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Installation and Servicing Instructions
GENUS HE SYSTEM
Gas fired condensing wall hung combination boilers
G.C.N : 41-116-24 (24 kW) G.C.N : 41-116-25 (30 kW)
GENUS HE SYSTEM 24 GENUS HE SYSTEM 30
Country of destination GB, IE
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INDEX
Overview General Information.................................................................................................3 Advice for the Installer.............................................................................................4 CE Labelling.................................................................................................................4 Data Plate Symbols...................................................................................................4 Safety Regulations.....................................................................................................5
Product description Control Panel...............................................................................................................6 Display...........................................................................................................................6 Overall View.................................................................................................................7 Overall Dimension.....................................................................................................7 Minimum Clearances................................................................................................7 Technical Information..............................................................................................8
Installation Reference Standards.................................................................................................9 Installing the Boiler................................................................................................ 12 Gas Connection....................................................................................................... 13 Water Connection................................................................................................... 13 Instructions for Opening the Casing and Performing an Internal Inspection................................................................................................. 13 Underfloor heating................................................................................................ 14 Water circuit diagram............................................................................................ 14 Connecting the Flue.............................................................................................. 15 Fitting the Coaxial Flue (Ø 60/100 Horizontal)............................................. 16 Fitting the 5" Flue (Ø 80/125 Horizontal / Vertical)..................................... 17 Fitting the Coaxial Flue (Ø 60/100 Vertical)................................................... 18 Fitting the Twin Pipe (Ø 80/80).......................................................................... 19 Electrical Connections.......................................................................................... 23 Power supply cable................................................................................................ 23 Peripheral unit connection.................................................................................. 23 Room Thermostat Connection........................................................................... 24 Outdoor Sensor Connection............................................................................... 24 Electrical Diagram................................................................................................... 25 Wiring diagram for connection to an open vented cylinder.................. 26 Wiring diagram for connection to an MTS unvented cylinder............... 27
Commissioning Initial Preparation................................................................................................... 28 Electricity Supply.................................................................................................... 28 Filling the Heating System................................................................................... 28 Filling of the DHW System................................................................................... 28 Gas Supply................................................................................................................. 28 Water Treatment...................................................................................................... 28 First Igniton Operation.......................................................................................... 29 Basic Set Up Instructions - Timer and Range Rating Power..................... 32 Test Function and Combustion Analysis........................................................ 34 AUTO Function......................................................................................................... 35
Boiler Protection Devices Boiler Protection Devices..................................................................................... 36 Anti-Frost Device..................................................................................................... 36 Table summarising error codes......................................................................... 36
Settings - Adjustment - Problem Identification Menus Accessing the Menus............................................................................................. 37 INFO............................................................................................................................. 45
Maintenance General Comments................................................................................................ 46 General Access......................................................................................................... 47 Electrical Unit........................................................................................................... 48 Hydraulic Unit.......................................................................................................... 50 Main Heat Exchanger............................................................................................ 55 Burner Unit................................................................................................................ 56 Fan Unit...................................................................................................................... 59 Gas Valve.................................................................................................................... 60 Annual Maintenance............................................................................................. 61 Spare Parts Short List............................................................................................. 62 Benchmark Commissioning Checklist............................................................. 63 Benchmark Service Interval Record................................................................. 64
overview
These instructions are suitable for GENUS HE SYSTEM boilers : Do not forget the Log Book! The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.
To The Installer As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the Householder. Please ensure that your customer is aware of the importance of keeping the Log Book safe as a record of the installation and the appliance service history.
Please ensure that your customer is aware of the correct operation of the system, boiler and controls.
MTS recommend the use of protective clothing, when installing and working on the appliance i.e. gloves.
CUSTOMER CARE
MTS, as a leading manufacturer of domestic and commercial water heating appliances is committed to providing high
quality products and a high quality after sales service.
Advice on installation or servicing can also be obtained by contacting the MTS Technical and Customer Service
Departments at High Wycombe.
TECHNICAL DEPARTMENT
CUSTOMER SERVICE
DEPARTMENT
Tel: 0870 241 8180
Tel: 0870 600 9888
Fax: 01494 459775
Fax: 01494 459775
GUARANTEE The manufacturer's guarantee is for 2 years from the date of purchase. The guarantee is invalidated if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler without delay.
CAUTION
In the United Kingdom, installation, start-up, adjustments and maintenance, must be performed by a competent person only, in accordance with the current Gas Safety (Installation & Use) Regulations and the instructions provided.
In the Republic of Ireland, the installation and initial start up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 "Domestic Gas Installations", the current Buidling Regulations, reference should also be made to the current ETCI rules for electrical installation.
All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI directly on:- 0800 915 0485.
Improper installation may cause damage or injury to individuals, animals and personal property for which the manufacturer will not be held liable. To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a competent person.
If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.
This instruction booklet is especially designed for appliances installed in the UK and the Republic of Ireland
overview
Advice for the installer The installation and first ignition of the boiler must be performed by qualified personnel in compliance with current national regulations regarding installation, and in conformity with any requirements established by local authorities and public health organisations. After the boiler has been installed, the installer must ensure that the end user receives the declaration of conformity and the operating manual, and should provide all necessary information as to how the boiler and the safety devices should be handled.
This appliance is designed for domestic use only. It should be connected to a heating system which must be compatible with its performance and power levels. The use of the appliance for purposes other than those specified is strictly forbidden.The manufacturer cannot be held responsible for any damage caused by improper, incorrect and unreasonable use of the appliance or by the failure to comply with the instructions given in this manual. Installation, maintenance and all other interventions must be carried out in full conformity with the governing legal regulations and the instructions provided by the manufacturer. Incorrect installation can harm persons, animals and possessions; the manufacturing company shall not be held responsible for any damage caused as a result. The boiler is delivered in a carton. Once you have removed all the packaging, make sure the appliance is intact and that no parts are missing. If this is not the case, please contact your supplier. Keep all packaging material (clips, plastic bags, polystyrene foam, etc.) out of reach of children as it may present a potential hazard. In the event of a fault and/or malfunction, turn the appliance off, turn off the gas cock and do not attempt to repair it yourself. Contact a qualified professional instead. Before any maintenance or repair work is performed on the boiler, make sure you have disconnected it from the electricity supply by switching the external bipolar switch to the "OFF" position and removing the fuse. All repairs, which should only be performed using original spare parts, should be carried out by a qualified professional. Failure to comply with the above instructions could compromise the safety of the appliance and invalidate all liability on the part of the manufacturer. In the event of any maintenance or other structural work in the immediate vicinity of the ducts or flue gas exhaust devices and their accessories, switch the appliance off by switching the external bipolar switch to the "OFF" position and shutting off the gas control valve. When the work has been completed, ask a qualified technician to check the efficiency of the ducting and the devices. Turn the boiler off and turn the external switch "OFF" to clean the exterior parts of the appliance. Clean using a cloth dampened with soapy water. Do not use aggressive detergents, insecticides or toxic products. If the appliance is used in full compliance with current legislation, it will operate in a safe, environmentally-friendly and cost-efficient manner. If using kits or optional extras, make sure they are authentic.
CE labelling The CE mark guarantees that the appliance conforms to the following directives: - 90/396/CEE
relating to gas appliances - 2004/108/CEE
relating to electromagnetic compatibility - 92/42/CEE
relating to energy efficiency - 2006/95/CEE
relating to electrical safety
Symbols used on the data plate
1 3
4 6
2 5
7
8
9
12
MAX MIN
14 15
13
10 11
16
17
18
Gas
mbar
Gas
19
20 21
mbar
22
Legend : 1. Brand
2. Manufacturer 3. Boiler model - Serial number 4. Commercial reference 5. certification number 6. Destination country - gas category 7. Gas setting 8. Installation type 9. Electrical data
10. Maximum domestic hot water pressure 11. Maximum heating pressure 12. Boiler type 13. NOx class / Efficiency 14. Input rating nominal heating 15. Power ouput heating 16. DHW specific flow rate 17. Boiler output efficiency 18. Input rating nominal DHW 19. Gases which may be used 20. Temperature ambiante de fonctionnement 21. Max. central heating temperature 22. Max. domestic hot water temperature
Safety regulations
Key to symbols:
Failure to comply with this warning implies the risk of personal injury, in some circumstances even fatal Failure to comply with this warning implies the risk of damage, in some circumstances even serious, to property, plants or animals.
Install the appliance on a solid wall which is not subject to vibration. Noisiness during operation. When drilling holes in the wall for installation purposes, take care not to damage any electrical wiring or existing piping. Electrocution caused by contact with live wires. Explosions, fires or asphyxiation caused by gas leaking from damaged piping. Damage to existing installations. Flooding caused by water leaking from damaged piping. Perform all electrical connections using wires which have a suitable section. Fire caused by overheating due to electrical current passing through undersized cables. Protect all connection pipes and wires in order to prevent them from being damaged. Electrocution caused by contact with live wires. Explosions, fires or asphyxiation caused by gas leaking from damaged piping. Flooding caused by water leaking from damaged piping. Make sure the installation site and any systems to which the appliance must be connected comply with the applicable norms in force. Electrocution caused by contact with live wires which have been installed incorrectly. Damage to the appliance caused by improper operating conditions. Use suitable manual tools and equipment (make sure in particular that the tool is not worn out and that its handle is fixed properly); use them correctly and make sure they do not fall from a height. Replace them once you have finished using them. Personal injury from the falling splinters or fragments, inhalation of dust, shocks, cuts, pricks and abrasions. Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions. Use electrical equipment suitable for its intended use (in particular, make sure that the power supply cable and plug are intact and that the parts featuring rotary or reciprocating motions are fastened correctly); use this equipment correctly; do not obstruct passageways with the power supply cable, make sure no equipment could fall from a height. Disconnect it and replace it safely after use. Personal injury caused by falling splinters or fragments, inhalation of dust, knocks, cuts, puncture wounds, abrasions, noise and vibration. Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions. Make sure any portable ladders are positioned securely, that they are suitably strong and that the steps are intact and not slippery and do not wobble when someone climbs them. Ensure someone provides supervision at all times. Personal injury caused by falling from a height or cuts (stepladders shutting accidentally). Make sure any rolling ladders are positioned securely, that they are suitably strong, that the steps are intact
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and not slippery and that the ladders are fitted with handrails on either side of the ladder and parapets on the landing. Personal injury caused by falling from a height. During all work carried out at a certain height (generally with a difference in height of more than two metres), make sure that parapets are used to surround the work area or that individual harnesses are used to prevent falls. The space where any accidental fall may occur should be free from dangerous obstacles, and any impact upon falling should be cushioned by semi-rigid or deformable surfaces. Personal injury caused by falling from a height. Make sure the workplace has suitable hygiene and sanitary conditions in terms of lighting, ventilation and solidity of the structures. Personal injury caused by knocks, stumbling etc. Protect the appliance and all areas in the vicinity of the work place using suitable material. Damage to the appliance or surrounding objects caused by falling splinters, knocks and incisions. Handle the appliance with suitable protection and with care. Damage to the appliance or surrounding objects from shocks, knocks, incisions and squashing. During all work procedures, wear individual protective clothing and equipment. Personal injury caused by electrocution, falling splinters or fragments, inhalation of dust, shocks, cuts, puncture wounds, abrasions, noise and vibration. Place all debris and equipment in such a way as to make movement easy and safe, avoiding the formation of any piles which could yield or collapse. Damage to the appliance or surrounding objects from shocks, knocks, incisions and squashing. All operations inside the appliance must be performed with the necessary caution in order to avoid abrupt contact with sharp parts. Personal injury caused by cuts, puncture wounds and abrasions. Reset all the safety and control functions affected by any work performed on the appliance and make sure they operate correctly before restarting the appliance. Explosions, fires or asphyxiation caused by gas leaks or an incorrect flue gas exhaust. Damage or shutdown of the appliance caused by out-of-control operation. Before handling, empty all components that may contain hot water, carrying out any bleeding if necessary. Personal injury caused by burns. Descale the components, in accordance with the instructions provided on the safety data sheet of the product used, airing the room, wearing protective clothing, avoid mixing different products, and protect the appliance and surrounding objects. Personal injury caused by acidic substances coming into contact with skin or eyes; inhaling or swallowing harmful chemical agents. Damage to the appliance or surrounding objects due to corrosion caused by acidic substances. If you detect a smell of burning or smoke, keep clear of the appliance, disconnect it from the electricity supply, open all windows and contact the technician. Personal injury caused by burns, smoke inhalation, asphyxiation.
product description
Control panel
1 2
ABCDEFGHIL123456
4 5 6 7
17
Display
14 Legend :
13
1. Display
12 2. Reset button
11
4. Pressure gauge
5. Heating temperature regulation knob/
10
"encoder" programming knob
6. Mode button
9
(Operation mode selection (summer/winter)
7. Menu/Ok button (Programming key)
8. Esc button
9. Time clock (optional)
10. ON/OFF button
11. Info button
8
12. Clock button
13. Auto button (To active Thermoregulation)
14. Led burner ON
19 18
ABCDEFGHIL123456
17 . Weekly programming Schedule programming Day of the week (Mon......Sun) Zone indication relating to the display/setting process of the Heating schedule programming (zone 1 and zone 2) Date and time
Heating schedule programming activated 18 . Operation and diagnostics
Digits indicating: boiler status and temperature indication menu settings error code signals Internal temperature displayed (with bus device optional) External temperature displayed (with external sensor optional) Reset button request
Technical assistance request
Digital pressure gauge
Flame detected with Power used indication or operation shutdown indication
Heating operation and indication of the set temperature level
ABCDE...
Scrolling text displaying operation information
19 . Room control and management of peripherals
AUTO function activated (Temperature regulation activated) with indication of any internal (BUS) or external sensors connected. See page 33 for AUTO function details
Display Info menu
Clip-in solar connected (optional) Constant = solar clip-in connected Flashing = use of solar energy activated
Overall view
1 2 3
4
6 7 8
11 12
13
product description
1. flue connector
25
2. manual air vent
3. burner
24
4. detection Electrode
6. C.H. Return temperature probe
7. C.H. Flow temperature probe
8. gas valve
11. trap
23
12. C.H. pressure relief valve
22
13. electrical box
15. C.H. circuit filter
17. circulation Pump with air release valve
19. water pressure sensor
21
20. silencer
21. modulating Fan
20
22. ignition electrodes
23. ignitor
24. thermal fuse
25. combustion Analysis Test Point
19
17
15
Overall Dimensions
200
200
120 120
24/30/38
180
770
132 67 65
28
150
A. Central Heating Flow C. Gas Inlet D. Cold Mains Connection E. Central Heating Return
770
25
Minimum clearances In order to allow easy access to the boiler for maintenance operations, The boiler must be installed in accordance with the clearances stated below.
550
550
450
300 300
product description
Technical Data
GENERAL NOTE
POWER SPECIFICATIONS
EMISSIONS
Model GENUS HE System
CE Certification (pin)
Boiler type
Max/min nominal calorific flow rate (Pci)
Qn
Max/min nominal calorific flow rate (Pcs)
Qn
Max/min power output (80°C-60°C)
Pn
Max/min power output (50°C-30°C)
Pn
Combustion efficiency (of flue gas)
Nominal calorific flow rate efficiency (60/80°C) Hi/Hs Nominal calorific flow rate efficiency (30/50°C) (condensation) Hi/Hs
Efficiency at 30% at 30°C (condensation) Hi/Hs Efficiency at 30% at 47°C Hi/Hs
Minimum calorific flow rate efficiency (60/80°C) Hi/Hs Efficiency rating (dir. 92/42/EEC)
SEDBUK rating Loss when stopped (T = 50°C)
Loss of burner gas when operating Available air pressure
NoX class (Class 5 = Less than 70mg/kWh) Flue gas temperature (G20) (80°C-60°C)
CO2 content (G20) (80°C-60°C) CO content (0%O2) (80°C-60°C)
O2 content (G20) (80°C-60°C) Maximum flue gas flow (G20) (80°C-60°C)
Excess air (80°C-60°C) Expansion chamber inflation pressure
Maximum heating pressure Expansion chamber capacity
Maximum water capacity within the appliance (75°C-35°C) Min/max heating temperature (high temperature range)
Min/max heating temperature (low temperature range) Domestic hot water max/min temperature
Specific flow rate of domestic hot water (T=30°C) Quantity of hot water T=25°C
Quantity of hot water T=35°C Hot water comfort rating (EN13203)
Hot water minimum flow rate Domestic hot water max/min pressure
Power supply frequency/voltage Total electrical power absorbed
Minimum ambient temperature for use Protection level for the electrical appliance
Weight Dimension (W x H x D)* * Height includes valve cover)
24
30
0085BR0347
B23-C13-C33-C43-C53-C83
kW
22.0/5.5
28.0/6.5
kW
24.4/6.1
31.1/7.2
kW
21.6/5.2
27.4/6.2
kW
23.5/6.0
30.0/6.9
%
97.9
97.9
%
98.0/88.2 98.0/88.2
%
107.0/96.4 107.0/96.4
%
108.0/97.3 108.0/97.3
%
101.0/90.9 98.2/88.4
% stars Band / %
%
95.0/85.5 ****
A / 90.3 0.2
95.6/86.1 ****
A / 90.3 0.1
%
2.1
2.1
Pa
137
141
class
5
5
°C
63
63
%
9.0
ppm
< 100
9.0 < 100
%
4.5
4.5
Kg/h
41.2
49.4
%
27
27
bar
1
1
bar
3
3
L
6,5
6,5
L
100/300
100/300
°C
35/82
35/82
°C
20/45
20/45
°C
36/60
36/60
l/mn
12,0
15,0
l/mn
14,4
18,0
l/mn
10,3
12,9
stars
***
***
l/mn
< 2
bar
10/0,3
< 2 10/0,3
V/Hz W
230/50 114
230/50 115
°C
+5
+5
PI
X5D
X5D
kg
32
35
mm 440/820/385 440/820/455
HEATING CIRCUIT
DOMESTIC HOT WATER CIRCUIT
ELECTRICAL
Reference Standards 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.
In the Republic of Ireland the installation and initial start-up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 "Domestic Gas Installations" and the current Building Regulations, reference should also be made to the current ETCI rules for electrical installation.
The installation of this appliance must be in accordance with the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the by-laws of the local authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635, "Electricity at Work Regulations 1989" and in the Republic of Ireland with the current edition of I.S. 813 and the Local Building Regulations (IE).
C.O.S.H.H. Materials used in the manufacture of this appliance are nonhazardous and no special precautions are required when servicing.
Codes of Practive Installation should also comply with the following British Standards Code of Practice:
BS 7593:1992
BS 5546:1990
BS 5440-1:2000 BS 5440-2:2000 BS 5449:1990 BS 6798:2000
BS 6891:1989
BS 7671:2001 BS 4814:1990 BS 5482:1994
Treatment of water in domestic hot water central heating systems Installation of hot water supplies for domestic purposes Flues Air supply Forced circulation hot water systems Installation of gas fired hot water boilers of rated input not exceeding 70kW Installation of low pressure gas pipes up to 28mm IEE Wiring Regulations Specification for expansion vessels Installation of L.P.G.
and in the Republic of Ireland in accordancce with the following codes of practice:
I.S. 813
Domestic Gas Installations
Avoid installing the boiler where the air inlet can be polluted by chemical products such as chlorine (swimming pool area), or ammonia (hair dresser), or alkalin products (launderette).
Flue Detailed information on flue assembly can be found in the "Connecting the Flue" section. The boiler must be installed so that the flue terminal is exposed to the free passage of external air at all times and must not be installed in a place likely to cause nuisance. It must not be allowed to discharge into another room or space such as an outhouse or closed lean-to.
Condensing boilers have a tendency to form a plume of water vapour from the flue terminal due to the low temperature of the flue gasses. The terminal should therefore be located with due regard for the damage or discolouration that may occur to
installation
building within the vicinity and consideration must also be given to adjacent boundaries, openable windows should also be taken into consideration when siting the flue.
The minimum acceptable clearances are shown below:
- A Directly below an opening, window, etc
300 mm
- B Horizontally to an opening, window, etc
300 mm
- C Below gutters, soils pipes or drain pipes
75 mm
- D Below eaves200 mm
- E From vertical drain pipe or soil pipe
75 mm
- F From internal or external corner
300 mm
- G Above ground, roof or balcony level
300 mm
- H From a surface facing the terminal2500 mm
- I From a terminal facing a terminal2500 mm
- J Vertically from a terminal on the same wall
1500 mm
- K Horizontally from an terminal on the same wall 300 mm
- L Fixed by vertical flue terminal
Note: The flue must not be installed in a place likely to cause a
nuisance and positioned to ensure that products of combustion do not discharge across a boundary
It may be necessary to protect the terminal with a guard, if this is the case it will be necessary to purchase a stainless steel terminal guard. Reference should be made to the Building Regulations for guidance.
Ventilation The room in which the boiler is installed does not require specific ventilation. If the boiler is installed in a cupboard or compartment ventilation is not required for cooling purposes.
Gas Supply The gas installation and tightness testing must be in accordance with the requirements of BS6891. Ensure that the pipe size is adequate for demand including other gas appliances on the same supply.
Electrical Supply The appliance requires an earthed 230V - 50 Hz supply and must be in accordance with current I.E.E. regulations. It must also be possible to be able to completely isolate the appliance electrically. Connection should be via a 3 amp double pole fused isolating switch with contact separation of at least 3mm on both poles. Alternatively, a fused 3 amp, 3 pin plug and unswitched socket may be used, provided it is not used in a room containing a bath or shower, it. It should only supply the appliance.
installation
Water Supply The boiler is suitable for sealed systems only. The maximum working pressure for the appliance is 3 bar. All fittings and pipework for the appliance should be of the same standard.
Flushing and Water Treatment The boiler is equipped with a stainless steel heat exchanger.
The detailed recommendations for water treatment are given in BS 7593:1992 (Treatment of water in domestic hot water central heating systems); the following notes are given for general guidance;
If the boiler is installed on an existing system, any unsuitable additives must be removed.
Under no circumstances should the boiler be fired before the system has been thoroughly flushed; the flushing procedure must be in line with BS 7593:1992.
We highly recommend the use of a flushing detergent appropriate for the metals used in the circuit. These include cleansers produced by Fernox BetzDearbon, whose function is to disolve any foreign matter that may be in the system.
In hard water areas or where large quantities of water are in the system the treatment of water to prevent premature scaling of the main exchanger is necessary.
The formation of scale heat compromises the efficiency of the thermic exchanger 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.
Demineralised water is more aggressive so in this situation it is necessary to treat the water with an appropriate corrosion inhibitor.
Any treatment of water by additives in the system for frost protection or for corrosion inhibition has to be absolutely suitable for all metals used in the circuit.
The use of a corrosion inhibitor in the sysem such as Fernox MB-1, BetzDearborn Sentinel X100 or Fernox System Inhibitor is recommended to prevent corrosion (sludge) damaging the boiler and system.
If anti-freeze substances are to be used in the system, check carefully that they are compatible with the metals used in the circuit.
MTS suggests the use of suitable anti-freeze products such as Fernox ALPHI 11, which will prevent rust and incrustation taking place. Periodically check the pH balance of the water/anti-freeze mixture of the boiler circuit and replace it when the amount measured is out of the range stipulated by the manufacturer (7 < pH < 8). DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE
In under-floor systems, the use of plastic pipes without protection against penetration of oxygen through the walls can cause corrosion of the systems metal parts (metal piping, boiler etc), through 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 10
4726/4729. If pipes of this kind are not used, keep the system separate by installing heat exchangers of those with a specific system water treatment.
IMPORTANT Failure to carry out the water treatment procedure will invalidate the appliance guarantee.
System Controls The boiler is electrically controlled and is suitable for most modern electronic time and temperature controls. The addition of such external controls can be beneficial to the efficient operation of the system. The boiler connections for external controls are 12V DC and so only controls of 12V DC that have voltage free contacts should be used. (page 24). MTS supply a range of wired and wireless system controls. Contact your supplier for more details.
Location The boiler can be installed on any suitable internal wall (suitable sound proofing may be required when installing onto a stud partition wall). Provision must be made to allow for the correct routing of the flue and siting of the terminal to allow the safe and efficient removal of the flue products. A compartment or cupboard may be used provided that it has been built or modified for this purpose. It is not necessary to provide permanent ventilation for cooling purposes. Detailed recommendations are given in BS 5440 Part 2. If it is proposed that it is to be installed in a timber framed building then reference should be made to British Gas Document DM2, GE/ UP/7 or advice sought from CORGI.
Where a room sealed appliance is installed in a room containing a bath or shower, the appliance and any electrical switch or appliance control, utilising mains electricity should be situated specifically in accordance with current IEE Wiring Regulations.
For unusual locations, special procedures may be necessary. BS 6798:2000 gives detailed guidance on this aspect.
Codensate Discharge The condensate discharge hose from the boiler must have a continuous fall of 2.5o and must be inserted by at least 50mm into a suitable acid resistant pipe - e.g. plastic waste or overflow pipe. The condensate discharge pipe must have a minimum diameter of 22mm, must have a continuous fall and preferably be installed and terminated to prevent freezing. The discharge pipe must be terminated in a suitable position:
i) Connecting into an internal soil stack (at least 450mm above the invert of the stack). A trap giving a water seal of at least 75mm must be incorporated into the pipe run, there also must be an air beak upstream of the trap.
ii) Connecting into the waste system of the building such as a washing maching or sink trap. The connection must be upstream of the washing machine/sink. If the connection
is down stream of if the waste trap then an additional trap giving a minimum water seal of 75mm 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 soakaway
installation
Note: If any condensate pipework is to be installed externally then it should be kept to a minimum and be insulated with a waterproof insulation and have a continuous fall. The total length of external pipe used should not exceed 3 metres.
3. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste - proprietary fitting).
Some examples of the type of condensate terminations can be found below.
1. Internal termination of condensate drainage pipe to internal stack.
4. External termination of condensate drainage pipe via condensate siphon
2. External termination of condensate drainage pipe via internal discharge branch (e.g. sink waste) and condensate siphon.
11
installation
Installing the Boiler Please check that you are familiar with the installation requirement before commencing work (pages 7 - 11).
The installation accessories described in the following list are included in the boiler packaging: - Hanging bracket - A paper template (showing the dimensions of the boiler with
5 mm side clearances) - Connection valves (compression) - Screws and washers - Filling loop - Installation, Servicing and Operating Instructions - Flue gasket
Method of positioning the boiler on the wall The paper template can be used to ensure the correct positioning of kitchen cabinets etc.
The paper template has to be fixed to the wall and used to locate the position of the hanging bracket and the centre for the flue hole. Drill and plug the wall and secure the hanging bracket using the screws provided ensure the hanging bracket is level. Remove the boiler from its packaging and remove the front casing panel. Place the boiler on the hanging bracket.
Note: The appliance must not be fitted on a combustible wall surface.
Connecting the Boiler to the System - Remove the boiler casing as described on page 13; - Remove the caps and connect the valves to the boiler using
the washers provided; - 3 x fibre washers for the CH flow and return and cold water
inlet ;
Safety Valve Discharge and Condense Outlet The pressure relief valve pipe is made of copper. It should terminate below the boiler safely outside the premises. Care should be taken that it does not terminate over an entrance or window or where a discharge of heated water could endanger occupants or passers by.
Warning ! Do not apply heat to the copper safety valve outlet pipe whilst it is connected to the 3 bar safety relief valve.
Fill the central heating and DHW system and bleed air from the system as described in the Commissioning instructions (page 26).
The system should be carefully checked for leaks, as frequent refilling could cause premature system corrosion or unnecessary scaling of the heat exchanger. The pipe from the trap should be connected to a drain as described in the relevant regulations.
Pay special attention not to bend the condensate silicone drain pipe is such a way as to interrupt the flow. Please only use drain pipe material compatible with condensate products (refer to BS 6798:2000).
The condensate flow can reach 2 litres/hour because of the acidity of the condensate products (Ph close to 2), take care before operation.
See page 11 for condensate discharge options.
12
Note: Connections viewed from behind boiler
A A
- remove the 2 screws A from the transport bar - dispose of the transport bar and reassemble
the fixing screws.
Gas connection
Make sure, using the labels on the packaging and the data plate on the appliance itself, that the boiler is in the correct country and that the gas category for which the boiler was designed corresponds to one of the categories available in the country where it will be used. The gas supply piping must be created and measured out in compliance with specific legal requirements and in accordance with the maximum power of the boiler; you should also make sure that the shut-off valve is the right size and that it is connected correctly. Check that the supplied gas corresponds to the type of gas for which the boiler was designed (see the data plate located on the appliance itself ). It is also important to check that the pressure of the gas (methane or LPG) you will be using to feed the boiler is suitable, because if it is insufficient the power may be reduced, causing inconvenience for the user.
installation
Instructions for opening the casing and performing an internal inspection Before performing any work on the boiler, first disconnect it from the electrical power supply using the external bipolar switch removing the fuse and shutting off the gas valve. To access the inside of the boiler, the following is necessary: 1. Remove the casing by unhooking it from the control panel (a) 2. Loosen the two screws on the front casing (b), pull it forwards
and unhook it from the upper pins (c) 3. Lower the control panel (d) 4. Unhook the two clips on the combustion chamber panel and
lift off (e).
(a)
(b)
Water connection
The illustration below shows the connections for the water and
gas attachments of the boiler. See valves configuration on page
(c)
12.
(d)
For the measuring of the pipes and of the heating bodies in the heating system, the residual head value should be calculated as a function of the requested flow rate, in accordance with the values shown in the circulation pump graph on page 14.
E D
F
C
H A
(e)
I
A. Central Heating Flow C. Gas Inlet D. Cold Mains Connection E. Central Heating Return F. Safety Valve Discharge H. Drain Valve I. Condensate Drain
13
installation
To calculate the size of the heating installation, refer to the "Available pressure" graph below. Graph representing the available circulation pump pressure T20oC
Water circuit diagram
mbar
500
450
1
400
350
3300k-W35 kW
3
22
300
24 kW
4
21
250
200
150
100
50
5
0
20
0
100 200 300 400 500 600 700 800 900 1000 1100 1200
l/h
6
Before the equipment is used, for the first time the trap
19
must be filled with water. To do this, add approximately
1/4 litre of water via the flue outlet before fitting the flue
system, or unscrew the cap on the trap positioned under-
18
neath the boiler, fill it with water and refit it
Warning! insufficient water in the trap can temporarily
8
17
cause the flue gas to be expelled into the surrounding
ambient air
10 11
12
14
G
E
D
F B
A
C H
I
Underfloor heating For appliances with underfloor heating, fit a safety thermostat onto the underfloor heating outlet. For the electrical connection of the thermostat see the section on "Electrical connections - page 24".
If the outlet temperature is too high, the boiler will stop both domestic hot water and the heating production and the error code 1 16 "floor thermostat contact open" will appear on the display. The boiler will restart when the thermostat is closed during automatic resetting.
If the thermostat cannot be installed, the underfloor heating equipment must be protected by a thermostatic valve, or by a by-pass to prevent the floor from reaching too high a temperature. 14
A
C
E
1. Manual air vent 3. Burner 4. Detection electrode 5. C.H. return temperature
probe 6. C.H. flow temperature
probe 8. C.H. pressure relief valve 10. By-pass 11. Drain valve 12. Condense trap
14. C.H. circuit filter 17. Water pressure sensor 18. Circulation pump 19. Expansion vessel 20. Modulating fan 21. Ignition electrodes 22. Thermal fuse
Connecting the Flue 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. The terminal should be located with due regard for the damage or discolouration that might occur on buildings in the vicinity, it must also be located in a place not likely to cause nuisance. In cold or humid weather water vapour may condense on leaving the flue terminal. The effect of such "steaming" must be considered. If the terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable stainless steel terminal guard must be fitted.
The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig. 1.
installation
Fig. 1
- A Directly below an opening, window, etc
300 mm
- B Horizontally to an opening, window, etc
300 mm
- C Below gutters, soils pipes or drain pipes
75 mm
- D Below eaves200 mm
- E From vertical drain pipe or soil pipe
75 mm
- F From internal or external corner
300 mm
- G Above ground, roof or balcony level
300 mm
- H From a surface facing the terminal2500 mm
- I From a terminal facing a terminal2500 mm
- J Vertically from a terminal on the same wall
1500 mm
- K Horizontally from an terminal on the same wall 300 mm
- L Fixed by vertical flue terminal
S4ee table on page 21
See table
181018 mm
118 mm
Fig. 2 15
installation
Warning The exhaust gas ducts must not be in contact with or close to inflammable material and must not pass through building structures or walls made of inflammable material. When replacing an old appliance, the flue system must be changed.
Important Ensure that the flue is not blocked. Ensure that the flue is supported and assembled in accordance with these instructions.
Installation without extension
Level
118
150 mm
Installation with extension *slpoepnete
Fig. 3
Level
slope*5pemntem5 mpmepramr meètrree
150 mm
Fitting the Coaxial Flue (Ø 60 / 100 Horizontal)
Contents: 1x Silicone O-Ring (60mm) 1x Elbow (90°) 2x Wall Seals (Internal & External) 1x Flue Pipe including Terminal (1 metre - 60/100) 2x Flue Clamps 4x Screws 2x Seals
Once the boiler has been positioned on the wall, fit the rubber flue seal into the internal flue turret (see Fig. 2),
insert the elbow into the socket and rotate to the required position. note: It is possible to rotate the elbow 360° on its vertical axis.
Using the flue clamp, seals and screws supplied (Fig 4) secure the elbow to the boiler.
The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact X dimension of 753mm.
Measure the distance from the face of the external wall to the face of the flue elbow (X - Fig 2), this figure must now be subtracted from 753mm, you now have the total amount to be cut from the plain end of the flue.
Draw a circle around the outer flue and cut the flue to the required length taking care not to cut the inner flue, next cut the inner flue ensuring that the length between the inner and outer flue is maintained. (Fig 4).
16
e.g. X = 555mm 753-555 = 198mm (Length to be cut from the plain end of the
flue).
Once cut to the required length, ensure that the flue is free from burrs and reassemble the flue. If fitting the flue from inside of the building attach the grey outer wall seal to the flue terminal and push the flue through the hole, once the wall seal has passed through the hole, pull the flue back until the seal is flush with the wall. Alternatively, the flue can be installed from outside of the building, the grey outer seal being fitted last.
Should the flue require extending, the flue connections are push fit, however, one flue bracket should be used to secure each metre of flue.
Note: See table for maximum and minimum flue runs.
Clamp
installation
Screws Seal
Fitting the 5" Flue (Ø 80 / 125 Horizontal/vertical)
Total length of vertical kit 1240 mm
180 mm
Fig. 5
Fig. 4
Once the boiler has been positioned on the wall, it is necessary to insert the Ø80/125 adaptor (Fig. 5) for both horizontal and vertical flue runs into the boiler flue socket (not supplied with flue kit - Part No 3318095).
Push the adaptor onto the boilers flue connection, grease the seals then add extensions or elbows as required, secure the adaptor, using the clamp and screws provided.
To fit extensions or elbows it is first necessary to ensure that the Useable length of lip seal is fitted correctly into the inner flue, once verified, it is vertical ue 575 mm* simply necessary to push them together, no clamps are neces-
sary to secure the flue components.
Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90° elbow 1 metre must be subtracted from the total flue length, and for each 45° 0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45° bend can be seen in Fig.6 and a 90° bend in Fig. 7).
Note: DO NOT cut the vertical flue kit.
Fig. 6
Fig. 7 17
installation
Fitting the Coaxial Flue (Ø 60 / 100 Vertical)
Total length of Vertical Kit 1355 mm
180 mm
Fig. 7
Fig. 8
Useable length of Vertical ue 690 mm*
Note: See table for maximum and minimum flue runs.
Contents: 1x Silicone O-Ring (60mm) 1x Conical Adaptor (60/100mm) 1x Vertical Flue Kit (80/125mm) 3x Screws
The vertical flue kit is supplied with a specially designed weather proof terminal fitted, it can be used either with a flat roof or a pitched roof.
The Vertical flue kits useable lengths with the pitched roof flashings are indicated in Fig. 7.
Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the maximum flue length is see table, for each additional 90° elbow 1 metre must be subtracted from the total flue length, and for each 45° 0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45° bend can be seen in Fig. 8).
Mark the position of the flue hole in the ceiling and/or roof (see Fig. 7 for distance from wall to the centre of the flue).
Cut a 130mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof.
DO NOT cut the vertical flue kit.
To connect the vertical flue kit directly to the boiler, place the vertical starter kit (Part No. 3318079) (see Fig. 7) onto the exhaust manifold and secure with the clamp, fit the vertical adaptor onto the vertical starter kit (note: there is no need to use a clamp to secure this as it is a push fit connection), the vertical flue kit must then be inserted through the roof flashing, this will ensure that the correct clearance above the roof is provided as the terminal is a fixed height.
Should extensions be required, they are available in 1 metre (Part No. 3318077), 500mm (Part No. 3318078) and 160mm lengths, they must be connected directly to the vertical starter kit before connecting the adaptor to allow the vertical flue kit to be fitted. In the event that extension pieces need to be shortened, they must only be cut at the male end and it must be ensured that the inner and outer flue remain flush.
When utilising the vertical flue system, action must be taken to ensure that the flue is supported adequately to prevent the weight being transferred to the appliance flue connection by using 1 flue bracket per extension.
When the flue passes through a ceiling or wooden floor, there must be an air gap of 25mm between any part of the flue system and any combustible material. The use of a ceiling plate will facilitate this. Also when the flue passes from one room to another a fire stop must be fitted to prevent the passage of smoke or fire, irrespective of the structural material through which the flue passes.
18
Fitting the Twin Pipe (Ø80 / 80)
installation
When siting the twin flue pipe, the air intake and exhaust terminals must terminate on the same wall, the centres of the terminals must be a minimum of 280 mm apart and the air intake must not be sited above the exhaust terminal (refer to Fig. 10). The air intake pipe can be run horizontally, however, the terminal and the final 1 metre of flue must be installed either horizontally or with a slight fall away from the boiler to avoid rain ingress.
It is also strongly recommended that the air intake pipe run be constructed of insulated pipe to prevent condense forming on the outside of the tube.
The maximum permissible flue length for twin flue is dependent on the type of run used (see table on page 21).
For further information relating to flue runs not illustrated, please contact the Technical Department on 0870 241 8180.
Use only the specific condensation flue kit
Note: See table for maximum and minimum flue runs.
Where it is not possible to terminate the flue within the distance permitted for coaxial flues, the twin flue pipe can be used by fitting a special adaptor to the flue connector and using the aperture for the air intake located on top of the combustion chamber.
Always ensure that the flue is adequately supported, using one flue bracket per extension and avoiding low points. (MTS supply suitable clamps as Part No. 705778). To utilise the air intake it is necessary to:
1) Take the air intake cover off the top of the appliance 2) Assemble the flange on the header supplied with the boiler 3) Insert the header on the tube or the elbow up until the lower stop (you do not have to use the washer). 4) Insert the elbow/header in the boiler air intake hole and fasten it with screws.
The twin flue pipes can be fitted with or without additional elbows and need no clamps, simply ensure that the red o-ring is inserted in the female end of the flue pipe and push the extension piece fully into the previous section of flue pipe or elbow, check that the o-ring is not dislodged when assembling the flue (greasing the seal will aid assembly).
Twin pipe can also be converted back to Coaxial flue to enable vertical termination with a coaxial kit by using the pipe bridge (Twin - Coaxial Adaptor - Part No. 3318089). When running the twin flue pipe vertically.
It is not possible to terminate concentrically horizontally. Termination is only possible with separate air and exhaust terminals.
19
installation
120
180
195 105
Fig. 9
AIR IN TAKE MUS T NO T BE FITTED ABOVE THE EXHAUS T
AIR IN TAKE
EXHAUS T
For coaxial systems, the maximum development value, mentioned in the table below also takes into account an elbow. For twin flue systems the maximum development value, mentioned in the table includes the exhaust gas/air intake terminal.
Type 5 outlets should respect the following instructions: 1- Use the same ø 80 mm flue pipes for the air intakes and
exhaust gas ducts. 2- If you need to insert elbows in the air intake and exhaust gas
ducts, you should consider for each one the equivalent length to be included in the calculation of developed length. 3- The exhaust gas duct should jut above the roof by at least 0.5 m. 4- The intake and exhaust gas ducts in Type C13 + C53 must be installed on the same wall, or where the exhaust is vertical and the air intake horizontal, the terminals must be on the same side of the building.
AIR IN TAKE
Fig. 10
20
Table of flue gas exhaust duct lengths
installation
COAXIAL SYSTEM
FLUE TYPE
C13
Flue gas exhaust and air suction duct through external wall in the same range
of pressure
24 kW
MAX LENGTH
12 m 36 m
DIAMETER of PIPE
60/100 80/125
Length equivalency for
45º elbow
0.5m
90º elbow
1.0 m
10 m 30 m
60/100 80/125
30 kW
24 kW
C 33 Flue gas exhaust and air suction duct from outside with roof terminal in the
same range of pressure
C43 Individual or shared flue gas exhaust and air suction through flue ducting built into
the building
24 kW
30 kW
12 m 42 m
60/100 80/125
10 m 35 m
60/100 80/125
12 m 0 m
60/100 80/125
10 m 0 m
60/100 80/125
30 kW
21
installation
TWIN-PIPE SYSTEM
FLUE TYPE
C13
Flue gas exhaust and air suction duct through external wall in the same range
of pressure
C 33
Flue gas exhaust andair suction duct from outsidewithroof terminalin the same range of pressure
C53
Flue gas exhaust leading outside and air suction duct through external wall not in
the same range of pressure
35 kW 30 kW 24 kW 35 kW 30 kW 24 kW 35 kW 30 kW 24 kW
MAX DIAMETER of
Length
LENGTH
PIPE
equivalency for
36 m (S1=S2)
45º elbow
1.4m
30 m (S1=S2)
18 m (S1=S2)
80/80
90º elbow
45º elbow
90º elbow
2.2 m 1.4m 2.2 m
60 m (S1=S2)
50 m (S1=S2)
21 m (S1=S2)
80/80
45º elbow
90º elbow
45º elbow
90º elbow
1.4m 2.2 m 1.4m 2.2 m
84 m (S1+S2)
70 m (S1+S2)
42 m (S1+S2)
80/80
45º elbow
90º elbow
45º elbow
90º elbow
1.4m 2.2 m 1.4m 2.2 m
S1 = Air intake S2 = Flue gas exhaust
S1 = S2 - Air intake and flue gas exhaust equal lengths S1 + S2 - Air intake and flue gas exhaust unequal lengths
22
WARNING Before performing any work on the boiler, first disconnect it from the electrical power supply using the external bipolar switch and remove the fuse.
Electrical connections For increased safety, ask a qualified technician to perform a thorough check of the electrical system. The manufacturer is not responsible for any damage caused by the lack of a suitable earthing system or by the malfunctioning of the electricity mains supply. Make sure that the system is able to withstand the maximum power absorbed by the boiler (this is indicated on the appliance data plate). Check that the section of the wires is suitable and is not less 0,75 mm2 The appliance must be connected to an effiecient earthing system if it is to operate correctly. The power supply cable must be connected to a 230V-50Hz network, where the L-N poles and the earth connection are all respected. Important! In the event that the power supply cable must be changed, replace it with one with the same specifications.
Power supply cable
120
140
H05V2V2-F
Important! The appliance is supplied with a fly-lead already connected, this must be connected to a 240V supply fused at 3 Amp and must facilitate completed electrical isolation of the appliance, by use od a fused double pole isolator having a contact separation of at least 3mm in all poles or alternatively by means of a 3A fused three pin plug and unswitched shuttered socket outlet both complying with BS1363.
The use of multiplugs, extension leads or adaptors is strictly prohibited. It is strictly forbidden to use the piping from the hydraulic, heating and gas systems for the appliance earthing connection. The boiler is not protected against the effects caused by lightning. If the mains fuses need to be replaced, use 2A rapid fuses.
installation
Peripheral unit connection To access peripheral unit connections carry out the following steps: - Disconnect the boiler from the power supply - Remove the casing by unhooking it from the instrument
panel - Rotate the control panel while pulling it forwards - Unscrew the three screws on the back cover of the instrument
panel - Unhook the right side clip and the right front clip; then lift the
flap
The terminal block (see figure) may be accessed in order to connect: Outdoor sensor Room thermostat 1 - other plugs: for managing multi-zones
multitemperatures, Solar kit, etc...
Optional P.C.B.s can also be installed for further accessories:
BUS P.C.B.
Clima Manager
Modulating Room Sensor
Programmable Room Thermostat
Outdoor Sensor
Caution! For the connection and positioning of the wires belonging to optional peripheral units, please refer to the installation manuals of these units.
23
installation
Room thermostat connection - Introduce the thermostat wire - Loosen the cable clamp using a screwdriver and insert the
wires leading from the room thermostat one at a time. - Connect the wires to the terminals as indicated in the figure
below, removing the link - Make sure that they are well connected and that they are
not subject to stress when the control panel lid is opened or closed - Close the flap again, then replace the control panel cover and the front casing.
TP/ TA1 TA2
SE
CARTE CHAUDIERE AMPC-GAL1
EmplaCcLeIPmIeNnt carte2oZptoinoensnelle Transmetteur BUS (Optionnel)
Connector TA on PCB (low voltage switching)
Connector TA on PCB (low voltage switching)
Connector TA on PCB (low voltage switching)
Outdoor sensor connection - Introduce the outdoor sensor wires - Loosen the cable clamp using a screwdriver and insert the
wires leading from the outdoor sensor one at a time. - Connect the wires to the terminals as indicated in the figure
below; - Make sure that they are well connected and that they are
not subject to stress when the control panel lid is opened or closed; - Close the flap again, then replace the control panel cover and the front casing. - Refer to page 41 for setting the parameters when using the outdoor sensor.
Outdoor Sensor
The boiler can be connected to a central heating system that uses two zone valves to allow connection to an indirect storage cylinder.
There are two wiring diagrams shown, one for connection to an Unvented Cylinder and one for connection to an open vented cylinder. In both cases the boiler connection is shown as TA1.
When connecting the boiler to an external cylinder do not run 240V cables and the cables for the room terminal together, use separate cables to prevent induced voltage on the low voltage switching circuit.
Note:
The use of a `Y' plan system is not possible with the GENUS HE SYSTEM boiler due to low voltage switching of the appliance, unless suitable relay controls are used.
Important! Ensure that a balancing valve is fitted on the cylinder return and balanced correctly at the commissioning stage.
Note:
Connector SE on PCB
When connecting the boiler to external controls, do not run 240V cables and cables for switching circuits (which are low voltage) together, use seperate cables to prevent induced voltage on the low voltage circuits.
24
LN
1 23 4 5 6 1 2 3 4
Electrical diagram For increased safety, ask a qualified technician to perform a thorough check of the electrical system. The manufacturer is not responsible for any damage caused by the lack of a suitable earthing system or by the malfunctioning of the electricity mains supply.
TP/ TA1 TA2
SE
Vdalivvoelartdeerv. movtoarlivzezata
Elettrovalvola riempimento
circulation Cpircuomlaptore
gas valve Valvola gas iAgcnceitnodritore
bus trbaunssC-ltLarItaoPnrsI(laoNtpotrional) (op2tiZonoaln)es
OptiosPrcnehaldeidbseopaoorsipdzziipoolnantaelei
FUSE 2AT
FLOW
25
TA1 RToeormotshteartmo oasmtabtie1nctoen1n-eoctpiotinon(Oalptional)
TP/TA2 LToewrmteomstpateoraatupraevfilmooernhtoeapteinrgimthpeiarmntoi stat
(afabctaosrsyestetmtinpger)ature - optional -(oseptttiaogngailo, odriRfoabobmritchae),rmo Toesrtmato2stcaotnonection -Asmeebpieanratem2et-evr e2d2i3p- a(roapmtieotnraol)223
SE ESxotnerdioaressetnersnoar c-oOnpnteiocntiaoln (optional)
ZONE1 FILLING1 PUMP PUMP FAN 1 SPEED
Connessione sonda solare
21
CN04
1110 9 8 7 6 5 4 3 2 1
4 3 21
VALVOLA ACCENDITORE GAS
CN22
121110 9 8 7 6 5 4 3 2 1
Collegamento schedino BUS
CN07
87654321
ON
Flussimetro sanitario
6
1
8
1
5
Display
1
Didspislpalyay
EARTH
FLAME
deteElcettitorondo elReilcetvraozdioene
CN04 1110 9 8 7 6 5 4 3 2 1
Sonda NTC sanitario P SWeantseorrepdrei pssreusrseiosneensor
CN22 13121110 9 8 7 6 5 4 3 2 1
mVeontdiluatloarteing fan
SonCd.aHN. TflCow mtaenmdapt.aprrisocb. e
SonCd.Ha .NrTeCturn rittoermnopr.ispcr.obe
Tscetarhmme.brpmiarotaotlerfezuiosene
installation
installation Wiring Diagram For Connection To An Open Vented Cylinder
26
Wiring Diagram For Connection To An MTS Unvented Cylinder
installation
27
commissioning
Initial preparation
BS 7593:1992 (Treatment of water in domestic hot water central
MTS(GB)Limited support the benchmark initiative. Onpages heating systems); the following notes are given for general
pages 63 and 64 of this manual the Benchmark Commissioning guidance;
Checklist and Service interval Record can be found. 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. If the boiler is installed on an existing system, any unsuitable
Please instruct your customer that they must have this manual additives must be removed;
with them whenever they contact a service engineer or us.
Under no circumstances should the boiler be fired before the
Preliminary electrical system checks to ensure electrical safety system has been thoroughly flushed; the flushing procedure
must be carried out by a competent person i.e. polarity, earth must be in line with BS7593:1992.
continuity, resistance to earth and short circuit.
Firstly fill the central heating system with the power off, and
Electricity supply
flush through cold, fill the central heating system again, adding
- Check that the voltage and frequency of the electricity supply a flushing detergent, run the boiler on central heating until it
correspond to the data shown on the boiler data plate;
reaches its operating temperature and flush the system, refill the
- Make sure that the earthing connection is efficient.
system with a suitable corrosion inhibitor,
Filling the Heating System: Remove the front casing panel and lower the control panel as described on page 13). Open the central heating flow and return cocks supplied with the connection kit; Lift the cap on the automatic air release valve and leave open permanently; Close all air release valves on the central heating system; Gradually open the valves at the filling point (filling loop)until water is heard to flow, do not open fully; Open each air release tap starting with the lowest point and close them only when clear water free of air is visible; Purge the air from the pump by unscrewing the pump plug anticlockwise, also manually rotate the pump shaft in the direction indicated by the pump label to ensure the pump is free; Refit the pump plug; Continue filling the system until at least 1.5 bar registers on the pressure gauge; Inspect the system for water tightness and remedy any leaks discovered.
Note:Failure to carry out the flushing procedure will result in the warranty becoming void.
Important! Manually vent the heat exchanger at the manual air vent. Failure to vent adequately may damage the heat exchanger (page 7, legend 2).
Gas Supply: Inspect the entire installation including the gas meter and test for tightness. The entire installation should be in accordance with the relevant standards. In GBthis is BS6891 and in IEthis is the current edition of I.S.813.
The connection on the the appliance is a 15mm nut and olive located at the rear of the gas service cock.
If the gas supply serves other appliances, ensure that an adequate supply is available both to the boiler and the other appliances when they are in use at the same time.
Pipe work must be of an adequate size. Pipes of less than 22mm should not be used, final connection being 15mm.
Open the gas cock (supplied with the connection kit) to the appliance and check the gas connection on the appliance for leaks.
Water Treatment: The boiler is equipped with a stainless steel heat exchanger. The detailed recommendations for water treatment are given in
28
FIRST IGNITION OPERATION
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer . . . . . . . . . . . . . . . . . . . . . . . . . . .
commissioning
1. Check the electrical supply.
Complete . . . . . . . . . . . . . . . . . . . .
2. Check the type of gas and change the gas if necessary.
Complete . . . . . . . . . . . . . . . . . . . .
3. Check the gas tightness.
Complete . . . . . . . . . . . . . . . . . . . .
4. Measure the gas inlet/ standing pressure
Complete . . . . . . . . . . . . . . . . . . . .
5. Check the flue installation. (See Connecting the flue)
Complete . . . . . . . . . . . . . . . . . . . .
6. Fill the installation and flush. See page 28
Complete . . . . . . . . . . . . . . . . . . . .
7. Check the hydraulic water tightness.
Complete . . . . . . . . . . . . . . . . . . . .
8. Spin the pump.
Complete . . . . . . . . . . . . . . . . . . . .
9. Purge air by pressing ESC button for 5 sec. & manually vent the exchanger
Complete . . . . . . . . . . . . . . . . . . . .
10. Change the language in the display (if necessary). Page 32.
Complete . . . . . . . . . . . . . . . . . . . .
13. Balance the central heating circuit.
Complete . . . . . . . . . . . . . . . . . . . .
11. Set the hour, and the date. See page 32
Complete . . . . . . . . . . . . . . . . . . . .
12. Set the heating power. See page 33
Complete . . . . . . . . . . . . . . . . . . . .
14. Measure the gas inlet working pressure.
Complete . . . . . . . . . . . . . . . . . . . .
15. Check the combustion rate. See page 34
Complete . . . . . . . . . . . . . . . . . . . .
16. Gas rate the appliance
Complete . . . . . . . . . . . . . . . . . . . .
17. Explain to the end user the working of the boiler and controls
Complete . . . . . . . . . . . . . . . . . . . .
29
commissioning
Ignition procedure Press the ON/OFF button on the control panel to switch on the boiler. The display shows:
- Start the deaeration cycle by pressing Esc for 5 seconds The boiler will start a deaeration cycle lasting about 7 minutes (See below). If you need to stop it press Esc, alternatively it is possible to manually vent the heat exchanger.
SumEtmé er
The operating mode will be indicated by the three figures marked out on the diagram above.
The first figure indicates the operating mode: 0 XX - Stand-by, the scrolling text show the operation mode
selected "summer" or "winter" C XX - "C.Heating active" - Central heating request c XX - "CH Pump Overrun" - Heating post-circulation b XX - DHW request (with storage cylinder connected) h XX - "DHW Pump Overrun" hot water post-circulation F XX - "Pump Frost Prot" - circulation pump anti-freeze
protection enabled - "Burn Frost Prot" - burner anti-freeze
protection enabled
The second and third figures indicate: - the flow temperature when no heating requests have been made - the flow temperature in central heating mode - the set temperature of the hot water in domestic hot water - the flow temperature in anti-freeze mode.
The indication of certain functions: P 1- "Purge in progress" = Deaeration cycle started
Electricity supply - Check that the voltage and frequency of the electricity supply
correspond to the data shown on the boiler data plate; - Make sure that the earthing connection is efficient.
menu 2 - Boiler parameters submenu 3 - parameter 1
Maximum Heating Power adjustment submenu 2 - parameter 0
Soft light Ignition submenu 3 - parameter 5
Heating ignition delay
First ignition 1. Make sure that:
- The gas valve is closed; - The electrical connection has been properly carried out.
Make sure that, in any case, the green/yellow earthing wire is connected to an efficient earthing system; - Use a screwdriver to lift the cap on the automatic air relief valve; - Switch on the boiler (by pressing the ON/OFF button) and use the Mode button to select the standby mode, where no hot water or heating requests are made.
SumEmtéer 30
DAéirgpauzarggee feunnctoiuorns - At the end, check that the system is completely deaerated
and, if not, repeat the procedure. - Bleed the air from the radiators; - The exhaust duct for combustion products should be suitable
and free from any obstructions; - Any necessary ventilation inlets in the room should be open
(type B installation). 2. Open the gas cock and check the connection seals, including
the boiler connection joints, making sure that the meter does not detect any passage of gas. Eliminate any leaks. 3. Start the boiler by selecting the heating or domestic hot water operation using the Mode button.
Description of Function Deaeration cycle During the filling stage or if there is excess air in the system, the deaeration cycle can be activated by holding the Esc button for 5 seconds. The boiler will start a cycle which lasts approximately 7 minutes. When this is complete the menu screen will be restored. The cycle may either be repeated, if necessary, or stopped by pressing Esc. Press the Esc button until the normal display screen is restored. If the cycle is stopped be sure to manually vent the appliance.
Maximum Heating Power adjustment The maximum heating power can be adjusted to between the maximum power allowed by the boiler and the minimum power). The display shows the value between 100% ("99" on the display) and 0% ("0") of this interval. To check the maximum heating power, access menu 2/sub menu 3/parameter 1, check the value and, if necessary, modify it as indicated in the Gas Regulation table. (See page 31 for more details).
3385 30
2245 18
12
Checking slow ignition power The soft light can be adjusted between the maximum power (shown on the display as "99", i.e. 100%) and the minimum power (shown on the display as "1", i.e. 1%). To check the slow ignition power, access menu 2/sub menu 2/ parameter 0.
Heating ignition delay adjustment This parameter menu 2/sub menu 3/parameter 5 - can be used to manually (0) or automatically (1) set the delay time before the subsequent reignition of the burner after it has switched off on reaching the desired temperature in central heating mode. By selecting manual, it is possible to set the delay in minutes using the successive parameter (menu 2/sub menu 3/parameter 6), to a time between 0 and 7 minutes. Automatic selection means that the boiler will establish the delay time based on the set-point temperature.
gas setting 24 kW
parameter G20 G31
30 kW G20 G31
38 kW G20 G31
lower Wobbe index (15°C, 1013 mbar) (MJ/m3)
45,67 70,69 45,67 70,69 45,67 70,69
minimum fan speed(%)
233
maximum central heating fan speed (%) 234
maximum D.H.W fan speed (%)
232
gas valve restrictor(ø)
gas flow max/min (15°C, 1013 mbar) (nat - m3/h) (GPL - kg/h)
max D.H.W max C.H.
min
05 05 01 01 01 01 85 85 80 80 70 70 98 98 89 89 89 89 NO 3,80 NO 4,50 NO 5,250 2,65 1,94 3,17 2,33 4,02 2,95 2,33 1,71 2,96 2,17 3,28 2,41 0,58 0,43 0,69 0,50 0,79 0,58
commissioning
31
commissioning
Basic set up instructions - Timer and Range Rating Power
When the GENUS HE appliance is first turned on, the language (optional), central heating timer and output power must be set up.. The following instructions detail the basic set up procedure which will satisfy most standard boiler installations. For more complicated installations, i.e. outside temperature sensing etc. additional settings may need to be altered to match the performance to the system requirements.
To begin, switch the electrical supply to the boiler on, press the ON/OFF button on the control panel once to switch the appliance on.
Setting the language Press the Menu/Ok button once (a flashing 0 appears on the left side of the display);
Press the Menu/Ok button again (00 appears on the display, the second 0 is flashing);
Press the Menu/Ok button again. The language appears at the bottom of the display.
Rotate the left hand control knob until the desired language is displayed;
Press Menu/Ok to save the setting;
`Value Saved' is displayed;
Press Esc twice to return to the normal display..
Setting the time, date, year and day of the week
Note:
The date is in yyyy/mm/dd format. Always use the left hand control knob to change settings.
Press the Menu/Ok button once (a flashing 0 appears on the left side of the display);
Press the Menu/Ok button again (00 appears on the display, the second 0 is flashing);
Rotate the control knob to change the display to 01. `Time + Date' is displayed at the bottom of the screen;
Press the Menu/Ok button, the days of the week will appear on the screen and hours will flash;
Rotate the controll knob to select the hour of the day and then press the mode button;
The minutes will flash. Rotate the control knob to select the minutes and press the mode button; The year will flash. Rotate the control knob to select the year and press the mode button;
The month will flash. Rotate the control knob to select the month and press the mode button;
The day of the month will flash. Rotate the control knob to select the day of the month and press the mode button;
The day of the week will flash. Rotate the control knob to select the day of the week;
32
Press the Menu/Ok button to save the settings;
`Value saved' is displayed;
Press Esc twice to return to the normal display.
Setting the time clock (same timed programme every day)
Using pre- set time settings
Press the Menu/Ok button once (a flashing 0 appears on the left side of the display);
Rotate the control knob to change the 0 to 01. `Set Timers' is displayed at the bottom of the screen;
Press the Menu/Ok button. 101 appears.
Rotate the control knob until 106 appears on the screen. `Pre-set timers' appears at the bottom of the display.
Press the Menu/Ok button. It is now possible to select one of three options: Preset Timers 1, 2 or 3.
Monday to Sunday Preset On Off Timer 1 5:30 22:00 Preset On Off On Off On Off Timer 2 6:00 8:00 11:30 13:00 17:00 22:00 Preset On Off On Off Timer 3 6:00 8:00 16:00 22:00
To select one of the preset times, rotate the control knob which scrolls between the three options;
Press Menu/Ok to save the selected option;
`Value Saved' is displayed;
Press `Esc' twice to return to the normal display.
To display the timer settings, the boiler MUST be in `Winter' mode, i.e. the radiator symbol (to the left of the tap symbol) is displayed.
To activate the `Winter' mode, press the mode button once, until the radiator symbol is displayed;
To initiate the timer press the button, the timer display is shown at the top of the screen;
For constant heating (`Winter' mode only - see above) press the so the timer display disappears. The boiler will now operate the central heating constantly;
To return to the timer function, press the button. The timer display will reappear.
Selecting your own times options (Monday to Sunday)
The time clock is initially set with all time segments selected for the 24 hour period i.e. constant operation.
If a pre-set time pattern has been selected, this will be displayed.
The following instructions assume the full 24 hour time period has been selected, i.e. constant operation. To set the on/off times for the boiler the relevant `OFF' periods must be set as follows:
Press the Menu/Ok button once (a flashing 0 appears on the left side of the display)
Rotate the control knob to change 0 to 1. `Set Timers' appears at the bottom of the display;
Press Menu/Ok button 101 appears on the screen. Monday Sunday appears at the bottom of the display;
Press the Menu/Ok button, the clock display appears and `Move Cursor' appears at the bottom of the display'
All time periods are selected (highlighted) for boiler operation;
`Move Cursor' appears at the bottom of the display;
Press the mode button. `ON Period' appears at the bottom of the display;
Press the mode button. `OFF Period' appears at the bottom of the display;
Rotate the control knob to move the cursor to the START of the desired ON Period. As the knob is rotated the time periods will become deselected i.e. they are no longer highlighted;
Press the mode button. `Move Cursor' appears at the bottom of the display'
Press the mode button. `ON Period' appears at the bottom of the display;
Rotate the control knob to select the ON Period, i.e. the times heat is required;
As the ON Period is selected, the 15 minute segments will remain highlighted on the display/ Cotinue until the required time period is highlighted;
Press the mode button to select the next OFF Period;
Rotate the control knob to move the cursor to the START of the desired ON Period. As the knob is rotated the time periods will become deselected i.e. they are no longer highlighted;
Press the mode button. `Move Cursor' appears at the bottom of the display'
Press the mode button. `ON Period' appears at the bottom of the display;
Rotate the control knob to select the ON Period, i.e. the times heat is required;
As the ON Period is selected, the 15 minute segments will remain highlighted on the display/ Cotinue until the required time period is highlighted;
Continue untill all required time periods are selected/ deselected;
Ensure any time periods after the last `ON Period' are deselected;
commissioning
When all selections have been made, press the Menu/Ok button to save the settings;
`Value Saved' is displayed;
Press `Esc' twice to return to the normal display.
To display the timer settings, the boiler MUST be in "Winter' mode, i.e. the radiator symbol (to the top left of the tap symbol) is displayed.
To activate `Winter' mode, press the mode button once, until the radiator symbol is displayed
To initiate the timer press the button, the timer display is shown at the top of the screen;
For constant heating (`Winter' mode only - see above) press the button so the timer display disappears. The boiler will now
operate the central heating constantly.
To return to the timer function, press the button. The timer display will reappear.
Range rating the power of the boiler to suit the central heating load When commissioning the appliance it is necessary to match the output of the boiler to that of the installed central heating system.
Press the Menu/Ok button once (a flashing 0 appears on the left side of the display);
Rotate the control knob to change the 0 to 2. `Boiler Parameters' appears at the bottom of the display;
Press the Men/Ok button. 21 appears (flashing 1) with `Service Code' at the bottom of the display;
Press the Menu/Ok button, 222/cod flashes. Rotate the control knob to show 234.
Press Menu/Ok
Press the Menu/Ok button. 22 appears (2nd 2 flashing) with `General' at the bottom of the display.
Rotate the control knob to change 22 to 23 `central heating - 1' appears at the bottom of the display;
Press the Menu/Ok button, 231 appears (flashing 1) `max CH adjustable' appears at the bottom of the display;
Press the Menu/Ok button, 60 appears (231 flashing intermittently)'
60 is the % output of the boiler in relation to its maximum output. Using the graph on page 28 set the correct % value for the output required;
Rotate the control knob to either increase or decrease the required percentage;
Press Menu/Ok to save the settings
`Value Saved' is displayed;
Press the Esc button three times to return to the normal display. 33
commissioning
Test function and combustion analysis The boiler has two pressure taps to measure the combustion gas temperature, the combustive air and the concentrations of O2 and CO2 on the outside of the flue gas header. to access these pressure taps, unscrew the screw which holds the blanking cover and its seal together.
Wait for the boiler to stabilise before carrying out the combustion analyses. Check the CO2 value according to the table below. Important: do not remove silencer 20
Maximum or minimum CO2 G20 G31
24 kW
9.0 ± 0.2 10.7 ± 0.2
30 kW
CO2 (%) 9.0 ± 0.2 10.0 ± 0.2
38 kW
9.4 ± 0.2 10.6 ± 0.2
N.B.: when the front combustion chamber panel is open, the CO2 value drops by 0.3%. If the values taken differ from the table, adjust the gas valve following the procedure described below.
Adjust the CO2 content to ± 0.2 by turning setting screw 50 (2.5 mm allen key)
- tighten to lower the CO2 value - unscrew to increase the CO2 value Set the content by turning the screw about a 1/4 of a turn then wait after each change for approximately 1 minute for the CO2 value to stabilise, then repeat.
Checking the gas setting To carry out analyses of combustion, the test function must be activated.
Test function The PCB allows the appliance to be forced to minimum or maximum power. Activate the test function by pressing the Reset button for 5 seconds, the boiler switches to maximum heating power, the following appears on the display:
8
Only a 2.5 mm allen key must be used. Do not use a screwdriver
2
50
MaMsasixmHaeRaitsicnagldPaomwenetro To select the function at maximum, turn the encoder, the following appears on the display:
MaxMDaossmimeastSicanHitoatriWa ater Power
To select the function at minimum, turn the encoder, the following appears on the display:
PMoteinnizmauMminiPmoawer The function is automatically deactivated after 10 minutes or by pressing the Reset button. Note: the appliance can be forced to minimum or maximum power from menu 7 (see the section on the display - setting diagnostics menu). WARNING! By activating the pigging function, the temperature of the water sent to the installation is limited to 88°C; caution is therefore required with regard to low-temperature installations.
Maximum gas flow combustion analysis Activate the test function at the maximum heating power t--
Minimum gas flow combustion analysis Activate the cleaning function at minimum power in heating. Wait for the boiler to stabilise before carrying out the combustion analyses. Check the CO2 value according to the table above. Important: do not remove silencer 20 N.B.: when the combustion chamber is open, the CO2 value drops by 0.3%. If the values taken differ from the table, adjust the gas valve following the procedure described below. To adjust the CO2 value, remove cap 2, adjust the CO2 content to ± 0.2 by turning setting screw 51 (4 mm allen key)
- unscrew to lower the CO2 value - tighten to increase the CO2 value
51
Only a 4 mm allen key must be used. Do not use a
screwdriver
Set the content by turning the screw about a 1/4 of a turn then wait after each change for approximately 1 minute for the CO2 value to stabilise, then repeat. Once the settings and analyses are complete, exit test mode, and reposition the blanking cover and its seal correctly.
34
AUTO function
This is a function which enables the boiler to automatically adapt its operation routine (the temperature of the heating elements) in line with the outdoor conditions, in order to achieve and maintain the requested room temperature conditions. Depending on the peripheral units connected and the number of zones controlled, the boiler adjusts its flow temperature automatically. The various corresponding parameters should therefore be set (see adjustments menu). To activate the function, press the Auto button.
external sensor
internal sensor
Inverno
commissioning
Example 1: Single zone system (high-temperature) with on/off room Thermostat: In this case the following parameters must be set: 4 21 - Activation of temperature adjustment using sensors
- Select 1 = Basic temperature adjustment 2 44 - Boost Time (optional)
The wait time for the flow temperature increase in steps of 4°C may be set. The value varies according to the type of system and installation. If the Boost Time value = 00 the function is not activated.
Example 2: Single zone system (high-temperature) with on/off room Thermostat + outdoor sensor: In this case the following parameters must be set: 4 21 - Activation of temperature adjustment using sensors
- Select 3 = outdoor sensor only 4 22 - Temperature adjustment curve selection
- Select the relevant curve according to the type of system, installation, heat insulation used in the building, etc. 4 23 - Perform a parallel curve shift if necessary, increasing or decreasing the set-point temperature (this may also be modified by the user, using the heating temperature adjustment knob, which, with the Auto function activated, is used to shift the curve in a parallel manner).
Example 3: Single zone system (high-temperature) with REMOCON remote Control +
outdoor sensor
In this case the following parameters must be set: 4 21 - Activation of temperature adjustment using sensors
- select 4 = outdoor sensor + room sensor 4 22 - Temperature adjustment curve selection
- Select the relevant curve according to the type of system, installation, heat insulation used in the building, etc 4 23 - Perform a parallel curve shift if necessary, increasing or decreasing the set-point temperature. (This may also be changed by the user by the encoder which, with the Auto function activated, is used to shift the curve in a parallel manner.) 4 24 - Influence of room sensor - used to adjust the influence the room temperature has on the calculation of the set-point flow temperature (20 = maximum, 0 = minimum).
Note: See page 37 for details on accessing menus.
35
Solar kit (optional)
boiler protection devices
Boiler protection devices The boiler is protected from malfunctioning by means of internal checks performed by the electronic microprocessor P.C.B., which stops the boiler from operating if necessary. In the event of the boiler being shut off in this manner, a code appears on the display which refers to the type of shut-off and the reason behind it.
There are two types of shut-off: Safety shut-off This type of error is "volatile", which means that the boiler starts up again automatically as soon as the problem which caused the shut-off is re-
moved; the error is indicated by the
symbol which appears on the
display and the error code.
In fact, soon as the cause of the shut-off disappears, the boiler starts up
again and continues to operate normally.
In the event of error 1 08 - Shut-off due to insufficient water pressure
inside the heating circuit - the boiler will perform a safety shut-off.
You can increase the pressure by filling the heating circuit.
In this case or if the re-balancing request is performed on a frequent basis,
switch the boiler off, turn the external electric switch to the OFF position,
shut off the gas cock and contact a qualified technician to check for any
leaks of water.
Shutdown
This type of error is "non-volatile", which means that it is not removed
automatically. To restore normal operation press the
button on the
control panel.
The first figure of the error code (e.g. 1 01) indicates within which
operational assembly the error occurred.
1 - Primary Circuit
3 - Internal Electronic Part
4 - External Electronic Part
5 - Ignition and Detection
6 - Air inlet - flue gas outlet
7 - Multi-zone Heating
Malfunction warning This warning is shown by the display in the following format: 5 P1 = FIRST IGNITION ATTEMPT UNSUCCESSFUL the first figure indicating the operational assembly is followed by a P (warning) and the code relating to the specific warning.
Important If this shutdown occurs frequently, contact an authorised Technical Service Centre for assistance. For safety reasons, the boiler will permit a maximum of 5 resets in 15 minutes (5 presses of the RESET button); at the 6th attempt within this 15-minute period the boiler will shut down and may only be operated again after the electricity supply has been disconnected. If the shutdown is occasional or an isolated event, this is not a problem. Anti-frost Device. The anti-frost function acts on the central heating flow temperature probe, independently from other regulations, when the electrical supply is turned on. If the primary circuit temperature is between 3°C and 8°C the pump will run (with the diverter valve switching between central heating and hot water every 1 minute) until the temperature reaches > 9°C. If the flow temperature remains between 3°C and 8°C the pump will continue to run for a maximum of 20 minutes unless a temperature above > 9°C is detected in the central heating flow, after this the the burner will fire (heating position) until a temperature of > 30°C is detected. If the central heating flow temperature is < 3°C, the burner will fire (heating position) at minimum power until the temperature reaches > 30°C, the burner will go out. If lockout is caused by overheat the burner will not fire but the pump will continue to run (heating position). The anti-frost device activates only when (with the boiler operating correctly): - the system pressure is correct; - the boiler is electrically powered; - there is a supply of gas.
Table summarising error codes
Central Heating circuit Display Description 1 01 Overheat 1 02 Pressure Sens Error 1 03 1 04 1 05 Insufficient circulation 1 06 1 07 1 09 System pressure > 3 bar 1 10 C.H. Flow temp. probe circuit open / short circuit 1 08 Insufficient water (request filling) 1 12 C.H. Return temp. probe circuit open / short circuit 1 14 External sensor circuit open / short circuit 1 16 Floor Thermostat contact open 1 18 Heating delevery probe problem 1 P1 1 P2 Insufficient circulation indication 1 P3
D.H.W. circuit 2 02 Bottom storage temperature probe open / short circuit 2 04 Solar collector temperature probe open / short circuit 2 07 Solar collector overheating 2 08 Collector frost protection temperature
Internal P.C.B.'s 3 01 EEPROM error 3 02 Comunication error 3 03 Main P.C.B. error 3 04 Too many (> 5) resets in 15 minutes 3 05 Main P.C.B. error 3 06 Main P.C.B. error 3 07 Main P.C.B. error
External P.C.B.'s 4 07 Room sensor circuit open 7 short circuit
Ignition and Detecion 5 01 No flame detected 5 02 Flame detected with gas valve closed 5 04 Flame lift 5 P1 1st Ignition Failed 5 P2 2nd Ignition Failed 5 P3 Flame cut-off
Air Inlet / Flue gas outlet 6 04 Insufficient fan speed 6 10 Thermofuse open
Multi-zone Heating (Heating Zone Modules - optional) 7 01 Zone 2 outgoing sensor defective 7 02 Zone 2 return sensor defective 7 03 Zone 3 outgoing sensor defective 7 04 Zone 3 return sensor defective 7 05 Hydraulic separation sensor defective 7 06 Zone 2 overheating 7 07 Zone 3 overheating
36
settings - adjustment - problem identification menus
Accessing the settings - adjustment - problem identification
menus The boiler can be used to manage the heating system in its entirety. Navigation within the menus enables the boiler system + connected peripheral units to be customised, optimising operation for maximum comfort and maximum saving. It also provides important information relating to the efficient operation of the boiler.
The following menus are available:
0 Time-Date-Language 0 0 Set Dispaly Language 0 1 Set Time-Date 0 2 British Summer Time 1 Set Timer 2 Boiler Parameter 2 1 Service code (234) 2 2 General setting 2 3 C.H. Parameters - Part 1 2 4 C.H. Parameters - Part 1 2 5 Domestic Hot Water (COMBI Only) 2 9 Menù 2 Reset to factory setting 3 Solar & Storage 3 0 General setting 3 1 Service code (234) 3 2 Special setting 4 Zone 1 Parameters 4 0 Set-point Zone1 4 1 Service code (234) 4 2 Zone 1 Setting 4 3 Diagnostics 4 4 Zone device mangement 5 Zone 2 Parameters 5 0 Set-point Zone2 5 1 Service code (234) 5 2 Zone 2 Setting 5 3 Diagnostics 5 4 Zone device mangement 5 5 Multizone 7 Test & Utilities 8 Service Parameter 8 1 Service code (234) 8 2 Boiler 8 3 Boiler Temperature 8 4 Solar & Storage 8 5 Service 8 6 Statistics 8 7 E@sy - NOT ACTIVE 8 8 Error History
See manual user's See manual user's
The parameters relating to each individual menu are listed in the following pages. The various parameters can be accessed and modified using the Menu/Ok button and the encoder (see fig. below). The description of the menus and of each individual parameter will be shown on the
display.
Encoder
(adjustment knob) Enables the set values to be increased or decreased
Menu/Okbutton
On the display, the information relating to the menus and to the individual parameters are indicated by the figures and by the scrolling text shown in the figure below.
ABCDEFGHIL123456
To access the Menus, open the cover and proceed as follows: 1. Press the Menu/Ok button; the first figure 000 will flash on the
display. 2. Turn the encoder to select a menu; the text on the display will
indicate the title of the pre-selected menu, for example: "200 Boiler parameters". 3. Press the Menu/Ok button; the first two figures on the display will flash and the access code will flash, e.g. "210 - Access code". Caution! The menus reserved for qualified technicians may only be accessed after setting the access code. 4. Press the Menu/Ok button; 222 will appear on the display unit. 5. Turn the encoder in a clockwise direction to select code 234 Correct code. 6. Press the Menu/Ok button to select the sub menu; the first two figures will flash, e.g. "220". 7. Turn the encoder to select a sub menu; the text on the display will indicate the title of the pre-selected sub menu, for example: "230 - Heating - Part 1". 8. Press the Menu/Ok button to access the sub menu parameters; the three figures will flash, for example: "230". 9. Turn the encoder to select a parameter; the text on the display will indicate the title of the pre-selected parameter, for example: "231 - Max. Adjustable Heating Power". 10. Press the Menu/Ok button to access the parameter; the display will indicate the value, e.g "70". Note: The parameter value will be displayed for 20 seconds, then will begin to flash in alternation with the parameter, e.g. "70 > 231. 11. Turn the encoder to select the new value, e.g. "75". 12. Press Menu/Ok to save the change or press Esc to exit without saving.
To exit, press the Esc button until the normal display screen is restored. For menus which do not require the access code, it is possible to pass directly from the menu to the sub menu.
37
settings - adjustment - problem identification menus
menu sub-menu parameter default setting
description 0 SETTING LANGUAGE - DATE - TIME 1 Programming TIMER 2 BOILER parameter SETTING 2 1 Entering access code
value
See pages 32 and 33 See pages 32 and 33
222 Turn the encoder clockwise to select 234 and press the Menu button
2 2 BOILER General SETTING 2 2 0 Slow ignition 2 2 1 Minimum ambient temperature for
antifreeze activation 2 2 2 NOT PRESENT 2 2 3 Underfloor thermostat or zone 2 ambient
thermostat selection
0 to 99 from 2 to 10 °C
0 = Floor safety thermostat 1 = Zone 2 ambient thermostat
60 5 Activated only with the modulating peripheral
device (optional)
0
2 2 4 Mechanical timer connection authorisation 0 = Absent 1 = Present
2 2 5 Heating ignition delay
0 = Deactivated 1 = 10 seconds 2 = 90 seconds 3 = 210 seconds
2 2 6 NOT PRESENT
2 2 7 NOT PRESENT
2 2 8 Boiler Version
0 to 5
Important!
0 = DO NOT USE
Adjust from 2 to 1 only for a tank
1 = tank NTC sensor
connection with an ARISTON System Plus Kit 2 = heating only or tank thermostat on/off
3-4-5 = DO NOT USE
2 3 BOILER Parameter - Part 1
2 3 0 NOT PRESENT
2 3 1 Maximum heating power setting 2 3 2 Domestic hot water maximum RPM
percentage CANNOT BE MODIFIED 2 3 3 Minimum RPM percentage CANNOT BE MODIFIED 2 3 4 Heating maximum RPM percentage CANNOT BE MODIFIED
0 to 99 0 to 99
0 to 99 0 to 99
2 3 5 Selection of ignition delay type when heating
0 = Manual 1 = automatic
2 3 6 Ignition delay when heating timer setting from 0 to 7 minutes
0 To be modified if mechanical timer is present (optional)
0 Activated only with zone 2 interface (optional)
2 RESERVED FOR TECHNICAL ASSISTANCE Only if the PCB is changed
See Page 31 RESERVED FOR TECHNICAL ASSISTANCE Only if the gas or PCB is changed see "gas setting" table
1 see section on "gas setting". Page 29. 3
2 3 7 Post-circulation when heating
from 0 to 15 minutes or continuous
3
2 3 8 Circulation pump operating type
0 = Low Speed
2
1 = High Speed
2 = Modulating
2 3 9 Setting the Delta T Circulation pump modulation
from 10 to 30 °C
20 to be set with operation of the circulation pump in modulating mode
These parameters allow the flow and backflow temperature difference to be set, which determines whether the circulation pump switches from low to high speed E.g.: param. 239 = 20 and T > 20°C- the circulation pump runs at high speed. If T < 20 - 2°C the circulation pump runs at
low speed. The minimum waiting time for changing speed is 5 minutes.
38
settings - adjustment - problem identification menus
menu sub-menu parameter default setting
description
value
2 4 BOILER PARAMETER - PART 2
2 4 0 NOT PRESENT
2 4 1 NOT PRESENT
2 4 2 NOT PRESENT
2 4 3 Post-ventilation after heating request
0 = OFF
0
1 = ON
2 4 4 Time delay after heating temperature increase from 0 to 60 minutes
16 activated only with thermostat On/Off and heating control activated (parameter 421 or 521 = 01
This parameter allows the time delay to be set before automatic increase of the flow temperature calculated in increments of 4°C (max 12°C). If this parameter retains the value 00, this function is not active.
2 4 5 NOT PRESENT
2 4 6 NOT PRESENT
2 4 7 Device indicator for heating circuit pressure
0 = temperature sensor only 1 = pressure switch at minimum 2 = pressure sensor
2 4 8 NOT PRESENT
2 5 DOMESTIC HOT WATER Parameter (COMBI Boilers Only)
2 5 0 COMFORT function - NOT ACTIVATED
2 5 1 Comfort Anti-cycling Time - NOT ACTIVATED
2 5 2 Hot water flow delay - NOT ACTIVATED
1 RESERVED FOR TECHNICAL ASSISTANCE Only if the PCB is changed
2 5 3 Extinction of the burner in domestic hot water - NOT ACTIVATED
2 5 4 Post-circulation and post-ventilation after a 0 = OFF
0
domestic hot water draw-off
1 = ON
OFF = 3 minutes post-circulation and post-ventilation after domestic hot water draw-off if the boiler temperature measured requires it. ON = always on for 3 minutes post-circulation and post-ventilation after domestic hot water draw-off.
2 5 5 Domestic hot water timer
from 0 to 60 minutes
0
2 9 RESET MENU 2
2 9 0 Automatically resetting to the default setting in Reset
menu 2
OK = yes
ESC = no
To reset all default parameter settings, press the MENU button
39
settings - adjustment - problem identification menus
menu sub-menu Parameter default setting
Description
value
3 BOILER WITH TANK (INTERNAL OR EXTERNAL) AND SOLAR APPLIANCE CONNECTION
3 0 General SETTING
3 0 0 NOT ACTIVATED
3 0 1 NOT ACTIVATED
3 0 2 NOT ACTIVATED
3 1 Entering access code
222
Turn the encoder clockwise to select 234 and press the Menu button
3 2 SPECIAL SETTING 3 2 0 Anti-legionella function NOT ACTIVATED 3 2 1 NOT ACTIVATED 3 2 2 NOT ACTIVATED 3 2 3 Collector delta temp pump ON 3 2 4 Collector delta temp pump OFF 3 2 5 Minimum collector temp pump ON 2 2 6 Collector kick 3 2 7 Recooling function 3 2 8 NOT ACTIVATED 3 2 9 Collector frost protection temperature
from 0 to 30°C from 0 to 30°C from 10 to 90°C ON or OFF ON or OFF
from -20 to +5°C
8
2
30
Enable only with Clip-In solar connected (option)
OFF
OFF
-20
40
settings - adjustment - problem identification menus
menu sub-menu parameter default setting
description 4 ZONE 1 PARAMETER 4 0 ZONE 1 TEMPERATURE SETTING
4 0 0 Zone 1 comfort temperature setting "Comfort ambience T"
4 0 1 Zone 1 reduced temperature setting "Reduced ambience T"
4 0 2 Heating fixed temperature setting "Heating fixed temp"
4 1 Entering access code
value
from 10 to 30 °C from 10 to 30 °C from 20 to 82 °C
4 2 ZONE 1 SETTING
4 2 0 Heating appliance temperature value setting
0 = from 20 to 45°C (low temperature) 1 = from 35 to 85°C (high temperature)
4 2 1 Basic heating control type selection type 0 = fixed flow temperature
depending on the peripheral devices 1 = device On/Off
connected
2 = ambient sensor only
3 = external sensor only
4 = ambient sensor + external
sensor
4 2 2 Slope
0_2 to 3_5
If the external sensor is used, the boiler calculates the most suitable heating flow temperature taking the external temperature and the type of appliance into account. The type of curve must be chosen according to the type of appliance radiator and the heat losses present in the building.
°C 100 90 80 70
19 Activated only with the modulating device connected (option)
16
70 Activated only with temperature control and fixed temperature
222 turn the encoder clockwise to select 234 and press the Menu/Ok button
1 select in the appliance type base
1 To activate heating control, press the AUTO button. The display lights up the AUTO symbol, indicating the peripheral device connected (if present)
1_5
3.5 3.0 2.5
2.0
1.5
1.2 1.0
High taltea tmepmeprerattaurrae
tempFleroatwuraTedimmapnedratatauallr'iempianto
lowbtaessam tpeemrpaerttaururea
60 50 40
30
Atemmvsapbeleioet2rrta5neitnutdergiactvaeoamn2mls0ubepieegennrtaae1tu5re°C 10
0.8 0.6 0.4 0.2
5 0 -5 -10 -15 -20 °C
Extetermnpaelratteumra epseterranature
4 2 3 Parallel shift
- 20 to + 20
0
To adapt the thermal curve to the appliance requirements, it is possible to perform a parallel shift of the curve in order to alter the calculated flow temperature and therefore the ambient temperature. The shift value between - 20 and + 20 is shown on the display. Each level corresponds to a 1°C increase in the flow temperature in relation to the initial setting.
4 2 4 Compensation
4 2 5 Zone 1 heating maximum temperature setting
0 to + 20
20
if setting = 0, the temperature taken from the ambient sensor does not affect the calculation of the setting. If setting = 20, the temperature taken has maximum influence on the setting.
35 to + 82°C
82 if parameter 420 = 1
20 to + 45°C
45 if parameter 420 = 0
4 2 6 Zone 1 heating minimum temperature setting
35 to + 82°C 20 to + 45°C
35 if parameter 420 = 1 20 if parameter 420 = 0
4 3 DIAGNOSTICS 4 3 0 Zone 1 room temperature 4 3 1 Zone 1 set temperature 4 3 2 Zone 1 heat request
4 3 3 Pump status
4 4 ZONE DEVICE MANAGEMENT 4 4 0 Pump control
0=OFF 1=ON 0=OFF 1=ON
0=OFF 1=ON
display only Activated only with the modulating device connected (option)
Active only with MGZ/MCM kit
Active only with MGZ/MCM kit 41
settings - adjustment - problem identification menus
menu sub-menu parameter default setting
description 5 ZONE 2 PARAMETER 5 0 ZONE 2 TEMPERATURE SETTING
value
5 0 0 Zone 2 comfort temperature setting "Comfort ambience T"
5 0 1 Zone 2 reduced temperature setting "Reduced ambience T"
5 0 2 Heating fixed temperature setting "Heating fixed temp"
5 1 Entering access code
from 10 to 30 °C from 10 to 30 °C from 20 to 82 °C
19 Activated only with the modulating device connected (option)
16
70 Activated only with temperature control and fixed temperature
222 turn the encoder clockwise to select 234 and press the Menu/Ok button
5 2 ZONE 2 SETTING
5 2 0 Heating appliance temperature value setting
0 = from 20 to 45°C (low temperature) 1 = from 35 to 85°C (high temperature)
1 select in the appliance type base
5 2 1 Basic heating control type selection type 0 = fixed flow temperature
depending on the peripheral devices 1 = device On/Off
connected
2 = ambient sensor only
3 = external sensor only
4 = ambient sensor + external
sensor
0 To activate heating control, press the AUTO button. The display lights up the AUTO symbol, indicating the peripheral device connected (if present)
5 2 2 Slope
0_2 to 3_5
1_5
If the external sensor is used, the boiler calculates the most suitable heating flow temperature taking the external temperature and the type of appliance into account. The type of curve must be chosen according to the type of appliance radiator and the heat losses present in the building.
see graph on the previous page
5 2 3 Parallel shift
- 20 to + 20
0
To adapt the thermal curve to the appliance requirements, it is possible to perform a parallel shift of the curve in order to alter the calculated flow temperature and therefore the ambient temperature. The shift value between - 20 and + 20 is shown on the display. Each level corresponds to a 1°C increase in the flow temperature in relation to the initial setting.
5 2 4 Compensation
5 2 5 Zone 2 heating maximum temperature setting
5 2 6 Zone 2 heating minimum temperature setting
5 3 DIAGNOSTICS 5 3 0 Zone 2 room temperature
5 3 1 Heating flow outlet temperature 5 3 2 Heating return temperature 5 3 3 Zone 2 set temperature
5 3 4 Zone 2 heat request
5 3 5 Zone 2 Pump status
5 4 ZONE DEVICE MANAGEMENT 5 4 0 Operation mode test
5 4 1 Valve control
5 4 2 Pump control
5 5 MULTIZONE 5 5 0 Heating collector temperature 5 5 1 Heating collector flow outlet
temperature offset
0 to + 20
20
if setting = 0, the temperature taken from the ambient sensor does not affect the calculation of the setting. If setting = 20, the temperature taken has maximum influence on the setting.
35 to + 82°C
82 if parameter 520 = 1
20 to + 45°C
45 if parameter 520 = 0
35 to + 82°C
35 if parameter 520 = 1
20 to + 45°C
20 if parameter 520 = 0
Activated only with the modulating device connected (option)
Active only with MGZ/MCM kit
0=OFF 1=ON
0=OFF 1=ON
Activated only with the modulating device connected (option)
Active only with MGZ/MCM kit
0=OFF 1=ON 2=manual
0=OFF 1=Open 2=Close
0=OFF 1=ON
Active only with MGZ/MCM kit
0 to 120°C 0 to + 40°C
0 Active only with MGZ/MCM kit 5
42
settings - adjustment - problem identification menus
menu sub-menu parameter default setting
description 7 TEST & UTILITIES 7 0 0 Function test - Cleaning
turn the encoder to select the operating mode
7 0 1 Bleed cycle 8 PARAMETER FOR TECHNICAL ASSISTANCE 8 1 Entering access code
value
t-- = funct. at Max heating power t-- = funct. at Max DHW power t-- = funct. at Min power press Menu
8 2 BOILER
8 2 0 NOT PRESENT
8 2 1 Fan status
ON or OFF
8 2 2 Fan speed (x100) rpm
8 2 3 Circulation pump speed
OFF - LS - HS
8 2 4 Distribution valve position
Domestic hot water - Heating
8 2 5 Water flow rate (l/min) (COMBI Only)
8 2 6 NOT PRESENT
8 3 BOILER TEMPERATURE
8 3 0 Heating adjustment temperature (°C)
8 3 1 Heating flow temperature (in °C)
8 3 2 Heating backflow temperature (in °C)
8 3 3 Domestic hot water temperature (in °C)
8 4 SOLAR APPLIANCE AND TANK
8 4 0 Accumulated measured temperature
8 4 1 Solar collector temperature
8 4 2 Solar appliance water input temperature
8 4 3 Solar appliance low tank sensor temperature
8 4 4 Layered tank set temperature
8 4 5 Total circulation pump operating time delay for solar appliance
8 4 6 Total solar collector overheating time delay
8 5 SERVICE - TECHNICAL ASSISTANCE
8 5 0 Time remaining before next service setting
8 5 1 Service warning authorisation
0 to 60 (months) ON or OFF
8 5 2 Clearing the service warning 8 5 3 NOT PRESENT
Reset OK = yes ESC = no
8 5 4 PCB hardware version
8 5 5 PCB software version
8 5 6 PUS peripheral device interface software version
t-- activation can also be obtained by pressing the Reset button for 10 seconds. The function is deactivated after 10 minutes or by pressing Reset
222 turn the encoder clockwise to select 234 and press the Menu button
activated only with the solar kit connected or external tank
24 once the parameter is set, the boiler will show the user the interval before the next service
OFF once the service has been performed, set the parameter to clear the warning
43
settings - adjustment - problem identification menus
menu sub-menu Parameter default setting
Description 8 6 STATISTICS
value
8 6 0 Number of hours burner operating in heater mode (xxh/10)
8 6 1 Number of hours burner operating in hot water mode (xxh/10) (COMBI Only)
8 6 2 Number of flame separations (nr/10)
8 6 3 Number of ignition cycles (nr/10)
8 6 4 Number of filling cycles performed
8 6 5 Average length of heating request (minutes)
8 7 E@SY HOTLINE NOT ACTIVE
870
871
8 8 ERROR LIST
8 8 0 10 last errors
from E00 to E99
This parameter allows the last 10 boiler errors flagged to be displayed, indicating the day, month and year. When the parameter is accessed, the errors are displayed listed from E00 to E99. For each error, the following sequence is displayed: E00 - error number 108 - error code A15 - A = day on which error E00 occurred - Only with CLIMA MANAGER connected B09 - B = month during which error E00 occurred - Only with CLIMA MANAGER connected C06 - C = year during which error E00 occurred - Only with CLIMA MANAGER connected
8 8 1 Error list reset
Reset OK = yes ESC = no
8 9 DATA - ASSISTANCE CENTRE 8 9 0 Enter the name of the assistance centre - it will be displayed if there is a fault which cannot be unlocked with the Reset button
"Assistance Centre Name" appears on the display, press the MENU button and start entering the letters by turning the encoder. To insert each letter, press the MODE button to confirm it and move on to the next letter. Enter the number of the assistance centre - it will be displayed if there is a fault which cannot be unlocked with the Reset button "Assistance Centre Number" appears on the display, press the MENU button and start entering the digits by turning the encoder. To insert each digit, press the MODE button to confirm it and move on to the next digit. Press the Menu button to confirm.
44
INFO ( ) - display only - accessed by pressing the button
Inverno
settings - adjustment - problem identification menus
If the Info button is pressed, a menu is accessed which enables the data listed in the table below to be displayed. The display scrolls through various information when the encoder is turned. Press the Esc button to exit.
Informations displayed
Time of day - Hour Heating circuit pressure (bar) External temperature (°C) -only with external sensor connected Room temperature (°C) - only active when the BUS device is connected D.H.W. Flow rate (l/m) (COMBI Only) Set C.H. temperature (°C) Set D.H.W. temperature (°C) Month until next maintenance Technical Assistance Centre telephone number and name (only display if setted parameters 890) D.H.W. comfort temperature (°C) - if activated AUTO Function "enabled" or "disabled" if the symbol flash on the display Storage temperature °C only for boiler with storage tank
45
maintenance
Important Maintenance is an essential part of the safe and efficient operation of the boiler and ensures its durability. It should be performed according to the instructions given in current legislation. Perform combustion analysis regularly in order to check the operating efficiency of the boiler and to make sure any polluting substances relased are within the boundaries set by current legislation. Before beginning maintenance work: - Disconnect the appliance from the electricity supply by
turning the external bipolar switch to the "OFF" position; - Close the gas valve and the central heating and domestic hot
water system valve. After the work has been completed the initial settings will be restored.
General comments It is recommended that the following inspections be carried out on the boiler at least once a year: 1. Check the seals in the water part and, if necessary, replace the
gaskets and restore the seal to perfect working order. 2. Check the seals in the gas part and, if necessary, replace the
gaskets and restore the seal to perfect working order. 3. Visually check the overall condition of the boiler. 4. Visually check the combustion and, if necessary, disassemble
and clean the burner. 5. Following the inspection detailed in point "3", disassemble
and clean the combustion chamber, if necessary. 6. Following the inspection detailed in point "4", disassemble
and clean the burner and injector, if necessary. 7. Cleaning the primary heat exchanger 8. Make sure the following heating safety devices are operating
correctly: - temperature limit safety device. 9. Make sure that the following gas part safety devices are operating correctly: - absence of gas or flame safety device (ionisation). 10. Perform a general inspection of the boiler operation. 11. Remove oxide from the detection electrode using an emery cloth. 12. These checks are not exhaustive. Further mechanical, electrical and combustion maintenance checks may be required.
Operational test After having carried out the maintenance operations, fill the heating circuit at a pressure of approximately 1.0 bar and release the air from the system. - Begin operating the boiler. - If necessary, release the air from the heating system again. - Check the settings and make sure all the command, adjustment
and monitoring parts are working correctly. - Check the flue system is sealed and operating correctly.
Draining procedures The heating system must be drained using the following
procedure: - Switch off the boiler, make sure the external bipolar switch is in
the OFF position and shut off the gas valve; - Loosen the automatic air relief valve; - Open the system drain off cock and collect the escaping water
in a container; - Empty the water from the lowest points of the system (where
applicable). If the system is to be left inactive in areas where the room temperature may fall below 0°C during winter, we recommend that anti-freeze liquid is added to the water in the heating system in order to avoid the need for repeated draining; when this liquid is used make sure it is compatible with the stainless steel used for the bodywork of the boiler. We recommend the use of anti-freeze products which contain PROPYLENE GLYCOLS as these inhibit corrosion and that they are used in conjunction with the anti-scaling and anti-corrosion function, in the quantities suggested by the manufacturer, at the mimimum temperature. Regularly check the pH level of the water/anti-freeze mix in the boiler circuit and replace it when the value measured is lower than the limit prescribed by the manufacturer. DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE. The manufacturer will not be held liable for any damage caused by the appliance or the system due to the use of inappropriate anti-freeze substances or additives.
WARNING Before handling, empty all components which may contain hot water, emptying where necessary. Descale the components in accordance with the instructions provided on the safety data leaflet supplied with the product used, make sure the room is well ventilated, wear protective clothing, avoid mixing different products, and protect the appliance and surrounding objects. Seal all openings used to take a gas pressure reading or to make any gas adjustments. Make sure that the nozzle is compatible with the supplied gas. If a smell of burning is detected or smoke is seen leaking from the appliance, or there is a smell of gas, disconnect it from the electricity supply, shut off the gas valve, open the windows and call for technical assistance.
Cleaning the primary exchanger Cleaning the smoke side The inside of the primary exchanger is accessed by removing the burner. Wash with water and detergent using a non-metallic rifletype brush, rinse with water.
Cleaning the trap The trap is accessed by emptying the condensate bowl located in the bottom section. Wash with water and detergent. Replace the condensate collection bowl in its housing. NB: in the event of prolonged use of the appliance, the trap must be filled before being used again. A lack of water in the trap is dangerous and may cause smoke to be released into the atmosphere.
46
1. GENERAL ACCESS
MAINTENANCE GUIDE: GENUS HE SYSTEM 1.3 GENERAL ACCESS
Tools
GENERAL ACCESS
MAINTENANCE GUIDE
Time
3 min
1
Unclip the cover to remove
Remove the two screws
Remove the front panel
2
Lower the electrical box
Remove the combustion chamber front panel by releasing the clips
47
MAINTENANCE GUIDE 2. ELECTRICAMLAIUNNTEITNANCE GUIDE: GENUS HE SYSTEM
2 ELECTRICAL UNIT
2.1 CONTROL BOX ACCESS
Tools
CONTROL BOX ACCESS
Time
4 min
1
Remove the front panel as above and pivot the electrical box
Remove the two screws and unlock the four clamps to gain access to the control box
2.2 FUSE
Tools
FUSE
Time
5 min
1 Open the control box as above Remove the fuse
Page. 7 of 20
48
MAINTENANCE GUIDE: GENUS HE SYSTEM
2.3 MAIN PCB Tools
MAIN PCB
MAINTENANCE GUIDE
Time
7 min
1
After opening the control box, disconnect the electrical plug
connectors
Unscrew the two screws and remove the PCB
2.4 DISPLAY PCB Tools
DISPLAY PCB
Time
7 min
1
Unclip the cover to remove
Lower the door and remove the Unscrew the four screws and
two control knobs
pull the assembly towards you
2
Disconnect the electrical plug connectors, unlock the two clamps,
and remove the PCB
Page. 8 of 20
49
MAINTENAMNACINETGEUNAIDNECE GUIDE: GENUS HE SYSTEM
3.3HYDHRYAUDLIRCAUNUITLIC UNIT
3.1 RIGHT HAND HYDRAULIC BLOCK ASSEMBLY
LEGEND
1. Auto air vent 2. Primary water pressure sensor 3. Pump 4. Central heating filter 5. Central heating return 6. Central heating drain valve
3.2 DRAINING Tools
DRAINING
Time
5 min
1
Turn the drain valve anti-clockwise to open and drain the water from the boiler.
3.3 AUTOMATIC AIR VENT
AUTOMATIC AIR VENT
Tools
Time
5 min
1
Drain boiler (see 3.2). Remove the clip and lift the AAV from the assembly
50
Page. 9 of 20
MAINTENANCE GUIDE: GENUS HE SYSTEM
MAINTENANCE GUIDE
3.4 PRIMARY WATER PRESSURE SENSOR
PRIMARY WATER PRESSURE SENSOR
Tools
Time
5 min
1
Drain boiler (see 3.2). Remove the fixing clip, unplug the electrical connector and lift the sensor from the assembly
3.5 PUMP Tools
PUMP
Time
10 min
1
Drain boiler (see 3.2). Remove the clip and the two screws
Disconnect the pipe and then move the pump to the right disengage
Remove the pump
2
Remove the sensor (see 3.4)
Remove the AAV (see 3.3)
Page. 10 of 20
51
MAINTENANCE GUIDE
MAINTENANCE GUIDE: GENUS HE SYSTEM 3.6 CH FILTER
CH FILTER
Tools
Time
5 min
1
Drain boiler (see 3.2) Remove the clip
Remove the filter
3.7 LEFT HAND HYDRAULIC BLOCK ASSEMBLY
1. Left hand hydraulic block 2. Safety valve & By-pass assembly 3. Central heating flow
3.8 SAFETY VALVE Tools
SAFETY VALVE
Time
5 min
1
Drain boiler (see 3.2). Disconnect the Remove the first clip on the left and
discharge pipe
pull the safety valve towards you
Page. 11 of 20
52
MAINTENANCE GUIDE: GENUS HE SYSTEM 3.9 BY-PASS ASSEMBLY
Tools
BY-PASS ASSEMBLY
MAINTENANCE GUIDE
Time
5 min
1
Drain boiler (see 3.2). Remove the second clip and pull the assembly
toward you
Push on the by-pass to disengage it
3.10 CONDENSE TRAP Tools
CONDENSE TRAP
Time
5 min
Unscrew the condense trap from the condense
1
body
Page. 12 of 20
53
MAINTENANCE GUIDE
MAINTENANCE GUIDE: GENUS HE SYSTEM
3.11 TEMPERATURE SENSORS
3.11 TEMPERATURE SENSORS & OVERHEAT THERMOSTAT
Tools
Time
5 min
TEMPERATURE SENSORS & OVERHEAT THERMOSTAT
Tools
Time
5 min
1
1
Unplug the electrical connectors
Remove the clip and the temperature
OT : WNThC1ite: Blwacikrewsires NTC1 : BNlTaCc2k: Gwreiyrewsires IMPORTANNTT! DCo2not :usGe rceonyduwcitrinegspaste
for
the
contact
sensors
Unplug the electrical because itcwoinll naletecr ttohersresistance
value.
Remove thescenlisporand the temperature sensor or overheat thermostat together
TEMIPMERPAOTURRTEANT!!!!RDESoISnToAtNuCsEe(kcOonmdhu)cting paste for the contact sensors because it will alter the resistance value.
0
27
1T0EMPERATURE (°C)17 RESISTANCE (kOmh)
20
0
12
27
25
10
10
17
30
20
8
12
40
25
5
10
50
30
4
8
40
5
50
4
60
3
70
2
80
1,5
3.12 MANUAL AIR VENT
Tools
MANUAL AIR VENT
Time
5 min
1
Drain boiler (see 3.2) Remove the clip and lift the manual air vent from the exchanger
54
Page. 13 of 20
MAINTENANCE GUIDE: GENUS HE SYSTEM 3.13 MAIN HEAT EXCHANGER
Tools
MAIN HEAT EXCHANGER
MAINTENANCE GUIDE
Time
20 min
1
Drain boiler (see 3.2). Remove the four clips and disconnect the two pipes between the exchanger and pump and between the exchanger and left hand hydraulic block
Isolate the gas supply. Remove the four screws and disconnect the gas pipe from the gas valve
Remove the four screws to free the heat exchanger
2
Pull the heat exchanger towards Remove the clip and lift the
you
manual air vent
Twist the thermal fuse to remove
Page. 14 of 20
55
MAINTENANCE GUIDE
MAINTENANCE GUIDE: GENUS HE SYSTEM
4 BURNER UNIT
1. Burner 2. Fan 3. Silencer 4. Gas inlet 5. Air inlet
56
LEGEND
6. Gas valve 7. Mixing tube 8. Detection electrode 9. Ignition electrode 10. Spark generator
Page. 15 of 20
MAINTENANCE GUIDE: GENUS HE SYSTEM
4.1 SPARK GENERATOR Tools
SPARK GENERATOR
MAINTENANCE GUIDE
Time
5 min
1
Unplug the ignition electrode from the spark generator
Remove the screw and the spark generator
4.2 ELECTRODES Tools
ELECTRODES
Time
5 min
1
Unplug the electrodes
Remove the screws and pull the electrodes towards you.
Page. 16 of 20
57
MAINTENANMCAEINGTUENIDAENCE GUIDE: GENUS HE SYSTEM
4.3 BURNER Tools
BURNER
Time
15 min
1
Remove the silencer
Isolate the gas supply. Remove the four screws and disconnect the gas pipe from the gas valve
Pull the assembly towards you
2
Remove the three screws to free the burner door
Pull the burner toward you. Replace any gaskets that are damaged or showing signs of
deterioration
2 1
1. Stainless Steel Burner 2. Ignition electrode 3. Detection electrode
58
3
Power 25 KW 30 KW 38 KW
Length 104.6 mm 135.8 mm 167 mm
Venturi Ø 42 mm
/ /
Page. 17 of 20
MAINTENANCE GUIDE: GENUS HE SYSTEM 4.4 FAN
FAN
Tools
MAINTENANCE GUIDE
Time
15 min
1
Remove the combustion assembly (see 4.3)
Remove the three screws to free the fan.
Twist the gas valve anti-clockwise to disengage it from the fan
1. Venturi 2. Gasket 3. Fan
Page. 18 of 20
Fan & mixer venturi according to the model
Power
Fan
Venturi diameter
25 KW EBM RG 128 45 W
Ø 17 mm
30 KW EBM RG 128 45 W
Ø 21 mm
38 KW EBM RG 128 45 W
Ø 25 mm
59
MAINTENANMCAEINGTEUNIDANECE GUIDE: GENUS HE SYSTEM
4.5 GAS VALVE Tools
GAS VALVE
Time
15 min
1
Remove the combustion assembly (see 4.3)
Twist the gas valve anti-clockwise to disconnect it from the fan
Replacement Gas Valves are not factory set and will need to
be set up (see page 34)
Bayonet connection
1. Venturi 2. Gas valve 3. Solenoids
60
4. Inlet test nipple 5. Offset adjustment 6. Throttle adjustment
Page. 19 of 20
MAINTENANCE GUIDE: GENUS HE SYSTEM
5 ANNUAL MAINTENANCE
By-pass & Safety valve Maintenance Interval: Annually How: Visual inspection / Clean as necessary Central heating filter Maintenance Interval: Annually How: Visual inspection / Clean as necessary Expansion vessel Maintenance Interval: Annually How: Check air pressure is at 1 bar (System drained) Ignition & detection electrodes Maintenance Interval: Annually How: Visual inspection / Clean as necessary / Distance from the burner / Ionisation current more than 1 µA Burner Maintenance Interval: Annually How: Visual inspection / Clean as necessary
Fan Maintenance Interval: Annually How : Visual inspection / Clean as necessary
Primary Heat exchanger Maintenance Interval: Annually How : Visual inspection / Clean as necessary
Condensate trap Maintenance Interval: Annually or after cleaning primary heat exchanger How : Visual inspection / Clean as necessary / Add water before replacing
Pump Maintenance Interval: At the first ignition and annually How: Check that the AAV is open / Visual inspection / Clean as necessary
Page. 20 of 20
MAINTENANCE GUIDE
61
MAINTENANCE GUIDE
SHORT LIST
407
537 401
615
136
530
135
538
607
112
616 134 111
517
110 507 504
GENUS
SGYESTNEUSM HE
Key N
Description
0100 BURNER ASSEMBLY 0110 IGNITION ELECTRODE 0111 IONIZATION ELECTRODE 0112 GASKET D:85-66.5-2.5 0134 ELECTRODE GASKET 0135 COMBUSTION CHAMBER LINING KIT 0136 DOOR GASKET
0400 GAS SECTION 0401 GAS VALVE 0407 FAN ASSY
0500 HYDRAULIC BLOCK 0504 OVERHEAT THERMOSTAT 100C 0507 TEMPERATURE PROBE + CLIP 0517 LOW PRESSURE SWITCH 0530 AUTO AIR VENT WITH O-RING 0537 PRESSURE RELIEF VALVE 0538 PUMP 6M 2V
0600 ELECTRICAL BOX 0607 IGNITER 0615 PRINTED CIRCUIT BOARD 0616 PRINTED CIRCUIT BOARD (DISPLAY)
Manf. Pt. N
Other
61317432 61317433 61314753 60000286 60000297 60000623
60000537 60000622
61010572 990686 65104321 65104703 61312668 60000591
61002105-20 60000566 60000739
Type
24 30
............
....
............
......
Manf. date from to
Ind 02 - 03/04/2007
62
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer's instructions may invalidate the warranty but does not affect statutory rights.
Customer Name Address
Telephone Number
Boiler Make and Model
Boiler Serial Number Commissioned by (print name)
CORGI ID Number
Company Name Company Address
Telephone Number
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate*:
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating
Time and Temperature Control to Hot Water Heating Zone Valves Hot Water Zone Valves Thermostatic Radiator Valves Automatic Bypass to System Boiler Interlock
Room Thermostat and Programmer/Timer
Programmable Room Thermostat
Load/Weather Compensation
Cylinder Thermostat and Programmer/Timer
Fitted
Fitted
Fitted
Fitted
Optimum Start Control
Combination Boiler Not Required Not Required Not Required Not Required Provided
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer's instructions What system cleaner was used? What inhibitor was used?
Yes
Quantity
litres
CENTRAL HEATING MODE Measure and Record:
Gas Rate Burner Operating Pressure (if applicable) Central Heating Flow Temperature Central Heating Return Temperature
m3/hr mbar
OR
OR
Gas Inlet Pressure
ft3/hr mbar °C °C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? If yes, has a water scale reducer been fitted? What type of scale reducer has been fitted? DOMESTIC HOT WATER MODE Measure and Record: Gas Rate Burner Operating Pressure (at maximum rate) Cold Water Inlet Temperature Hot water has been checked at all outlets Water Flow Rate
Yes
No
Yes
No
m3/hr OR mbar OR
Gas Inlet Pressure (at maximum rate)
Yes
Temperature
ft3/hr mbar °C °C l/min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer's instructions and/or BS5546/BS6798
Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following
CO2
The heating and hot water system complies with the appropriate Building Regulations
% OR CO
ppm OR CO/CO2 Ratio Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer's instructions
Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer
Yes
The manufacturer's literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer's Signature
Customer's Signature (To confirm satisfactory demonstration and receipt of manufacturer's literature)
*All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
A Building Regulations Compliance Certificate will then be issued to the customer.
©Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer's instructions may invalidate the warranty but does not affect statutory rights.
Customer Name Address
Telephone Number
Boiler Make and Model
Boiler Serial Number Commissioned by (print name)
CORGI ID Number
Company Name
Telephone Number
Company Address Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate*:
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating
Time and Temperature Control to Hot Water Heating Zone Valves Hot Water Zone Valves Thermostatic Radiator Valves Automatic Bypass to System Boiler Interlock
Room Thermostat and Programmer/Timer
Programmable Room Thermostat
Load/Weather Compensation
Cylinder Thermostat and Programmer/Timer
Fitted
Fitted
Fitted
Fitted
Optimum Start Control
Combination Boiler Not Required Not Required Not Required Not Required Provided
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer's instructions What system cleaner was used? What inhibitor was used?
Yes
Quantity
litres
CENTRAL HEATING MODE Measure and Record:
Gas Rate Burner Operating Pressure (if applicable) Central Heating Flow Temperature Central Heating Return Temperature
m3/hr mbar
OR
OR
Gas Inlet Pressure
ft3/hr mbar °C °C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? If yes, has a water scale reducer been fitted? What type of scale reducer has been fitted? DOMESTIC HOT WATER MODE Measure and Record: Gas Rate Burner Operating Pressure (at maximum rate) Cold Water Inlet Temperature Hot water has been checked at all outlets Water Flow Rate
Yes
No
Yes
No
m3/hr OR mbar OR
Gas Inlet Pressure (at maximum rate)
Yes
Temperature
ft3/hr mbar °C °C l/min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer's instructions and/or BS5546/BS6798
Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following
CO2
The heating and hot water system complies with the appropriate Building Regulations
% OR CO
ppm OR CO/CO2 Ratio Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer's instructions
Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer
Yes
The manufacturer's literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer's Signature
Customer's Signature (To confirm satisfactory demonstration and receipt of manufacturer's literature)
*All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
A Building Regulations Compliance Certificate will then be issued to the customer.
©Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
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 Customer Service: 0870 600 9888
Professional Team Limited Suites 9 & 10, Plaza 256 Blanchardstown Corporate Park 2 Ballycoolin Dublin 15 Telephone: (01) 810 3723 Fax: (01) 810 3727 Internet: www.mtsgroup.com/ie E-mail: info@ie.mtsgroup.com Technical Advice: (01) 437 0121 Customer Service: (01) 437 0121
420010096805 - 06/2008
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