Malvern tentwenty Installation & Service Instructions Manual Download

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GC No.

41 555 17
41 555 18, 41 555 19

Serial Number:

0087

ten

twenty

twentysix

Condensing Boilers

Installation & Service Instructions

Note to the Installer: Natural and Propane Gas

Please leave these Instructions adjacent to the meter.

Summary of Contents for tentwenty

Page 1: ...1 555 18 41 555 19 Serial Number 0087 tentwenty twentytwentysix Condensing Boilers Installation Service Instructions Note to the Installer Natural and Propane Gas Please leave these Instructions adjac...

Page 2: ...P 20 kg 28 kg 1 4 litres 3 bar 1 m 30 82 C 10 12 litres m 5 litres m 22mm Copper 230V 50Hz 40W 1 Amp 20mm 3 Amp 790 High 400 Wide 330 Deep 450 Front 30 Above 25 Below 30 Left Right Concentric 160 High...

Page 3: ...s may require the addition of a bypass an automatic bypass is preferred The boilers also contain integral frost protection the boiler will fire if the temperature within it approaches 4 to 5 degrees C...

Page 4: ...he purpose Details of essential features of cupboard compartment design including airing cupboard installations are given in BS 6798 In siting the boiler the following limitations MUST be observed 1 T...

Page 5: ...ter system if applicable should be in accordance with the relevant recommenda tions of BS 5546 Copper tubing to BS 2871 1 is recommended for water carrying pipework The hot water storage cylinder MUST...

Page 6: ...The boiler is supplied for 230V 50Hz Single phase Fuse rating is 3A The method of connection to the mains electricity supply MUST facilitate complete electrical isolation of the boiler preferably by t...

Page 7: ...cut off during installation Right or Left Outlet 1 Secure the 50mm flue tube with ELBOW connec tor on the saddle using the Velcro strap See Fig 7 2 Measure carefully and saw off the 50mm tube to give...

Page 8: ...and Side Trim 3 With the bottom of the boiler away from the wall hang the top of the back panel onto the Mounting Box Now by gently lowering the bottom of the boiler against the wall the fan spigot sh...

Page 9: ...minimum flow conditions An automatic bypass is preferred The boiler waterside is completely copper so all good corrosion inhibitors are suitable Designs The following designs are all acceptable 1 Seal...

Page 10: ...pletely normal It is recommended that the gas cock is turned off during this early stage Because of a built in delay the boiler is always held off for a minimum of 120 seconds However for commissionin...

Page 11: ...em hot check again for water sound ness Refit the case to the boiler Add remainder of corrosion inhibitor Balance the system in the normal way to obtain even heating of all radiators If fitted set the...

Page 12: ...fill system adding 3 4 of the inhibitor Do not light boiler Vent all radiator and air release points Run pump for 5 10 second bursts and revent Condensing Boiler 11 06 06 01 Do not light boiler Run pu...

Page 13: ...ngths Minimum 200mm Maximum 22m horizontal 90mm 90 bend 4 0m 45 bend 1 3m Suggested core drill Suggested core drill 128mm Flue 100 to 2000mm Left right or rear Flue Air Concentric Flues Service Access...

Page 14: ...NSOR 12 Way connector GV1 GV2 N 4 Core to Gas Valve Fan 4 way Molex 10 way Molex GV1 GV2 1 Amp 20mm CONTROL BOARD Or Or Br Br R W Bk Gy Br R Bk Br G G Y G Y G Y B G Y V Gy Br R Or W Bk Gy V G Y B Brow...

Page 15: ...Condensing Boiler 14 06 06 01 Physical Wiring Diagram Fig 4...

Page 16: ...Wall Fixing Holes 2 Lower Wall Fixing Holes Core Drill 128mm 118 Use 2 at the top and any other 2 below 236 288 167 92 32 17 kW For Concentric 270 For Twin Pipe Core Drill 90 mm Condensing Boiler 15...

Page 17: ...1 Boiler Panel Assembly Control Board Chassis Electrical Cover Top Trim Front Burner Baffle Side Trim Fig 6 Pressure Cover Concentric Flue Boiler Mounting Box Fan Protection Hoop Lower Burner Baffle T...

Page 18: ...e Positions Fig 7 Fig 8 Flue Duct Air Duct 100mm Condensate Drain Connection connects to drain point on Flue Spigot Adapter Flue Spigot Adapter Drain Point Twin Pipe Boiler Mounting Box Assembly Conne...

Page 19: ...me is detected and the control board stops sparking and then energises the main gas valve and the burner lamp is illuminated The pilot flame lights the burner and it stays alight until turned off by t...

Page 20: ...Condensing Boiler 19 03 07 03 Fault Diagnosis...

Page 21: ...quired If in doubt drain the system and remove for inspection 2 Condensate Syphon With a suitable bowl to catch the water un screw the drain cap s on the underside of the Syphon trap and drain the wat...

Page 22: ...NCE CASE COULD RESULT IN LEAKAGE OF COMBUSTION PRODUCTS INTO THE ROOM 3 Fan Assembly Lower the Electrical Tray Remove the Case Undo the wing nut holding the Fan Protec tion Hoop Pull the electrical co...

Page 23: ...ove the Case Pull off the HT lead from the Control board Undo the left and right screws holding the Front Burner Baffle Remove the front baffle Release the tube nut holding the electrode to the Pilot...

Page 24: ...04 Fan Assembly 17 kW M1095 Fan Assembly 24 kW M0910 106 435 Control Board M3752 Control Assembly M3915 Gas Valve Sigma 840 M3783 Air Pressure Switch Concentric Flues 7712 379 091 Air Pressure Switch...

Page 25: ...ces Flue Thermostat Fan Assembly Secondary Heat Exchanger Fibre Washer 2 Places Flow Pipe Control Sensor O H Stat Primary Heat Exchanger Gas Manifold HT Lead Pilot Assembly Main Injector Electrode Pil...

Page 26: ...Trap Air Gap Air Gap 110mm Soil Pipe or Drain Soakaway Insulate against freezing 150mm Land Drain Filled with Gravel 750mm deep Condensate Drain from Boiler Air Pressure Switch pipe connection Vent Sy...

Page 27: ...e specification without notice Your statutory rights are not affected Malvern Boilers Ltd Enigma Business Park Spring Lane Malvern WORCS WR14 1BW Telephone 01684 893777 Fax 01684 893776 www malvernboi...

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