SERIES Installation and Servicing Instructions Type C Boilers G.C.N: G.C.N: G.C.N: G.C.
TABLE OF CONTENTS 1. GENERAL INFORMATION 1.1. 1.2. 1.3. 2. 3.6. 3.6.1. 3.6.2. 3.6.3. 3.6.4. 3.6.5. 3.6.6. 3.7. 3.8. 3.9. 3.10. 3.11. 5.
1. GENERAL INFORMATION 1.1. 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. Read the instructions and recommendations in these Installation and Servicing Instructions carefully to ensure proper installation, use and maintenance of the appliance.
General Info Name CE Certification Flue Type Energy Performance Heat Input max/min (Central Heating) Heat Input max (Domestic Hot Water) Heat Output max/min Efficiency of Nominal Heat Input (60/80°C) Efficiency of Nominal Heat Input (30/50°C) Efficiency at 30% of Nominal Heat Input (47°C) Efficiency at 30% of Nominal Heat Input (30°C) Efficiency at Minum Input Efficiency (Dir.
General Info Name CE Certification Flue Type Energy Performance Heat Input max/min (Central Heating) Heat Input max (Domestic Hot Water) Heat Output max/min Efficiency of Nominal Heat Input (60/80°C) Efficiency of Nominal Heat Input (30/50°C) Efficiency at 30% of Nominal Heat Input (47°C) Efficiency at 30% of Nominal Heat Input (30°C) Efficiency at Minum Input Efficiency (Dir.
1.2. OVERALL VIEW 27/32 RFFI SYSTEM 27/32 MFFI 1 26 1 26 2 3 25 2 3 25 4 5 4 5 6 7 8 6 7 8 24 24 9 9 23 23 22 22 21 20 10 10 20 11 19 19 18 18 12 13 14 15 16 17 12 14 15 16 17 FIG. 1.0 LEGEND: 1. Flue connector 2. Mixer 3. Fan 4. Spark generator 5. Burner 6. Ignition and detection electrode 7. Air release valve 8. Main heat exchanger (aluminium) 9. Central Heating flow temperature probe 10. Automatic by-pass 11. Domestic Hot Water temperature probe 12.
2. INSTALLATION 2.1. REFERENCE STANDARDS The technical information and instructions provided herein below are intended for the installer / Servicing Technician so that the unit may be installed and serviced correctly and safely. In the United Kingdom the installation and initial start up of the boiler must be by a CORGI Registered Installer in accordance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI.
OVERALL DIMENSIONS 27/32 RFFI SYSTEM 143 450 130 35 2.3. 130 225 750 225 5 785 132 132 93 118 123 acqua gas 45 50 F 93 280 FIG. 2.1 450 280 FIG. 2.0 2.4. MINIMUM CLEARANCES LEGEND: In order to allow access to the interior of the boiler for maintenance purposes, the boiler must be installed in compliance with the clearance requirements indicated in the diagram below.
2.6. ELECTRICAL CONNECTION 27/32 RFFI SYSTEM 300 The boiler operates with alternating current, as indicated in the technical data table (Section 1.2), where the maximum absorbed power is also indicated. Make sure that the connections for the neutral and live wires correspond to the indications in the diagram. The appliance electrical connections are situated on the reverse of the control panel (see the Servicing Instructions for further information Section 6).
2.8. WATER CONNECTIONS VIEW OF THE BOILER CONNECTIONS 27/32 MFFI Legend: A B C D E H I J I A B C D J 27/32 RFFI SYSTEM I C H FIG. 2.4 10 J Central Heating Flow Domestic Hot Water Outlet Gas Inlet Domestic Cold Water Inlet Central Heating Return Condensate discharge Safety valve discharge Drain valve E H A = = = = = = = = E Central Heating Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance.
ii) Connecting into the waste system of the building such as a washing machine or sink trap. The connection must be upstream of the washing machine/sink (If the connection is down stream of the waste trap then an additional trap giving a minimum water seal of 75 mm and an air break must be incorporated in the pipe run, as above. iii) Terminating into a gully, below the grid level but above the water level. iv) Into a soakway.
WATER TREATMENT The boiler is equipped with an aluminium alloy main heat exchanger.
2.9. FLUE CONNECTIONS FLUE SYSTEM The provision for satisfactory flue termination must be made as described in BS 5440-1. The appliance must be installed so that the flue terminal is exposed to outdoor 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.
32 MFFI Coaxial Systems Exhaust Type Maximum Extension Diameter of Pipes Exhaust/Air (mm) (m) C13 4 Ø 60/100 C13, C33, C43 24 (S1=S2) Ø 80/80 C53, C83 1+48 (S1+S2) Ø 80/80 Twin Pipe Systems In FIG. 2.8 (PAGE 11), several different types of flue systems are shown. For additional information regarding the flue accessories, please consult the Flue Pipe Accessories manual. FIG. 2.
2.10. ACCESSORY CONNECTION IMPORTANT!! Before carrying out any repairs to the appliance always ensure that the external power supply has been isolated. The boiler will remain live even when the ON/OFF knob is in the “O”(off) position. FIG. 2.9 In order to gain access to the external control connections, it is first necessary to remove the casing (as shown in Section 3.2) then proceed as follows: 1. Remove the cover of the main PCB box (FIG 2.9). 2.
CN4 CN1 CN3 N VG CN2 CN5 7 8 9 10 1112 CI AC CN12 CN1 WFS 1 CN8 CN11 FUSE NTC1 NTC2 FS CN10 7 8 9 10 1112 CN6 CN9 NTC3 PA CN7 CN12 O P CN8 Day CN11 h MV CN5 L CN16 N 1 L 2 12 11 10 9 8 7 6 5 4 3 2 1 1 2 Nr Mr Rs Bn Az 2 Bl Mr 1 Rs Nr Mr Bl R/N Mr Bl Nr Nr 1 4 TIMER 1 Bl Bl 1 Gr Gr Bn Bn Gr 1 Bn Bn 2 3 FIG. 2.
Legend: A B C D E F G H I J K L M N - ON/OFF button Multifunction display RESET button Green led (indicates burner on) Comfort function yellow LED Red LED (indicates lockout) COMFORT button Programming key + Programming key Menù button Central Heating temperature adjustment Domestic Hot Water temperature adjustment Eepron Interface PCB (optional) FS NTC1 NTC2 NTC3 OP VG M - CI MV AC PA TA TS CR SE US - Domestic hot water flow switch Central Heating flow temperature probe Central Heating return temper
2.12. WATER CIRCUIT DIAGRAM 27/32 MFFI 20 1 2 3 4 5 6 19 18 7 8 9 17 16 10 15 14 11 12 13 FIG. 2.
27/32 RFFI SYSTEM 21 1 2 3 4 5 6 20 19 7 8 9 18 17 10 11 E A C D 15 12 13 16 B 14 FIG. 2.14 LEGEND: 1 Fan Burner 2 Ignition/detection electrode 3 4 Air release valve 5 Main heat exchanger Central heating flow temperature probe 6 Condensate Trap 7 Gas valve 8 9 Pressure gauge Safety valve 10 D.H.W.
3. COMMISSIONING 3.1. INITIAL PREPARATION initiative. Within the MTS (GB) Limited support the information pack you will find a copy of the Log Book. It is important that this is completed in the presence of your customer, they are shown how to use it, and it is signed by them. Please instruct your customer that they must have their Log Book with them whenever they contact a service engineer or us. Preliminary electrical system checks to ensure electrical safety must be carried out by a competent person i.
the system the treatment of the water to prevent premature scaling of the main heat exchanger is necessary. The formation of scale strongly compromises the efficiency of the thermic exchange because small areas of scale cause a high increase of the temperature of the metallic walls and therefore add to the thermal stress of the heat exchanger. Demineralized water is more aggressive so in this situation it is necessary to treat the water with an appropriate corrosion inhibitor.
3.2. REMOVING THE CASING A To remove the front casing panel, follow these steps: 1. Remove the screws “A” (FIG 3.1); 2. Remove the four screws from case hooks (two at the top and two at the bottom) and rotate anti-clockwise (FIG 3.2); 3. Lift and unhook the case panel (FIG 3.3). A FIG. 3.2 FIG. 3.1 FIG. 3.
3.3. CONTROL PANEL 27/32 MFFI I A H G B F C E D FIG. 3.4 Button Description Description ON/OFF Switch A Green LED (illuminated = burner on) “COMFORT” Function Push-button B Time clock C Selector knob for Summer/Winter Central Heating Temperature Adjustment Knob D Control Panel Cover E Domestic Hot Water Temperature Adjustment Knob F Heating System Pressure Gauge G “COMFORT” Function L.E.
27/32 RFFI SYSTEM I A H G B F C D FIG. 3.4 Button Description Description ON/OFF Switch A Green LED (illuminated = burner on) Heating only B Time clock C Selector knob for Summer/Winter Central Heating Temperature Adjustment Knob D Control Panel Cover F Heating System Pressure Gauge G Heating only L.E.
3.4. INITIAL START-UP H C FIG. 3.6 1. Make sure that: - the cap of the automatic air release valve is loosened; - the system pressure is at least 1 bar on the pressure gauge “F” (Fig. 3.4); - the gas cock is closed (Fig. 3.5); - the electrical connection has been carried out in the correct manner. To allow the air to escape from the system, FIG. 3.5 proceed as follows: - push the On/off button and turn the knob “C” (Fig. 3.6) to the “winter” position.
3.5.
3.6. OPERATING PARAMETERS The boiler has been designed to allow easy intervention with regard to the operating parameters. 3.6.1 REGULATION MENU TABLE Summary of the functions accessed when the RESET button and the menu button are pushed at the same time for 5 seconds. On the display will appear the parameters indicated on table 3A. To modify the parameters push the programming keys and . Fig. 3.10 TAB.
left-hand display right-hand display r from00 to 01 p from90 to 91 p6 from-20 to +20 Correction of heat curve translation P5 from 0_3 to 3_0 Curve incline t A Function selects low temperature systems or std systems Temperature regulation controlled by external sensor factory setting 01 90 Test Function 81 Bus Address (Do not modify) b0 Set-point second heating zone b1 GSM value b 20 NOT USED b 30 NOT USED b 40 NOT USED b 50 NOT USED b 60 NOT USED b 70 NOT USED Impor
Soft light adjustment 1 The soft light can be adjusted between the maximum power (shown on the display as “00”, i.e. 100%) and the minimum power (shown on the display as “01”, i.e. 1%). The boiler is factory set to a value which is suitable for the ignition with any type of gas (approx. 33%). The value set expressed as a percentage, can be displayed and adjusted as indicated in Section 3.6.1 (parameter 1) FIG. 3.
Boiler types F Factory setting: 00 - ACO 27 / 32 MFFI (C.H. + D.H.W.) 02 - ACO 27 / 32 RFFI SYSTEM (C.H. only) THIS PARAMETER MUST NEVER BE ADJUSTED. Secondary outlet Function E (This parameter can be modified only with the interface PCB connected) With the interfa ce PCB connected, it is possible to set the boiler to operate with one of the following accessories, (see Section 2.10 for further information).
SETTING THE TEMPERATURE FIELD r Using the programming keys and it is possible to make the following adjustments: 00” signifies that the flow temperature (which may be set by “0 means of the knob on the front control panel) may be regulated from 20 to 75°C. 01” signifies that the flow temperature (which also may be set by “0 means of the knob on the front control panel) may be regulated from 42 to 82 °C. FIG. 3.
SETTING THE CURVE INCLINE P 5 FIG. 3.22 FIG. 3.23 WARNING (*) - If curve 0_3 or 0_5 is set, a system safety thermostat must be connected to the main terminal board (see paragraph 2.10) With parameter P 5 it is posslbe to adjust the heat curve setting to those shown in fig. 4.16). Using programming keys and , the curve setting may be changed.
3.6.2 SETTINGS DISPLAY The boiler is designed to monitor some operating variables and settings by means of the display on the front control panel. Keeping, at the same time, the reset and the menu key pressed for over 10 seconds will allow access to the “readout” function of the main system variables.
3.6.3 GAS REGULATION CHECK Supply pressure check 1. Loosen screw “1” (Fig. 3.31) and conect the pressure gauge connection pipe into the test point. 2. Turn the boiler on at maximum power, enabling the “flue sweep” function (press the RESET key for 5 seconds and press the programming keys + and - together). The supply pressure should correspond to that shown for the type of gas the boiler is designed for methane gas G20. 3. When the check is over, tighten screw “1” and make sure it is securely in place. 4.
3.6.4 IGNITION DELAY ADJUSTMENT The ignition delay can be adjusted to between 0 and 7 minutes. The delay is factory set to 2 minutes. The value set can be displayed and modified as illustrated in paragraph 3.6.1 (parameter 3). 3.6.5 ADJUSTING THE MAXIMUM HEATING POWER The maximum heating power can be adjusted to between the maximum power allowed by the boiler (24 kW) and the minimum one (8 kW). The value is factory set to 70% of the maximum power.
3.8. BOILER SAFETY SYSTEMS There follows a list of the shutdown modes and the respective codes shown on the display. A” type): if such a situation occurs, it is necessary to Shutdown (“A reset the boiler using the appropriate key. If this shutdown occurs frequently, your local Service Agent should be contacted. DISPLAY - SAFETY SHUTDOWN: for this group of errors E”) the situation (characterised on the display by the letter “E is automatically removed as soon as the cause behind it is resolved.
DAILY TEST. In order to prevent the shutdown of the components, the boiler carries out a self-diagnosing test every 21 hours: the pump turns on for 15 seconds and the diverter valve moves. ANTI-FROST DEVICE. The anti-frost function acts on the central heating flow temperature probe, independently from other regulations, when the board is turned ON. If the primary circuit temperature falls below 8°C the pump will for 2 minutes.
4. ZONE VALVES The boiler is capable of managing a heating system that uses zone valves. The electrical connection of these valves is carried out by means of the appropriate ter minal board (indicated in the “ELECTRICAL CONNECTION” section). By way of example, two possible types of systems would be: 1. System with 2 valves with independent regulation of the zones (day and night). 2. System with 1 valve (regulation of the night zone subordinated to that of the day).
5. MAINTENANCE 5.1. GENERAL REMARKS IMPORTANT!! Every time that the combustion chamber cover or the primary heat exchanger is removed from the boiler, the combustion chamber seal must be replaced (code: 65102217). The silicone grease provided with the gasket must be spread around the area the gasket fits to ensure an airtight seal. Only the grease provided must be used, however, should more grease be needed it must have a temperature range of between –40 deg C and +200 deg C” 5.2.
7. 7.1. FAULT FINDING 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. Model 27/32 MFFI MAKE SURE THAT: 1. There is sufficient water in the system 2. The gas is turned on 3. The electrical supply is turned on PRESS THE ON/OFF BUTTON TO THE ON POSITION NO IS THE DISPLAY ON? YES TABLE I and II DOES AN ERROR CODE APPEAR ON THE DISPLAY? 1. Check the fuses 2.
Model 27/32 RFFI SYSTEM MAKE SURE THAT: 1. There is sufficient water in the system 2. The gas is turned on 3. The electrical supply is turned on PRESS THE ON/OFF BUTTON TO THE ON POSITION NO IS THE DISPLAY ON? YES TABLE I and II DOES AN ERROR CODE APPEAR ON THE DISPLAY? 1. Check the fuses 2. Check the power supply to the control panel 3. Check/replace the ON/OFF button 4. Check the connection between the main and display P.C.B.s 5. Check/replace the main and display P.C.B.
A IS THE PUMP RUNNING? NO YES POWER TO THE PUMP? YES WAS THE PLAUSIBILITY TEST OK? (E95: test failed) YES NO NO 1. Check/replace pump cable Release/Replace pump 1. Check the pump cable 2. Check/replace the pump 3. Check/replace the NTC probes 4. Replace the main P.C.B.
B NO IS THE FAN RUNNING? DOES CODE A33 APPEAR? YES NO Replace the main P.C.B. DOES THE AIR PRESSURE SWITCH CLOSE? (E33) YES 1. Check the fan cable 2. Replace the fan 3. Replace the main P.C.B. NO 1. Check the exhaust flue duct 2. Check the APS cable 3. Check if there is condensate in the silicone pipes 4. Check/Replace the APS 5. Check/Replace the main P.C.B. YES ARE IGNITION SPARKS GENERATED REGULARLY? NO 1. Check/replace ignition electrode 2. Check ignition cable 3. Check/replace the main P.C.
8.
Key no. 1 10 14 18 21 22 29 31 32 35 37 42 46 54 55 75 90 91 101 107 107 126 130 132 136 136 203 204 215 216 60 G.C. part no. Description Flue restrictor Spark generator Main P.C.B.
27/32 RFFI SYSTEM 59 58 4 1 2 3 4 5 5 60 6 7 8 56 55 54 53 57 6 61 62 51 50 57 119 120 121 118 63 9 52 122 117 10 11 116 115 64 123 114 112 12 65 109 110 108 105 106 111 113 111 107 108 107 49 RESET ON/OFF 8 7 6 62 61 103 68 13 72 99 73 48 93 94 74 71 14 94 98 70 69 102 101 100 6 66 67 104 95 97 85 29 86 75 92 77 78 91 29 76 15 47 96 16 46 45 17 18 90 85 29 44 46 79 80 45 43 89 84 81 33 34 86 19 42 20 22 23 24 25 26 27
Key no. 1 10 14 42 26 28 31 40 44 52 53 75 85 86 93 93 112 116 118 122 122 203 204 216 217 62 G.C. part no. Description Flue restrictor Spark generator Main P.C.B. Manifold (CH Return) Safety valve (3bar) Pressure gauge Gas valve Pump Automatic air vent Expansion vessel Air pressure switch Hose clip Retaining clip (NTC CH) NTC (CH) Main exchanger (27 KW) Main exchanger (32 KW) Ignition electrode Detection electrode Fan Burner (27kW) Burner (32kW) Cable (Time Clock) Time Clock Display P.C.B.
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Merloni TermoSanitari SpA - Italy Commercial subsidiaries: MTS (GB) LIMITED MTS Building Hughenden Avenue High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 Fax: (01494) 459775 Internet: www.mtsgroup.com/uk E-mail: info@uk.mtsgroup.com Technical Advice: 0870 241 8180 MTS Heating Limited Damastown Industrial Park Damastown Avenue Mulhuddart Dublin 15 Telephone: (01) 810 3723 Fax: (01) 810 3727 Internet: www.mtsgroup.com/ie E-mail:info@ie.mtsgroup.
