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.
1.1 GENERAL INSTRUCTIONS Read the instructions and recommendations in these Installation Instructions carefully to ensure proper installation, use and maintenance of the appliance. Keep this manual in a safe place. You may need it for your own reference while our Servicing Centre technicians or your installer may need to consult it in the future. This is an appliance for the production of central heating (C.H.). This appliance must be used only for the purpose for which it is designed.
1.2 OVERALL VIEW LEGEND: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
2.2 SITING THE APPLIANCE The appliance may be installed in any room or indoor area, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland, the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the appliance in a room containing a bath or shower.
The boiler operates with alternating current, as indicated in the technical information table in section 7, 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 under the inspection cover (see the ser vicing manual for fur ther information) FIG. 2.
CENTRAL HEATING Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990, the following notes are given for general guidance. 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.
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.
IMPORTANT! COAXIAL SYSTEMS For all flue systems, a restrictor must always be inserted into the boiler’s flue connector; the restrictor must be Ø 44 in diameter depending on the length of piping indicated in TABLE 2.1. FIG 2.9 and FIG 2.10 illustrate some of the various designs for coaxial or twin pipe flue systems. For fur ther infor mation on discharge/ventilation accessories, see the FLUE PIPE ACCESSORIES MANUAL. FIG. 2.9 Exhaust Type Restrictor ø 44 mm C12 (xx) C32 (xx) C42 (xx) L min = 0.
2.11 ELECTRICAL DIAGRAM Legend: A B C D E F - On/Off Switch On/Off L.E.D. Heating Switch Heating L.E.D. Reset Button Ignition Failure (Lockout) L.E.D.
FIG. 2.13 GAS AND WATER CIRCUITS 2.12 LEGEND: FIG. 2.14 17 1 2 16 3 4 5 6 7 8 9 15 10 14 13 11 12 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 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 A.
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: FIG. 3.4 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. 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 10 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.
4.2 CONTROL PANEL LEGEND: A B C D E F G H I J - On/Off button - On/Off L.E.D. green (frost protection active) - Central Heating button - Cental Heating active L.E.D. green - Ignition failure (lockout) and/or overheat reset button - Ignition failure (lockout) and/or overheat L.E.D. red - Central heating temperature adjustment - Energy Saving System (ESS) - Knock-out for time clock - Heating system pressure gauge 4.3 FIG. 4.
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.
4.7 BOILER SAFETY SYSTEMS The boiler is fitted with the following devices (see section 4.2 for references). 1 - IGNITION FAILURE: This indicates ignition failure when a flame is not detected within 7 seconds of starting an ignition sequence. The L.E.D. “F” will illuminate to signal the shutdown status. The system can be reset by pressing and releasing the button “E” after checking to make sure that the gas cock is open.
5. GAS ADJUSTMENTS TABLE 5.1 Methane Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 MJ/m3h mbar mbar 45.67 20 17 80.58 29 20 80.58 37 25 mm ø m3/h Kg/h 1.30 --1.22 ---- 0.77 2.9 ---0.91 0.77 2.9 ---0.90 mbar 8.3 22.9 29.5 CATEGORY II2H3+ Lower Wobbe Index (15°C;1013mbar) Nominal Delivery Pressure Minimum Delivery Pressure 10 RFFI [1 mbar = 10,197 mmc.a.] 5.1 CHANGING THE TYPE OF GAS The outlet pressure of the gas cock is obtained by completely loosening the screw on the solenoid.
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 by-products (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 10 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 FIG. 1.6 D 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 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); E 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 I H Fig. 1.16 J FIG. 1.17 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.
1.4 SERVICING AND REMOVAL OF THE GAS VALVE 1.4.1 Setting the gas pressures 1 B A VG003Aa 2 D C E Setting 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”.
6. Remove the pipe from the pressure gauge and connect screw “C” to the pressure outlet in order to seal off the gas. 7. Carefully check the pressure outlets for gas leaks (valve inlet and outlet). IMPORTANT! Whenever you disassemble and reassemble the gas connections, always check for leaks using an approved soap and water solution. 10 RFFI TABLE A TB016A Gas restrictor ¿ 1.22 0.91 Kg/h 0.90 Kg/h ----- ------ Kg/h ------ Kg/h 2.9 2.9 20 28 mbar 37 mbar 8.3 22.9 mbar 29.
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 10 RFFI Key no. 2 6 13 16 18 19 21 22 23 25 26 27 29 30 31 33 45 48 49 55 60 74 79 82 83 84 78CD 85A 85B 85C 85D 89AC 89BD 95 97 100 106AB 106CD 351 352 353 354 361 362 22 G.C. part no. 164 282 164 225 164 229 164 261 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.
