Users Guide Installation and Servicing Instructions TP 23 - G.C. Number 47-116-32 TP 30 - G.C.
TABLE OF CONTENTS USERS GUIDE 1. 2. 3. 4. GENERAL INFORMATION OPERATING INSTRUCTIONS BOILER SHUTDOWN SITUATIONS TIME CLOCK INSTALLATION AND SERVICING INSTRUCTIONS 5. GENERAL INFORMATION 5.1 5.2 General Instructions Overall View 6. INSTALLATION 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.
USERS GUIDE 2. Operating Instructions 1. General Information Installation, start-up, adjustments and maintenance must be performed by a competent per son only, in accordance with the current Gas Saf ety (Installation & Use) Regulations and the instructions pr ovided. Improper installation ma y cause damage or injury to individuals, animals and personal property, for which the manufacturer will not be held liab le.
3. Boiler Shutdown Situations Winter and Summer Operating Modes In the ‘winter operating mode’, the boiler will produce both Centr al Heating and Domestic Hot Water. In the ‘summer operating mode’, the boiler will produce only domestic hot water. Press button “F” to select winter mode . The green LED “G” will illuminate. The boiler is equipped with saf ety devices that inter vene in certain situations and shut it off.
3. Boiler Shutdown Situations 4. Time clock Shutdown Due To Insufficient Circulation If the boiler is off , one possible cause for this state is an insufficient pressure of water in the system. Check the system pressure on the pressure D gauge “D” and if it is less than 0.
INSTALLATION AND SERVICING INSTRUCTIONS 5. GENERAL INFORMATION 5.1 General Instructions Check the following at least once a year: 1 - Check the seals f or the w ater connections; replace any faulty seals. 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of combustion by-products (see section 3.6) and cleaning of the burner if needed. 5 - If called for by point.
General Information 5.2 Overall View Legend: 1 28 2 27 3 4 26 5 25 6 7 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 24 9 10 11 23 12 13 14 22 21 20 Fig. 5.
6. INSTALLATION 6.1 Reference Standards 6.2 The technical information and instructions provided herein below are intended f or the installer / Ser vicing Technician so that the unit may be installed and ser viced correctly and safely. Siting the Appliance The appliance ma y be installed in an y room or indoor area, although particular attention is dr awn to the requirements of the current I.E.E.
Installation 6.3 Overall Dimensions 6.5 MOUNTING THE APPLIANCE After removing the boiler from its packaging, remove the template from the separate box containing the connection kit. Note: Pay particular attention to any test water that may spill from the appliance. FIG. 6.1 QT002A Legend: A = Central Heating Flow (3/4”) B = Domestic Hot Water Outlet (1/2”) C = Gas Inlet (3/4”) D = Domestic Cold Water Inlet (1/2”) E = Central Heating Return (3/4”) 6.4 Clearances FIG. 6.3 FIG. 6.
Installation 6.7 6.5.1. Drill the wall and plug using those supplied with the con nections kit, position the br acket and secure with the w all bolts supplied. Note: It is highly recommended that a spirit level be used to position the appliance to ensure that it is perfectly level. Gas Connection The local gas region contr actor connects the gas meter to the service pipe.
Installation A B C D E Note: The installer should ensure that there are no leaks as frequent filling of the heating system can lead to premature scaling of the main exchanger and failure of hydraulic components. Domestic Water: The domestic water must be in accordance with the relevant recommendation of BS 5546:1990.
Installation 6.9 Flue Connections IMPORTANT! For all flue systems, a restrictor may need to be inserted into the exhaust manifold, the size of the restrictor and details of fitting requirements are sho wn in Table 6.1 (Page 18). FLUE SYSTEM The provision for satisfactory flue ter mination must be made in accordance with BS 5440-1. The appliance must be installed so that the flue ter minal is exposed to outside air. The terminal must not discharge into another room or space such as an outhouse or lean-to.
Installation face of the flue elbo w (X - FIG 6.8), add 22 mm to this measurement, you now have the total length of flue required (including the terminal), this figure m ust now be subtracted from 860mm, y ou now have the total amount to be cut from the plain end of the flue. FIG 6.9 Cut the flue to the required length ensur ing that the distance between the inner and the outer flue is maintained (FIG 6.10). e.g. X = 508mm + 22mm = 530mm 860 - 530 = 330mm (Length to be cut from the plain end of the flue).
Installation The Vertical flue kits maxim um and minim um useable lengths with both flat and pitched roof flashings are indicated in (Figs. 6.14 & 6.15). FIG 6.13 Before proceeding to fit the flue , ensure that the maxim um flue length has not been e xceeded and that all elbo ws and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90o elbow 1 metre must be subtracted from the total flue length, and f or each 45 o 0.
Installation According to Table 6.1 (Page 18) decide if condensation will form within the flue. If yes, there are two options; 1) Where condense will form but can be negated with insulated flue, install the insulated flue with a fall of 5mm in every metre away from the boiler. 2) The exhaust flue will have a fall of 3o back to the boiler and a suitable trap will be fitted on the exhaust as close to the boiler as possible, condense will then be suitably disposed of. Where the flue runs through cold spots, i.
Installation For flue runs with the intak e and exhaust pipes under the same atmospheric conditions (T ype 4) the maxim um length is 43 metres (80) and 28 metres (100), f or runs with the ter minals under different atmospheric conditions (Type 5) the e xhaust terminal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the e xhaust and air intak e pipes are located on the same side of the building).
Installation FIG. 6.19 Type 1 Type 3 Type 2 Type 5 Type 4 Note: Drawings are indicative of flueing options onl y. AIR INTAKE MUST NOT BE FITTED ABOVE THE EXHAUST AIR INTAKE EXHAUST AIR INTAKE FIG 6.
Installation TP 23 Table 6.
Installation 6.10 2 Control Panel K J I HGF A B E D To dismantle the front casing panel it is necessar y to: 1 - Remove the two screws “B”; 2 - Move the front casing panel up and lift f orward. C 3 LEGEND: A B C D E F G H I J K - On/Off button Central heating temperature adjustment Domestic hot water temperature adjustment Heating system pressure gauge Time clock (knock out) Central heating selector Central heating L.E.D. (green) Flue sensor L.E.D.
Installation 6.
Installation 6.12 Fitting the Time Clock (continued) 7 MECHANICAL TIME CLOCK 5 4 3 2 DIGITAL TIME CLOCK 3 1 RED GREY 2 1 RED GREY BLACK BLACK FIG. 6.
Installation 6.13 Room Thermostat Connection To connect a room ther mostat, it is necessary to: 1. - Open the control panel as indicated in SECTION 6.11. 2.- Remove the link “A” from the terminal block on the reverse of the control panel. 3. - Insert the thermostat cable through the cable grommet and fasten it by means of the cable-clamp provided. 4. - Connect the ther mostat wires to the ter minal block (Diagram A). 5.
Installation 6.14 ELECTRICAL/SYSTEM DIAGRAMS CN104 FUSE A CN104 CN103 S 5 CN101 R 2 CN100 B Q P J L M O N FIG. 6.
Installation 6.15 Water Circuit Diagram Legend: FIG. 6.24 21 1 20 2 3 4 5 6 19 18 7 8 17 9 10 16 15 11 12 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. A. B. C. D. E. 14 24 Fan Heat Exchanger Overheat Thermostat Burner Detection Electrode Ignition Electrodes Main Circuit Temperature Probe Pressure Gauge Low Water Pressure Switch Safety Valve Domestic Hot Water Temperature Probe Secondary Exchanger Gas Valve D.H.W. Flow Switch D.H.W.
7. COMMISSIONING 7.1 Initial Preparation 7.2 Initial Start-up THE CHECKS TO BE RUN BEFORE INITIAL START-UP ARE AS FOLLOWS: 1.
Commissioning 7.4 7.6 Combustion Analysis The boiler is fitted with the f ollowing devices (see SECTION 6.10 for references). 1 - Ignition Failure: This indicates ignition f ailure when a flame is not detected within 7 seconds of starting an ignition sequence. The L.E.D. “I” will illuminate to signal the shutdown status. The system can be reset by pressing and releasing the button “J” after checking to mak e sure that the gas coc k is open.
Commissioning 7.7 Draining the System 7.10 Draining the Heating System The heating system must be drained as follows: - Turn off the boiler; - Attach a hose pipe and open the dr ain valve; - Drain the system at the lowest points (where present). When the heating system is unused for an extended period of time, it is recommended that y ou add antifreeze with an eth ylene glycol base to the w ater in the heating pipe w ork and radiators if the ambient temper ature drops below 0°C during the winter.
8. GAS ADJUSTMENTS Model CATEGORY II2H3+ TP 23 TP 30 Lower Wobbe Index (15°C;1013mbar) MJ/m3h Nominal Delivery Pressure Minimum Delivery Pressure TP 23 TP 30 8.1 Main Burner: n. 14 jets (ø) Consumption (15°C; 1013mbar) Consumption (15°C; 1013mbar) Gas Burner Pressure max - min Main Burner: n. 14 jets (ø) Consumption (15°C; 1013mbar) Consumption (15°C; 1013mbar) Gas Burner Pressure max - min Methane Gas Liquid Butane Gas G20 G30 Liquid Propane Gas G31 mbar mbar 45.67 20 20 80.58 29 28 80.
Gas Adjustments 5. To set the minimum power, disconnect a supply terminal “F1” from the modureg and adjust scre w “F” (ensure that the 10mm nut is held in position). Turn the scre w clockwise to increase the pressure and anti-cloc kwise to decrease the pressure (displayed on the pressure gauge) corresponding to the minimum power (see TABLE A page 28). 6.
Gas Adjustments TP 30 MFFI TP 23 MFFI TABLE A 2.80 2.09 Kg/h 2.06 Kg/h 1.16 0.87 Kg/h 0.85 Kg/h 20 28 mbar 37 mbar 10.3 28.1 mbar 35.6 mbar 2.0 5.0 mbar 6.8 mbar 14 x 1.25 14 x 0.72 14 x 0.72 3.49 2.60 Kg/h 2.56 Kg/h 1.48 1.10 Kg/h 1.09 Kg/h 20 28 mbar 37 mbar 11.5 26.8 mbar 34.0 mbar 2.2 5.3 mbar 6.5 mbar 14 x 1.35 14 x 0.80 14 x 0.
9. MAINTENANCE It is recommended that the following inspections be carried out on the boiler at least once a y ear: 1 - Check the seals for the water connections; replace any faulty seals. 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of combustion by-products (see section 3.6) and cleaning of the burner if needed. 5 - If called for by point. 3, dismantling and cleaning of the combustion chamber.
10. SERVICING INSTRUCTIONS To ensure efficient saf e operation, it is recommended that the boiler is serviced annually by a competent person. FIG. 10.3 Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool. Before and after ser vicing, a comb ustion analysis should be made via the flue sampling point (please ref er to SECTION 3.4 for further details).
Servicing Instructions 10.2.2 Removing the sealed chamber front cover 10.2.3 Removing the side panels 1. Remove the screws “C” (FIG. 10.6); 2. Lift the sealed chamber front cover from the locating pins (FIG. 10.7). 1. Remove the four screws “D” for each side panel (F IG.10.8); 2. Pull the panel a way from the boiler at the base , then lift the panel up and remove from the boiler (F IG.10.9). FIG. 10.8 FIG. 10.6 D C C D FIG. 10.7 D FIG. 10.
Servicing Instructions 10.3 Access to the Combustion Chamber 10.3.3 Removing the electrodes Before carrying out this procedure, unscrew and slide the burner forward (see previous section). 1. Remove rubber gasket “G” (FIG. 10.13); 2. To remove the detection electrode disconnect the cab le at its connection point close to the P.C.B. (FIG. 10.14); 3. Remove screw “H” (FIG. 10.15); 4. Gently slide the electrode downward (FIG. 10.16). 10.3.1 Removing the combustion cover 1. Remove the screws “E” (FIG. 10.
Servicing Instructions 10.3.4 Removing the main heat exchanger FIG. 10.21 1. Drain the boiler of water; 2. Remove the side panels (see 10.2.3) 3. Remove the overheat thermostat sensor “I” (FIG. 10.17); 4. Remove the clip “J” (FIG. 10.18); 5. Remove the “U” clip “K” (FIG. 10.19); 7. Pull down the pipe (F IG. 10.20); 4. Pull it straight out (FIG. 10.21). Fig. 10.17 I 10.3.5 Removing the air pressure switch 1.
Servicing Instructions 10.3.6 Removing the fan 10.4 Access to the Gas Valve 1. Disconnect electrical connections “O” and silicone pipe “P” (FIG.10.25); 2. Remove screw “Q” and remove the fan collar clamp “R” (FIG. 10.26); 3. Remove screws “S” (FIG. 10.27); 4. Remove fan and mounting plate (F IG. 10.28). 10.4.1. Removing the spark generator 1. Disconnect ignition leads “T” by pulling upward (FIG. 10.29); 2. Remove the screw “U” (FIG. 10.30); 3.
Servicing Instructions 10.4.2 Removing the gas valve 10.5 Important! Before removing the gas v alve, ensure the gas supply is turned off. Important! Before any component is remo ved, the boiler must be drained of all water. 1. 2. 3. 4. Disconnect all the cables from the solenoid and modureg; Remove the spark generator (see previous section); Release the nuts “V” (FIG. 10.32); Remove the screws “W” from the bottom of the gas valve (FIG. 10.33); 5. Remove the gas valve (FIG. 10.34).
10.5.3 Removing the safety valve FIG. 10.38 1. Disconnect the discharge pipe work from below the boiler; 2. Unscrew and remove the valve “A1” (FIG. 10.41). A1 10.5.2 Removing the pump pressure switch 1. Remove the pump pressure s witch electrical connections “Z” (FIG 10.39); 2. Unscrew the pump pressure switch by using a spanner on the nut (FIG 10.40); 3. Remove the pump pressure switch . FIG. 10.41 10.5.4 Removing the automatic air vent FIG. 10.39 1. Remove the U-clip “B1” (FIG. 10.42); 2.
Servicing Instructions 10.5.5 Removing the pump 10.5.6 Removing the pressure gauge 1. Remove the electrical connection “ C1” (FIG. 10.44); 2. Remove the allen screw “D1” (FIG. 10.45); 3. Remove the pump (FIG. 10.46). 1. Remove the U-clip “E1” (FIG. 10.47) 2. Push the pressure gauge through the control panel from the rear (FIG. 10.48). FIG. 10.47 E1 C1 FIG. 10.44 D1 D1 D1 D1 FIG. 10.48 FIG. 10.45 FIG. 10.
Servicing Instructions 10.5.7 Removing the expansion vessel 10.5.8 Removing the overheat thermostat 1. 2. 3. 4. 1. Disconnect the overheat thermostat electrical connections “I1” (FIG. 10.53); 2. Then remove the ther mostat from its mounting b y releasing the securing clip (FIG. 10.54 /10.55). Release nuts “F1” and remove the gas pipe (F IG. 10.49); Release nut “G1” (FIG. 10.50); Remove back-nut “H1” (FIG. 10.51); Remove the expansion vessel (FIG. 10.2). FIG. 10.53 FIG. 10.49 F1 FIG. 10.50 I1 FIG.
Servicing Instructions 6.5.12 Removing the divertor valve actuator 10.5.10 Removing the D.H.W. temperature sensor (N.T.C.) 1. Unplug the electrical connector “L1” (FIG. 6.60); 2. Release the retaining clip “M1” and remove the divertor valve actuator (FIG. 6.61). 1. Pull off the electrical connector and unscrew the sensor probe using a suitable spanner (FIG. 10.57). FIG. 10.57 L1 FIG. 6.60 10.5.11 Removing the D.H.W. flow switch 1. Unplug the electrical connector “J1” (FIG. 10.58); 2.
Servicing Instructions 10.6 Access to the Control System Important! Isolate the electr ical supply to the boiler bef accessing the control panel. 10.6.2 Removing the P.C.B. 1. Isolate electricity; 2. Remove the inspection co ver from the re verse of the control panel; 3. Unplug all electrical connections from the P.C.B. 4. Remove the screws “N1” (FIG. 10.64); 5. Separate the facia panel from the rear of the control panel ; 6. Remove the screws “O1” and remove the P.C.B. (FIG. 10.65). ore 10.6.
11. FAULT FINDING 11.1 Fault Finding Guide (Flow-charts) These fault finding guides are not exhaustive. However, it is possible to detect and correct man y defects by using the standard fault finding diag rams described in this chapter , ensure these guides are carried out in the set order. To ensure that the external controls do not interfere with the fault finding, disconnect the wires from the ter minal block on the rear of the control panel and pro vide a solid link betw een the ter minals.
Fault Finding 44
Fault Finding 45
Fault Finding 0.55mbar (23kW) 0.90mbar (30kW) 46 0.55mbar (23kW) 0.
Fault Finding 47
12.
Short Spares Parts List Key Part Number Description 16 65101294 28 995903 Pump Pressure Switch 32 997088 Safety Valve (3 Bar) 35 65101390 36 995948 D.H.W.
13. TECHNICAL INFORMATION CE Certification Heat Input Heat Output Efficiency of Nominal Heat Input Efficiency at 30% of Nominal Heat Input Heat Loss to the Casing ( ∆T=50°C) Flue Heat Loss with Bur ner Operating Flue Heat Loss with Bur ner Off Max Discharge of Products of Combustion (G20) Residual Discharge Head Consumption at Nominal Capacity(G20) Gas Consumption after 10 Minutes* (15°C, 1013 mbar) (G30-G31) Temp.
