE A NUISANCE.

It may be necessary to protect the terminal with a guard, if this is the case it will be necessary to purchase a stainless steel terminal guard. Reference should be made to the Building Regulations for guidance.

Ventilation

The room in which the boiler is installed does not require specific ventilation. If it is installed in a cupboard or compartment

permanent ventilation is not required for cooling purposes.

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

Flue

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

. The boiler must be installed so that the flue terminal is exposed to the free passage of external air at all times and

Gas Supply

The gas installation and soundness testing must be in accordance with the requirements of BS 6891. Ensure that the pipe size is adequate for demand including other gas appliances on the same supply.

Page 15

10. Installation requirements (continued)

Electrical Supply

he appliance requires an earthed 230V - 50 Hz supply and

T must be in accordance with current I.E.E. It must also be

ossible to be able to completely isolate the appliance

p electrically. Connection should be via a 3 amp fused doublepole isolating switch with contact separation of at least 3 mm on both poles. Alternatively, a fused 3 Amp. 3 pin plug and unswitched socket may be used, provided it is not used in a room containing a bath or shower. It should only supply the appliance.

The boiler is suitable for sealed systems only. The maximum

orking pressure for the appliance is 6 bar. All fittings and

w pipework connected to the appliance should be of the same standard. If there is a possibility of the incoming mains pressure exceeding 6 bar, particularly at night, then a

uitable pressure limiting valve must be fitted.

s The boiler is designed to provide hot water on demand to multiple outlets within the property. If there is a requirement for greater demands, for example if the property has several bathrooms and cloakrooms, a vented or unvented hot water storage system may be used.

Showers

Any shower valves used with the appliance should be of a thermostatic or pressure balanced type. Refer to the shower manufacturer for performance guidance and suitability.

Flushing and Water Treatment

The performance of the appliance could be impaired by system debris or the effects of corrosion. When the installation and filling are completed, flush the system while cold, refill, turn on the Central Heating System ( page 6) and run it until the boiler reaches its 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 the use of a central heating flushing detergent is compulsory, whose function is to disolve any foreign matter that may be in the boiler and system following the flushing procedure.

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

The use of an inhibitor is also compulsory to prevent corrosion (sludge) damaging the boiler and system.

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

For more information on the use of corrosion inhibitors, flushing and descaling agents, advice can be sought from the manufacturers of water treatment products such as:

Betz Dearborn Ltd Foundry Lane Widnes Cheshire WA8 8UD Tel: 0151 424 5351

Section 2

System Controls

he boiler is electrically controlled and is suitable for most

T modern electronic time and temperature controls. The

ddition of such external controls can be beneficial to the

a efficient operation of the system. The boiler connections for external controls are 24V and so only controls of 24V or that have voltage free contacts should be used. (Section 13 Electrical Connections - page 27).

Location

The boiler can be installed on any suitable internal wall. Provision must be made to allow the correct routing of the flue

nd siting of the terminal to allow the safe and efficient

a removal of the flue products. A compartment or cupboard may be used provided that it has been purpose-built or modified for the purpose. It is not necessary to provide permanent

entilation for cooling purposes. Detailed recommendations

v are given in BS 5440 pt 2. If it is proposed that it is installed in a timber framed building then reference should be made to British Gas Document DM2, or advice sought from CORGI.

Where a room sealed appliance is installed in a room containing a bath or shower, the appliance and any electrical switch or appliance control, utilising mains electricity should be situated specifically in accordance with current IEE Wiring Regulations.

For unusual locations, special procedures may be necessary.

BS 6798:2000 gives detailed guidance on this aspect.

Condensate Discharge

The condensate discharge hose from the boiler must have a continuous fall of 2.5oand must be inserted by at least 50mm into a suitable acid resistant pipe - e.g. plastic waste or overflow pipe. The condensate discharge pipe must have a minimum diameter of 22mm, must have a continuous fall and preferably be installed and terminated to prevent freezing. The discharge pipe must be terminated in a suitable position:

Connecting into an internal soil stack (at least 450mm

above the invert of the stack). A trap giving a water seal of at least 75mm must be incorporated into the pipe run, there also must be an air break upstream of the trap.

ii) Connecting into the waste system of the building such as

a washing machine or sink trap. The connection must be upstream of the washing machine/sink. If the connection is down stream of the waste trap then an additional trap giving a minimum water seal of 75mm and an air break must be incorporated in the pipe run, as above.

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

the water level. Into a soakaway.

iv)

OTE: If any condensate pipework is to be installed

N externally then it should be kept to a minimum and be insulated with a waterproof insulation and have a continuous fall. The total length of external pipe used should not exceed 3 metres.

Some examples of the type of condensate terminations can be found on page 13.

Fernox Manufacturing Britannica Works Clavering Essex CB11 4QZ Tel: 01799 550811

Page 16

10. Installation requirements (continued)

1. Internal termination of condensate drainage pipe to internal stack

2. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste) and condensate siphon

3. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste - proprietary fitting).

4. External termination of condensate drainage pipe via condensate siphon

Page 17

11. Installing the boiler

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

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

Hanging bracket

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

- Connection tails and valves

- Screws and washers

- Connection washers

- Installation, Servicing and Operating Instructions

Method of positioning the boiler on the wall.

The paper template can be used to ensure the correct positioning of kitchen cabinets etc. It also details the commissioning instructions. The paper template has to be fixed to the wall and used to locate the position of the hanging bracket and the centre for the flue hole. Drill and plug the wall and secure the hanging bracket using the screws provided. Remove the boiler from its packaging as shown in Fig. 16 and unscrew the two clamp locking bolts Place the boiler on the wall on the hanging bracket (Fig. 18).

NOTE: TH

Connecting the boiler to the system

- Remove the boiler casing as described in Section 18.

- Push in the tabs “P” (Fig. 18) on either side of the boiler and pivot the electrical box forward to gain access to the valve

- Remove the caps and connect the boiler to the taps using washers provided in the plastic bag.

E APPLIANCE MUST NOT BE FITTED ON A COMBUSTIBLE WALL SURFACE

connections

4 x fibre washers for the C/H flow and return, hot water outlet and cold water inlet connections 1 x rubber washer for gas connection

A and remove the casing (Fig. 17).

Safety valve discharge

The pressure relief valve tube is made of copper. It should terminate below the boiler safely outside the premises. Care should be taken that it does not terminate over an entrance or window or where a discharge of heated water could endanger occupants or passers by.

Fill the Central Heating and DHW system and bleed air from system as described in Section 14. The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. The pipe from the siphon (11 Fig. 11) should be connected to a drain as described in the relevant Brittish regulations. Pay special attention to not bend the condensate silicone drain pipe such as the flow will be interrupted. Please use exclusively drain pipe material compatible with condensate products. (refer to The condensate flow can reach 2 litres / hour; because of the acidity of the condensate products (Ph close to 2), take care before operation.

Fitting the Horizontal Flue Attention ! Before starting the boiler, the siphon (11 Fig. 11) must be filled with water. Before fitting the flue l onto the boiler, pour 1/4 litre of water in the exhaust pipe as shown in Fig. 20.

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

IMPORTANT!!

Use only the specific condensation flue kit supplied by C&M.

BS 6798 : 2000)

Page 18

11. Installing the boiler (continued)

ig. 16

Fig. 17

Fig. 18

Fig. 19

Page 19

12. Connecting the Flue



150 mm

* slope 5 mm per metre

150 mm

* slope

118

The boiler should only be installed with a flue system supplied by MTS (GB) Limited. These kits are supplied separately to the appliance in order to respond to different installation solutions. For more information with regard to the inlet/outlet accessories consult the accessory catalogue. The boiler is supplied ready for connection to a

oncentric flue system.

:SE

IMPORTANT!!

BEFORE CONNECTING THE FLUE, ENSURE THAT 1

WATER HAS BEEN POURED INTO THE EXHAUST CONNECTION TO FILL THE CONDENSATE TRAP (FIG. 20). SHOULD THE

RAP BE EMPTY THERE IS A TEMPORARY RISK OF FLUE

GASSES ESCAPING INTO THE ROOM

E PAGE

24 F

OR MAXIMUM AND MINIMUM FLUE RUNS

(TA

LITRE OF

BLES

A, B ANDC)

ig. 20

Warning

The exhaust gas ducts must not be in contact with or close to inflammable material and must not pass through building structures or walls made of inflammable material. When replacing an old appliance, the flue system must be changed.

Ø 60/100 mm

Fig. 21

Installation without extension

Important

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

Level

Installation with extension

Fig. 22

Level

Page 20

12.1 Fitting the coaxial flue (Ø 60/100 Horizontal)

CO 1X SI

NTENTS

LICONE

-R

60mm)

(

O 1X ELBOW (90O) 2X WALLSE

X FLUE PIPE INCLUDING TERMINAL (1 METRE - 60/100)

1 1X FLUECL 1X SC

REWS

x Seal

Once the boiler has been positioned on the wall, insert the elbow into the socket and rotate to the required position. N

ALS

AMP

(IN

TERNAL

&EX

TERNAL

)

: It is

OTE

possible to rotate the elbow 360oon its vertical axis.

sing the flue clamp, seals and screws supplied

The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact

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

ubtracted from 815mm, you now have the total amount to be cut from the plain end of the flue.

Fig 23)secure the elbow to the boiler.

(

X dimension of 815mm.

(X - Fig 21), this figure must now be

Draw a circle around the outer flue and cut the flue to the required length taking care not to cut the inner flue, next cut the inner flue ensuring that the length between the inner and outer flue is maintained.

(Fig 23).

e.g.

X = 555mm 815-555 = 260mm (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 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.

Clamp

Screws

Seal

Fig. 23

12.2 Fitting the 5” Flue (Ø 80 / 125 Horizontal/vertical)

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

OTE:SEE

PAGE

19 FOR

MAXIMUM

Once the boiler has been positioned on the wall, it is necessary to insert the vertical flue runs into the boiler flue socket (not supplied with flue kit -

Push the adaptor onto the boilers flue connection, grease the seals then add extensions or elbows as required, secure the adaptor, using the clamp and screws provided.

AND MINIMUM FLUE RUNS

Ø80/125 adaptor (FIG. 24) for both horizontal and

Part No 3318095).

To fit extensions or elbows it is first necessary to ensure that the lip seal is fitted correctly into the inner flue, once verified, it is simply necessary to push them together, no clamps are necessary to secure the flue components.

Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables on Page 19) and that all elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90 1 metre must be subtracted from the total flue length, and for each 45

0.5 metres must be subtracted from the total flue length

elbow

(the height of the vertical adaptor and a 45obend can be seen in Fig. 25 and a 90obend in Fig. 26).

OTE: DO NOT CUT THE VERTICAL FLUE KIT.

Page 21

Fig. 24

Fig. 25

Fig. 26

Page 22

12.3 Fitting the Coaxial Flue (Ø 60 / 100 Vertical)

NOTE:

E PAGE

OR MAXIMUM AND MINIMUM FLUE RUNS

CONTENTS: 1X SILICONE O-RING (60mm) 1X CO

NICALADAPTOR

1X VE

RTICALFLUEKIT

X SC

REWS

(60/100mm)

(80/125mm)

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.

The Vertical flue kits useable lengths with the pitched roof flashings are indicated in

Fig. 27.

elbow

1 metre must be subtracted from the total flue length, and for each 45o0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45obend can be seen in Fig. 28).

Mark the position of the flue hole in the ceiling and/or roof (see

Fig. 27 for distance from wall to the centre of the flue).

Cut a 120mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof.

DO NOT cut the vertical flue kit.

To connect the vertical flue kit directly to the boiler, place the vertical starter kit

(Part No. 3318079) (see Figs. 27 & 28) onto the

exhaust manifold and secure with the clamp, fit the vertical adaptor onto the vertical starter kit (note: there is no need to use a clamp to secure this as it is a push fit connection), the vertical flue kit must then be inserted through the roof flashing, this will ensure that the correct clearance above the roof is provided as the terminal is a fixed height.

Should extensions be required, they are available in 1 metre

(Part No. 3318077), 500mm (Part No. 3318078) and 160mm

lengths, they must be connected directly to the vertical starter kit before connecting the adaptor to allow the vertical flue kit to be fitted. In the event that extension pieces need to be shortened, they must only be cut at the male end and it must be ensured that the inner and outer flue remain flush.

When utilising the vertical flue system, action must be taken to ensure that the flue is supported adequately to prevent the weight being transferred to the appliance flue connection by using 1 flue bracket per extension.

When the flue passes through a ceiling or wooden floor, there must be an air gap of 25mm between any part of the flue system and any combustible material. The use of a ceiling plate will facilitate this. Also when the flue passes from one room to another a fire stop must be fitted to prevent the passage of smoke or fire, irrespective of the structural material through which the flue passes.

Fig. 27

Fig. 28

Page 23

12. Connecting the flue (continued)

123.5 141

230 MIN *

200

132

12.4 Fitting the twin pipe (Ø80/80)

NOTE:

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 c

A To utilise the air intake it is necessary to:

1) Take the air intake cover off

2) Assemble the flange on the header supplied with the boiler

3) Insert the restrictor if necessary, on the tube or the elbow

4) Insert the header on the tube or the elbow up until the lower stop (you do not have to use the washer).

5) Insert the elbow/header in the boiler air intake hole and fasten it with screws

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.

It is not recommended that the pipe bridge 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 5mm in every metre back to the boiler, and where the 60mm 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.

EE PAGE 24 FOR MAXIMUM AND MINIMUM FLUE RUNS (TABLE C

hamber.

lways ensure that the flue is adequately supported, avoiding low points. (MTS supply suitable clamps as Part No. 705778).

)

When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals

33). 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.

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

The maximum permissible flue length for twin flue is dependent on the type of run used.

For flue runs with the intake and exhaust pipes under the same atmospheric conditions (T metres (24kW and 30kW), for runs with the terminals under different atmospheric conditions (T 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 T

The maximum length is reached by combining the total lengths of both the air intake and exhaust pipes. length of 60 metres for example, will allow a flue run of 30 metres for the air intake and 30 metres for the exhaust pipes, also for each 90 from the total flue length.

Some of the acceptable flue configurations are detailed page 25.

For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 241 8180.

must be a minimum of 280 mm apart and the air intake must not be sited above the exhaust terminal (refer to Fig.

YPE 4) the maximum length is 60

YPE 5) the exhaust terminal

YPE 5 also, the maximum permissible combined length is 60 metres (24kW and 30kW).

Therefore a maximum

elbow 2.2 metres must be subtracted from the total length and for each 45oelbow 1.4 metres must be subtracted

Fig. 29

Fig. 30

Page 24

123.5

200

107

12. Connecting the flue (continued)

ø 100

60 mm

ig. 31

In the event that twin flue pipes are used, and the boiler has a side clearance of less than 60mm from the wall, it is necessary to cut a larger diameter hole for the flue pipe, this should be ø100 mm, this will then allow for easier assembly of the air intake elbow and the tube outside the wall (see Fig. 32).

TABLE

Concentric outlet

60/100

24 , 30 and 35 kW

(Type 1, Type 2, Type 3)

Concentric outlet

80/125

24 , 30 and 35 kW

(Type 1)

24 , 30 and 35 kW

(Type 2, Type 3)

Twin flue outlet

24 , 30 and 35 kW

Type 4

80/80

Type 5

80/80

Min length Max. length

0.3 m 5m

Min length Max. length

0.3 m 10 m

Min length Max. length

10 m

(30m air / 30m exhaust)

60 m

Fig. 32

Length

equivalency for

elbow

0.5 m

1 m

0.5 m

1 m

1.4 m

2.2 m

For coaxial systems, the maximum development value, mentioned in the table above also takes into account an elbow. For twin flue systems the maximum development value, mentioned in the table includes the exhaust gas/air intake terminal.

Type 5 outlets should respect the following instructions: 1- Use the same ø 80 mm flue pipes for the gas intakes and exhaust gas ducts. 2- If you need to insert elbows in the gas intake and exhaust gas ducts, you should consider for each one the equivalent length to be included in the calculation of developed length. 3- The exhaust gas duct should jut above the roof by at least 0.5 m. 4- The intake and exhaust gas ducts in Type 5 must be installed on the same wall, or where the exhaust is vertical and the air intake horizontal, the terminals must be on the same side of the building.

Page 25

EXHAUST

AIR INTAKE

AIR INTAKE MUST NOT BE

FITTED ABOVE THE EXHAUST

12. Connecting the flue (continued)

TYPE 1

TYPE 4

NOTE: DRAWINGS

TYPE 2

TYPE 5

ARE INDICATIVE OF FLUEING OPTIONS ONLY

TYPE 3

Fig. 33

Page 26

13. Electrical connections

aking the Electrical Connections

Hinge down the electrical box to gain access to the

Fig. 34)

lectrical connections. Push in the tabs

e on either side of the boiler and pivot the box for-

ard.

Remove the PCB cover (see Section 18.4 - page

50). Connect the live neutral and earth wires to the main cable.

If using a room thermostat or other external con-

rol, they can be connected in place of the link on

t the terminal block (Diagram A- Fig.36).

Note: Use only controls designed for voltage free switching or 24V supply. Do not connect to a 230V supply, and do not run 230v cables alongside the

ow voltage cables.

All necessary settings for room thermostat operations are described in Section 17 ADJUSTMENTS AND SETTINGS.

P (

Fig. 34

Fig. 35

LEGEND

1 NTC 2 Display Connectors 3 EEPROM 4 24V 5 Fan Connector 6 Flame Detection Connector 7 Fuses 2A

Connectors

Key

Supply

230V (X2)

8 230V

9 Auxillary 230V Connector 10 Actuators 230V 11 Time Clock Connector (Internal) 12 Room Thermostat Connector 13 Remote Control 14 Under Floor Heating Connector 15 Not Used

Connector

Page 27

13. Electrical connections (continued)

- If a remote time clock is to be fitted, using a volt-free switching time clock, remove the link wire and connect the switching wires from the time clock following points above (see also

If using an external time clock and room thermostat, remove the link wire and connect in series as above (see also

iagram C Fig. 36).

Live and Neutral connections to operate the clock motor must be taken from a suitable source.

Diagram B Fig. 36).

Connector refer to those provided with the clock or page 8 of this manual.

11 (Fig. 36), is provided for connecting an optional integral time clock or programmer, for fitting instructions, please

CONNECTOR 12 ON PCB, SEE FIG. 35

Fig. 36

Page 28

14. Commissioning and testing

14.1 Initial preparation

MTS (GB) Limited support the initiative. In Sections 24 and 25 (pages 59 and 60) of this manual the

Commissioning Checklist and Service Interval Record can be found. It is important that this is completed in the presence of your customer, they are shown how to use it, and it is signed by them. Please instruct your customer that

hey must have this manual with them whenever they contact

t a service engineer or us.

Preliminary electrical system checks to ensure electrical

afety must be carried out by a competent person i.e.

s polarity, earth continuity, resistance to earth and short circuit. F

LLING THEHEATINGSYSTEM

Remove the front casing panel and lower the control panel

s described in Section 18.1 (page 37).

a Open the central heating flow and return cocks supplied with the connection kit; 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 the valves at the filling point (filling loop) 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 anti-clockwise, also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free.

When installation and filling are completed, adequately purge the gas installation of air, flush the sytem while cold, refill, turn on the Central Heating system (

un it until the boiler operating temperature has been

r reached. The system must then be immediately flushed

hrough.

t 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.

uring this operation, we highly recommend the use of a

D central heating flushing detergent (Fernox Superfloc or equivalent), whose function is to disolve any foreign matter that may be in the boiler and sytem following the flushing procedure.

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

The use of an inhibitor is also compulsory to prevent corrosion (sludge) damaging the boiler and system.

Failure to carry out this procedure will invalidate the

Section 2 - page 6) and

14.2 Initial start-up

appliance warranty.

The checks to be run before initial start-up are as follows:

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.

ILLING OF THE DHW SYSTEM:

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

AS SUPPLY:

Inspect the entire installation including the gas meter and test for soundness. The entire installation should be in accordance with the relevant standards. In GB this is BS 6891 and in IE this is the current edition on I.S.813.

The connection on the the appliance is a 15mm copper tail located at the rear of the gas service cock (

If the gas supply 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 less than 22mm should not be used.

Open the gas cock (supplied with the connection kit) to the appliance and check the gas connection on the appliance for leaks.

39 Fig. 2 - page

1. Make sure that:

- The screw on the automatic air valve has been loosened when the system is full;

- If the water pressure in the system is below 1.5 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

) the green led indicator light will illuminate;

(Fig. 1

-Turn the central heating control knob maximum and switch the time clock (if fitted) to constant and turn up the room thermostat (where fitted);

- After 7 seconds, the boiler will signal a shutdown due to ignition failure. Leave the boiler as it is until all 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 hot water taps for a short period;

- Check the system pressure and , if it has dropped, open the filling loop again to bring the pressure back up to 1.5 bar;

2. Make sure that all radiator valves are open;

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

4. Press the reset button ignition. If the burner does not light the first time, wait 1 minute and repeat the procedure;

5. Check the minimum and maximum CO rates;- Adjust if necessary using the values indicated in the table in Fig. 31

(page 32)

28 (Fig. 1) the boiler will re-attempt

29 (Fig. 1) to

values and gas

Page 29

14. Commissioning and testing (continued)

14.3 Adjusting the CO2

. Remove the casing panel as described in Section 18

(page 42);

. Connect a combustion analyser to the test point on top of

the boiler

3. Access the seetings menu by pressing the and keys together for 5 seconds;

4. Press the menu button to access Menu 5 and press the setting button once to switch the combustion rate control mode to maximum;

. Adjust the screw on the gas valve (Fig. 38) to set the CO

to 9.2% +/- 0.2% (NG) or 10% +/- 0.2% (LPG);

. Press the setting button once to set the combustion

control rate mode to minimum, and, if necessary, adjust the screw on the gas valve to set the CO (NG) or 9.2% +/- 0.2% (LPG);

7. Press the setting button again to set the combustion rate control mode to maximum and if necessary adjust the screw on the gas valve to set the CO (NG) or 10% +/- 0.2% (LPG);

8. Reassemble in reverse order.

Q (Fig. 37);

to 9.2% +/- 0.2%

14.5 Adjusting the maximum heating power

To adjust the maximum heating power it is necessary to

access the settings menu by pressing the and buttons together for five seconds, and proceed as follows;

. Press the menu button 3 times to access Menu 4;

2. Press the button to access Menu 4.9;

3. The value is adjustable between 0 and 10, 0 being the

minimum output and 10 being the maximum, please refer

o the chart on page 32 (Fig. 43) for the settings;

4. The maximum central heating output can now be adjusted by pressing the setting button ;

5. To exit the setting mode, do not press any buttons for 1

inute, the boiler will automatically exit the Setting Menu.

14.6 Fitting the external sensor

The external sensor should be fitted 1.5 meters above the floor on a North to North West facing wall.

To connect the external sensor, it is first necessary to remove the casing panel as described in Section 18 (page

42);

Remove the PCB cover as described in Section 18.4 and connect the external sensor as described in Section 18.5; Reassemble in reverse order.

Fig. 37

14.4 Gas Conver

To convert from Natural Gas (G20) to LPG (G31), it is necessary to insert a diaphragm and restrictor between the gas valve and air/gas arm.

Once the conversion has been made, the CO2 setting will need to be checked as described in Section 14.3, for LPG the CO2 reading should be 10% +/- 0.2%.

To convert from LPG (G31) to Natural Gas (G20), it is necessary to remove the diaphragm and restrictor from between the gas valve and air/gas arm. Once the conversion has been made, the CO2 setting will need to be checked as described in Section 14.3, for NG the CO2 reading should be 9.2%

sion

+/- 0.2%.

Adjustment screw

14.7 External sensor set-up (where fitted)

Should the external sensor be fitted, it will be necessary to set the heating curve and adjust the parrallel shift depending on the type of heating system used.

To set up the external sensor, proceed as follows;

1. Access the settings menu by pressing the and

buttons together for five seconds;

2. Press the

3. Press the button, the 3rd and 4th digits will flash;

4. Press the

not fitted ) to 0 (sensor fitted) and press the button

again to select the change;

5. Select the thermal curve required from

31);

6. Press the or buttons to change to Section 6.2;

7. To adjust the thermal curve, press the button, the 3rd

and 4th digits will begin to flash;

8. Press the or buttons to select the parameter that

best meets your temperature requirement shown in

(page 31);

9. Once the correct parameter has been set, press the key

again to confirm the selection.

button 5 times to access menu 6;

or buttons to change from 1 (sensor

Table D (page

Table

Fig. 38

Page 30

14. Commissioning and testing (continued)

14.10 Operational checks

1. The system must be visually checked for soundness;

2. Fill the condensate trap with water, by pouring 1/2 a litre of water into the exhaust flue connector (see Fig.

42). N.B. In the event of a prolonged period of system

hutdown, the condensate trap should be filled before

s any renewed use. A shortage of water in the trap could possibly lead to a leakage of fumes into the air, until it refills itself.

3. Ensure that the flue is fitted correctly.

4. Allow the central heating system to warm up and adjust

he central heating temperature control knob

t check the burner modulates between the high and low

ettings;

BLE

14.8 Setting the parallel shift

In the event that the thermal curve set is giving too high or too low a temperature, there are two options, you can either alter the thermal curve as described in Section 14.7 or adjust the parallel shift of the curve.

To adjust the parallel shift, proceed as follows:

1. Access the settings menu by pressing the and buttons together for five seconds;

2. Press the button 5 times to access menu 6;

3. Press the button, the 3rd and 4th digits will flash;

4. Press the or buttons to adjust the parallel shift up and down in steps of 1 between 0 and 20 (see

Table E).

5. Range rate the thernal power for central heating as etailed in Section 14.5. To adjust the maximum heating

d power it is necessary to follow the steps in Section 14.5 Menu 4 (page 38). and adjust in relation to the chart on Page 31 (Fig. 39);

6. Run the domestic hot water and adjust to the correct

water flow rate, adjust the domestic hot water temperature control knob between the high and low settings;

7. Balance the central heating system until all return

temperatures are correct and equal;

8. Turn the boiler off by pressing the On/Off button

to OFF, disconnect the gas pressure gauge, retighten the screw and relight the boiler;

9. Re-examine the central heating, domestic hot water and

cold water supplies for soundness.

10. If external controls have been disconnected, reconnect

and test.

11. Refit the boiler casing.

29 (Fig.1) to ensure the burner modulates

Fig.1),

30(

26 (Fig.1)

TABLE E

14.9 Completion

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 edition of I.S.813.

In addition it is necessary to complete the Commissioning Checklist in Section 24 of this manual (page

59).

Fig. 42

14.11 Instructing the end user

1. Hand over these instructions and explain how to use the time clock and room thermostat (if fitted) and explain how to register the guarantee;

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. Instruct the end user on the correct procedure for checking and refilling the boiler;

6. 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.

Page 31

Central Heating Output (kW)

24 kW

30 kW

123

789

Steps (Value P min - P max - Menu 4)

12.5

17.5

22.5

27.5

32.5

9.6

11.2

12.8

14.4

17.6

19.2

20.8

22.4

5 kW

14. Commissioning and testing (continued)

15. Fitting the casing

Fitting the casing

Remove the protective film on the casing:

- Locate the lower clips into the slots in the chassis

- Engage hooks

- Fit the top of the panel in place

- Close the panel mounting clamps (Fig. 41)

- Screw in the two clamp locking bolts

Note: it is essential to refit both locking bolts A

N on the casing in notches R on the side panels M operation (Fig. 40)

Fig. 39

Fig. 40

Fig. 41

Page 32

16. Sequence of operation

16.1 Central Heating Mode

Activation of the time clock and/or room thermostat starts the boiler. The display panel indicates the flow temperature s in central

eating as illustrated below:

Central heating

ode

Room thermostat contact ON

ith the boiler in rest, the diverter valve is in the domestic hot water position, activation of the central heating changes the

W position of the motorised valve head, moving the diverter valve into the central heating position.

The start of the pump is delayed for 7 seconds to allow the movement of the diverter valve. The PCB checks the pressure of the primary circuit, if the pressure measured is 0.8 bar or lower, the boiler will lockout after 40 seconds. The error code appear on the LCD and the pump will stop.

If the pressure measured is above 0.8 bar, the boiler ignition sequence will begin.

At first, the fan starts and the speed increases to the required ignition speed (3460 rpm), once this speed has been achieved, the safety coil of the gas valve is supplied with 230V DC, after 8 seconds the boiler checks that the burner has lit, if the boiler does not sense that the burner has lit, the error code relight two more times (20 seconds between each attempt). After this, should the boiler still not sense a flame, error code appear on the LCD.

Should the boiler detect that the burner has lit, the boiler continues to regulate as follows.

E04 will appear on the display, should this error occur, the boiler will attempt to

E02 will

A03 will

The NTC fitted on the outlet of the primary circuit exchanger is the only NTC to adjust the heat output of the boiler according to the adjustable setting point. This point is adjustable from 25°C to 85°C by the user. This NTC relays information to the PCB, which in turn modulates the burner by adjusting the speed of the fan.

When the NTC senses that the set temperature has been achieved (+ 4°C to the temperature set by the user), the burner will go out. To avoid excessive burner lighting, an anti-cycle timer can be set between 0 to 7 minutes in menu Adjustments and Settings).

The speed of the pump can be set at two levels. The PCB controls the speed of the circulation pump depending on the speed set in menu modulate between high and low speed depending on the ∆T between the inlet and the outlet. If the ∆T is greater than 20°C the pump will run on high speed and if the ∆T is less than 20°C the pump will run on low speed.

4 line 41. Setting 410 will cause the pump to operate continually at high speed, and setting 411 will cause the pump to

OTE:THE DEFAULT SETTING FOR THE PUMP IS HIGH SPEED.

4 line 48 (see Section 17

Page 33

16. Sequence of operation

16.2 Domestic Hot Water Mode

The Domestic Hot Water (DHW) production always has priority over the Central Heating (CH) mode.

When a hot tap is turned on, the DHW flow switch is activated. The minimum DHW flow rate is 2 l/min. If the diverter valve is in

he CH position it will motor into the DHW position and the boiler will start.

The LCD will show that the boiler is working in hot water mode as below:

The appliance follows the same operating logic as described in Section 16.1 Central Heating Mode.

In domestic hot water mode NTC1 limits the maximum temperature of the primary heating circuit to 78°C during DHW production, re-ignition will occur at 74°C. The domestic hot water temperature is limited to 64°C, re-ignition will occur at 62°C.

The NTC

The DHW setting is adjustable from 40°C to 60°C by the user.

The PCB compares the values of the DHW NTC with the setting of the DHW control knob. If the temperature of the DHW NTC is 4°C greater than the temperature set on the DHW control knob, the burner will go off, it will restart when the temperature of the DHW NTC is less than + 2°C of the temperature set on the DHW control knob.

at the end of the plate heat exchanger is the only NTC used for the regulation according to the DHW setting.

Page 34

17. Adjustments and settings

The boiler is delivered with pre-set values described

n menus 3 and 4.

i All settings must only be changed by the installer or

qualified person. To gain access to the setting

a buttons please, open the front door

ollow the instructions below.

P. (Fig. 42) and

Fig. 42

Fig. 43

DISPLAY

On/Off push button Comfort button

Menu button - button

+ button

2nd digit

1st digit

Reset push button

Setting button

3rd digit

4th digit

Pressing the, comfort, reset, menu, +, -, or setting buttons will make the display light. The light will go out 30 seconds after the

last key has been pressed.

To gain access to the setting menus press and buttons together for 5 seconds. (Fig. 38). Menu 1 is displayed on the

1st digit.

Changing the menu :

Press the Menu button

the next menu

(Fig.47). The menu number is displayed for 3 seconds. Press the menu button to change to

Setting a parameter in a section :

Press the key or the key to change from between sections.

Note : When you arrive at the last section of a menu, pressing the button will change to the the 1st section. When

you are at the first section, pressing the key will change to the

last section of the menu.

Changing section in a menu (available only for menu 3 and 4) :

Press the setting button to enter the modification mode, The 3rd and 4th digits will be flashing, press the or

button to select the correct value then press the setting button to select this modification and to exit the setting mode. The

3rd and 4th digit stop flashing.

Recalling the basic configuration :

Select menu 3 or 4 then press the + buttons together for more than 5 seconds. The digits will flash CM for a

while to indicate that the operation is completed.

Clearing Menu 1 (default register) :

Select menu 1 then press the + buttons together for more than 5 seconds. The digits will flash CM for a while to

indicate that the operation is completed.

Note : To exit from setting mode, leave the boiler for approx. 1 minute, the display will switch back to user mode.

Page 35

ACTION CONFIGURATION

ISPLAY

5 ”

x times

once

Menu - 1 - Default register

Record of the last 10 defaults

Section Digit 1 Digit 2 Digit 3 and 4

Last default occured 1 0 code from 01 to 99

Last but one default occurred 1 1 code from 01 to 99

... 1 ... code from 01 to 99

ast default occurred before the previous

L one

ote --is displayed if no default is recorded

1 9 code from 01 to 99

Menu - 2 - Boiler conditions

Indicates the conditions or the configurations of the boiler

Section Digit 1 Digit 2 Digit 3 and 4

Software version of display PCB 2 0 code from 01 to 99

x times

Software version of main PCB 2 1 code from 01 to 99

Flue type 2 2 4 : Condensation

0 : no

Room thermostat is calling for heat 2 3

1 : yes

0 : DHW

Theoretical position of the 3 way valve 2 4

1 : CH

DHW flow temperature in °C 2 5 from 01 to 99

Hot water tank Temperature in °C 2 6 from 01 to 99

CH flow temperature in °C 2 7 from 01 to 99

CH return temperature in

Outside temperature (Flashing when negative temperature)

2 8 from 01 to 99

2 9 from 01 to 99

Page 36

CTION

once

ection

HW Confort mode

ONFIGURATION

Menu - 3 - Boiler options

igit 1

3 0

igit 2

igit 3 and 4

0 : permanent

1 : 30 mn

DISPLAY

setting

Factory

x times

DHW thermostatic kit fitted to boiler? (limits DHW temp to 60°C)

Internal time clock action 3 2

DHW flow switch Delay

(time before DHW flow detection to override pressure peak problem)

3 1

3 6 0 to 20 1/10 second

0 :

1 : yes

0 : central heating and

DHW comfort mode

1 : DHW comfort mode

2 : central heating

Page 37

CTION

once

x times

ONFIGURATION

Menu - 4 - Boiler settings

Section Digit 1 Digit 2 Digit 3 and 4

Stop pump after burner stops 4 0

Pump speed 4 1

0 :

1 : yes

0 : High speed

1 : Low speed

DISPLAY

setting

Factory

Pump post circulation duration 4 2

4 3

Maximum Central Heating flow temperature

Minimum Central Heating flow temperature

CH anti-cycling delay 4 8

CH maximum output limitation 4 9

4 4

4 5

4 6

0 to 5 min by step

0.5 min

50° to 80°

by steps of 1°

25° to 50°

by steps of 1°

0 to 7 min by step

0.5 min

Value from 0 to 10

Pmin & Pmax general

Page 38

CTION

ONFIGURATION

Menu - 5 - Combustion rate control mode (test mode)

Effect Display

DISPLAY

once

x times

ombustion rate control mode OFF

Combustion rate control mode ON The main exchanger temperature

appears on the display. The digit - on the display shows the gas

utput level.

o (Top = max, bottom = min).

Gas output setting To modify the gas output use the + and -

buttons.

To cancel the combustion rate control mode press the “Menu” button.

The combustion rate control mode will be inactive when :

- boiler is in stand by mode

- room thermostat is not calling for heat

- boiler in lockout mode

- after the default settings have been restored or if the main supply fails (power cut)

- if the operator exits the 5th menu

- after 5 minutes if no buttons are pressed

Note : As soon as the combustion rate control mode is active, the Central Heating and Domestic Hot Water

control knobs become inactive.

Page 39

CTION

ONFIGURATION

Menu - 6 - Automatic heating regulation

DISPLAY

once

x times

Section Digit 1 Digit 2 Digit 3 and 4

Regulation on 6 0

Heating setting in

6 1

automatic/manual mode

Water law gradient (see table

Foot of water law gradient (see table

6 2

6 3

0 : External sensor present

1 : No external sensor

(factory adjustment)

Adjustment with inactive external

0 :

sensor (factory adjustment)

1 : Automatic adjustment with active

external sensor

0,3 0,5

1 1,2 1,5

2 2,5

from 0 to 20

by step 1

setting

Factory

In the event of connection of the external sensor, you must:

1. Declare the sensor (menu 6.0)

2. Activate the external sensor automatic adjustment (menu 6.1)

3. Program the curves (menu 6.2)

4. Program the compensations (menu 6.3)

Page 40

17. Adjustments and settings (continued)

H anti cycling delay setting :

If you would like to change the setting of CH anti cycling delay, if you want 3 min, proceed as follows: (NOTE : THE FACTORY SETTING IS 2 MIN 30 SECONDS AND THE FOLLOWING EXPLANATION REFER TO MENU 4 SECTION 8)

Display

witch to installer mode, press key

and for 5 seconds, the

display shows :

default in the default register.

Press 3 times on menu key

gain access to menu

shows :

Change to section 8 (CH anti cycling

delay), press on key 8 times, the

display shows :

setting 2 min 30 seconds)

4 = menu 4

8 = section 8

2.5 = 2.5 min (2 min 30 seconds)

10=0 if there is no

4, the display

40=0 or 40=1

48=2.5 (factory

5 ”

x 3

x 8

Press the setting key one time,

the 3rd and 4th digits flash together,

Then press the

CH anti cycling delay, the display

shows :

48=3.0 press the setting key to

confirm the value. The display stops

flashing.

Setting procedure is finished.

To exit from setting mode, leave the

boiler for approx. 1 minute then the

computer will switch back to user

mode.

After programming please close the

door P (Fig. 46 page

to change the

35)

Page 41

SERVICING INSTRUCTIONS

To ensure efficient safe operation, it is recommended that the

oiler is serviced annually by a competent person.

efore starting any servicing work, ensure both the gas and

B electrical supplies to the boiler are isolated and the boiler is

ool.

Before and after servicing, a combustion analysis should be made via the flue sampling point.

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

PORTANT

AFTER AN ANNUAL SERVICE, THE SERVICE INTERVAL RECORD (SECTION 25, PAGE 60) MUST BE COMPLETED.

18. 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 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.

18.1 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.

1. Unlock the two clamps locking A (see Figs. 44 & 45);

2. Remove the front panel from the rest of the

casing (see Fig. 46).

Section 19 will help to locate

Fig. 44

Fig. 45

18.1.1 Removing the front panel :

1. Remove the front panel;

2. Unlock the two clamps locking and pivot the

electrical box downward (see Fig. 47).

18.1.2 Lowering the control panel :

Fig. 46

Fig. 47

Page 42

18.2 Access to the Combustion Chamber

18.2.1 Removing the air gas assembly

arry out step 18.1.1

1.C

;

2. Remove the silencer (Fig. 52);

isconnect the detection

3. D

electrode cable (Fig. 53);

emove the earth cable from the

4.R

ignition electrode (Fig. 50), and remove the ignition electrode cable from the ignitor (Fig. 53

Fig. 48

5. Unplug the gas valve and fan connectors (Figs. 52 and 53);

Fig. 52

6. Unscrew the 6 nuts D on the

combustion chamber (Fig. 54);

Fig. 49

Fig. 53

7. Unscrew the gas valve nut E

(Fig. 55);

Fig. 50

Fig. 51

7. Remove the air gas assembly and combustion chamber front (Fig. 56);

8. Reassemble in reverse order.

Fig. 54

Fig. 55

Fig. 56

Page 43

18.2.2 Removing the burner

arry out step 18.1.1 and18.2.1

1.C

emove the 3 screws

2.R

F f

air/gas manifold (Fig. 57);

rom the

;

lide the burner out from the

3.S

ront, taking care not to damage

f the insulation (Fig. 58);

eassemble in reverse order

4.R

nd checking all seals are

a undamaged and the burner is positioned correctly (Fig. 59).

Fig. 57

18.2.3 Removing the detection electrode

1. Carry out step 18.1.1;

3. Pull the electrode from the

2. Remove the 2 screws G from the

electrode manifold (Fig. 60);

Fig. 61

18.2.4 Removing the ignition electrode

Fig. 58

combustion chamber (Fig. 62);

Fig. 62 Fig. 63

Fig. 59

4. Disconnect the detection electrode cable (Fig. 63).

5. Reassemble in reverse order.

1. Carry out step 18.1.1;

2. Remove the earth cable from the

electrode (Fig. 64);

Fig. 64 Fig. 65 Fig. 66

3. Remove the electrode cable H

from the ignitor (Fig. 65);

4. Unscrew the 2 screws I on the electrode (Fig. 66);

Page 44

18.2.5 Removing the fan

1. Carry out step 18.1.1;

2. Remove the air gas manifiold as

8.2.1(Fig. 67)

in 1

;

3. Unscrew the two screws from

the venturi J and remove with

he gas valve (Fig. 68);

4. Unscrew the three screws K on

the air/gas pipe and remove (Fig. 69);

5. Reassemble in reverse order.

Fig. 67 Fig. 68 Fig. 69

18.2.6 Removing the gas valve

1. Carry out step 18.1.1;

2. Remove the air gas manifiold as

in 18.2.1 (Fig. 70);

3. Unscrew the three screws L on

the air/gas pipe and remove (Fig. 71);

4. Unscrew the three screws holding the gas valve on the venturi (Fig. 72);

Fig. 70

5. Remove the gas valve from the venturi. (Fig. 73);

6. Reassemble in reverse order;

7. The gas valve settings will need

to be adjusted (see Section 14.5 page 30);

8. Test for tightness on reassembly

Fig. 71

Fig. 72

Fig. 73

Page 45

18.2.7 Removing the heat exchanger

1. Carry out step 18.1.1;

2. Remove the air gas manifiold as

n 18.2.1 (Fig. 74)

Fig. 74

;

5. Remove the heat exchanger from the boiler by sliding out. (Fig. 77);

6. Reassemble in reverse order.

3. Unscrew the three bolts M from

the main heat exchanger (Fig.

75);

Fig. 75 Fig. 76

4. Remove the flow and return pipes and the condense drain pipe from the heat exchanger. (Fig. 76);

Fig. 77

18.2.8 Removing the spark generator

1. Carry out step 18.1.1;

2. Disconnect the earth cable from

the ignition electrode. (Fig. 78);

Fig. 78

3. Disconnect the ignition electrode, live, neutral and earth cables from the ignitor. (Fig. 79);

Fig. 79

4. Remove the two screws N from

the ignitor and remove (Fig. 80);

5. Reassemble in reverse order.

Fig. 80

Page 46

18.3 Access to the Water Circuit

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

18.3.1 Drain down

DHW : close the DHW inlet tap and open a tap on the installation / CH : Close the flow and return isolating valve and

open the pressure relief valve.

8.3.2 Removing the 3 way valve

1. Carry out step 18.1.1 and 18.1.2;

isconnect the wire from the 3 way valve;

2.D

emove the clip “P2”and the 3 way valve motor (see Figs. 81 and 82)

3.R

nscrew the two screws “P3” (Fig. 86) and remove the 4 clips “Q1

4.U

(see Figs. 83 to 85);

5. Remove the 3 way valve body by pulling it toward you (see Fig. 87);

6. Reassemble in reverse order;

* -

;

Q4”

See the paragraph

18.3.1 before removing the clips.

Fig. 82

Fig. 83

Fig. 85

Fig. 81

Fig. 84

Fig. 87

18.3.3 Removing the float of the flow switch

1. Remove the clip “Q1” fixing the brass connector (see Fig. 83);

2. Disconnect the connecting pipe;

3. Pull down the brass connector and catch

simultaneously the float (see Figs. 88 & 89);

4. Reassemble in reverse order;

Fig. 86

Fig. 88

Fig. 89

Page 47

18.3.4 Removing the secondary heat exchanger

arry out step 18.1.1 and 18.1.2

1.C

emove the 3 way valve motor as in step 18.3.2

2.R

;

3. Disconnect the expansion vessel pipe.

Fig. 90

18.3.5 Removing the pump

1. Carry out step 18.1.1;

2. Lower the electrical box cover as in step 18.1.2;

3. Remove the PCB cover;

4. Remove the pump plug from the control board and

earth plug from earth socket

(see Fig. 92);

4. Unscrew the two fixing screws R and pull the heat

xchanger toward you (see Figs. 90 & 91);

5. Reassemble in reverse order; he heat exchanger is so designed that it cannot be

T remounted incorrectly;

Fig. 91

4. Unscrew the pump nut (see Fig. 93);

Fig. 92

5. Remove the clip S2 on the pump volute (see Fig. 94);

Fig. 94

Fig. 93

6. Pull the pump toward you and remove the clip S3

securing the pressure gauge (see Fig. 95);

7. Reassemble in reverse order.

Fig. 95

Page 48

18.3.6 Removing the pressure relief valve

1. Carry out step 18.1.1 and 18.3.1;

2. Remove the clip securing the valve

(see Fig. 99) and pull it toward you;

eassemble in reverse order; take care

3.R

to ensure the valve is in the correct position;

18.3.7 Removing the expansion vessel

ig. 96

1. Carry out step 18.3.1;

2. Isolate the gas supply and disconnect all

pipe connections;

3. Remove the boiler from the wall

4. Remove the two screws T (see Fig. 97);

5. Unscrew the nut U (see Fig. 98);

6. Pull the expansion vessel toward you to

remove it;

7. Reassemble in reverse order.

18.3.8 Removing the overheat thermostat

1. Remove the casing as in step 18.1.1;

2. Pull off the thermostat connections.

Then remove the thermostat from the pipe by releasing it’s securing clip (see Fig. 99).

Fig. 97

Fig. 99

Fig. 98

18.3.9 Removing the temperature sensors (N.T.C’s)

1. Remove the casing as in step 18.1.1;

2. Pull off the NTC connections. Then

remove the NTC from the pipe by releasing it’s securing clip (see Fig. 100).

Fig. 100

Page 49

18.3.10 Removing the pressure gauge

18.3.11 Removing the pressure switch

1. Carry out step 18.4.6;

2. Remove the pressure gauge by releasing the two

clips V and pulling the pressure gauge out. (see

ig. 101

)

Fig. 101

18.4 Access to the Control System

18.4.1 Removing the P.C.B.s

1. Carry out steps 18.1.1 and 18.1.2;

2. Remove the screw W1 from the electrical box (see

Fig. 103);

emove the casing as in step 18.1.1

1.R

ull off the connections. Then remove the pressure

2.P

;

switch by releasing it’s securing clip (see Fig. 102).

Fig. 102

3. Release the three clips W2 and remove the

electrical box cover (see Fig. 104);

Fig. 103

4. Remove the two screws W3 from the front control

panel and lower the front control panel (see

Fig.

105);

Fig. 104

5. Remove all electrical connections from the display PCB (see Fig. 106);

Fig. 105

Fig. 109

Page 50

6. To remove the display PCB, remove the two crew W3and lift the PCB out (see Fig. 107);

7. Reassemble in reverse order;

Fig. 107

8. To remove the main PCB disconnect all electrical onnections and remove the two screws W5(see

c Fig. 110);

o not forget to swap the EEPROM key when

D removing the old PCB in order to replace it on the new one.

9. Reassemble in reverse order.

Fig. 108

18.4.2 Removing the fuses

1. Carry out step 18.4.1;

2. Remove the fuses “X” (see Fig. 111)

3. Reassemble in reverse order.

NOTE: FUSE

RATING

= 2AMP

FAST FUSE

Fig. 109

18.5 Connecting the external sensor

1. Reach to the main PCB as in step 18.4.1;

2. Install the interface module supplied in the kit

on the main PCB (see Fig. 110)

3. Connect the wires between the external sensor and the interface

(see Fig. 110).

Fig. 110

Fig. 113

Page 51

19. Incorrect function

In case of problem, or when the boiler has displayed an error code, the display flashes 2 digits. Please refer to the table below to diagnose the fault.

For faults 01 and 03, press the reset button 28.

verheating lock out

FAULT

ode

A 03

A 36

A 37

A 39

A 40

A 41

E 02

E 04

E 05

E 06

E 07

E 08

E 09

E 10

E 11

E 12

E 13

E 14

E 15

E 16

E 18

E 20

E 22

E 23

E 29

E30

E33

E 37

E 38

Fault description

Overheating lock out

No flame after safety timer

Flue pipe too high temperature

CPU fault

MCU fault 1

MCU fault 2

Fan error

Pump protect

No flame detection

Anti freezing system, pump on

Anti freezing system, pump and burner on

No water circulation in primary circuit

No water in the primary circuit

DHW sensor open circuit

DHW sensor short circuit

Flow sensor open circuit

Flow sensor short circuit

Return sensor open circuit

Return sensor short circuit

Outdoor sensor open circuit (if fitted)

Outdoor sensor short circuit (if fitted)

Flame lift

Flame detect with gas valve off

Fault air pressure switch

Low extractor speed

Room sensor open circuit

Room sensor short circuit

Floor heating thermostat open circuit (if fitted)

Communication problem with the main PCB

Reset button pressed 5 times in 15 minutes

A appears on the display, the boiler is locked and the reset button illuminates (28). To reset the boiler

Fig. 114

Page 52

19. Incorrect function (continued)

Fault Cause Solution

The boiler doesn’t start

ed indicator alight

Noises in CH system

Radiators rise in temperature During summer season

If these solutions do not cure the fault, call a qualified professional

No gas, no water or no electricity

Air in the gas pipe Purge the air from the gas pipe

Room thermostat switched off Turn the room thermostat up

Air presence in CH system or. Insufficient pressure

Gravity effect in the CH system

Control gas, water and electrical

supply, fuses…

ait for a few minutes

W Press the reset button 28 (Fig. 115) the

ed led goes out and the boiler attempts to

r re-light.

f the red indicator lights too frequently,

I please call your local service centre.

Purge the system of air and increase the system pressure (Section 2, page 6)

Close the heating flow isolating valve (41 Fig. 2, page 5). Don’t forget to open it again before starting the heating.

20. Maintenance

20.1 General remarks

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

1. Check the seals in the water group, and if necessary, replace the gasket and restore the seal to perfect working order;

2. Check the seals in the gas group, and if necessary replace the gaskets and restore the seal to perfect working order;

Visually check the overall condition of the boiler;

4. Visually check the combustion, and if necessary, disassemble and clean the burner;

5. Following inspection 3, disassemble and clean the combustion chamber as necessary;

Following inspection 4, disassemble and clean the

6. injector, if necessary;

7. Clean the primary heat exchanger. (see Section 20.2);

10. Check the correct operation of the flow switches;

11. Check the correct operation of the low pressure switch;

12. Check the diverter valve movement;

Check the correct operation of the gas group safety

13. devices:

- absence of gas or flame safety device (ionisation);

Check that the electrical connections are correct (as

14. described in Section 13, page 27 Fig 38);

15. Check the efficiency of the production of domestic hot water (test the flow rate and temperature rise);

16. Carry out a general inspection of the boiler;

17. Check the flue and termination point;

18. Remove any oxide from the detection electrode by using an emery cloth.

8. Check and adjust the CO

Section 14.3);

9. Check the correct operation of the heating safety devices:

- Overheat thermostat

emissions as necessary (see

20.2 Cleaning the primary exchanger

Cleaning the exhaust side

Remove the air gas assembly (Section 18.2.1). Check that the exhaust passages are free, if there are deposits present, clean the exchanger with compressed air or wash with water

Page 53

20. Maintenance Instructions (continued)

or a vinegar based detergent.

Cleaning the water side

Use detergents that dissolve CaCO3. Leave to act for a short time and then rinse.

20.3 Operational test

ake sure that the detergent does not remain inside the

M exchanger.

Unscrew the lower part of the condensate trap and clean it.

ill it with water and replace.

After carrying out the maitenance operation, fill the heating circuit to a pressure of approximately 1.5 bar and release the air from the system. Also fill the domestic hot water system.

- Place the boiler in operation.

- If necessary, release the air again from the heating system.

- Check the settings, seals and the correct functioning of the system for expelling the products of combustion and drawing combustion air.

- Check the settings and correct operation of all the control, regulation and monitoring components.

- Check that the burner ignites properly and carry out a visual check of the burner flame.

- Check that the 3 bar safety valve is operating correctly.

- Check the operation of the time control and room thermostat (if fitted).

OTE:THESE CHECKS ARE NOT EXHAUSTIVE

ONVE THE BOILER HAS BEEN SERVICED IT IS NECESSARY TO

OMPLETE THE

SERVICE INTERVAL RECORD (SECTION 25, PAGE 61)

Page 54

21. Short spares list

231

110

204

401

101

407

554

537

589

507

543

502

506

531

532

538

709

707

705

DescriptionKey N°

100 BURNER ASSEMBLY

101 BURNER 24KW 61313760

BURNER 30KW 61313763 BURNER 35KW 61314834

200 FAN ASSEMBLY

204 TEMPERATURE PROBE 990686 231 GASKET D:129.4 61306030

400 GAS SECTION

401 GAS SECTION ASSY 61307584

GAS SECTION ASSY 61310129 GAS SECTION ASSY 61315410

407 FAN ASSY 61314434

500 HYDRAULIC BLOCK

502 MOTOR - THREE-WAY VALVE 61302483 506 VALVE KIT 61311597 507 OVERHEAT THERMOSTAT 100 531 AIR SEPARATOR HEAD ASSEMBLY 61304608 532 GASKET KIT 61304618 537 PRESSURE RELIEF VALVE 61312668 538 PUMP + AIR SEPARATOR 15/50 61301964

PUMP + AIR SEPARATOR 15/60 61303461

543 STOPPED WATER THROTTLE 61311745 554

PRESSURE SENSOR 0.8B 61310364

589 WATER/WATER HEAT EXCHANGER 61302409

WATER/WATER HEAT EXCHANGER 61314111 WATER/WATER HEAT EXCHANGER 61311400

G.C N°

Manf. Pt. N°

61010572

Type

...

MINIMA HE

Manf. date

from to

700 ELECTRICAL BOX

705 PRESSURE GAUGE 61313561 707 PRINTED CIRCUIT BOARD 65102353

PRINTED CIRCUIT BOARD ADJUST. 61312782 PRINTED CIRCUIT BOARD CONNECT. 61314958

709 IGNITER 61002105-20

...

Page 55

22. Notes

Page 56

23. Technical data

Model Minima HE 24

E certificate

erformance category

NoX class 5

EDBUK Band (%)

ategory

Heating output 80°C/60°C kW 7 to 24

Heating output 50°C/30°C kW 7 to 26

ariable hot water power Pn max kW

Nominal gas flow rate (15 °C-1013 mbar) min max

Central Heating & DHW flow rate Qn kW 7.5 25

G 20 (NG H -Lacq) 34.02 MJ/m3under 20 mbar Vr m3/h 0.79 2.65

G 31 (Propane) 46.4 MJ/kg 37 under mbar Vr kg/h 0.58 1.94

Membrane Diameter (mm)/marking

G 20 mm without

G 31 (propane) mm 4.4

312-BP-4083

***

(90)

I2H3P

Adjustable heating outlet temperature: °C 25 to 85

Central heating minimum flow rate I/h 300

Central heating circuit maximum pressure Pw max bar

Central heating expansion vessel capacity L 6

Expansion vessel inflation pressure bar 0.7

Adjustable hot water temperature °C 40 to 70

DHW ignition flow rate l/min. 2

DHW specific flow rate (∆T: 30 K) D I/min. 12.0

DHW start minimum pressure

Maximum pressure of DHW circuit Pw max bar

DHW expansion vessel

Electric voltage 230 volt, single phase - 50 Hz

Electrical input power W 150

Electrical protection IPX 4D

Fresh air flow rate required for combustion V m3h. 29

Mass flow rate for combustion products g/s 10.9

Fume temperature (60-80) °C 79

Fume temperature (30-50) °C 60

CO2 G20 % 9.5

CO2 G31 % 10

Dimensions Height / Width / Depth (mm) 720 / 390 / 296

Weight kg 37

Pw min bar

0.5

without

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

Page 57

Model Minima HE 30

CE certificate 1312-BP-4084

Performance category ****

NoX class 5

SEDBUK Band (%) A (90.2)

ategory

Heating output 80°C/60°C kW 9 to 29

eating output 50°C/30°C kW

Variable hot water power Pn max kW 29

Nominal gas flow rate (15 °C-1013 mbar) min max

Central Heating & DHW flow rate Qn kW 9,4 30

G 20 (NG H -Lacq) 34.02 MJ/m3under 20 mbar Vr m3/h 0.99 3.17

G 31 (Propane) 46.4 MJ/kg 37 under mbar Vr kg/h 0.73 2.33

Membrane Diameter (mm)/marking

G 20 mm without

G 31 (propane) mm 4.8

Adjustable heating outlet temperature: °C 25 to 85

Central heating minimum flow rate I/h 300

Central heating circuit maximum pressure Pw max

Central heating expansion vessel capacity L 6

Expansion vessel inflation pressure bar 0.7

Adjustable hot water temperature °C 40 to 70

DHW ignition flow rate l/min. 2

DHW specific flow rate (∆T: 30 K) D I/min. 15.0

DHW start minimum pressure Pw min bar 0.5

Maximum pressure of DHW circuit Pw max bar 10

DHW expansion vessel L without

Electric voltage 230 volt, single phase - 50 Hz

Electrical input power W 150

Electrical protection IPX 4D

Fresh air flow rate required for combustion V m3h. 36

Mass flow rate for combustion products 13.5

Fume temperature (60-80)

Fume temperature (30-50)

CO2 G20 % 9.2

CO2 G31 % 10

Dimensions Height / Width / Depth (mm) 720 / 390 / 360

Weight kg 40

Flue duct type C13 C33 C43 C53

bar

°C

I2H3P

to 32

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

Page 58

Model Minima HE 35

CE certificate 1312-BP-4084

Performance category ****

NoX class 5

SEDBUK Band (%) A (90.1)

ategory

Heating output 80°C/60°C kW 9 to 32

Heating output 50°C/30°C kW 9 to 35

Variable hot water power pn max kW 35

Nominal gas flow rate (15 °C-1013 mbar) min max

Central Heating & DHW flow rate Qn kW 10 33.5

G 20 (NG H -Lacq) 34.02 MJ/m3under 20 mbar Vr m3/h 1.05 3.54

G 31 (Propane) 46.4 MJ/kg 37 under mbar Vr kg/h 0.78 2.60

Membrane Diameter (mm)/marking

G 20 mm without

G 31 (propane) mm 5

Adjustable heating outlet temperature: °C 25 to 85

Central heating minimum flow rate I/h 300

Central heating circuit maximum pressure Pw max bar 3

Central heating expansion vessel capacity L 6

Expansion vessel inflation pressure bar 0.7

Adjustable hot water temperature °C 40 to 70

DHW ignition flow rate l/min. 2

DHW specific flow rate (∆T: 30 K) D I/min. 16.7

DHW start minimum pressure Pw min bar 0.5

Maximum pressure of DHW circuit Pw max bar 10

DHW expansion vessel L without

Electric voltage 230 volt, single phase - 50 Hz

Electrical input power W 150

Electrical protection IPX 4D

Fresh air flow rate required for combustion V m3h. 40

Mass flow rate for combustion products 15

Fume temperature (60-80)

Fume temperature (30-50)

CO2 G20 % 9.1

CO2 G31 % 9.8

Dimensions Height / Width / Depth (mm) 720 / 390 / 360

Weight kg 41

Flue duct type C13 C33 C43 C53

I2H3P

This appliance is suitable for Natural gas or LPG. A gas conversion must be made by a competent person.

Page 59

24. Benchmark Commissioning Checklist

Page 60

23. Service Interval Record

606162

Page 61

Page 62

Page 63

Page 64

TERMS AND CONDITIONS OF GUARANTEE

Please read these terms and conditions which are in addition to any terms and conditions detailed in this book or any registration card supplied with your appliance.

charge will be made to the owner of the appliance if:

• The reason for any service visit is as a direct result of a failure to install the appliance in accordance with the manufacturer’s instructions.

• Your installer does not complete the necessary commissioning process and procedure as detailed in the Installation and Operating Instructions.

• Your appliance is not serviced on or before the 12 month anniversary of installation - this only applies to appliances with a 2 and 5 year guarantee.

• Our service engineer calls as requested and the failure is a non-manufacturing defect.

Failure to pay an invoice for any such occurence will be assumed by MTS that you accept that your appliance has not been installed correctly and understand that any manufacturer’s guarantee has been withdrawn.

On the 12 month anniversary of the appliance installation, you must have it serviced to continue any guarantee offered into the following year. Failure to do

illinvalidate your guarantee and should an MTS

o w

s engineer be required to attend and no proof of service documentation is made available, then MTS

As part of the commissioning process, it is a legal requirement to register all boiler installations or replacements with CORGI. Upon registration a “Certification Number” will be issued followed by a “Declaration of Safety” Certificate. MTS (GB) Ltd cannot be called upon to carry out any work under the manufacturer’s guarantee without proof of registration. The registration number must be quoted when requesting a service visit, and the “Declaration of Safety” Certficate subsequently shown to the service engineer. If the certificate is not made available, the engineer will not work on the appliance and a wasted call charge will be made.

If you have a problem with commissioning on installation, please contact our

1315867a - 05/2005

will charge.

Technical Department on 0870 241 8180

Please remove the completed boiler

commissioning checklist sticker from the

front of the boiler and place in this box

for customer reference

Commercial subsidiary: MTS

Manufacturer: Chaffoteaux & Maury - France

(GB) Limited,

Building, Hughenden Avenue, High Wycombe, Bucks HP13 5FT

MTS

prior notice and accepts no liability for any errors or omission in the information contained in this document.

Chaffoteaux & Maury are continuously improving their products and therefore reserve the right to change specifications without

C&M Minima HE, Minima HE 24 NAT, Minima HE 30 NAT, Minima HE 35 NAT Installation, Servicing And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual