Mikrofill Ethos 30/36, Ethos 42/46, 30/36, 42/46 Instructions Manual
E &OE
Mikrofill Ethos
Condensing combination boiler
Installation & Maintenance Instructions
30/36
42/46
E &OE
Contents
1 SAFETY PROVISIONS.........................1
2 TECHNICAL DATA ..............................2
2.1 Drawing of front view.........................................2
2.2 Technical data.....................................................3
3 INTRODUCTION..................................4
3.1 Function..............................................................4
3.2 Control................................................................4
3.3 Products of combustion.......................................5
3.4 Modulating fan....................................................5
3.5 Multi speed pump................................................5
3.6 Discription ofappliance..........................................5
3.7 Combination models..............................................5
4 INSTALLATION....................................5
4.1 Contents..............................................................5
4.2 Siting the boiler ..................................................6
4.3 Mounting the boiler................................................7
4.4 Air inlet-flue gas outlet connection......................7
4.5 Inlet and outlet air system....................................9
4.6 Influence of exhaust removal on load...................9
4.7 Flue material...........................................................9
4.8 Flue resistance table..........................................10
4.9 Removal of condensation ..................................11
4.10 CH and hot water circulation.............................11
4.10.1 General....................................................11
4.10.2 Connecting the expansion vessel ..............11
4.10.3 Domestic hot water circuit........................11
4.10.4 Multi speed pump.......................................12
4.11 Frost protection................................................. 12
4.12 Connecting the gas supply................................. 12
5 ELECTRICAL INSTALLATION
INSTRUCTIONS................................. 13
5.1 Terminal board ..................................................13
5.2 Wiring diagram................................................. 15
6 COMMISSIONING ............................. 16
6.1 Control panel ....................................................16
6.1.1 Display.........................................................16
6.1.2 Keypad Control............................................16
6.2 Sensors .............................................................17
6.3 Installer's programme...................................... 19
6.4 Filling and venting boiler and CH installation....25
6.5 Initial Operation................................................27
6.5.1 General ........................................................27
6.5.2 Starting up for the first time..........................27
6.6 Adjusting and setting load.................................27
6.6.1 Setting maximum load .............................27
6.6.2 Setting minimum load..............................27
6.7 Conversion to another type of gas...................... 28
6.8 Hot water temperature.......................................28
6.9 Closing down....................................................31
7 Faults ...................................................32
7.1 Cause of faults........................... 34
7.2 Table of solutions..................................36
8 MAINTENANCE............................. ...39
9 USERS' INSTRUCTIONS................ ...41
10 EXPLODED VIEW DRAWING.......42
11 SPARES LIST......................................45
12 GUARANTEE...........................................46
Tables
Table 1, Technical data ...........................3
Table 2, Mikrofill resistance table.........10
Table 3, Hot water ................................11
Table 4, Programme numbers................20
Table 5, CH Water Content...................20
Table 6, Hot water ...............................21
Table 7, Faults ......................................32
Table 8, Other faults .............................33
Table 9, Rotational speed......................28
Table 10, Gas settings...........................28
Table 11, Minimum setting ...................28
Table 12, Maximum setting...................30
Table 13, Possible faults .......................34
Table 14, Fault Finding.........................36
Installation manual MIKROFILL ETHOS
Page 1
1 SAFETY PROVISIONS
Conditions:
MIKROFILL shall not be held responsible for damage arising from inadequate compliance
with the installation instructions.
For service purposes, only original MIKROFILL spare parts should be used
General conditions:
All Mikrofill boilers must be installed by a competent person with regard to the relevant
requirements of the Health and Safety regulations, The Building Regulations, IEE
Regulations, Water Supply (Water Fittings) Regulations, Water Byelaws (Scotland), The Gas
(Installation and Use) Regulations and any local planning requirements.
1. UK Building regulation Part L1 (Domestic) Part L2 (Commercial) in which reference is
made to the following norms:
Directives for existing gas installations compiled by British Gas
2. IM16 Guidance notes on the installation of gas pipework
3. BS6644 Installation of gas fired hot water boilers ratedeinputs above 60kW but not greater
that 2 mW
4. Britisg Standards Code of Practice – BS6880 – Code of practice for low temperature hot
water heating
5. CP342 – Code of Practice part 2 – Centralised hot water supply
The Mikrofill ETHOS range of boilers are built in total compliance with EN
Installation manual MIKROFILL ETHOS
Page 2
2 TECHNICAL DATA
2.1 Drawing of front view
1 = Condense trap end cap
2 = CH flow (22mm)
3 = Domestic hot water (15mm)
4 = Gas
5 = Cold water inlet (15mm)
6 = CH return (22mm)
7 = Air Vent
8 = Manometer
9 = Condense drain outlet
10 = Cable entry
11 = Drain cock
12 = Air intake
13 = Air intake concentric
14 = Flue gas spigot
15 = Air inlet spigot
Installation manual MIKROFILL ETHOS
Page 3
2.2 Technical data
Table 1, Technical data
General
CE Product ID number CE 0063 BL 3615- 2000
Dimensions (h x w x d) 550mm x 450mm x 350mm
Category II2L3P
Type of appliance Ethos
30/36 42/46
CH water content of appliance Litre 2,1 2,7
CH water content heat exchanger hot
water
Litre 1,5 1,5
Weight (empty) Kg 39 41
CH connections supply/return mm 22 22
Gas connection mm 15 15
Hot water, hot/cold mm 15
15
Flue gas connection mm 80 80
Air inlet mm 80 80
Concentric mm 80/125 80/125
Electrical power required kW 0.115 115
IP classification IP44 IP44
Capacity CH Operation
Nominal load (output) kW (min – max) 4.3 – 28.5 5.4 – 38.7
Nominal load (input) kW (min – max) 4.8 – 31.7 6.0 – 43
Max. gas use m³/hour 3.0 4.4
Efficiency at 50/30°C, full load % 106 106
Efficiency at 50/30°C, partial load % 109.5 109.5
Efficiency at 40/30°C, RAL 61 % 110 110
Nominal capacity at 80/60°C kW 4.1 – 27 5.3 – 38
Nominal capacity at 50/30°C kW 4.6 – 30 5.8 – 42
Gas approval HR Label 107 107
NOx emissions, RAL 61 mg/kWh <15 <15
CO emissions, RAL 61 mg/kWh <20 <20
Capacity Hot water
Nominal load (lower value) Kw 4.3 – 36 5.4 – 46
Nominal load (upper value) kW 4.8 – 40.0 6.0 – 51.0
Tap quantity at 60°C ( ?T=50K)
l/min 10 12.9
Tap quantity at 40°C ( ?T=30K)
l/min 17 21.4
WRAS Approval number 0204111
Annual use efficiency for EPC
calculation
% 83 82
Hot water (preset value) °C 60 60
Technical data
CO2 content flue gas % 9
Dew point of the flue gas °C 52
Temperature flue gas at 80/60 (with an
ambient temperature of 20 °C)
°C 75
Permitted resistance exhaust system* Pa Up to 100
PH value of the condensate 4 to 5.5
Available CH pump pressure kPa
15 at ?T20°C 28 at ?T25°C
Maximum supply temperature °C 90
Working pressure CH min/max. bar 1 / 3
Connection pressure sanitary water minmax
bar 0.2 - 10
NOx-class 6
Installation manual MIKROFILL ETHOS
Page 4
3 INTRODUCTION
This manual is intended for the installer/user of the MIKROFILL range of
condensing boilers.This manual contains the necessary information relating to the
installation and settings of the Ethos 30/36 and 42/46.
You need to consult this manual before installation in order to ensure that you carry
out all the work correctly. In addition, it is advisable to keep this manual beside the
boiler, so it is immediately available if needed later.
3.1 Function of the appliance
High efficiency is achieved by means of a stainless steel heat exchanger, in which
the flue gases are cooled to below the condensation point, condense and release
further energy.
This is expressed in the efficiency exceeding 100%. The European method of
calculation assumes an efficiency of 100% for appliances in which provision is not
made for the condensation of flue gases and as a maximum efficiency of 110% in
condensing appliances.
In condensing boilers the flue gases are therefore at a low temperature (below
75°C), a stainless steel or thick-walled aluminium (1) HR [HE] approved flue
system or purpose designed plastic pipe needs to be used.
(1) When using an aluminium flue pipe, it is advisable to fit a condensation trap in
the flue system, to prevent pollution by aluminium corrosion.
The appliance is approved in accordance to all associated European norms (CE),
and the Netherlands requirements for Clean Air (SV), high efficiency (107% HR)
and the quality mark (Gas) as well as the quality mark for hot water (hot water class
CW) and as reheater for solar panels (NZ approval).
3.2 Control
The boiler can be controlled by way of a conventional
thermostat, or a modulating electronic room thermostat
(open therm), which can control the boiler output and
modulate between 12% and 100% of the total output of
the boiler.
The heat output is continuously adjustable ensuring that
the output of the boiler maintains a constant
temperature in the home irrespective of weather
conditions and provides hot water (combination boilers
only) at a constant temperature.
This variable heat output can also be achieved by
means of the built-in weather-compensation, by way
of an independent control or in conjunction with the
above thermostats. All forms of control can be used
with a conventional time clock.
MTC
15
16 17 18 19 20 21 22 23
ETHOS
20
30 90 20 10 0
-10
-20
Ambient temperature
°C 40 50 60 70 80
CH water temperature
°C
supply
return
Installation manual MIKROFILL ETHOS
Page 5
3.3 Products of combustion
As a result of the variable combustion and the burner used, the results achieved for
combustion comply with the strictest norms in Europe. Sedbuk A Rated, Ultra low Nox, Ultra
low CO.
3.4 Modulating fan
An energy saving 24 volt high efficiency fan is used with variable speed and current use.The
fan revolves more slowly when the heat requirement is less, thus saving electricity.
3.5 Multi-speed pump
The appliance is fitted with a Grundfos pump (type UBS 15 – 60 HP) provided with a 3
speed switch for regulating the speed to enable the correct flow rate to be selected.
3.6 Description of appliance
The appliance is suitable for supplying a central heating installation. It has a variable
capacity between 12 and 100%.
3.7 Combination Models
These boilers have a built-in heat exchanger with a limited provision for hot water supply. All
connections are internal, while a built-in flow restrictor provides a maximum quantity of hot
water maintaining a hot water temperature of approximately 60°C.
The hot water is set at 60°C to prevent contamination with “Legionella” bacteria.
4 INSTALLATION
4.1 Contents
Installation & Users’ Manual
Vent key
Mounting bracket
2 spare fuses
3 spare burner plate nuts for fixing the burner plate (fixed on the front of the gas valve)
Strainer syphon with tightening nut and packing
Check the contents immediately on receipt.
Any damage must be reported to the supplier immediately.
Mikrofill appliances are completely assembled
Installation manual MIKROFILL ETHOS
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4.2 Siting the boiler
:
Mikrofill appliances are suitable for all gas
groups G20.
The flue, whether single or concentric, must be
installed in compliance with the current flue
recommendations BS5440
Combination boilers should be sited as close as
possible to the hot water draw off point to avoid
excessive water wastage.
The installer will need to select and install an
expansion vessel which will be sized according to
performance requirements, along with a pressure
relief valve.
Installation manual MIKROFILL ETHOS
Page 7
For maintenance and service purposes the front
and underside of the appliance need to be
accessible; both sides need to be at least 20mm
from a wall or cupboard wall.
The following need to be available in the room
where the appliance is to be mounted
a. 240v 1ph Electric.
b. A suitable drain for condensation water.
c. The wall on which the appliance is going to be
mounted must be capable of bearing the weight of the
appliance.
d. ETHOS boilers incorporate a modulating fan.
Although noise levels are minimal care should be
taken in siting the boiler to reduce disturbance from
noise.
4.3 Mounting the boiler
a. Using the mounting bracket, mark the holes for the
mounting plate and determine the position for
connection of the inlet and outlet pipes..
Warning! 1.
Make sure when you mark the position of the bracket
that it is level.
Warning! 2
The head of the fixing bolt, must not be more than 6
mm.
b. Secure the mounting bracket to the wall using screws
and plugs.
c. Mount the boiler.
4.4 Air inlet-flue gas outlet connection
General
There are 2 options of flue connection:
A.: separate air inlet and flue outlet;
B.: concentric connection (pipe in pipe)
A. Separate air inlet and flue outlet.
The optimum connection for air inlet and flue gas removal is achieved by using a corrosionresistant inlet system.
The dimension of the flue gas outlet pipe is 80 mm; the air inlet is similarly 80 mm.
The air inlet can be placed on either the left or right hand side of the flue gas outlet pipe.
?
Installation manual MIKROFILL ETHOS
Page 8
B. Concentric connection , a set is available for a concentric connection: air inlet 125 mm and
flue gas outlet 80 mm diameter.
Always place the plastic inlet connection on top of the mouth of the air inlet pipe. This plastic
connecting piece prevents damage to the appliance if there is moisture present in the inlet pipe
The air inlet with an 80 mm diameter, must be closed with the seal supplied with it.
4.6(T)
1 = ETHOS 30/36
2 = ETHOS 42/46
kW
40 35 30 25 20 15 42
Load
100
200
300
400
500
( Pa )
Resistance
1
2
Installation manual MIKROFILL ETHOS
Page 9
4.5 Air inlet and flue outlet system.
The MIKROFILL boiler is a room sealed appliance that does not use any oxygen from the
room in which it is installed; the casing is air tight, so that oxygen is provided only through
the air inlet pipe. The boiler must not be operated without the casing in place.
Note that horizontal parts need to have a gradient of 1% towards the boiler (1 cm per 1 m
length). If this is overlooked, condensation can collect in the flue gas outlet pipe which can
cause problems.
The resistance of the inlet and outlet system is 100 Pa in instances where the resistance is
greater than 100 Pa the maximum output of the boiler will be effected please refer to 4.6(T).
4.6 Influence of exhaust removal on load
The following table gives the ratio between the load and the resistance of the inlet and outlet
resistance of the system.
Up to a resistance of 100 Pa the load will remain near enough equal, with greater resistances
this changes with respect to the values on the type plate.
The resistance and change in the load influence only the maximum load and not the minimum
load.
Take account of possible load changes with hot water production and the transmission
calculation.
4.7 Flue material
The appliance must only be connected to systems manufactured from approved flue material
and must incorporate water tight seals to eliminate leakage of condensate.
To avoid exterior nuisance pluming (mist) we thoroughly recommend vertical flueing.
Installation manual MIKROFILL ETHOS
Page 10
4.8 Flue resistance table
The load of the appliance is influenced by the resistance of the air inlet and outlet system
through the gas-air connection of the control of the appliance.
With a resistance up to 100 Pa., the load will be equivalent to what is shown on the type plate
of the appliance. The flue pipe induced draught is: 3 Pa/vertical metre.
Table 2, Flue resistance table
Example of calculation
Boiler type: 30/36 ETHOS
Air inlet pipe: diameter 80 mm; horizontal length: 5 m; vertical 25 m; 2 x 90° bend
Flue gas outlet pipe: diameter 80 mm; horizontal length 5 m; vertical 25 m; 2 x 90° bend
Concentric vertical flue terminal 80/125
Air inlet: Resistance
90° bend: 2 pieces 2 x 1.0 2.0 Pa
Straight pipe : 30 m. 30 x 0.8 24.0 Pa
Flue gas outlet
90° bend: 2 pieces 2 x 2.0 4.0 Pa
Straight pipe : 30 m. 30 x 2.0 60.0 Pa
Vertical terminal 4.5 Pa
94.5 Pa
Total resistance is now 94.5 Pa minus the vertical flue pipe induced draught of 3 Pa/vertical
metre therefore (25 x 3 Pa = 75) = 19.5 Pa (thus below 100 Pa); so that the capacity of the
boiler is not changed by the resistance.
Concentric Flue System (mm) Resistance inlet-outlet system
[Pa]
Part
ETHOS 30/36 ETHOS 42/46
Vertical Terminal 80/125 4.5 12.0
Horizontal Terminal 80/125 3.0 8.0
straight pipe/m 80/125 1.8 4.0
45° bend 80/125 0.9 2.0
90° bend 80/125 1.8 4.0
Two Pipe System (mm) Resistance inlet-outlet system
[Pa]
Air Inlet Part
ETHOS 30/36 ETHOS 42/46
straight pipe/m 80 0.8 2.2
45° bend 80 0.5 1.2
90° bend 80 1.0 2.0
Flue Gas Outlet
Vertical terminal 80 4.5 12.0
Horizontal terminal 80 3.0 8.0
straight pipe/m 80 2.0 4.0
45° bend 80 1.0 2.0
90° bend 80 2.0 4.0
Installation manual MIKROFILL ETHOS
Page 11
4.9 Removal of condensation
The condensation outlet is on the underside of the appliance, on the right, and has a ¾”
diameter hose; place this flexible hose in the drain with an open connection .
Only use plastic parts for the condensation water outlet. Metal pipes are not permitted.
The appliance is provided with an in-built siphon, therefore the connection from the appliance
can be directly linked with the water supply in the house.
WARNING: blockage of this outlet can cause damage to the appliance. The guarantee for the
appliance does not cover any damage that arises in this way. In the correct situation the
condensation water flows away visibly, for example via a tundish.
The appliance is constructed in such a way that if the siphon becomes blocked the appliance
switches off before damage can occur to the burner.
4.10 Central heating and hot water circulation
4.10.1 General
If plastic pipes are used for supply and return, for radiators or under-floor heating, the pipes
should incorporate an oxygen diffusion barrier. In the absence of this barrier it is essential that
a Mikrofill air and dirt seperator or similar appliance is installed. This is good practice even
on steel/copper systems. This prevents contamination of the heat exchanger with system
debris and magnetite caused by oxidation of the pipework. The MIKROFILL guarantee may
be invalidated by failure to comply.
4.10.2 Connecting the expansion vessel.
Combination boilers
Combination boiler versions require an expansion vessel, safety relief valve and system
isolating valves. These can be supplied by Mikrofill.
System boilers
An expansion vessel needs to be fitted with a volume suited to the contents of the central
heating installation and static pressure; the expansion vessel is preferably fitted in the water
return pipework.
4.10.3 Domestic hot water circuit (Combination boilers only)
The boiler incorporates a domestic hot water flow control valve which must be adjusted
according to table 3 below.
Connect the cold water supply according to the current UK water regulations (April 2000); it
is advisable to fit a Mikrofill WRAS approved “quick fill loop” to enable recharging of the
boiler water system
Table 3, Hot water class
Appliance Setting HW class
ETHOS 30/36 10 l/min 5
ETHOS 42/46 12.9 l/min 6
Installation manual MIKROFILL ETHOS
Page 12
To achieve a tap water temperature of 45°C or higher within 30 seconds, the hot water pipe
between the boiler and the outlet must be not more than approximately 20 metres long.
4.10.4 Multi speed pump
The pump has a multi speed regulator which is set at the highest level: in the models ETHOS
30/36, 42/46, setting II will usually be sufficient: Warning: Do not use level I, because the
flow rate will be insufficient.
The appliance has a built-in pump control with a delayed switch-off time of 3 minutes as
standard.
If more heat is demanded the pump will operate at maximum capacity; when the heat demand
ceases the pump will run for a further 3 minutes, and then stop.
Similarly the pump will run for 1 minute every 24 hours to reduce the possibility of the pump
seizing due to debris in the system.
This 24-hour period begins the moment that the electrical power to the appliance is switched
on.
4.11 Frost protection
The appliance has built-in frost protection, which activates the the central heating pump when
the water temperature in the boiler drops to 8°C.
At a boiler water temperature of 5°C, the burner ignites and burns until the feed temperature
reaches 10°C.
4.12 Connecting the gas supply
The gas supply must be suitable sized to ensure that there is no more than 1mbar of pressure
drop from the meter to the appliance, this is a mandatory requirement
Check the gas pipe for leaks. If an inert gas i.e. nirogen is to be used for the gas test,
precautions must be taken to ensure that the maximum pressure in the gas system is below
100mbar.
For the fitting of the gas pipe and valve only, to test for gas leaks, a pressure of 100 mbar is
briefly permitted.
Purge the gas pipe carefully, before the appliance is used for the first time.
Installation manual MIKROFILL ETHOS
Page 13
5 ELECTRICAL INSTALLATION INSTRUCTIONS
Connection to mains voltage.
The appliance has an earthed mains plug. The appliance needs to be connected to an earthed
240v single phase supply. Minimum cross-section is 3 x 0.75 mm²; the electrical installation
must of course conform to the current regulations (see page 1).
A terminal board is provided for the further connections..
Care must be taken to ensure that the isolator for this mains cable is accessible at all times, so
that, for servicing for example, the appliance can be disconnected from the power supply.
5.1 Terminal board
The following parts can be connected to the terminal connection board provided, see also the
diagram below:
1-2 PWM pump cable for the modulating signal for a modulating domestic or CH pump .
3-4. External sensor for weather compensation. If desired, the CH installation can be
regulated on the basis of the external temperature: if the external temperature drops,
the water temperature in the boiler is increased; the water temperature in the boiler is
therefore not subject to external influences such as the “sun” in the room, or an open
fire.
This regulation can be supplemented by a room thermostat.
If a room thermostat is not fitted, a wire loop needs to be fitted between terminals 5
and 6.
5-6. Room thermostat/ Time clock/BMS control can be connected here.
Maximum switch capacity is 2 VA.
7-8
Modulating thermostat (open therm)
Mikrofill has a series of modulating thermostats in its range, with which the boiler
modulation can be controlled.
9-10-11 External three-way valve - 24V only. If an external three-way valve is connected for
an indirect cylinder for instance, the three-way valve motor needs to be connected
here; in which case gate 9 is the neutral terminal, and terminals 10 and 11 are intended
for the 24 V AC Power open/Power closed.
These terminals can also be used for other 24V AC supply not exceeding 3VA
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