Ariston MICROCOMBI 23 MFFI User guide

microCombi 23/27 MFFI

Installation and Servicing

Instructions

Type C Boilers

G.C.N: 47-116-16 (23kW)

G.C.N: 47-116-24 (27kW)

LEAVE THESE INSTRUCTIONS WITH

THE END-USER

Country of destination: GB, IE

TABLE OF CONTENTS

1. GENERAL INFORMATION PAGE.3

1.1 GENERAL INSTRUCTIONS PAGE.3

1.2 OVERALL VIEW PAGE.4

2. INSTALLATION PAGE.4

2.1 REFERENCE STANDARDS PAGE.4

2.2 SITING THE APPLIANCE PAGE.5

2.3 OVERALL DIMENSIONS PAGE.6

2.4 CLEARANCES PAGE.6

2.5 MOUNTING THE APPLIANCE PAGE.7

2.6 ELECTRICAL CONNECTION PAGE.7

2.7 GAS CONNECTION PAGE.8

2.8 WATER CONNECTION PAGE.8

2.9 FLUE CONNECTION PAGE.10

2.10 CONTROL PANEL PAGE.17

2,11 REMOVING THE FRONT PANEL PAGE.17

2.12 ROOM THERMOSTAT

CONNECTION PAGE.18

2.13 ELECTRICAL/SYSTEM DIAGRAMS PAGE.19

2.14 WATER CIRCUIT DIAGRAM PAGE.20

3. COMMISSIONING PAGE.21

3.1 INITIAL PREPARATION PAGE.21

3.2 INITIAL START-UP PAGE.22

3.3 OPERATIONAL ADJUSTMENTS PAGE.22

3.4 COMBUSTION ANALYSIS PAGE.23

3.5 PRODUCT OF COMBUSTION

DISCHARGE MONITORING PAGE.23

3.6 BOILER SAFETY SYSTEMS PAGE.23

3.7 DRAINING THE SYSTEM PAGE.24

3.8 COMPLETION PAGE.24

3.9 OPERATIONAL CHECKS PAGE.24

3.10 INSTRUCTING THE END USER PAGE.25

4. GAS ADJUSTMENTS

4.1 CHANGING THE TYPE OF GAS PAGE.26

4.2 ADJUSTING THE GAS PRESSURES

(SIT SIGMA)PAGE.26

ADJUSTING THE GAS PRESSURES

(HONEYWELL)PAGE.28

5. MAINTENANCE PAGE.30

6. SERVICING INSTRUCTIONS PAGE.31

6.1 REPLACEMENT OF PARTS PAGE.31

6.2 TOGAIN GENERAL ACCESS PAGE.31

6.2.1 REMOVING THE FRONT

PANEL PAGE.31

6.2.2 REMOVING THE SEALED

CHAMBER FRONT PANEL PAGE.32

6.2.3 REMOVING THE SIDE

PANELS PAGE.32

6.3 ACCESS TO THE COMBUSTION

CHAMBER PAGE.33

6.3.1 REMOVING THE

COMBUSTION CHAMBER PAGE.33

6.3.2 REMOVING THE BURNER

AND JETS PAGE.33

6.3.3 REMOVING THE

ELECTRODES PAGE.33

6.3.4 REMOVING THE MAIN HEAT

EXCHANGER PAGE.34

6.3.5 REMOVING THE AIR

PRESSURE SWITCH PAGE.35

6.3.6 REMOVING THE FAN PAGE.35

6.4 ACCESS TO THE GAS VALVE PAGE.36

6.4.1 REMOVING THE SPARK

GENERATOR (SIT SIGMA)PAGE.36

6.4.2 REMOVING THE SPARK

GENERATOR (HONEYWELL)PAGE.36

6.4.3 REMOVING THE GAS VALVE

(SIT SIGMA)PAGE.37

6.4.4 REMOVING THE GAS VALVE

(HONEYWELL)PAGE.37

6.5 ACCESS TO THE WATER CIRCUIT PAGE.38

6.5.1 REMOVING THE PUMP

PRESSURE SWITCH PAGE.38

6.5.2 REMOVING THE SAFETY

VALVE PAGE.38

6.5.3 REMOVING THE AUTOMATIC

AIR VENT PAGE.38

6.5.4 REMOVING THE PUMP PAGE.39

6.5.5 REMOVING THE PRESSURE

GAUGE PAGE.40

6.5.6 REMOVING THE EXPANSION

VESSEL PAGE.40

6.5.7 REMOVING THE OVERHEAT

THERMOSTAT PAGE.41

6.5.8 REMOVING THE CENTRAL

HEATING TEMPERATURE

SENSOR (N.T.C.) PAGE.41

6.5.9 REMOVING THE D.H.W.

TEMPERATURE SENSOR

(N.T.C.) PAGE.41

6.5.10 REMOVING THE D.H.W.

FLOW SWITCH PAGE.42

6.6 ACCESS TO THE CONTROL SYSTEM PAGE.42

6.6.1 CHECKING THE FUSES PAGE.42

6.6.2 REMOVING THE TIME CLOCK PAGE.43

6.6.3 REMOVING THE P.C.B. PAGE.43

7. FAULT FINDING PAGE.44

7.1 FAULT FINDING GUIDE

(FLOW-CHARTS)PAGE.44

8. SHORT SPARE PARTS LIST PAGE.49

9. TECHNICAL INFORMATION PAGE.52

This manual is an integral and essential part of the product. It should be kept

with the appliance so that it can be consulted by the user and our authorised

personnel.

Please carefully read the instructions and notices about the unit contained in

this manual, as they provide important information regarding the safe

installation, use and maintenance of the product.

For operating instructions please consult the separate Users Manual.

Read the instructions and recommendations in these Installation and Servicing

Instructions carefully to ensure proper installation, use and maintenance of the

appliance.

Keep this manual in a safe place. You may need it for your own reference while

Servicing Technicians or your installer may need to consult it in the future.

This is a combined appliance for the production of central heating (C.H.) and

domestic hot water (D.H.W.).

This appliance must be used only for the purpose for which it is designed.

The manufacturer declines all liability for damage caused by improper or

negligent use.

No asbestos or other hazardous materials have been used in the fabrication of

this product.

Before connecting the appliance, check that the information shown on the data

plate and the table in section 7 comply with the electric, water and gas mains of

the property.You will find the data plate on the reverse of the control panel.

The gas with which this appliance operates is also shown on the label at the

bottom of the boiler.

Do not install this appliance in a damp environment or close to equipment

which spray water or other liquids.

Do not place objects on the appliance.

Do not allow children or inexperienced persons to use the appliance without

supervision.

If you smell gas in the room, do not turn on or off light switches, use the

telephone or any other object which might cause sparks.

Open doors and windows immediately to ventilate the room.

Shut the gas mains tap (at or adjacent to the gas meter) or the valve of the gas

cylinder and call your Gas Supplier immediately.

If you are going away for a long period of time, remember to shut the mains gas

tap or the gas cylinder valve.

Always disconnect the appliance either by unplugging it from the mains or

turning off the mains switch before cleaning the appliance or carrying out

maintenance.

In the case of faults or failure, switch off the appliance and turn off the gas

tap. Do not tamper with the appliance.

For repairs, call your local Authorised Servicing Agent and request the use of

original spare parts. For in-guarantee repairs contact MTS (GB) Limited.

1. GENERAL

INFORMATION

1.1 GENERAL INSTRUCTIONS

2.1 REFERENCE STANDARDS

2. INSTALLATION

LEGEND:

1. Flue connector

2. Air intake for twin pipe flue systems

3. Fan

4. Combustion chamber hood

5. “Twin-pass” heat exchanger

6. Domestic hot water temperature probe

7. Combustion chamber

8. Combustion chamber insulation panel

9. Burner

10. Detection electrode

11. Ignition electrodes

12. Gas valve

13. Spark generator

14. Pump pressure switch

15. Safety valve (3 bar)

16. Automatic By-pass

17. D.H.W. Flow switch

18. Domestic hot water inlet filter

19. Circulation pump with automatic air release valve

20. Safety thermostat

21. Main circuit temperature probe

22. Expansion vessel

23. Air pressure switch tube

24. Air pressure switch

25. Combustion analysis points

1.2 OVERALL VIEW

FIG. 1.0

IN028C

The technical information and instructions provided herein

below are intended for the installer / Servicing Technician

so that the unit may be installed and serviced correctly and

safely.

In the United Kingdom the installation and initial start up of

the boiler must be by a CORGI Registered Installer in

accordance with the installation standards currently in

effect, as well as with any and all local health and safety

standards i.e. CORGI.

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 Building

Regulations, reference should also be made to the current

ETCI rules for electrical installation.

This appliance must be installed by a competent

installer in accordance with current Gas Safety

(installation & use) Regulations.

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

bylaws of the local water 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, the Local

Building Regulations (IE).

C.O.S.H.H.

Materials used in the manufacture of this appliance are

non-hazardous and no special precautions are required

when servicing.

Installation should also comply with the following British

Standard Codes of Practice

and in the Republic of Ireland in accordance with the

following Codes of Practice:

The appliance may be installed in any room or indoor area,

although particular attention is drawn to the requirements

of the current I.E.E. Wiring Regulations, and in Scotland,

the electrical provisions of the Building Regulations

applicable in Scotland, with respect to the installation of

the combined appliance in a room containing a bath or

shower, the location of the boiler in a room containing a

bath or shower should only be considered if there is no

alternative.

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 so that it cannot be

touched by a person using the bath or shower,

specifically in accordance with current IEE Wiring

Regulations.

The location must permit adequate space for servicing and

air circulation around the appliance as indicated in Section

2.4.

The location must permit the provision of an adequate flue

and termination.

For unusual locations special procedures may be

necessary.

BS 6798-1987 gives detailed guidance on this aspect.

A compartment used to enclose the appliance must be

designed specifically for this purpose. No specific

ventilation requirements are needed for the installation

BS 7593:1992 Treatment of water in domestic hot water

central heating systems

BS 5546:1990 Installation of hot water supplies for

domestic purposes

BS 5440-1:2000 Flues

BS 5440-2:2000 Air supply

BS 5449:1990 Forced circulation hot water systems

BS 6798:1987 Installation of gas fired hot water boilers of

rated input not exceeding 60kW

BS 6891:1989 Installation of low pressure gas pipe up to

28mm

BS 7671:2001 IEE wiring regulations

BS 4814:1990 Specification for expansion vessels

BS 5482:1994 Installation of L.P.G.

I.S. 813 Domestic Gas Installations

2.2 SITING THE APPLIANCE

FIG. 2.2 DM001B

In order to allow access to the interior of the boiler for

maintenance purposes, the boiler must be installed in

compliance with the minimum clearances indicated in FIG.

2.2

2.4 CLEARANCES

within a cupboard.

This appliance is not suitable for outdoor installation.

The type C appliances (in which the combustion

circuit, air vent intake and combustion chamber are

air-tight with respect to the room in which the

appliance is installed) can be installed in any type of

room.

Secondary ventilation is not required with this boiler. The

boiler must be installed on a solid, non-combustible,

permanent wall to prevent access from the rear.

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”)

2.3 OVERALL DIMENSIONS

FIG. 2.1 QT002A

For safety purposes, have a competent person carefully

check the electrical system in the property, as the

manufacturer will not be held liable for damage caused by

the failure to earth the appliance properly or by anomalies

in the supply of power. Make sure that the residential

electrical system is adequate for the maximum power

absorbed by the unit, which is indicated on the rating plate.

In addition, check that the section of cabling is appropriate

for the power absorbed by the boiler.

The boiler operates with alternating current, as indicated in

the Technical Information table in Section 10, where the

maximum absorbed power is also indicated. Make sure

that the connections for the neutral and live wires

correspond to the indications in the diagram. The

appliance electrical connections are situated on the

reverse of the control panel.

IMPORTANT!

In the event that the power supply cord must be changed,

replace it with one with the same specifications.

Note: The diagrams for the electrical system are indicated

in section 2.13.

Warning, this appliance must be earthed.

External wiring to the appliance must be carried out by a

competent person and be in accordance with the current

I.E.E. Regulations and applicable local regulations.

The appliance is supplied with a fly-lead already

connected, this must be connected to a 240v supply fused

2.6 ELECTRICAL CONNECTION

FIG. 2.3

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.

Place the template in the position the appliance is to be

mounted and after ensuring it is hanging squarely, use it to

drill the holes for the hanging bracket and flue pipe(s) NB:

For further information relating to the flue installation

please refer to Section 2.9 FLUE CONNECTION. (If the

appliance is to be fitted on a wall of combustible material,

the wall must be protected by a sheet of fireproof

material).

If the appliance is to be fitted into a timber framed building,

guidance should be sought from the Institute of Gas

Engineers document REF: IGE/UP/7.

2.5.1. Drill the wall and plug using those supplied with

the connections kit, position the bracket and secure with

the wall bolts supplied. NOTE:It is highly recommended

that a spirit level be used to position the appliance to

ensure that it is perfectly level.

2.5.2. Position the appliance on the hanging bracket and

connect the isolating valves supplied in the connection kit

as shown on the wall template (see also Sections 2.7 Gas

Connections, 2.8 Water Connections & FIG. 2.3).

2.5 MOUNTING THE APPLIANCE

VIEW OF THE BOILER CONNECTIONS

LEGEND:

A = Central Heating Flow

B = Domestic Hot Water Outlet

C = Gas Inlet

D = Domestic Cold Water Inlet

E = Central Heating Return

F = Safety Valve Outlet

2.8 WATER CONNECTIONS

2.7 GAS CONNECTION The local gas region contractor connects the gas meter to the service pipe.

If the gas supply for the boiler 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 a smaller size than the

boiler inlet connection should not be used.

at 3A and must facilitate complete electrical isolation of the appliance, by the

use of a fused double pole isolator having a contact separation of at least 3

mm in all poles or alternatively, by means of a 3 A fused three pin plug and

unswitched shuttered socket outlet both complying with BS 1363.

The point of connection to the Electricity supply must be readily accessible

and adjacent to the appliance unless the appliance is installed in a bathroom

when this must be sited outside the bathroom (see section 2.2).

Should external controls be required, the design of the external electrical

circuits should be undertaken by a competent person, see section 2.12 for

further information.

FIG. 2.4

FIG. 2.5 KT007A

SC005A

PIPE WORK:

Copper tubing to BS EN 1057:1996 is recommended for water pipes.

Jointing should be either with capillary soldered or compression fittings.

Where possible pipes should have a gradient to ensure air is carried

naturally to air release points and water flows naturally to drain taps.

The appliance has a built-in automatic air release valve, however it should

be ensured as far as possible that the appliance heat exchanger is not a

natural collecting point for air.

Except where providing useful heat, pipes should be insulated to prevent

heat loss and avoid freezing.

VR003A

RESIDUAL HEAD OF THE BOILER

Particular attention should be paid to pipes passing through ventilated

spaces in roofs and under floors.

BY-PASS:

The appliance includes an automatic by-pass valve, which protects the main

heat exchanger in case of reduced or interrupted water circulation through

the heating system, due to the closing of thermostatic valves or radiators.

SYSTEM DESIGN:

This boiler is suitable only for sealed systems.

DRAIN COCKS:

These must be located in accessible positions to permit the draining of the

whole system and should be fitted at all low points. The taps must be at least

15mm nominal size and manufactured in accordance with BS 2870:1980.

SAFETY VALVE DISCHARGE:

The discharge should terminate facing downward on the exterior of the

building in a position where discharging (possibly boiling water & steam) will

not create danger or nuisance, but in an easily visible position, and not

cause damage to electrical components and wiring.

The discharge must not be over an entrance or a window or any other type

of public access.

AIR RELEASE POINTS:

These must be fitted at all high points where air naturally collects and must

be sited to facilitate complete filling of the system.

The appliance has an integral sealed expansion vessel to accommodate the

increase of water volume when the system is heated.

It can accept up to 6 litres (1.3 gal) of expansion water. If the heating circuit

has an unusually high water content, calculate the total expansion and add

an additional sealed expansion vessel with adequate capacity. This should

be located on the return pipe work as close as possible to the pump inlet.

MAINS WATER FEED - CENTRAL HEATING:

There must be no direct connection to the mains water supply even through

a non-return valve, without the approval of the Local Water Authority,

therefore a temporary method for initially filling the system and replacing lost

water during servicing in accordance with current Water Regulations and

bylaws must be provided (FIG. 2.6). 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. Copper tubing to BS EN 1057:1996 is

recommended for water carrying pipe work and must be used for pipe work

carrying drinking water, a scale reducer should also be used to reduce the

risk of scale forming in the domestic side of the heat exchanger.

CENTRAL HEATING

Detailed recommendations are given in BS 6798:1987 and BS 5449-1:1990,

the following notes are given for general guidance.

FIG. 2.6 Fill01

Ø 60/100 mm

FIG. 2.8

2.9 FLUE CONNECTIONS FLUE SYSTEM

The provision for satisfactory flue termination must be made in accordance

with BS 5440-1.

The appliance must be installed so that the flue terminal is exposed to outside air.

The terminal must not discharge into another room or space such as an

outhouse or lean-to.

It is important that the position of the terminal allows a free passage of air

across it at all times.

The terminal should be located with due regard for the damage or

discolouration that might occur on buildings in the vicinity and consideration

must be given to adjacent boundaries.

In cold or humid weather water vapour may condense on leaving the flue

terminal. The effect of such “pluming” 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 terminal guard must

be fitted. When ordering a terminal guard, quote the appliance model

number.

A suitable terminal guard is available from:

TOWER FLUE COMPONENTS

Morley Road

Tonbridge

Kent TN9 1RA

The minimum acceptable spacing from the terminal to obstructions and

ventilation openings are specified in FIG. 2.7.

ERMINAL

OSITION

A - Directly below an openable window or other opening 300

B - Below gutters, solid pipes or drain pipes 75

C - Below eaves 200

D - Below balconies or car-port roof 200

E - From vertical drain pipes and soil pipes 150

F - From internal or external corners 300

G - Above ground or balcony level 300

H - From a surface facing a terminal 600

I - From a terminal facing a terminal 1200

J - From an opening in the car port

(e.g. door, window) into dwelling 1200

K - Vertically from a terminal in the same wall 1500

L - Horizontally from a terminal in the same wall 300

M - Horizontally from an opening window 300

N - Fixed by vertical flue terminal

FIG. 2.7 FU010ARev1

FU003A

FU002A/Rev.1

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 SHOWN IN TABLE

2.1 (PAGE 16).

NOTE:THE FLUE MUST NOT TERMINATE IN A PLACE LIKELY TO CAUSE NUISANCE

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