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Mikrofill Ethos 28 Series, Installation And Operating Manual

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29. Commissioning  
 
29.1 Electrical Checks  

A “Preliminary Electrical System Check” should be carried out to ensure earth continuity, 
short circuit, polarity and resistance to earth using a suitable multi meter.  

 

29.2 Gas Supply  

Check the gas installation and purge the supply in accordance with current Gas Safety 
Regulations.  

 

The gas valve fitted to the boiler is not designed to withstand pressures in excess of 60 
mbar. When carrying out the pressure test on the service pipe-work it is essential that 
the gas cock fitted to the boiler is in the closed position, failure to do so will result in 
serious damage to the boiler.  

 

If using LPG, care should be taken to ensure that the storage tank has been correctly 
vented.  

 

29.3 Connection to Pipe-work  

The boiler is a low water content unit. When connecting to an existing installation it is 
important that old system deposits are removed and are not allowed to contaminate the 
appliance.  

 
29.4 Water Treatment  

In order to protect and prolong the working life of the appliance, it is important the 
general condition of older systems is carefully considered.  The removal of debris, flux 
residue, grease, metal swarf etc. from new systems and any rust , black magnetic iron 
oxide sludge and lime-scale from old systems is essential.  

 

Consider high pressure flushing to remove all debris in badly contaminated systems. 

 

 

Fit in-line filters for full protection. All installations should be treated and maintained with 
Fernox MB1 at a concentration of 4%. 

 

29.5 Flushing System Pipe-work  

Before the final flow and return connections are made to the boiler, the system must be 
thoroughly flushed.   Ensure that all radiator valves are open.   Flush the system with 
clean water until the discharge runs clear.  Make good final connections to boiler.  

 

29.6 Filling and Venting the System  

Using a suitably approved filling loop connected to the incoming mains cold water 
supply, fill the system.  The correct filling pressure is between 1 and 2 bar.  Depending 
on the type of unit, the following steps must be completed:  

 

Venting is achieved automatically after switching on the appliance or after a reset. The 
boiler control has a special start-up programme for venting the unit.  

 

This programme is started when the unit is powered for the first time and there is a heat 
demand present. This start-up venting programme takes 1 minute to complete.  

Summary of Contents for Ethos 28 Series

Page 1: ...Installation and Operating manual Ethos 28cc Ultra High Efficiency Gas Fired Condensing Combination Boiler ...

Page 2: ... 9 2 EC 16 23 31 and 38 HS 10 9 3 EC 16 23 31 and 38 S 10 10 Technical Information 11 11 Main Component Specification 13 11 1 Head Height of the Central Heating Circuit 13 11 2 Air Fan Details 13 11 3 Gas Control Valve 13 12 Unpacking Items Supplied 14 13 Accessories 14 14 Operation 15 14 1 Variable Controlled Output 15 14 2 Variable pump 15 14 3 Frost Protection 15 14 4 Year Long Protection 15 15...

Page 3: ... Hydraulic Resistance 30 20 3 Condensate Drain 30 20 4 System By Pass 30 21 Electrical Connections 33 22 Heating Control Options 33 22 1 240 Volt Connections 33 22 2 Low Voltage Connections 34 22 3 Built in clock 34 23 Boiler Control panel 34 24 Boiler Control Panel 35 24 1 System water pressure gauge 35 24 2 On off switch 35 24 3 Lcd control display 35 24 4 Menu reset button 35 24 5 Summer winter...

Page 4: ...29 4 Water Treatment 47 29 5 Flushing System Pipe work 47 29 6 Filling and Venting the System 47 30 Combustion Ratio 48 30 1 Commissioning NG and LPG 48 31 Setting the Maximum CO2 Value 48 31 1 Flue System Check 49 31 2 STB Test Button Green 49 32 Diagnostics 49 32 1 Control panel 49 33 Fault Finding 50 34 Handing the boiler over 54 34 1 Customer Familiarisation 54 35 Annual Servicing 54 35 1 Serv...

Page 5: ...6 Vertical Wall Terminal 23 Figure 17 Vertical Flue Application 23 Figure 18 Modular Installation 23 Figure 19 Vertical Roof Terminals 24 Figure 20 Concentric flue fittings 25 Figure 21 Concentric 80mm adaptor 25 Figure 22 80mm Flue Tubes 25 Figure 23 Fan Flued Terminal Positions 26 Figure 24 H Type Hydraulic system design 31 Figure 25 HS Type Hydraulic system design 31 Figure 26 S Type Combi Hydr...

Page 6: ...ing Functions 39 Table 13 Installer Functions 39 Table 14 Minimum Maximum fan speeds 48 Table 15 CO2 Outputs 49 Table 16 LCD Display NON FLASHING 50 Table 17 LCD NON FLASHING burner off 50 Table 18 Fault Display FLASHING 51 Table 19 Non Display Faults and Errors 51 Table 20 Reasons For Error Display 52 ...

Page 7: ...ensure that any necessary personal protective clothing or equipment is worn appropriate to parts that could be considered as being hazardous to health and Safety This appliance may contain some of the items below INSULATION AND SEALS Glass Rope Mineral Wool Insulation Pads Ceramic Fibre Glass Insulation Which may be harmful if inhaled and may be irritating to the skin eyes nose or throat When hand...

Page 8: ...able for CORGI registered installers Please contact Mikrofill for more information This installation manual contains all the necessary information required to install and commission the Ethos 28 range of boilers Please read this manual thoroughly before commencing installation The installation must be carried out in accordance with the manual otherwise the warranty will be void Use only original p...

Page 9: ...ns prior to Connection IMPORTANT All Ethos boilers are low water content units In order to protect and prolong the working life of the appliance it is important the general condition of older systems is carefully considered When connecting to an existing installation it is important that system deposits are removed and are not allowed to contaminate boiler This involves the application of a cleans...

Page 10: ...ansion vessel An additional suitable sized expansion vessel may be required to accommodate water volume change on larger capacity systems Select an expansion vessel that matches the volume of the CH system and the static pressure Please contact Mikrofill Technical Department for assistance is required Installation should comply with BS7074 part 1 and BS5449 ...

Page 11: ...quirements for cleaner combustion RAL UZ61 7 4 Additional Features Corrosion resistant stainless steel heat exchanger Integral sensors PTC for monitoring flow and return water temperatures 3 way valve and facilities for connection to DHW storage Computer controlled combustion analysis with built in fault diagnosis facility 8 Description of Appliances 8 1 Ethos 28cc This model is suitable for a cen...

Page 12: ...s Model Ethos 28cc E28 Maximum Rated Input kW 22 Nominal Output To Heating 80 600C kW 21 4 Minimum Output To Heating 80 600C kW 3 1 Nominal Output To Heating 50 300C kW 23 1 Minimum Output To Heating 50 300C kW 3 6 CO2 content at max min load CO2 9 9 Dew Point of Flue Gases 00C 52 Flue Gas Temp 80 600C Amb 200C 00C 75 Maximum Flue Resistance Pa 100 pH value of condensate water PH 4 5 5 Pump Pressu...

Page 13: ...er Specifications Model EC23 Maximum Rated Input kW 28 0 Modulating Output kW 3 4 28 Hot Water Flow rates at ô 30K S type L min 13 4 Maximum Tap Water Pressure bar 10 Table 5 Power Details Min Max Gas Pressure mbar 15 50 Minimum Input Rate Natural Gas m h3 0 36 Maximum Input Rate Natural Gas m h3 2 67 Electrical Supply VAC 230 Power Consumption Average W 60 ...

Page 14: ...th the boiler Replacement fuses located top left of control panel Vent key Mounting bracket Outside air temperature sensor 13 Accessories The following items are also available from Mikrofill at extra cost Colour coded 1 4 Turn Isolating Valves Stainless Steel Flexible Pipe Connections In line Filter Strainers ...

Page 15: ...d Concentric Flue 80 125 500mm length Galvanised Concentric Flue 80 125 Galvanised 90 degree elbow 80 125 Galvanised 45 degree elbow 80mm 1000mm flue pipe 80mm 45 degree Elbow 80mm 45 degree connector 80 125 Roof Terminal Pitched roof tile flashing Aluminium flat roof terminal chimney top flashing 80mm Wall Fixing Clamp 125mm Wall Fixing Clamp 80mm flexible flue liner per metre 80mm flexible flue ...

Page 16: ... flow and return temperatures on systems using radiators 14 3 Frost Protection If the flow temperature falls below 80C in order to provide frost protection the pump will run even though there may be no demand for heat If the temperature continues to fall at 50C the burner will also ignite At 100C the appliance will return to standby mode Remember when handing over the appliance to advise the end u...

Page 17: ...ombustible material and are capable of supporting the weight of the boiler and any other ancillary equipment Where installation will be in an unusual location special procedures may be necessary Detailed guidance on this subject can be found in BS 6798 15 1 Timber Framed Dwellings When installing the boiler into a timber framed dwelling it must be fitted in accordance with the British Gas publicat...

Page 18: ...m 6 Gas Inlet 15mm 7 Return Domestic Hot Water 22mm 8 Heating Return 22mm 9 Condensate Discharge M I 16 4 S Connections 16 5 Clearances 1 Cable Gland 2 Syphon Flush No permanent connection required 3 Heating Flow 22mm 4 Additional Cable Entry Point 5 Flow Domestic Hot Water 22mm 6 Gas Inlet 15mm 7 Cold Mains Water 22mm 8 Heating Return 22mm 9 Condensate Discharge M I For ease of installation neces...

Page 19: ...verings is not prevented Unpack the appliance and ensure that the items listed on have been supplied 16 8 Removing the Casing To remove the casing lay the unit down on the floor with the casing facing upper most Loosen the centre screw and undo the two toggle casing clips located on the bottom of the unit Pull the casing upwards lifting up and off the internal locating lugs Place the casing to one...

Page 20: ...asured at the base of the panel Failure to observe this will result in condensate becoming trapped inside the heat exchanger Component failures as a result of incorrect installation will not be covered by the boilers normal warranty Please remember when using power tools to take all necessary safety precautions and always wear safety goggles 17 Flues and Ventilation The internal boiler flue system...

Page 21: ...nce For installations requiring greater flue lengths please contact the Mikrofill technical department for advice The flue should terminate with a suitable terminal 17 3 Pluming The siting of the terminal is not critical with regard to the performance of the appliance However In certain locations the flue outlet may be susceptible to high winds or air turbulence Sudden gusts may create a negative ...

Page 22: ... ensure the safe and satisfactory operation of the boiler the chimney system must be capable of the complete evacuation of combustion products at all times 17 5 Flue Options The boiler may be installed either as a room sealed fanned flued appliance using the Mikrofill P P S plastic 125mm 80mm concentric flue system or alternatively conventionally flued using a single skin 80mm P P S plastic pipe 1...

Page 23: ...mply with figure 23 or where pluming is a nuisance The Mikrofill flue system has been designed to overcome this and the 80mm P P S flue pipe may be simply re routed to terminate in a more suitable location To do this simply remove the 80mm stainless steel flue grill and insert either a 900 or 450 bend Note two 450 may be used to form a swan neck returning the flue pipe back to the wall for clippin...

Page 24: ...llations Mikrofill supply a range of larger diameter flues Sizes are available in 150mm 200mm and 250mm For assistance in flue design and specification please call the Mikrofill technical department Concentric vertical flue fittings are available from Mikrofill Concentric flue components have push together spigot and socket joints The inner flue gas tube has silicone seal rings located in the sock...

Page 25: ...mbly and assurance that the joints have been fully pushed home the seal rings and make ends of tubes and fittings should be lightly lubricated with silicone grease Additional 80 125mm concentric flues tubes and fittings are available 17 9 Fan Flued Terminal Positions ...

Page 26: ...oiler inlet gas connection The gas supply to the boiler must be capable of maintaining a minimum pressure of 20 mbar measured at the inlet to the boiler with all other gas appliances working The installer should install a pressure test point adjacent to the gas inlet connection 18 2 LPG Gas Supply For LPG the gas supply to the boiler must be capable of maintaining a minimum pressure of 37 mbar mea...

Page 27: ...and electricity supplies Disconnect the unions either side of the gas valve Screw the 3 5 injector into the gas inlet side of the valve and the 5 7mm injector into the gas outlet side of the valve Close the hole in the front of the air box attached to the air fan assembly using a plastic plug included in the conversion kit Re connect the gas valve making sure the sealing washers are located proper...

Page 28: ...n by blocking or flooding BS 5540 2 Table 9 Ventilation Vent Position Into room or internal space Direct to outside air High level 9 cm2 per kW of input 4 5 cm2 per kW of input Low level 9 cm2 per kW of input 4 5 cm2 per kW of input In a room or internal space None required None required Conventionally flued appliance Vent Position Into room or internal space Direct to outside air High level 9 cm2...

Page 29: ...cessible positions which permit the draining of the whole system including the boiler Drain taps should be at least 1 2 inch BSP nomin al size and be in accordance with BS 2879 In order to facilitate servicing of the unit full flow isolating valves must be fitted to all water and gas connections 20 1 Expansion Vessel For systems having a larger water capacity multiply the total w ater content boil...

Page 30: ... blocked drainage system the condense disposal pipe should include a tundish In these cases the pipe work connected to the internal household drainage system should be fitted with a deep seal running trap Horizontal runs of condense discharge pipe must fall at a rate of 40mm per metre and any external sections of pipe must be protected against the risk of freezing Due care should be taken when ins...

Page 31: ...tegral expansion vessel and modulating circulating pump Hot water production has priority controlled by spring return to heating diverter valve wired to boiler Flow temperature to hot water is constant temperature to heating may be fixed or variable weather compensated ...

Page 32: ...d plug connector for connection to the mains as part of the wiring centre located at the bottom left hand side of the boiler Any external wiring to the boiler must be carried out in accordance with the IEE Wiring Regulations and any local regulations ...

Page 33: ...o the Wieland connector as shown in figure 28 22 Heating Control Options There are various methods of controlling the heating system from the boiler Using a regular room thermostat If a room thermostat is installed there must not be any thermostatic radiator valves on the radiator in that room Using a modulating room stat With this special type of room thermostat the boiler can be regulated in a m...

Page 34: ...ulating mixing valve fo r a secondary circuit The mixing valve and pump for this circuit has to be wired back to the control unit MR03 available formMikrofill an additional pump greater than 500watts may also be connected 22 2 Low Voltage Connections The low voltage terminal strip can be used to connect the following Hot water cylinder sensor External temperature sensor RE2132 Modulating room sens...

Page 35: ... e g HW DEMAND and either S summer or W winter D day or n night b the lower line indicates on the left hand side the current boiler water temperature and on the right hand side the time If the button is pressed briefly the following data may be viewed in the following order Press 1 T1 supply temperature in the system Press 2 T3 tap water temperature Press 3 T4 return temperature in the system Pres...

Page 36: ...ce The unit will operate continuously at 50 sensors or room units will not switch it off only the maximum control thermostat This mode is meant for measuring emissions CO CO NOx Press twice The unit can now operate at all loads by pressing the and buttons if the menu button is also pressed seven times the display will show t he speed This mode is used to set the gas valve both at minimum and at ma...

Page 37: ...his function allows you to select the maximum temperature for the water in the cylinder To access the TEMP DHW option press the MENU button until _____ oC flashes on the screen press or to enter a value then press MENU button once to confirm entry Temperature range 40 60oC Default 60oC 26 2 Day temperature function When the boiler is set up for outside temperature control with or without a room th...

Page 38: ...on once to arrive at CopySU MO ignore this and press the button once to arrive at SWITCH ON 1 MO 00 00 Press the MENU button once and the hours 00 part of the display will start flashing This sets the hour the heating will start for the first of three possible on times per day Adjust the hour by pressing the and buttons When the correct time is displayed confirm by pressing MENU button once and th...

Page 39: ...ndays times to Tuesday by pressing MENU or alternatively program in new times by pressing button and repeating the process described in theprevious section To copy the previous days program Press the MENU button you arrive at MON TUESDAY Press the MENU button once to copy and the display will change to WEDNESDAY Press the MENU button you arrive at TU WEDNESDAY Press the MENU button once to copy an...

Page 40: ...OTE If the difference between the daytime temperature and night time setback temperature is considerable the start time of the central he ating unit must be set earlier than required to compensate Statistically it has been proven that a night time decrease of 5 C is best if a lower night time temperature is set heating in the morning requires too much energy With SETBACK displayed on the screen pr...

Page 41: ...amming A number of programming options are provided for the installer These can onl y be accessed and programmed by means of a code If this code is entered 21 the following parameters can be changed Table 13 Installer Functions Programme No Programme name Setting range 1 Heating plan at 20 C outside temperature 0 40 C 2 Heating plan at 15 C outside temperature 10 85 C 3 Minimum pump speed 20 50 4 ...

Page 42: ... can only be set if an outside temperature sensor has been installed can only be set if a modulating pump has been installed 28 Outside Temperature Control The weather compensating factory settings are as figure 30 below ...

Page 43: ......

Page 44: ...still maintain a sufficient flow 28 5 Flow temperature secondary circuit When a secondary circuit control has been connected MR 03 available fromMikrofill to the boiler the heating curve between the flow temperature of this circuit has to be set Enter the required flow temperature when outside air temperature is 20 C normally no heating would be necessary and the setting should be 20 C adjust if n...

Page 45: ... fan speeds the influence of the wind across the flue terminal outlet can lead to flame lift The minimum fan speed should be increased until burner pressure is equalised This minimum is also the minimum output for central heating 28 12 Maximum DHW Capacity If the boiler starts to cycle during how water production then a lower value could be set However due to the boilers modulating control this is...

Page 46: ... mixing valve Function No Room Temp Control Max Flow Temperature 24 With two RE 2132 70 C primary 25 With two RE 2132 85 C primary 26 With one RE 2132 70 C primary 27 With one RE 2132 85 C primary 28 240v Room Stat 70 C primary 29 240v Room Stat 85 C primary Without room unit thermostat or outside temperature control constant flow temperatures without a mixing or secondary circuit Function No Room...

Page 47: ...rature controlled without mixing circuit Function No Room Temp Control Max Flow Temperature 37 RE 2132 55 C 38 RE 2132 70 C 39 RE 2132 85 C 40 240v Room Stat 55 C 41 240v Room Stat 70 C 42 240v Room Stat 85 C TRV s 55 C 44 TRV s 70 C 45 TRV s 85 C 43 Outside temperature controlled with mixing circuit Function No Room Temp Control Max Flow Temperature 46 With two RE 2132 70 C primary 47 With two RE...

Page 48: ...132 85 C primary 64 240v Room Stat 70 C primary 65 240v Room Stat 85 C primary Without room unit thermostat or outside temperature control constant flow temperatures without a mixing or secondary circuit Function No Room Temp Control Max Flow Temperature 66 None 55 C 67 None 70 C 68 None 85 C Without room unit thermostat or outside temperature control constant flow temperatures with a mixing or se...

Page 49: ...Analogue cascade manager with signal 0 3 Volts Function No Cascade manager Max Flow Temperature 72 Analogue 0 3 Volts CH temp on manager ...

Page 50: ...s carefully considered The removal of debris flux residue grease metal swarf etc from new systems and any rust black magnetic iron oxide sludge and lime scale from old systems is essential Consider high pressure flushing to remove all debris in badly contaminated systems Fit in line filters for full protection All installations should be treated and maintained with Fernox MB1 at a concentration of...

Page 51: ...or Fernox MB 1 at 4 For further information about filling the system contact theMikrofill Technical Support Department 30 Combustion Ratio Due to the precise Variable Controlled Output of the boiler it is highly recommended that flue gas analysis equipment be used when setting up the burner The setting up of the boiler using gas pressures should be used as a temporary or emergency measure only 30 ...

Page 52: ... sealing nut and fibre washer Insert the probe of the gas analyser 2cm into the heat exchanger and measure the CO2 level The burner will have a red surface If necessary fine tune using the adjusting screw 4 Q Max until the required CO 2 see table 15 value is reached Turn the screw clockwise to lower the CO 2 reading and anti clockwise to increase the CO2 Remember to allow 2 minutes for the analyse...

Page 53: ... than 20 6 31 2 STB Test Button Green This button is used to test the correct operation of the overheat thermostat high limit thermostat 32 Diagnostics 32 1 Control panel The control panel of the unit has a LCD screen displayin g two lines of data This screen provides information about the operation of the boiler it displays operation messages non flashing and fault messages flashing display The f...

Page 54: ...he LCD display as a flashing message The following list indicates the messages shown and the descriptions of the faults The numbers shown in the left hand column suggest the possible cause By using the numbered lists attached the cause of the fault can be quickly identified and a repair effected Table 18 Fault Display Flashing Display message FLASHING Type of fault Check table row number STB suppl...

Page 55: ...n system or internal leak in expansion vessel Table 20 Reasons for Error Display Fault Suggested Remedy 1 room thermostat connected incorrectly check or replace cable 2 room thermostat fails to switch off Replace room thermostat or replace cable 3 Relevant sensor short circuits in cable or internally Replace sensor or identify fault in cable 4 Pump not running or sticks Try to release pump shaft o...

Page 56: ...hon blocked Open the flushing pipe bottom left of the back panel by taking the cap off Hold a bowl underneath to collect any water that may escape Pinch pipes to both to the upper left and the upper right Rinse syphon trap If necessary take the burner unit from the unit and pour water into the heat exchanger to rinse the syphon 23 Open and close manual bleed valve after bleeding Bleed and vent as ...

Page 57: ...electrode incorrect Replace 36 Moisture on gas valve cables Dry if necessary using hot air hair dryer and check for proper functioning replace if necessary 37 Moisture on electronics box See 36 38 Moisture in pump wiring See 36 39 Moisture on fan or and or connections Remove the connection and dry by blowing or using hair dryer 40 Fan connector incorrectly connected Connector must point in the dir...

Page 58: ...tified Lift the casing of the boiler and inspect all pipes for water leaks or water damage Sweating joints or leaks should be repaired immediately Inspect the top of the boiler for water leak or traces or evidence of water leaking from the 125mm air inlet tube or the automatic air separator The cause of any water or moisture entering the boiler through the 125mm airinlet tube should be found and r...

Page 59: ... When the impeller of the fan is dirty every blade has to be carefully cleaned until the original plastic material is clearly visible When dirt is left on the blades the fan will run out of balance and due to the fast fan speeds 6000 rpm additional and unnecessary loads will be placed on the fan bearings significantly reducing the lifetime of the component Check the distance of the electrode to th...

Page 60: ...nd the central heating system are completely drained down 37 3 Built in clock the appliance has a unique built in three channel programmable time clock This enables not only the setting of the heating times for various temperatures but also the heating times for hot water During programmed off periods Combi models will maintain a minimum storage temperatureof 40oC For H and HS type appliances conn...

Page 61: ......

Page 62: ...1 supply temperature in the system Press 2 x T3 tap water temperature Press 3 x T4 return temperature in the system Press 4 x T5 water if connected or the maintained temperature of the built in tap water exchanger of the boiler Press 5 x T6 outside temperature Press 6 x Room 1 heat demand value of connected room unit Press 7 x Speed 1 fan speed Press 8 x Pump pump speed in relation to maximum Only...

Page 63: ...press or to enter a value then press MENU button once to confirm entry After expiry of the extension time set the night time temperature will start if the lower night temperature had already started at the time of setting the party time the daytime temperature will be obtained for the duration of the time set after which the night time temperature will be resumed Range 0 24 hours Default 0 hours 3...

Page 64: ... This menu has two submenus a the days of the week b the start and end times of each block To access this function from the main menu display press MENU button for three seconds You will arrive at PARTY O HOURS in the display Press the button three times to arrive at SET CH TIMER Press the MENU button once and the first display will be Monday use the and buttons to scroll through this submenu to r...

Page 65: ...ue to programme the unit or return to the operating display menu by pressing repeatedly until you arrive at BACK then exit by pressing menu 38 6 Setting the hw timer This programme enables the setting of 3 time blocks 3 start and 3 end times per day 24 hours for higher and lower temperatures of the supply of tap water This menu has two submenus a the days of the week b the startand end times of ea...

Page 66: ... for an extended period then to save energy adjust the nig ht time temperature to 10 C After the number of days has expired the unit will start operating according to the clock programme set Remember when you return to re adjust the night time temperature to it s original setting Having completed the setting press the MENU button to confirm the new value 38 10 Installer This function is for the se...

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