Installation Instructions Type C Boilers G.C.
TABLE OF CONTENTS 1. GENERAL INFORMATION 1.1 GENERAL INSTRUCTIONS 1.2 OVERALL VIEW 2. INSTALLATION 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 REFERENCE STANDARDS SITING THE APPLIANCE OVERALL DIMENSIONS CLEARANCES MOUNTING THE APPLIANCE ELECTRICAL CONNECTION GAS CONNECTION WATER CONNECTIONS FLUE CONNECTION ROOM THERMOSTAT CONNECTION ELECTRICAL DIAGRAMS GAS AND WATER CIRCUITS 3. D.H.W. STORAGE CYLINDER 3.1 2 PORT AND 3 PORT VALVE INSTALLATIONS 3.2 DOMESTIC HOT WATER PRIORITY KIT 4.
1. GENERAL INFORMATION This manual is an integral and essential part of the product. It should be kept with the appliance so that it can be consulted by the user and our authorised personnel. Please carefully read the instructions and notices about the unit contained in this manual, as they provide important information regarding the safe installation, use and maintenance of the product. For operating instructions please consult the separate User’s Manual. 1.
- Visual check of the combustion process or analysis of combustion byproducts (see section 4.5) and cleaning of the burner if needed. 5 - If called for by point. 3, dismantling and cleaning of the combustion chamber. 6 - If called for by point. 4, dismantling and cleaning of the burner jets. 7 - Visual check of the primary heat exchanger: - check for overheating in the blade assembly; - clean the exhaust fan if needed.
2. INSTALLATION The technical information and instructions provided herein below are intended for the installer so that the unit may be installed correctly and safely. 2.1 REFERENCE STANDARDS The installation and initial start up of the boiler must be by a CORGI Registered Installer in compliance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI .
OVERALL DIMENSIONS 400 mm 2.3 LEGEND: 60 mm A C E mm 2.4 = Central Heating Flow (3/4”) = Gas Inlet (3/4”) = Central Heating Return (3/4”) = Clearances CLEARANCES 450 mm In order to allow for access to the interior of the boiler for maintenance pur poses, the boiler must be installed in compliance with the minimum clearances indicated in FIG. 2.1 2.5 132 C FIG. 2.1 E Fasten the boiler in place using the template and anchors supplied with the unit.
marked “L”. Note: The diagrams for the electrical system are indicated in section 2.12. Warning, this appliance must be earthed. External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regulations and applicable local regulations. The microSYSTEM range of boilers are supplied for connection to a 230 V~ 50 Hz supply. The supply must be fused at 3 A.
PIPE WORK: Copper tubing to BS EN 1057:1996 is recommended for water pipes. Jointing should be either with capillary soldered or compression fittings. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps. The appliance has a built-in automatic air release valve, however it should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air.
2.9 FLUE SYSTEM The provision for satisfactory flue termination must be made in accordance with BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outside air. The terminal must not discharge into another room or space such as an outhouse or lean-to. It is important that the position of the terminal allows a free passage of air across it at all times.
In addition, it is also possible to use a split (twin pipe) system by fitting a special adaptor to the flue connector and using the aperture for the air vent intake located on the top part of the combustion chamber. To utilise the air intake it is necessary to: 1. Remove the bottom of the air intake by cutting it with a suitable knife (see FIG. 2.7); 2. Insert the elbow into the air intake until it reaches the lower end. (There is no need to use gaskets or sealing compounds). FIG. 2.7 Ø 80 mm FIG. 2.
Restrictor ø 46 mm C12 (xx) C32 (xx) C42 (xx) L min = 0.5 m L max = 1 m Exhaust Type Restrictor ø 41 mm C12 (xx) C32 (xx) C42 (xx) L min = 0.5 m L max = 1 m Exhaust Type Restrictor ø 46 mm C12 (xy) C32 (xy) C42 (xy) L max = 25 m 34 m 34 m 34 m 3.0 m 4.5 m 12.5 m 16.0 m C52 (xy) C82 (xy) L max = 22 m 31 m 3.3 m 4.8 m 14.0 m 17.
2.10 ROOM THERMOSTAT CONNECTION To connect a room thermostat and/or time clock, it is necessary to: 1. - Open the control panel as indicated in section 4.3; 2.- Remove screws “A” and remove the inspection cover from the reverse of the control panel; 3. - For the room-thermostat connect the thermostat switching wires to the position 5 and 6 and remove the wire link (for three-wire thermostats connect the neutral to terminal N); 4.
2.11 ELECTRICAL DIAGRAM LEGEND: A11 - Overheat Thermostat A12 - Spark Generator/Gas Valve Supply A13 - Detection Electrode A - On/Off Switch B - On/Off L.E.D. C - Heating Switch D - Heating L.E.D. E - Reset Button F - Ignition Failure (Lockout) L.E.D.
FIG. 2.13 GAS AND WATER CIRCUITS 2.12 LEGEND: FIG. 2.14 15 Fan Main heat exchanger Overheat thermostat Burner Ignition electrodes Detection electrode Regulation thermostat Frost thermostat Gas valve Pump pressure switch Safety valve (3 bar) Boiler drain valve Automatic by-pass Pressure gauge Circulation pump with automatic air release valve 16. Expansion vessel 17. Air pressure switch 10 14 13 A. Central Heating Flow B. Inlet Gas C. Central Heating Return 11 12 17 1 2 16 3 4 5 6 7 8 9 14 1.
3. D.H.W. STORAGE CYLINDER 3.1 2 PORT AND 3 PORT VALVE INSTALLATIONS The microSYSTEM can be connected to a storage cylinder (both open-vented and unvented) for the production of domestic hot water (D.H.W.). Cylinders of different capacities can be used depending on site requirements (see TABLE 3.1 for a selection of ARISTON unvented cylinders). 2 port valve installation 3 port valve installation FIG. 3.1 FIG. 3.2 FIG. 3.
Wiring to 3 port valve installation using an external 2 channel programmer Type Danfoss FP715 Type Honeywell ST6400C NOTE: When using a 3 port valve installation in conjunction with an unvented cylinder it will be necessary to use a 2 port valve on the cylinder flow connection in addition to the 3- port valve to satisfy Building Regulations. FIG. 3.4 TABLE 3.1 Technical Data C.H.W. Flow/rate m3/h D.H.W. Flow/rate It/h Max Heating Output kW Heat Ioss It.
3.2 DOMESTIC HOT WATER PRIORITY KIT Boiler microSYSTEM 21 RFFI The microSYSTEM is able to be connected to a specially designed kit for the management of D.H.W. production. This kit gives priority to production of D.H.W. unlike traditional systems where the boiler power is split between C.H. and D.H.W. This generally enables a smaller storage cylinder to be chosen as the boiler’s full output will be channelled into the cylinder allowing for a quick heat-up.
When the installation and filling are completed turn on the central heating system (section 4.4) and run it until the temperature has reached the boiler operating temperature. The system must then be immediately flushed through. The flushing procedure must be in line with BS 7593:1992 code of practice for treatment of water in domestic hot water central heating systems.
4 5 B To dismantle the front casing panel it is necessary to: 1 - Remove the two screws “B”; 2 - Move the front casing panel up and lift forward. 4.4 INITIAL START-UP 4.5 THE CHECKS TO BE RUN BEFORE INITIAL START-UP ARE AS FOLLOWS: 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.
4.6 FUME DISCHARGE MONITORING In the boiler, it is possible to monitor the correct operation of the flue exhaust/air intake, checking for a loss of general pressure in the system. Through the use of a differential manometer connected to the test points of the combustion chamber, it is possible to detect the ∆P of operation of the air pressure switch. The value detected should not be less than 0.
5. GAS ADJUSTMENTS TABLE 5.1 Methane Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 45.67 20 17 80.58 29 20 80.58 37 25 mm m3/h Kg/h 1.30 2.4 - 1.05 ---- 0.77 ---1.78 - 0.78 0.77 ---1.76 - 0.77 mbar 8.5 - 1.7 27.5 - 6.2 37.4 - 8.0 m3/h Kg/h 1.30 3.15 -1.26 ---- 0.77 ---1.78 - 0.78 0.77 ---1.76 - 0.77 mbar 11.0 - 1.6 27.7 - 4.6 35.5 - 6.
6. MAINTENANCE It is recommended that the following inspections be carried out on the boiler at least once a year: 1 - Check the seals for the water connections; replace any faulty seals. 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of combustion byproducts (see section 4.5) and cleaning of the burner if needed. 5 - If called for by point. 3, dismantling and cleaning of the combustion chamber.
6. TECHNICAL INFORMATION 21 RFFI CE Certification Heat Input Heat Output Efficiency of Nominal Heat Input Efficiency at 30% of Nominal Heat Input Heat Loss to the Casing (∆T=50°C) Flue Heat Loss with Burner Operating Flue Heat Loss with Burner Off Maximum Discharge of Fumes (G20) Residual Discharge Head Consumption at Nominal Capacity(G20) Gas Consumption after 10 Minutes* (15°C, 1013 mbar) (G30-G31) Temp.
Servicing Instructions Type C Boilers G.C.
TABLE OF CONTENTS 2 1. SERVICING INSTRUCTIONS 1.1 REPLACEMENT 1.2 TO GAIN GENERAL ACCESS - Removing the front panel - Removing the sealed chamber front cover - Removing the side panels 1.3 ACCESS TO THE COMBUSTION CHAMBER - Removing the combustion cover - Removing the burner and jets - Removing the electrodes - Removing the main heat exchanger - Removing the air pressure switch - Removing the fan 1.
1. SERVICING INSTRUCTIONS To ensure efficient safe operation, it is recommended that the boiler is serviced annually by a competent person. Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool. Before and after servicing, a combustion analysis should be made via the flue sampling point (please refer to the Installation Manual for further details).
1.2.2 Removing the sealed chamber front cover 1.2.3 Removing the side panels 1. Remove the screws “C” (FIG. 1.6); 2. Lift the sealed chamber front cover from the locating pins (FIG. 1.7). 1. Remove the four screws “D” for each side panel (FIG.1.8); 2. Pull the panel away from the boiler at the base, then lift the panel up and remove from the boiler. FIG. 1.8 D D C C D FIG. 1.6 FIG. 1.
1.3 ACCESS TO THE COMBUSTION CHAMBER 1.3.1 Removing the combustion cover 1. Remove the screws “E” (FIG. 1.9); 2. Lift off the combustion cover. Fig. 1.11 1.3.3 Removing the electrodes E E E Before carrying out this procedure, unscrew and slide the burner forward (see previous section). 1. Remove rubber gasket “G” (FIG. 1.12); 2. To remove the detection electrode disconnect the cable at its connection point close to the P.C.B. (FIG. 1.13); FIG. 1.12 FIG. 1.9 1.3.2 Removing the burner and jets 1. 2.
3. Remove screw “H” (FIG. 1.14); 4. Gently slide the electrode downward (FIG. 1.15). 1.3.4 Removing the main heat exchanger 1. Drain the boiler of water; 2. Release the overheat thermostat sensor “I” (FIG. 1.16); 3. Release the two connection nuts “J” connecting the exchanger to the flow and return pipes (FIG. 1.17); 4. Remove the heat exchanger by sliding forward (FIG. 1.18). FIG. 1.14 H I Fig. 1.16 FIG. 1.
1.3.5 Removing the air pressure switch 1.3.6 Removing the fan 1. Disconnect the electrical connections “K” and silicone pipes “L” from their connection points (FIG. 1.19); 2. Remove screws “M” on the top of the sealed chamber (FIG. 1.20); 3. Lift out the air pressure switch (FIG. 1.21); 4. Unscrew to remove the switch from the plate. 1. Disconnect electrical connections “N” and silicon pipe “O” (FIG.1.22); 2. Remove screw “P” and remove the fan collar clamp “Q” (FIG.1.23); 3. Remove screws “R” (FIG.1.
SERVICING AND REMOVAL OF THE GAS VALVE 1.4.1 Setting the gas pressures 1 B A VG002Ac 2 D C E VG002Ad 3 F VG002Af 4 G Setting the minimum and the maximum power of the boiler 1. Check that the supply pressure to the gas valve is a minimum of 20 mbar for natural gas. Turn off the gas supply at the isolation point under the boiler 2. To do this, slacken the screw “A”. Fit the pipe of the pressure gauge to the inlet pressure test point of the gas valve “B”.
GAS BURNER PRESSURE Regulating the heating power for natural gas (G20) 21 kW 28 kW OPERATING POWER CG005A GAS BURNER PRESSURE Regulating the heating power for butane gas (G30) 21 kW 28 kW OPERATING POWER CG004A GAS BURNER PRESSURE Regulating the heating power for propane gas (G31) 21 kW 28 kW OPERATING POWER CG006A 21 RFFI TABLE A 2.4 84.7 1.78 62.8 1.76 62.1 1.05 37.0 0.78 27.5 0.77 27.2 TB005A 28 RFFI 20 8.5 3.3 27.5 10.7 37.4 14.6 1.7 0.7 6.2 2.4 8.0 3.1 3.
1.4.2 Removing the spark generator 1.4.3 Removing the gas valve 1. Disconnect ignition leads “S” by pulling upward (FIG. 1.26); 2. Remove the screw “T” (FIG. 1.27); 3. Remove the spark generator by pulling forward from the gas valve. Important! Before removing the gas valve, ensure the gas supply is turned off. 1. Disconnect all the cables from the solenoid and modureg; 2. Remove the spark generator (see previous section); 3. Release the top nut “U” (FIG. 1.28); 4.
1.5 ACCESS TO THE WATER CIRCUIT 1. 5. 2 Removing the safety valve Important! Before any component is removed, the boiler must be drained of all water. 1.5.1 Removing the pump pressure switch 1. Loosen nut “Y” (FIG. 1.33); 2. Disconnect the discharge pipe work from below the boiler; 3. Unscrew and remove the valve. 1. Remove the cable of the pump pressure switch “W” (Fig. 1.31); 2. Unscrew the pump pressure switch by using a spanner on the nut “X”(FIG. 1.32); 3. Remove the pump pressure switch. Y FIG.
1.5.4 Removing the pump 1. 2. 3. 4. 5. 6. Remove the U-clips “ A1” and “B1” (FIG. 1.36); Remove the retaining clip “C1” (FIG. 1.37); Release the nut “D1” (FIG. 1.38); Remove the pipe “E1” (FIG. 1.39); Remove the screw “F1” (FIG. 1.40); Remove the pump (FIG. 1.41). A1 E1 FIG. 1.39 B1 F1 FIG. 1.36 FIG. 1.40 C1 FIG. 1.37 FIG. 1.41 D1 FIG. 1.
1.5.5 Removing the pressure gauge 1.5.6 Removing the expansion vessel 1. Remove the U-clip “G1” and remove the pressure gauge coupling (FIG. 1.42); 2. Push the pressure gauge through the control panel from the rear (FIG. 1.43). 1. 2. 3. 4. Release nuts “H1” and remove the gas pipe (FIG. 1.44); Release nut “I1” (FIG. 1.45); Remove lock-nut “J1” (FIG. 1.46); Remove the expansion vessel (FIG. 1.47). H1 G1 H1 FIG. 1.44 FIG. 1.42 I1 FIG. 1.45 FIG. 1.43 J1 FIG. 1.46 FIG. 1.
1.5.6 Removing the overheat thermostat 1. Disconnect the overheat thermostat electrical connections “K1” (FIG. 1.48); 2. Then remove the thermostat from its mounting by releasing the securing clip (FIG. 1.49). FIG. 1.51 K1 1.5.8 Removing the regulation thermostat FIG. 1.48 1. Remove the regulation thermostat sensor from its mounting by releasing the securing clip “M1” (FIG. 1.52); 2. Separate the facia panel from the rear of the control panel (see section 1.6.2); 3.
1.6 ACCESS TO THE CONTROL SYSTEM 1.6.2 Removing the P.C.B.s Important! Isolate the electrical supply to the boiler before accessing the control panel. 1.6.1 Checking the fuse 1. Isolate electricity; 2. Remove the screws “O1” (FIG. 1.56); 3. Separate the facia panel from the rear of the control panel; 4. Unplug all electrical connections from the P.C.B. and remove the screws “P1” and remove the P.C.B. (FIG. 1.57). 1. Remove the inspection cover on the reverse of the control panel (FIG. 1.54); 2.
2. FAULT FINDING 2.1 FAULT FINDING GUIDE (FLOW-CHARTS) It is possible to detect and correct any defect by using the standard fault finding diagrams described in this chapter. PRELIMINARY CHECKS MAKE SURE THAT : 1 - THERE IS SUFFICIENT WATER IN THE SYSTEM 2 - THE GAS IS TURNED ON 3 - T HE ELECTRICAL SUPPLY IS TURNED ON PRESS THE ON/OFF BUTTON IS THE SUPPLY L.E.D. ILLUMINATED? NO 1 - CHECK THE FUSES 2 - CHECK THERE IS POWER SUPPLIED TO THE P.C.B.S 3 - CHECK/REPLACE THE P.C.B.
A IS THE PUMP RUNNING? NO YES POWER T O THE PUMP? NO YES 1 - CHECK THE PUMP CABLE 2 - CHECK/REPLACE P.C.B. (CT1) 3 - CHECK THE SYSTEM PRESSURE GAUGE IS AT 1.5 BAR 1 - CHECK THE OPERATION OF THE PUMP 2 - RELEASE/REPLACE THE PUMP IS THE FAN RUNNING? YES NO BOILER SHUTDOWN? YES 1 - RESET THE BOILER NO B 1 - CHECK/REPLACE AIR INTERNAL P.C.B.
B IS THE AIR PRESSURE SWITCH ACTIVATED? NO 1 - CHECK AIR PRESSURE SWITCH CABLE 2 - CHECK/REPLACE AIR PRESSURE SWITCH 3 - CHECK/REPLACE P.C.B. (CBM2) ∆P≤0.5 mbar YES DOES THE SPARK SEQUENCE START? ∆P 0.5 mbar CHECK ∆P ON PRESSURE TEST POINT 1234- CHECK EXHAUST DISCHARGE CHECK VENTURI AND TUBES CHECK THE FAN EFFICIENCY REPLACE FAN 1 - CHECK/REPLACE IGNITION ELECTRODES 2 - CHECK THE CABLES 3 - CHECK SPARK GENERATOR 4 - CHECK IGNITION ELECTRODE NO 5 - C HECK /R EPLACE P.C.B.
3. ELECTRICAL DIAGRAMS LEGEND: A - On/Off Switch B - On/Off L.E.D. C - Heating Switch D - Heating L.E.D. E - Reset Button F - Ignition Failure (Lockout) L.E.D.
SF008A 20 B063
4.
microSYSTEM 21/28 RFFI Key no. 2 5 13 16 18 19 21 22 23 25 26 27 29 30 31 33AB 33CD 45 48 49 55 60AB 60CD 73 75 76AB 76CD 78AB 78CD 81 83A 83B 83C 83D 87AC 87BD 93 95 97 98 99 351 352 353 354AB 354CD 361 362 22 G.C. part no. 164 282 164 225 164 229 164 261 E03 818 E24 076 E24 075 ARISTON Part No.
NOTES B063 23
Merloni TermoSanitari SpA - Italy Commercial subsidiary: MTS (GB) LIMITED MTS Building Hughenden Avenue High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 Fax: (01494) 459775 Internet: http://www.mtsgb.ltd.uk E-mail: info@mtsgb.ltd.
