3
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Installation & Servicing
GENERAL
CONTENTS
Boiler Clearances. ............................................................ 7
Commissioning and Testing. ......................................... 32
Electrical Connections. .................................................. 14
Electrical Supply. .............................................................. 5
Fault Finding. ................................................................... 36
Flue System Design. ......................................................... 4
Gas Safety Regulations .................................................... 3
Gas Supply. ........................................................................ 5
Introduction. ...................................................................... 3
Initial Lighting. ................................................................. 32
Installation. ...................................................................... 11
Performance Data. ........................................................... 2
Servicing. ........................................................................ 34
Short List of Parts. ......................................................... 39
Ventilation. ...................................................................... 10
Water Circulation. ............................................................ 5
Water Connections. ......................................................... 7
Water System Requirements. ......................................... 9
Water Treatment. ............................................................. 5
Wiring Diagrams. ............................................................ 17
Natural Gas only
PI No. 0049 BM 3615
Destination Countries: GB, IE
Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water.
B23 =
An appliance intended to be connected to a flue which
evacuates the products of combustion to the outside of
the room containing the boiler. The combustion air is
drawn directly from the room. The fan is up stream of
the combustion chamber.
C63 = A room sealed appliance intended to be connected to a
separately approved and marketed system for the
supply of combustion air and discharge of combustion
products. The fan is up stream of the combustion chamber.
INTRODUCTION
The
boilers are fully automatically controlled, floor
standing, fanned, super efficient, low NOx condensing appliances.
The comprehensive boiler controls built into the appliance
include:
•
0-10V BMS
•
Volt free alarm contacts
•
Burner hours run meters
•
Weather compensating heating curve using outside
temperature sensor (supplied with boiler)
The boilers can draw their combustion air from the room or via
ducting from the outside.
Through a sophisticated control system combined with premix
burner technology and an aluminium heat exchanger, the boilers
are capable of high operating efficiencies of >94% (gross) and
low emissions.
These boilers are certified to meet the requirements of the EC
Gas Appliance Directive, Boiler Efficiency Directive, EMC and
Low Voltage Directive.
DUTY
The range of boilers is suitable for: combined indirect pumped
domestic hot water and central heating systems; independent
indirect pumped domestic hot water or central heating systems.
Fully pumped systems may be open vented or sealed.
The range of boilers is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
4. Single feed indirect cylinders.
CONSTRUCTION
The construction is of a sectional design with individual burners,
fans, gas valves and ignition/supervision controls. A non-return
valve ensures no reverse circulation of flue products through
modules not operating. The sectional heat exchanger is of cast
aluminium. A stainless steel sump collects the flue products
and diverts them to the flue, whilst allowing drainage of
condensate products.
LOGIC OF OPERATION
When the boiler receives a call for heat, the Modular Boiler Drive
(MBD) calculates the necessary output according to the
difference between the set flow temperature (or compensated
flow temperature for a CH call when using an outside sensor)
and the boiler modules combined flow temperature. The
circulation pump is started whilst operating a DHW control valve,
if required, and the first module fan is run up to starting speed. A
spark is started and the gas valve opens. Ignition must occur in
5 seconds and once detected the module starts operating.
Subsequently, additional modules are likely to start in the same way.
The boiler principle method of operation is to run as many
modules simultaneously, at the lowest possible load, for
maximum efficiency. For example:
If an
F160 with 160kW max. input is only requested to
provide 72kW.
72
÷
4 = 18kW per module
Therefore, the boiler operates all modules at 18kW.
If the required load is less than the min. 12kW per module, then
one module after the other is automatically shutdown and the
load shared by the remaining modules. The modules with the
lowest number of hours run are automatically chosen to satisfy
the demand.
OPTIONAL EXTRA KIT
•
Tank Sensor Kit
SAFETY
Current Gas Safety (Installation and Use) Regulations or rules
in force.
It is the law the that all gas appliances are installed and
serviced by a CORGI registered installer, or in IE a competent
person, in accordance with the regulations below. Failure to
install appliances correctly could lead to prosecution. It is in your
own interest, and that of safety, to ensure the law is complied
with.