TriStar OPTIMA 28 SB, OPTIMA 28 CB, Tristar OPTIMA 28 SB, Tristar OPTIMA 28 CB Installation Instructions Manual

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Page 1

OPTIMA 28 CB AND 28 SB

WALL MOUNTED GAS BOILERS

INSTALLATION

INSTRUCTIONS

Page 2

pag. 2

8 Control panel

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

pag. 17

8.1 Starting the appliance

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

pag. 17

8.2 Use of controls

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

pag. 17

8.3 Reading and setting boiler parameters

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

pag. 19

9 Operation with external probe

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

pag. 20

9.1 Installing and connecting external probe

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

pag. 20

9.2 Setting heating curve

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

pag. 20

9.3 Adjusting heating curve

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

pag. 20

10 Combustion analysis

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

pag. 21

10.1 Conversion from natural gas to propane

or viceversa (with KITGPL02)

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

pag. 22

11 Adjusting maximum working capacity

of boiler in heating function

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

pag. 23

12 Checking boiler safety equipment

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

pag. 23

13 Useful tips

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

pag. 23

14 Temporary failure and blockage of appliance

. . . . . . . . .

pag. 24

14.1

Identification codes of irregularities causing a

temporary failure or fault

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

pag. 24

14.2 List of fault codes

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

pag. 25

15 Examples of installation

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

pag. 26

16 Accessories

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

pag. 27

17 Periodic appliance maintenance and cleaning

. . . . . . . . .

pag. 28

18 Short parts list

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

pag. 31

19 Balanced flue kits

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

pag. 33

1 Warnings

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

pag. 3

1.1 Use of anti-freeze liquid

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

pag. 4

1.2 Features under floor heating system

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

pag. 4

1.3 Safety advice

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

pag. 4

2 General features

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

pag. 5

2.1 Winter operation

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

pag. 5

2.2 Summer operation (CB models)

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

pag. 5

2.3 Hard water areas

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

pag. 5

3 Technical features of the appliance

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

pag. 6

3.1 Overall dimension and connections

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

pag. 7

3.2 Hydraulic diagram

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

pag. 7

3.3 Features of circulator/generator load loss

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

pag. 8

4 Unit assembly

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

pag. 8

4.1 Hydraulic connection

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

pag. 8

4.2 Flue system

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

pag. 9

5 Access to boiler

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

pag. 14

6 Electrical connections

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

pag. 15

7 Preliminary checks to be carried out before appliance

start-up

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

pag. 16

7.1 Loading the system

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

pag. 16

7.2 Starting the circulating pump

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

pag. 16

7.3 Checking system pressure and possible

water recovery

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

pag. 16

Page 3

pag. 3

1 WARNINGS

This booklet, together with the user and service manual should be kept by the user and must always accompany the boiler even when passed on to another owner or user and/or when transferred to another system. Read the instructions and warnings in this booklet and in the user manual carefully, as they provide important directions for safe installation, usage and maintenance.

- This boiler is used to heat water at a temperature lower than boiling point at atmospheric pressure. It must be connected to a heating system and/or a domestic hot water system at the limits of its performance and its power. Any other use of this boiler must be considered incorrect and therefore hazardous.

- Installation, maintenance and repair must be carried out by a CORGI Registered Installer and be in accordance with the relevant requirements of the current Gas Safety (Installation and Use) Regulations, the Building Regulations (Scotland)(Consolidation), the Local Building Regulations, the current I.E.E.Wiring Regulations and the bye laws of the Local Water Undertaking. Where no specific instruction is given reference should be made to the relevant BRISITH STANDARDS CODES OF PRACTICE. For Ireland install in accordance with IS 813 “Installation of Gas Appliance”

B.S. Codes of Practice

Standard Scope

BS 6891 Gas Installation BS 5546 Installation of hot water supplies for

domestic purposes. BS 5449 Part.1 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary

equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water

centrai heating systems.

ARNING – The addition of anything that may interfere with

the normal operation of the appliance without the express written permission of Trianco Ltd could invalidate the appliance warranty and infringe the Gas Safety (Installation and Use) Regulations.

Incorrect installation may cause harm to people, animals and pro-

perty. The manufacturer is not liable for damage caused by incorrect installation and by non-observance of the instructions accompanying the boiler

Installation, maintenance and any other operation must be carried

out in compliance of current regulations and instructions supplied by the manufacturer.

Installation is the purchaser's responsibility.

The boiler is supplied in a carton pack; when it is removed, ensure that the appliance is complete and that all the parts are supplied.

The packing components (clips, plastic bags, polystyrene foam, etc) must be kept out of reach of children, since they are a hazard for them.

The technical notes and instructions contained in this document are to help fitters install the system correctly.

Any repair should be carried out using solely original spares and operations involving the removal of the appliance must only be carried out by qualified engineers. Failure to abide by the above exempts the manufacturer from any liability and may jeopardise the the safety of the unit.

It is forbidden to climb on to the unit.

INSTALLATION AND INITIAL START-UP OF THE BOILER MUST BE CARRIED OUT BY QUALIFIED PERSONNEL, IN ACCORDANCE WITH CURRENT NATIONAL REGULATIONS ON INSTALLATION AND ANY DIRECTIONS FROM LOCAL AUTHORITIES AND PUBLIC HEALTH BODIES.

When turning the boiler on or off, the fan may make a slightly louder noise because of the rapid increase or reduction in the number of rotations.

The expansions of the materials that make up the unit, due to rises or falls in temperature, may cause slight tapping noises. This may normally occur after the boiler is turned off or on.

An excessively high flow-rate of domestic hot water may cause a slight noise in the circuit and a drop in temperature at the domestic water outlet.

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pag. 4

1.1 USE OF ANTIFREEZE LIQUID

1.2 FEATURES OF UNDER FLOOR

HEATING SYSTEMS

● If you smell gas:

- do not operate electrical appliances

- extinguish any fires

- close the stopcock upstream of the meter

- open the windows and ventilate the room

- call your local authorised engineer

● Do not store or use flammable materials near the boiler.

● Do not obstruct intake/exhaust terminals.

● To guarantee boiler efficiency and correct operation, it is

imperative to have yearly maintenance, and combustion analysis every two years, carried out by qualified engineers, and to have the system booklet prepared, as stipulated by law.

● It is forbidden to touch the boiler either with bare feet

and/or with wet parts of the body.

● In order to clean the outside parts, turn off the boiler turn

off the power at the isolating switch. Clean with a damp cloth. Do not use detergents and/or harsh liquids, or toxic products.

● In order to carry out any work on the boiler, do not mount

it on chairs, stools, ladders or unstable stands.

● Before carrying out any work on the boiler always turn

the power off at the isolating switch

● The user is forbidden to carry out any maintenance work

on the boiler that must be carried out by a specialised engineer.

● In the case of structural work or maintenance near the

pipes, flue systems or any accessories, switch off the appliance and, when the work is completed, have the system checked by a qualified engineer to ensure the system is in good working order.

1.3 SAFETY ADVICE

In floor systems, the use of plastic pipes without protection against penetration of oxygen through the walls can cause corrosion of the system's metal parts (metal piping, boiler, etc), the formation of oxides and bacterial agents.

To prevent this problem, it is necessary to use pipes with an "oxygen-proof barrier", in accordance with standards DIN 4726/4729.

If pipes of this kind are not used, keep the system separate by installing heat exchangers or those with a specific system water treatment.

In floor systems, a system safety thermostat must be installed to protect against overtemperature calibrated at around 45°C (see wiring diagram on page 14).

TRIANCO is not liable for damage caused to the unit or the system due to failure to comply with the above.

If antifreeze substances are used in the system, check carefully that they are compatible with the aluminium that forms the body of

the boiler. In particular, DO NOT USE ordinary ETHYLENE GLYCOL, since it is corrosive in relation to aluminium and its alloys, as well being toxic. Trianco suggests the use of suitable antifreeze products and in the correct dose, which will prevent rust and incrustation taking place.

Periodically check the pH of the water-antifreeze mixture of the boiler circuit and replace it when the amount measured is lower than the limit stipulated by the manufacturer.

DO NOT MIX DIFFERENT TYPES OF ANTIFREEZE

TRIANCO is not liable for damage caused to the boiler or system as a result of the use of incorrect antifreeze or additive substances.

Page 5

pag. 5

The TriStar OPTIMA boiler is a sealed-type electronic condensing gas wall mounted boiler with high seasonal efficiency.

The burner, of premix type, guarantees high efficiencies and safe combustion at all power ratings, with minimal pollutant emissions.

The electronic board provides for a periodic selfdiagnostic of the functions, with indications of any irregularities or failures by means of a code that appears on the control panel display.

It is simple to use and has fully automatic operation, and thus user operations are reduced to the basic simple operations.

The production of domestic hot water is always activated and has priority over the heating function.

The external temperature probe (OPTIMAZER) must be fitted to ensure maximum running efficency.

The boiler is started and regulated automatically so as to meet the requirement of the heating system.

With the outside temperature probe, the system’s water temperature is regulated automatically according to the heating curve set, guaranteeing maximum comfort in all conditions.

DOMESTIC HOT WATER DRAW OFF (CB MOD.)

When calling for domestic hot water, the boiler, by means of an appropriate sensor, automatically switches over in order to guarantee supply of the correct amount of water at the desired temperature.

Regulation of the domestic water temperature is also carried out precisely and automatically by the boiler’s electronics.

The domestic hot water comfort function is activated automatically at the end of every withdrawal and guarantees a quick response for subsequent withdrawals for the programmed time.

2 GENERAL FEATURES

2.1 WINTER OPERATION

The boiler is started and regulated automatically so as to meet the domestic water requirement.

Switching from summer to winter operation and viceversa may be carried out by hand or automatically (if external probe present) depending on the outside temperature set.

2.2

SUMMER OPERATION (CB MODELS)

If the boiler is to be installed in a area recognised for having hard water, it is recommended that a suitable water treatment device is installed in the mains supply to the boiler. The water hardness can be determined by using the standard test paper or by contacting your local water authority.

2.3

HARD WATER AREAS

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3 TECHNICAL FEATURES OF THE APPLIANCE

Key to boiler models

CB = Combi Boiler SB = System Boiler

Operating gas NAT. GAS (G20) LPG (G31)

OPTIMA model CB SB CB SB

Maximum heat output Qmax (80°/60°C) kW 28,0 28,0 28,0 28,0 Minimum heat output Qmin (80°/60°C) kW 5,6 5,6 7,3 7,3 Maximum heat output (50°/30°C) kW 29,7 29,7 29,7 29,7 Minimum heat output (50°/30°C) kW 6,1 6,1 8 8 Maximum heat range kW 28,7 28,7 28,7 28,7 Minimum heat range kW 5,7 5,7 7,5 7,5 Working efficiency at max output (80°/60°C) % 97,6 97,6 97,6 97,6 Working efficiency at max output (50°/30°C) % 103,5 103,5 103,5 103,5 Working efficiency at 30% max output (Average T=50°C) % 107,0 107,0 107,0 107,0 Working efficiency at min output (80°/60°C) % 98,2 98,2 97,3 97,3 Working efficiency at min output (50°/30°C) % 107,0 107,0 106,7 106,7 Flue losses with burner in operation % 2,1 2,1 2,1 2,1 Flue losses with burner extinguished % <0,1 <0,1 <0,1 <0,1 Shell losses % 0,3 0,3 0,3 0,3 Flue Gas temperature °C 73,0 73,0 73,0 73,0 %CO2 in dry fumes % vol 9,8 9,8 11,5 11,5 Class of NOx emissions (EN 483) Cl. 5 5 5 5 Combustion efficiency % 97,9 97,9 97,9 97,9 Flue Gas mass range at nominal capacity kg/h 43,5 43,5 43,5 43,5 Residual flue gas discharge head Pa 73 73 73 73 Gas consumption (15°C, 1013 mbar) m3/h 3,0 3,0 1,17 1,17 Max. production of condensation water l/h 2,4 2,4 2,4 2,4 Water content l 2,4 2,4 2,4 2,4 Available head (∆T=20°C) kPa 28 28 28 28 Max. operating pressure bar 3 3 3 3 Expansion vessel volume l 10 10 10 10 Expansion vessel preload press. bar 1 1 1 1 Nominal G20 natural gas press. mbar 20 20 -- -Nominal G31 LPG gas press. mbar -- -- 37 37 Max. heating temperature °C 90 90 90 90 Min. heating temperature °C 20 20 20 20 Specific domestic water range (∆T=30°C) l/min 13,4 – 13,4 – Max. domestic circuit pressure bar 8 – 8 – Min.domestic water withdrawal l/min 2,3 – 2,3 – Max. domestic hot water temperature °C 60 – 60 – Min. domestic hot water temperature °C 30 – 30 – Power supply V/Hz 230/50 230/50 230/50 230/50 Max. power consumed W 110 110 110 110 Degree of electrical protection IPX4D IPX4D IPX4D IPX4D Weight kg 56,5 52 56,5 52 Noise at 1m at nominal capacity dB(A) 41,8 41,8 41,8 41,8 Appliance class ΙΙ 2H 3P Appliance type

B23, C13, C33, C43,C53, C83

Appliance CE Certificate No.

Page 7

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465

365

221

181

67 67 65

120

155

175 (gas)

890

827

37545 45

- posizione attacchi con gruppo idraulico installato

bar

AC G D B

bar

AG D B

KEY:

1 - Burner 2 - Manual air valve 3 - Boiler shell 4 - Gas valve 5 - Boiler water pressure sensor 6 - Automatic air valve 7 - Pump 8 - Return temperature sensor 9 - Safety valve 10 - Pressure gauge 11 - Expansion vessel 12 - Drain tap 13 – System Filling Valve 14 - Domestic water pressure switch 15 - Domestic water temperature sensor 16 - Bypass 17 - Delivery temperature sensor 18 - Three-way valve 19 – Condensation Trap

A - Heating Flow B - Domestic hot water Flow C - Gas inlet D - Domestic cold water inlet E - Heating return

A - Heating delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4”

B - Heating Return

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4”

C - Domestic hot water flow**

. . . . . . . . . . . . . . . . . . . . . . . 1/2”

D - Domestic cold water inlet ** . . . . . . . . . . . . . . . . . . . . . 1/2”

E - Precut for air intake pipe

. . . . . . . . . . . . . . . . . . . . . . . . ø80 mm

F - Collar for concentric fume pipe

. . . . . . . . . . . . . . . . . ø60/100mm

G - Gas Inlet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4”

H - Holes for mounting plate to wall . . . . . . . . . . . . . . . . ø8mm

** = present on CB models only

3.2 HYDRAULIC DIAGRAM

3.1 OVERALL DIMENSIONS AND CONNECTIONS

OPTIMA CB

OPTIMA SB

fig. 3.1-1

fig. 3.2-1

fig. 3.2-2

* position of connections

with hydraulic unit installed

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pag. 8

The boiler must be installed in an accessible position that complies with the dimensions set out in the drawing below, so as to make any maintenance and cleaning operations easier.

For positioning use the template included in the pack and, with a spirit level check the boiler is horizontal. Then mark and drill the holes for mounting the wall plate and the hydraulic connections. Then mark and drill the holes for the boiler mounting plate, insert appropriate rawlplugs in them, fix the plate in position and attach the boiler to it.

Caution: Before mounting the boiler, remove rear cross pieces shown in figure 4-

For optimum performance after installation this Boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS7593 “Treatment of water in domestic hot water central heating systems. It is also advisable to install suitable stop gate valves on the systems delivery and return piping.

DIMA DI CARTONE

4.1 HYDRAULIC CONNECTION

3.3 FEATURES OF CIRCULATOR / GENERATOR LOAD LOSS

4 UNIT ASSEMBLY

400

Caution: the pressure relief valve is set at 3 bar therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward and preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water / steam could discharge from the pipe.

For hydraulic connection of the boiler, use the equipment kit and follow the directions given on the attached instruction sheet.

The 10 Ltr expansion vessel supplied with the boiler is suitable for a system volume of approx. 140 Ltr. An additional vessel will be required for system volumes above this, following this formula:

V= 0,07 x C

V = Expansion vessel volume (Ltr) C = Water system volume (Ltr)

fig. 4-1

fig. 4-2

fig. 4-3

0,0 0,4 0,8 1,2 1,6 2,0

Q [m3/h]

[m c.a.]

[kPa]

Prevalenza disponibile all’impianto alla massima velocita’ del circolatore

Area di lavoro del circolatore

MAX

TECHNICAL FEATURES OF STANDARD CIRCULATOR INSTALLED

Capacity absorbed

max (W) min (W) Maximum speed 91 73 Minimum speed 49 40

Note: Circulator speed is regulated automatically by boi-

ler control board

Head available to system at maximum circulator speed

Circulator working area

TEMPLATE

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pag. 9

B,C

H,I

The following guidelines indicate the general require-

ments for siting balanced flue terminals. Recommendations for flues are given in BS 5440 Pt.1.

If the terminal discharges onto a pathway or passage-

way, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway.

If a terminal is less than 2 metres above a balcony,

above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

4.2 FLUE SYSTEM

Terminal position with minimum distance mm

A Directly below an openable window, air vent

or any other ventilation opening. 300

B Below gutter, drain/soil pipe. 150

C Below eaves. 200

D Below a balcony/car port roof. 200

E From vertical drain pipes and soil pipes. 75

F From internal or external corners. 300

G Above adjacent ground or balcony level. 300

H From a surface facing a terminal. 600

I Facing a terminal. 1200

J From opening (door/window) in carport

into dwelling. 1200

K Vertically from a terminal on the same wall. 1500

L Horizontally from a terminal on the same wall. 300

M Above an opening, air brick, opening

window etc. 300

N Horizontally to an opening, air brick,

opening window etc. 300

Vertical Flues - minimum distance to edge of terminal mm

P Above the roof level (to base of terminal). 300

Q From adjacent wall to flue. 300

R From adjacent opening window. 1000

S From another terminal. 600

Important: since the TRISTAR OPTIMA is a condensing boiler, exhaust temperature is very low; therefore it is normal for part of the residual water vapour in the exhaust fumes to be capable of condensing in the flue pipe

You are advised to pay attention to the following:

a - to the positioning of the exhaust terminals (they

may drip and also produce a ploom of condensation)

b - to the incline of the flue pipe so as to avoid con-

densation becoming stagnant;

c - to the correct positioning of the condensation col-

lection parts;

d - to connecting the condensation drain correctly.

The TRISTAR OPTIMA boiler is a type C certified Appliance (sealed boiler).

Connection of the flue exhaust pipes is made according to the diagrams attached.

For the parts to use, please refer to the TRIANCO catalogue of boiler installation accessories.

IMPORTANT: As with all flues the kit must be installed taking due account of the current issue of BS5440 parts 1 & 2 and timber frame housing REF IGE/UP/7/1998. Also note that the requirements will vary depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with recommendations of the relevant codes of practice.

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REAR OUTLET

HORIZONTAL BALANCED FLUE

HIGH LEVEL HORIZONTAL BALANCED FLUE

765mm 30" MAX 315mm 12.5" MIN

175 MIN

4000mm (SEE NOTE)

MAX/MIN WALL THICKNESS IS WITH KIT SUPPLIED

EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

765mm 30" MAX

315mm 12.5" MIN

175 MIN

1095 MAX

4000 mm

MAX/MIN WALL THICKNESS AND HEIGHT IS WITH KIT SUPPLIED

EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

HORIZONTAL BALANCED FLUE KIT (SEE PAGE 32)

IMPORTANT: As with all flues the kit must be installed taking

due account of the current issue of BS 5440 parts 1 & 2 and timber frame housing REF IGE/UP/7/1998. Also note that the requirements will vary depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with the recommendations of the relevant codes of practice.

EXPOSED PIPE: any pipe exposed to the elements should be protected with a suitable material, and maintained regularly.

Installing the Balanced Flue Kit

1 Having decided the position of the boiler, accurately mark

out the position of the terminal and boiler fixing holes using the template provided. Cut a ø120mm hole through the wall to accept the terminal, and drill 2 ø8mm holes to accept rawlplugs and mounting bolts.

2 Fix the boiler to the wall using the wall-mounting bracket.

3 Pass the terminal through the wall, and fit the internal wall

seal to the terminal.

4 Fit the ø60mm (black) seal to the inner spigot on the boiler

flue off-take (Fig. 1).

5 Fit the ø100mm and Ø60mm (blue) seal into the 90° con-

centric bend.

6 Fit the 90° concentric bend into the boiler flue off-take, and

secure in position with clamp.

7 Slide the terminal into the 90° bend ensuring it is pushed

home firmly, and ensure wall seal is fitted against wall.

8 Fit the external wall seal to the terminal.

9 To extend the terminal length, use the 500mm concentric

pipe and cut to length, ensuring the inner is cut 20mm longer than the outer.

NOTE: For High Level Balanced flue Kit

1 Measure vertically 950mm (max) from position of the cut-

out on the template to give position of terminal required.

2 Cut the 1000mm concentric pipe to required length. Fit the

ø100mm and ø60mm (blue) seal into the pipe.

3 Fit the concentric pipe into the boiler flue off-take, and secu-

re in position with clamp.

4 Fit 90° concentric bend into pipe, and fit remaining compo-

nents as above.

IMPORTANT:

When installing the flue system, it is important that the flue assembly inclines slightly up from the boiler. This will allow any condensation formed to run back to the condense drain

BOILER OFF-TAKE INNER SPIGOT

ø60mm SEAL (BLACK)

Fig. 1

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pag. 11

R/H SIDE OUTLET

HORIZONTAL BALANCED FLUE

HIGH LEVEL HORIZONTAL BALANCED FLUE

MAX/MIN WALL THICKNESS IS WITH KIT SUPPLIED

EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

687mm 34" MAX

417mm 16.5" MIN

4000mm (SEE NOTE)

175 MIN

765mm 30" MAX

315mm 12.5" MIN

175 MIN

1095 MAX

4000 mm

MAX/MIN WALL THICKNESS AND HEIGHT IS WITH KIT SUPPLIED

EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

L/H SIDE OUTLET

HORIZONTAL BALANCED FLUE

HIGH LEVEL HORIZONTAL BALANCED FLUE

MAX/MIN WALL THICKNESS IS WITH KIT SUPPLIED EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

650mm 25.5" MAX 437mm 17" MIN

4000mm (SEE NOTE)

175 MIN

437mm 17" MAX

175 MIN

1095 MAX

4000 mm

MAX/MIN WALL THICKNESS IS WITH KIT SUPPLIED EXTRA PIPES CAN BE PURCHASED TO EXTEND TO 4 MTRS

Note: 500mm Extension pipe must be used for left-hand side

Page 12

pag. 12

VERTICAL BALANCED FLUE

6000mm MAX

VERTICAL BALANCED FLUE KIT (SEE PAGE 32)

Installing the Balanced Flue Kit

1 Having decided the position of the boiler, accurately mark

out the position of the boiler fixing holes using the template provided. Drill 2 Ø8mm holes to accept rawlplugs and mounting bolts.

2 Cut a Ø150mm hole in the ceiling and roof.

3 Determine the flue length required, ensuring the maximum

permissible flue length is not exceeded. If it is necessary to cut one of the pipes to achieve the required ensure the inner is cut 20mm longer than the outer, and both inner and outer are de-burred.

4 Fit Ø60mm (black) seal to the inner spigot on the boiler flue

off-take (Fig. 1).

5 Fit the Ø100mm and Ø60mm (blue) seal into the concentric

flue pipes.

6 If possible, pre-assemble the entire flue on a flat surface,

ensuring all sections are pushed firmly home. Secure bottom section to boiler with clamp.

7 Fit a roof flashing sleeve to the roof (not supplied), and

insert Vertical Flue Terminal through flashing from the outside.

8 Starting at the appliance end assemble the extension pipes,

ensuring each joint is pushed firmly home. Ensure none of the flue joints are situated within the joist space.

9 Fit ceiling plate centrally around pipe, ensuring that the

outer flue pipe has a minimum clearance of 25mm from any combustible material. Pack space with glass fibre insulation.

10 Fit wall clamp around terminal and secure to roof member,

ensure weight of terminal is carried by the wall clamp and not the roof flashing sleeve.

11 Ensure flue is adequately supported.

IMPORTANT: FLUE SEALING

TO FIT FLUE PIPES TOGETHER, IT IS ESSENTIAL TO APPLY A THIN BEAD OF LUBRICANT (E.G. WASHING UP LIQUID, VASELINE) AROUND ALL RUBBER SEALING RINGS.

AS THE FLUE SYSTEM OPERATES UNDER POSITIVE PRESSURE, IT IS ESSENTIAL TO ACHIEVE A TOTAL SEAL ON ALL FLUE JOINTS.

Page 13

pag. 13

A+B = 2500mm MAX

C+D = 4000mm MAX

NOTE: For each additional elbow reduce straight lengths by the relevant elbow dimension 90° 1500mm and 45° 750mm

90° BEND = 1000mm 45° BEND = 750mm

Page 14

pag. 14

In order to access the electrical panel, proceed as follows:

- disconnect voltage to appliance

- open boiler front control panel cover

- remove upper screws A from front cover

- gently lift cover and pull towards you.

- remove screws V1 and V2 that secure control panel (fig 5-2)

- Lower the control panel until it stops approximately 45°

- - To unlock it and bring it down completely, lift up front control panel cover until it is supported on control panel and lower them both together (fig. 5-3)

5 ACCESS TO ELECTRICAL PANEL FOR CON-

NECTING ADDITIONAL UNITS

CONTROL

PANEL

BOILER

CONTROL

PANEL COVER

fig. 5-2

fig. 5-3

fig. 5-1

In order to connect any external controls and wire the controls into the specific terminals on terminal board M (fig. 5-5).

The wires must pass under panel P and retained using cable clips F.

fig. 5-4

fig. 5-5

To wire in any external valves it is necessary to gain access to the inside of the control panel. To do this, remove rear screws C and take off protection panel P.

For electrical assembly and connection, follow the directions given on the instruction sheets attached

fig. 5-6

Page 15

pag. 15

After having fixed the boiler to the wall and connected all the hydraulic connections from the system, make the electrical connections.

To gain access to the board, follow the directions in paragraph 5, “Access to boiler”, pass all electrical cables through one of the cable ducts.

For related connections to the board, consult the wiring diagram below.

IMPORTANT: In connecting the appliance to the mains, strictly observe the phase-neutral polarity stated in the diagram. Electrical wiring to the boiler must be in accordance with current I E E wiring regulations. NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only. In the event of replacement, use a cable with the same features as that fitted (section 3 x 0.75 - maximum external ø8mm)

X50

X40

X30

X15

X14X13X12X11

X10

X2 X1

Boiler pump

230 VAC

Diverting valve

230 VAC

Configurable connection (230 VAC)

Ionisation probe

Gas valve mains

gas 230 VAC

Ignition

electrode

Ignition

transformer

230 VAC

AC 24V

Transformer

Fan motor

2 3

4 5

2 3

4 5 6

2 3

4 5 6 7 8 9 10 11 12

earth

Fuse

electrical supply

~ 230V 50 Hz

high-temp. safety

therostat

for floor heating

230V 24V

GND

HALL

+UB

PWM

heating

BROWN

WHITE

BLACK/RED

Domestic Hot water

USER

INTERFACE

BOILER BOARD

AGU 2.303A153

LMU 54.030A153

❶

= Accessories available on request

To be fitted by the installer

main

switch

Warning: respect the indicated polarity phase/neutral when connecting the mains

To be fitted only with floor heating

X10-01 X10-02 X10-03 X10-04 X10-05 X10-06

X3-01X3-02X3-03X3-04 X2- 0 1X2-02X2-03X2-04X2- 05

12121212311212121

212121212121

X1-01X1-02

12312

DHW pressure switch (CB model)

or DHW tank thermostat (SB model)

DHW tank thermostat (SB model)

DHW temperature probe (CB model)

Return flow temp. probe Boiler temp. probe

Room thermostat

Programmer QAA73

DHW tank NTC temperature sensor

❶

External probe QAC34/101

❶

CR TA SB SE TB

PWM boiler pump

Avaiable only for SB models

Warning: they cannot be used at the same time

6 ELECTRICAL CONNECTIONS

fig. 6-1

Page 16

pag. 16

Before starting the boiler, check that:

- the gas line is not closed upstream of the appliance;

- the gas and water stopcocks are open;

- the appliance has been correctly connected to the mains electricity and in such a way that the phaseneutral polarity is observed;

- the system has been correctly filled with water (see point 7.1).

In order to fill the system, gain access to the inside of the sealed chamber, loosen the automatic escape valve cap on the automatic air vent (fig. 7.1-1) and screw V of the manual escape cock on the top of the exchanger (fig.7.1-2) and gradually open the filling valve tap.

The boiler operates correctly at a water pressure between 1 and 1.5 bar this should be checked on the pressure gauge located on the lower side of the boiler. Once all the air has been vented from the system, close the escape cocks and, when the desired pressure has been reached, close the filling valve tap.

Control pressure gauge

manual air vent

automatic air vent

7.1 LOADING THE SYSTEM

7 PRELIMINARY CHECKS TO BE CARRIED

OUT BEFORE APPLIANCE START-UP

The water pressure is checked periodically on the pressure gauge described in paragraph 7.1.

In order to reset the pressure to within the preset values, gradually open the filling valve; when the desired pressure has been reached, close the tap.

If, during normal operation, the appliance frequently looses pressure or the boiler safety valve comes into operation, consult your installer or service engineer.

7.3 CHECKING SYSTEM PRESSURE AND POSSIBLE WATER RECOVERY

On initial start-up, the pump may be slightly noisy. This may be caused by a small amount of air still trapped in the pump. In order to let it out, proceed as follows:

- Loosen cap A (adjacent fig.) and let out any air present.

- fasten cap A.

If pump not turning:

- remove screw A

- attempt to turn rotator knob using the device on the shaft, taking care not to apply excessive force so as not to damage it

- replace cap A checking that there are no water losses

Before proceeding, take suitable precautions to avoid possible scalds from hot water and risks of damage to components due to water losses from pump.

7.2 STARTING THE CIRCULATING PUMP

fig. 7.1-2fig. 7.1-1

fig. 7.1-4

fig. 7.2-1

Page 17

pag. 17

Press switch A: the switch pilot light and the display will go on; after a few seconds the boiler is ready for operation.

The boiler temperature appears on the display.

HEATING TEMPERATURE REGULATION KNOB (B)

When the heating is activated, with this knob the heating circuit water temperature is set.

The figure set is displayed for a few seconds directly on the display, after which the boiler temperature reappears.

If the external probe is fitted, by operating knob B the calculated ambient temperature is displayed for a few seconds, after which the boiler temperature reappears.

DOMESTIC HOT WATER TEMPERATURE REGULATION KNOB (C)

For models CB and for the SB ones with a boiler unit with NTC sensor connected, domestic hot production is always activated.

The figure set is displayed for a few seconds directly on the display, after which the boiler temperature reappears.

In model SB used for heating only, regulation has no effect.

Note: The settings made with knobs B and C

(Heating and domestic hot water temperatures) remain unchanged even after power supply failure.

MODE

BUTTON

The MODE button makes it possible to switch from summer to winter operation, and viceversa. Pressing the button activates or deactivates the heating indicated by the LED F going on. If the external temperature probe is connected to the boiler, switching from winter operation (heating + domestic hot water) to summer operation (domestic hot water) is made automatically when the outside temperature is higher than 20°C.

Mode

Auto

8 CONTROL PANEL

A - On/off switch

B - Heating temperature setting control knob

C - Domestic hot water temperature setting

control knob

D - MODE button

E - Boiler automatic operation indicator LED

F - Heating operation indicator LED

G - RESET button

H - Burner operation indicator LED

I - Fault alarm LED

L - SELECT button

M -Boiler temperature reading indicator LED

N - Boiler operating/diagnostic phase reading

indicator LED

O - MAINTENANCE button

P - Display

°C

bar

Reset

Select

Mode

Auto

8.1 STARTING THE APPLIANCE

8.2 USE OF THE CONTROLS

fig. 8-1

fig. 8.1-1

fig. 8.2-1

fig. 8.2-2

fig. 8.2-3

Page 18

pag. 18

In this case the LED AUTO lights up, while the LED F, if lit, indicates winter operation; if not lit, it indicates summer operation. In the case where you wish to deactivate automatic switching, press the MODE button (the LED AUTO goes out).

SELECT

BUTTON

When in operating phase, the digital display indicates the boiler delivery temperature (LED °C lit and continuous). As well as this, by repeatedly pressing the SELECT button, the following can be displayed in rotation:

1 - reading of domestic hot water temperature (flas-

hing LED °C)

2-–.–

boiler operating phase reading (LEDS °C and bar off); at that moment the active phase is shown by codes that have the following meanings:

0 - pause, no heat request 10 - system heating mode 11 - domestic hot water production mode

4 - Fault code or information on boiler operating sta-

tus (alternating flashing between LEDS °C and

bar).

By pressing the SELECT button once again, the display returns to reading 1; in all cases, after some minutes the boiler temperature display is reset.

RESET

BUTTON

(RESETTING THE APPLIANCE)

After an operating irregularity, the boiler stops for safety reasons (fault: the red LED I goes on). To reset the operation, action must be taken by holding down the fault RESET button for around 2 seconds. If the fault has to be checked again, check that the gas stopcock and those possibly fitted on the heating delivery and return pipes and domestic water inlet and outlet pipes are open and that the boiler water pressure is correct; if the fault persists, call your installer or service engineer.

°C

bar

Select

MAINTENANCE

BUTTON

The maintenance button is used by the maintenance engineer to perform the calibration and required for correct operation of the appliance and UNDER NO CIRCUMSTANCES MUST IT BE OPERATED BY THE USER.

If it is accidentally pressed, do not press any other button and switch off and relight the boiler using button A. Further uses of the maintenance button are described in paragraphs 10 and 12.

Reset

fig. 8.2-4

fig. 8.2-5

fig. 8.2-6

Page 19

pag. 19

In order to read and set the values of some boiler parameters the SELECT button is used. By keeping it pressed, a series of letters (A, b, C, d and P) appear in rotation on the display. By releasing the button when the letter appears and pressing it again briefly the desired parameter is activated (a number appears to the right of the letter). In order to return the display to standard parameter (1) (boiler delivery temperature), enable parameter 1. After approximately 8 minutes from the last operation performed. The display will return to parameter 1.

The series of parameters which can be accessed are as follows:

One letter only:

A1 - letter of boiler delivery temperature (°C) A2 - letter of domestic hot water temperature (°C) A3 - not used A4 - letter of boiler operating phase A0 - Technical value according to programming of the

board

b1 - letter of boiler return temperature (°C) b2 - not used b3 - not used b4 - letter of outside temperature (°C) b5 - not used b6 - not used b7 - second zone circuit temperature (°C)

C1 - letter of ionisation current value (µA) C2 - letter of number of fan revolutions (thousands

and hundreds)

C3 - fan PWM (%) C4 - letter of boiler relative heat output value (%) C5 - not used C6 - not used

d1 - Setpoint calculated on basis of operation in

domestic hot water or heating

d2 - value of calculated temperature of boiler

delivery (°C)

d3 - Display of value of ambient temperature set (°C);

If external probe is not present, value is fixed at

20°C.

d4 - setting of value of domestic hot water temperatu-

re (°C)

d5 - not used d6 - maximum fan speed in heating function

Parameters that can be set:

In order to alter the value of the parameter, use at the buttons SELECT (to increase it) and MAINTENANCE (to decrease it). In order to store the new value in the memory, hold down the SELECT button until the display value flashes twice, and then release the button.

P3 - not used P4 - not used P5 - Value of slope of heating curve P6 -Value of parallel shift of heating curve

8.3 READING AND SETTING BOILER PARAMETERS

Page 20

pag. 20

9 EXTERNAL PROBE

9.1 INSTALLING AND CONNECTING EXTERNAL PROBE

9.2 SETTING HEATING CURVE

9.3 ADJUSTING HEATING CURVE SET

When the external probe is used, the electronic board calculates the boiler delivery temperature according to the outside temperature. The ratio of these temperatures is summarised in the diagram in figure 9.2-1.

THIS MUST BE FITTED OTHERWISE BOILER WILL NOT PERFORM

AT THE MAXIMUM EFFICENCY.

The most suitable curve should be chosen according to the design temperature and the type of building. To set a new curve (see “parameters that can be set” in paragraph above):

- access parameter P5

- set the preselected value

- store to set value in memory

To mount the external probe:

- remove protective cover as shown here

- insert probe cable through hole intended to be used. We recommend mounting a rubber cable duct if the rear route is used (see ref. 1), a suitable cable holder if the lower one is used (see ref. 2); cable duct and cable holder are not supplied.

If solution 2 is used, remove the lower section the protective cover.

- connect the wires to the probe and the boiler following the wiring diagram on page 14.

-20 -15 -10 -5 0 5 10 15 20

Temperatura esterna mediata (°C)

Valore della pendenza della curva di riscaldamento

Curve di riscaldamento

Valore della pendenza della curva di riscaldamento impostato in fabbrica= 15

1/2 H

min. 2,5 m

In order to adjust the heating curve, parameter P6 is used. In this mode, the heating curve is shifted in parallel so as to change the delivery temperature calculated (see example in fig. 9.2-2).

To set the shift, proceed as follows (see “parameters that can be set” in paragraph above):

- access parameter P6

- set preselected value

- store set value in memory

fig. 9.1-1

fig. 9.1-2

fig. 9.1-3

fig. 9.2-1

DO NOT INSTALL EXTERNAL PROBE IN POSITIONS INDICATED BELOW:

CORRECT INSTALLATION POSITION:

PROBE SHOULD BE INSTALLED ON A NORTH ORNORTH EAST FACING WALL AND SHELTERED FROM THE EFFECT OF THE SUN’S RAYS AND FROM OTHER HEAT SOURCES

value of slope of heating curve heating curve

Factory-set value of slope of heating curve = 15

Mean outside temperature (°C)

Calculated flow temperature (°C)

Page 21

pag. 21

Analysis of maximum heat capacity:

Run the boiler in maximum operation capacity by holding down MAINTENANCE button for slightly over 7 seconds (the display changes the presentation flashing alternately the boiler delivery temperature and the number 1 00 while the fault red LED l flashes); from this moment the boiler will operate at maximum in heating mode

T - Capacity regulator clo-

sure cap 1 - Pressure regulator 2 - Capacity regulator

In order to perform combustion analysis, a particular function must be activated by means of the MAINTENANCE button. When this is activated, the three-way valve switches towards the system (CB models), the boiler temperature limits are inhibited and the single maximum safety temperature (85°C) remains activated. if a second mixed zone is present the set value is 55°C.

In cases of floor radiant panel systems, for CB models, in order to feed the circuit with hightemperature water, it is necessary to discharge the heat in the domestic hot-water circuit (see below). In the SP models (heating only), stop boiler operation when temperature exceeds 45°C and resume when system has cooled.

THE BOILER IS ALREADY PRESET: THIS INFORMATION IS ONLY FOR CHECK ONLY

Combustion analysis is carried out in heating mode; if however there is a situation in which it is difficult to use the heating system (eg. in summer or with a floor radiant panel system), it is possible to use the domestic hot water circuit by proceeding as follows:

- rotate the control panel forward (para. 5“access to boiler”)

- with a screwdriver, release the three-way valve motor M fastening spring, taking care to hold the motor in one hand (fig. 10-2)

- remove the motor, open one or more hot water taps in order to discharge the heat produced by the boiler in calibration and perform analysis, following the directions below.

On completion of the analysis, close the taps, replace the motor, push it downwards and insert the fastening spring back in its housing.

10 COMBUSTION ANALYSIS

To make a further adjustment of the heating curve, use heating knob B. With the knob in intermediate position, the calculated ambient temperature is 20°C. In relation to this position, by rotating the knob a variation of ±1 0°C in the calculated ambient temperature is produced (see example in fig. 9.2-3).

Tamb= 10°C

Tamb= 30°C

-20 -15 -10 -5 0 5 10 15 20

Tamb= 20°C

- 31°C

+ 31°C

-20 -15 -10 -5 0 5 10 15 20

fig. 9.2-2

fig. 10-3

fig. 10-2

fig. 9.2-3

fig. 10.1

Preparations for performing analysis:

Remove screw V in figure, plate and corresponding gasket in order to access the sockets for analysis analysis and connect the fume analyser probe therein (fig. 10-1).

Mean outside temperature (°C)

Calculated flow temperature (°C)

Mean outside temperature (°C)

Calculated flow temperature (°C)

Exhaust

Gases

Air

Page 22

pag. 22

Analysis at minimum heat capacity:

From the above situation, to run boiler operation to minimum capacity, rotate domestic hot water temperature regulation knob C anticlockwise up to end of stroke (the display changes the presentation flashing alternately boiler delivery temperature and the number 0): from this moment the boiler will operate at minimum.

Wait for the boiler to stabilise, perform combustion analysis by checking to the settings shown below:

If the values found are different, proceed as follows:

- Turn gas valve pressure regulator 1 (figure 10-3): clockwise to increase, anticlockwise to decrease value of CO

read

(given the sensitivity of the screw, minimal adjustments

will be sufficient);

- wait several seconds until the CO

2 is stabilised, then check its

value and if necessary repeat theoperations.

On completion of calibration, recheck CO2values at maximum output.

If the values found remain between the limits shown in the table, no further calibration must be made.

After these operations, it is advisable to check the gas capacity at the meter, following the directions stated in the table of technical details. N.B.: After completing the checks, the boiler must be returned manually to normal operation by holding down MAINTENANCE button for approximately 2 seconds.

Wait for the boiler to stabilise and perform combustion analysis by checking what is described below:

If the values found are different, proceed as follows:

- Turn gas valve capacity regulator 2 (figure 10-3): clockwise to increase, anticlockwise to decrease value of CO

2 reading

(given the sensitivity of the screw, minimal adjustments will be sufficient);

- wait several seconds until the CO

2 is stabilised, then check its

value and if necessary repeat theoperations.

To convert boiler FROM NATURAL GAS TO PROPANE GAS, proceed as follows:

- disconnect voltage to appliance

- close gas tap

- access internal parts in sealed chamber (see para. 5 “access to boiler”)

- unscrew ring nut A shown in figure and loosen threaded connection

- insert capacity reducer B as shown in figure below

- check condition of gasket and, if necessary replace it.

- reconnect gas pipe and open gas tap

- reconnect voltage to appliance

- start boiler, check tightness of gas pipe and make gas valve calibration, observing the figures given in the tables shown in the paragraph above.

- refit the cover of the sealed chamber and the other parts of the boiler covering

- replace the gas identification plate showing new settings

To convert the boiler FROM LPG GAS TO NATURAL GAS, proceed as described above and remove capacity reducer B.

10.1 CONVERSION FROM NATURAL GAS TO

PROPANE OR VICE VERSA (WITH KITGPL02)

Nominal heat capacity kW 28,7

Check calibrations values natural gas

G20 % vol 9,3÷9,7

MAXIMUM OUTPUT

LPG

G31 % vol

10,8÷11,3

Minimum heat capacity kW 5,7

Check calibrations values natural gas

G20 % vol 8,8÷9,2

MINIMUM OUTPUT

LPG

G31 % vol

10,4÷10,8

fig. 10.1-1

fig. 10.1-2

fig. 10-4

Page 23

pag. 23

To check the boiler’s safety equipment the MAINTENANCE button is used.

By holding it down for around 4 seconds, the letters SF and the boiler delivery temperature appear alternately on the display. From this moment, the appliance will operate at the maximum capacity set in heating function (see paragraph above) until boiler safety devices come into operation (boiler goes into fault, red LED l on).

To reset operation, hold RESET button down for around three seconds.

12 CHECKING BOILER SAFETY EQUIPMENT

In order to guarantee production of domestic hot water at all times, do not turn off the boiler but use the room thermostat (or timer thermostat) or deactivate the heating by pressing the MODE button (LED F goes out). This will ensure that the antiseize function and other functions designed for the appliance safety and comfort still operate. Note: the boiler’s main exchanger is made of aluminium alloy. Only use additives in the water circuit with this type of material.

If the system is to remain off for long periods at temperatures below zero, it is advisable to drain off the water. This operation is essential if there are no antifreeze additives in the system.

13 USEFUL TIPS

The boiler is modulating in type, and therefore the capacity of the boiler does not need adjustment since it self regulates in an optimum way in terms of heat required, detected by means of the appliance’s temperature sensors.

11 ADJUSTING MAXIMUM HEAT CAPACITY OF

THE BOILER IN HEATING FUNCTION

Page 24

pag. 24

TEMPORARY FAILURE

Temporary failures are due to some operating parameters being momentarily exceeded and are different from those of faults in that manual reset by means of the RESET button is not necessary. Temporary failure is indicated by the alternating flashing of the LEDS °C and bar. If the operating conditions return to normal figures, the appliance is reset and resumes normal operation, otherwise the status of the fault is checked (LED I on). The resetting of the functions may be automatic or may require the operator to do it, depending on the case. For example, if the system pressure falls below the minimum figure (see para. 7.3), once restored, the boiler resumes its functions.

FAULT WITH THE APPLIANCE

When an operating irregularity occurs, the boiler stops and goes into “fault”, displaying this condition by the red LED I going on and the LED °C and bar alternately flashing. Numbers appear on the diplay representing the fault code (see below). An attempt may be made to reset the operation by holding

down the RESET button for around 2 seconds, after which the boiler performs a self-diagnostic cycle and possible restart; if the fault persists, call your local installer or service engineer.

FAULT/TEMPORARY FAILURE CODE DISPLAY

A fault or temporary failure is indicated by a three-figure code appearing on the display. Two of them can be presented on the display and then the code is indicated, showing alternatively the first figure and then the other two (eg. for the code 154, the display will be shown indicating first 1 and then 54). The display is also accompanied by the alternate flashing of the LEDS °C and bar. This display is repeated twice followed by an interval of around 7 seconds in which the delivery temperature is indicated. The code and delivery temperature are displayed in turn continuously.

14 TEMPORARY FAILURE AND FAULT WITH

APPLIANCE

They indicate the type of irregularity by means of a three-figure number

14.1 IDENTIFICATION CODES OF THE IRREGULARITIES CAUSING A TEMPORARY FAILURE OR FAULT

CODE CAUSE EFFECT / REMEDY

1 11 Delivery T°C > Max T°C permitted burner turned off, circulator in post-circulation 1 19 Boiler water pressure too low Restore pressure by following directions in para. 7.3

(in SB models only)

1 33 does not light or show flame attempt to restart boiler; after three attempts goes to ‘fault’

1 54 Return T°C > delivery T°C or

difference in temperature boiler turned off, circulator in post-circulation between delivery and return too high or boiler temperature increase too rapid

1 64

No water circulation in boiler -Air in system; blow it out (para. 7.1)

-Circulator blocked; follow directions in para. 7.2

Page 25

pag. 25

14.2 LIST OF FAILURE OR FAULT CODES

Code Description

10 Short-circuit of external probe

20 Delivery probe:

Display 20 alternating to oo = probe short-circuit

Display 20 alternating to - - = probe disconnected

28 Incorrect setting made by means of remote control QAA73 (fume probe, not used)

40 Return probe:

If display in b1 = oo : probe short-circuit

If display in b1 = - - : probe disconnected

50 DHW probe: boiler does not produce domestic hot water (CB mod. and SB mod. with boiler unit with NTC sensor)

Display domestic hot water temperature (see use of SELECT button in para.8.2);

If display = oo : probe short-circuit

If display = - - : probe disconnected

61 Disturbances in remote control

62 Line or remote control breakdown

78 Incorrect configuration of pressure sensor

81 Bus line short-circuit or disconnected (not used)

82 Incompatible LPB address (not used)

91 Fault inside board

92 Fault inside board

100 Incorrect configuration of clocks in connection with RVA (not used)

110 Fault due to overtemperature

111 Temporary failure due to overtemperature

119 Boiler water pressure too low (for SB models only)

133 No flame after end of safety time (repeats attempt to light three times then goes to fault)

134 Flame disappears during operation

135 Fan malfunction

140 Incorrect setting of segment in connection with RVA (not used)

148 Incompatibility of parts in connection via LPB (not used)

151 Fault inside board

152 Incompatible setting of parameter values (not used)

153 Manually activated safety fault (reset boiler by holding down RESET button for two seconds)

154 Return temperature higher than delivery temperature or boiler temperature increase too rapid

160 Fan does not reach required speed

161 Fan exceeds maximum speed set

164 No water circulation in boiler (for CB models only)

Page 26

pag. 26

CR / TA

CR TA

Togliere

il ponte

15 EXAMPLES OF INSTALLATION

CR / TA

OPTIMA CB AND SB MOD.

SE = external probe CR / TA = QAA73 programmer / room thermostat SI = high-temp. safety therostat for floor heating

SINGLE HEATING CIRCUIT CONNECTION WITH AMBIENT THERMOSTAT OR QAA73 PROGRAMMER

fig. 15-1

WITH ROOM THERMOSTAT WITH QAA73 PROGRAMMER

CR / TA

OPTIMA SB MOD.

SE = External probe CR/TA = QAA73 programmer / room thermostat YD = 3-way valve for hot water production TB = Domestic hot water tank temperature probe SI = high-temp. safety therostat for floor heating

SINGLE HEATING CIRCUIT CONNECTION WITH ROOM THERMOSTAT OR QAA73 PROGRAMMER AND AN EXTERNAL TANK FOR DOMESTIC HOT WATER PRODUCTION

fig. 15-2

WITH ROOM THERMOSTAT WITH QAA73 PROGRAMMER

CR TA

Togliere

il ponte

Remove

link

Remove

link

terminal board

(see para. 5)

terminal board

(see para. 5)

terminal board

(see para. 5)

terminal board

(see para. 5)

Page 27

pag. 27

16 ACCESSORIES

QAA73 P

ROGRAMMER

cod. E1226/92

Modern remote control, according to weekly and hourly setting (with yearly date setting), which has functions of monitoring boiler and programming, zone sensor, alarm indicators and advanced diagnostics.

fig. 16-1

NATURAL GAS TO PROPANE CONVERSION KIT

cod. KITGPL02

fig. 16-2

Page 28

pag. 28

CONTROL

PANEL

BOILER

CONTROL

PANEL COVER

CCESS

CCESSTTOO

BOILER

To access internal parts of the boiler, proceed as follows:

- isolate electrical supply to boiler

- open boiler front control box cover

- remove upper screws A from front cover

- gently lift up cover and pull towards you.

fig. 17-1

Annual Servicing

For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. Ensure that the boiler is cool Ensure that both the gas and electrical supplies to the boiler are isolated. Caution: All gaskets removed must be checked and possibly replaced if they are damaged or worn.

To access inside of sealed chamber, remove screws D and take off front panel D1.

When replacing front panel D1, first attach the top side of panel on to sealed chamber and then move panel into position and replace screws.

fig. 17-2

17 SERVICING THE BOILER

- remove screws V1 and V2 that hold control panel in position (fig. 17-3)

- to lower control panel completely lift up front control box cover until it is supported on the control panel and then lower both panels together (fig. 17-4)

fig. 17-3

fig. 17-4

Page 29

pag. 29

- Distributor D is fixed to conveyor B; if necessary, distributor can be removed and cleaned (fig. 17-7);

- Remove screws F1, remove mixer G from fan and clean it inside, using a brush or compressed air (fig. 17-8).

- If it is deemed necessary, clean fan F with a brush..

To prevent dust possibly infiltrating the fan motor bearing, it is advisable NOT TO USE compressed air.

fig. 17-7

fig. 17-8

- Remove pneumatic and electrical fan connections and disconnect gas pipe.

- Remove nuts E1, unthread MIXER (E) - FAN (F) unit (fig. 17-6).

- Extract internal choke G and inspect O-ring; with the aid of a brush or compressed air, clean the choke (fig. 17-6).

- Remove nuts A1, loosen nuts A2, remove conveyor B and extract burner C (fig. 17-6).

- With the aid of a brush, clean burner as shown in fig. 17-7; take care not to damage outside of burner.

fig. 17-6

- Gently push the left-hand side of the sealed chamber until it detaches

fig. 17-5

OILER

SHELL

MAINTENANCE

Page 30

pag. 30

- remove connection of condensation drain from sea-

led chamber

- remove siphon load pipe from boiler drain cock

- unscrew fixing screw S from siphon support clamp

- extract siphon from bottom of boiler

- When siphon has been removed, undo parts 1, 2 and 3 (fig. 17-15); check that in cap 2 there are no deposits, and if necessary remove them With a brush clean siphon channels.

- Remove flue H from boiler shell (fig. 17-6) and with the aid of a brush and vacuum cleaner, clean between the exchange rungs (fig. 17-9)

When the parts are replaced, take care to reinsert them in the correct order; pay special attention to inserting the choke correctly in the mixer (the side recess of the choke should match the mixer guide, see fig 17-10).

fig. 17-9

Injector

Location

slot

O-ring

Location

rail

Gas mixer unit

fig. 17-15

fig. 17-10

fig. 17-11

AINTENANCE

AINTENANCEOFOF

CONDENSA

TION

DRAIN

SIPHON

fig. 17-12

fig. 17-13

fig. 17-14

Page 31

pag. 31

18 SHORT PARTS LIST

OPTIMA CB

23 40 45

21 19 32

61 16 41

49 36 37

POS. DESCRIPTION CODE

10 BOILER BOARD A160/1

12 USER BOARD A161

16 TRANSFORMER CFE01001

19 IGNITION ELECTRODE BFE01019

21 DETECTION ELECTRODE BFE01064

23 CENTRIFUGE FAN W150/4

32 IMMERSION SENSOR S300/1

36 CIRCULATOR P158

37 AUTOMATIC ESCAPE VALVE G207/1

39 WATER GAUGE G603/3

40 GAS VALVE UNIT GRVAL001

41 CIRCULATOR CONSENSUS

DIFFERENTIAL PRESSURE GAUGE L998099

45 ACTUATOR M227

46 HEAT EXCHANGER G1325/4

49 DOMESTIC WATER DIFFERENTIAL

PRESSURE GAUGE CFM01043

61 IGNITION TRANSFORMER T134

00 EXTERNAL PROBE S736/1

SHORT PARTS LIST

46 00

Page 32

pag. 32

OPTIMA SB

21 19

23 39

56 16 36

35 35/1

10 12 00

POS. DESCRIPTION CODE

10 BOILER BOARD A160/1

12 USER BOARD A161

16 TRANSFORMER CFE01001

19 IGNITION ELECTRODE BFE01019

20 ELECTRODE GASKET CFG01009

21 DETECTION ELECTRODE BFE01064

23 CENTRIFUGE FAN W150/4

32 SENSOR S300/1

35 CIRCULATOR P158

35/1 AUTOMATIC ESCAPE VALVE G207/1

36 MINIMUM PRESSURE GAUGE Q122

38 WATER GAUGE G603/3

39 GAS VALVE UNIT GRVAL001

56 IGNITION TRANSFORMER T134

00 EXTERNAL PROBE S736/1

SHORT PARTS LIST

Page 33

pag. 33

19 BALANCED FLUE KITS

72356567

1 23

Item Part No. Description Qty

1 510021 terminal 1

2 510023 90° concentric bend 1

3 510031 clamp with seal 1

4 510029 ø60mm seal (Black) 1

5 510027 ø60mm seal (Blue) 2

6 510028 ø100mm seal 2

7 510033 Wall seal 2

8 510026 500mm concentric flue pipe 1

Item Part No. Description Qty

1 510025 1000mm concentric flue pipe 1

2 510027 ø60mm seal (Blue) 1

3 510028 ø100mm seal 1

Item Part No. Description Qty

1 510023 90° concentric bend 1

2 510027 ø60mm seal (Blue) 1

3 510028 ø100mm seal 1

Item Part No. Description Qty

1 510024 45° concentric bend 1

2 510027 ø60mm seal (Blue) 1

3 510028 ø100mm seal 1

Item Part No. Description Qty

1 510026 500mm concentric flue pipe 1

2 510027 ø60mm seal (Blue) 1

3 510028 ø100mm seal 1

Item Part No. Description Qty

1 510022 terminal with cap 1

2 510032 wall clamp 1

5010 - HORIZONTAL BALANCED FLUE KIT

5011 - 1000mm CONCENTRIC FLUE PIPE

5012 - VERTICAL BALANCED FLUE KIT

5013 - 90° CONCENTRIC BEND

5014 - 45° CONCENTRIC BEND

5015 - 500mm CONCENTRIC FLUE PIPE

Page 34

Page 35

Page 36

TRIANCO

Thorncliffe, Chapeltown, Sheffield S35 2PZ

Tel: Sheffield (0114) 257 2300

Fax: (0114) 257 1419

www.trianco.co.uk

Guarantee

Our service division will repair or replace free of charge any defect or component that is due to faulty material or workmanship, provided that such a defect occurs within the guarantee period:

1 Our service division is notified promptly of any defects. Under the terms of guarantee the appliance must

be made available for service during normal working hours Monday to Friday (weekend work not accepted).

2 The Flue Kit is installed in accordance with these instructions.

3 The guarantee does not apply if the Flue Kit is repaired or modified by any person other than a member

of your service division. The guarantee does not cover misuse or improper installation.

Issue 1 - Rev. 0 October 2003 Item No. 510005

LB1301 - 20/10/2003