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25

7. COMMISSIONING

Preliminary  electrical  system checks  to ensure electr ical  safety
must be carried out by a competent person i.e. polarity, earth con-
tinuity, resistance to earth and short circuit.
F

ILLING THE

H

EATING

S

YSTEM

:

Lower  the control panel and remo ve  the case panels (see
S

ECTION

6.11 for further information).

Open the central heating flow and return cocks supplied with
the connection kit (there are tw o isolation points on the retur n
connection).
Unscrew  the cap on the automatic air release v alve  one full
turn and leave open permanently.
Close all air release valves on the central heating system.
Gradually open valve(s) at the filling point (filling-loop) connec-
tion to the centr al heating system until w ater is heard to flo w,
do not open fully.
Open  each air release tap star ting  with the lo west  point and
close them only when clear water, free of air, is visible.
Purge the air from the pump by unscrewing the pump plug
anticlockwise, also manually rotate the pump shaft in the
direction indicated by the pump label to ensure the pump
is free.
Refit the pump plug.
Continue filling the system until at least 1.5 bar registers on the
pressure gauge.
Inspect the system for water soundness and remedy any leaks
discovered.

Filling of the D.H.W. System:

Close all hot water draw-off taps.
Open the cold water inlet cock supplied with the connection kit.
Open slowly each draw-off tap and close them only when clear
water, free of bubbles, is visible.

Gas Supply:

Inspect the entire installation including the gas meter , test for
tightness and purge the supply as described in BS 6891:1988.
Open  the gas coc k  (supplied with the connection kit) to the
appliance and check the gas connections on the appliance for
leaks.

When the installation and filling are completed, flush the system
while  cold, refill, tur n  on the Centr al  Heating system (

Section

7.2) and run it until the temperature has reached the boiler oper-
ating temperature. The system must then be immediately flushed
through.
The flushing procedure must be in line with BS 7593:1992 code
of  practice  for  treatment of w ater  in domestic hot w ater  central
heating systems.
During this operation, we highly recommend the use of a centr al
heating  flushing detergent (F ernox  Superfloc or equiv alent),
whose function is to dissolv e any foreign matter that ma y be in
the system.
Substances different from these could create serious pr ob-
lems to the pump or other components.
The  use of an inhibitor in the system such as F

ernox  MB-1 or

equivalent  is strongly recommended to pre

vent  corrosion

(sludge) damaging the boiler and system.
Failure to carry out this procedure may invalidate the appli-
ance warranty.

7.1

Initial Preparation

7.2

Initial Start-up

T

HE CHECKS TO BE RUN BEFORE INITIAL START

-

UP ARE AS FOLLOWS

:

1. Make sure that:

- the screw on the automatic air valve has been loosened when

the system is full;

-  If the water pressure in the system is below 1 bar, bring it up

to the appropriate level;

- Ensure that the gas cock is closed;
- Make  sure that the electr ical  connection has been made

properly and that the ear th wire is connected to an efficient
earthing system;

- Supply power to the boiler by pushing the On/Off button 

“A”

(see

F

IG

. 6.16) - the L.E.D. “K” will illuminate. Then push the

button 

“F” in for  central heating - the L.E.D. “G” will illumi-

nate. This will start the circulation pump. After 7 seconds, the
boiler will signal a shutdown due to ignition failure. Leave the
boiler as it is until all of the air has been b led from the sys-
tem.

- Loosen the cap on the head of the pump to eliminate an y air

pockets;

- Repeat the procedure for bleeding the radiators of air;
- Open the taps for a brief period;
- Check the system pressure and, if it has dropped, open the

filling loop again to bring the pressure back up to 1 bar.

2. Make sure that all gate valves are open;
3. Turn on the gas cock and check the seals on the connections

with an approved soap solution and eliminate any leaks.

4. Press the reset b utton 

“I” for the lighting system; the spark

will light the main burner. If the burner does not light the first
time, wait 1 minute and repeat the procedure.

5. Check  the minimum  and maximum  burner  pressure values;

adjust  if needed using the v alues  indicated in the tab le  in
S

ECTION

4.

To access the areas in which adjustments are made , it is neces-
sary to open the control panel, as indicated in 

Section 6.11, then

remove the rear inspection cover by unscrewing the two screws.
Access is thereby provided to the P.C.B. and to the following com-
ponents:

1. The power supply cable connector;
2. The fuses;
3. The soft-light potentiometer the setting f or which can r ange

from the minimum thermal power to the maximum;

4. The  maximum  thermal  heating po wer  potentiometer

adjustable by the minimum to maximum power (already cali-
brated in the factory to 70% of the maximum thermal power);

5. The jumper for adjusting the ignition dela y (anti-cycling) fea-

ture, which can be set from 0 to 2 min utes (set in the factory
at two minutes);

6. Fan/Pump  Over-run  (Electrical Diagram). When  the jumper is

set to position A the F an and Pump o ver-run is activated. (The
jumper is factory set in position B)

7. The time clock connector.

7.3

Operational  Adjustments

 

 

   

               

 

 

                 

Содержание INTESA TP23

Страница 1: ...Country of destination GB IE Users Guide Installation and Servicing Instructions TP 23 G C Number 47 116 32 TP 30 G C Number 47 116 33 Manufacturered by Merloni TermoSanitari spa Italy...

Страница 2: ...rts 10 2 To Gain General Access 10 2 1 Removing the Front Panel 10 2 2 Removing the Sealed Chamber Front Panel 10 2 3 Removing the Side Panels 10 3 Access to the Combustion Chamber 10 3 1 Removing the...

Страница 3: ...d entering the appliance If the water is very hard it is recommended that a water soften er be added to the system so as to reduce the f ormation of limescale in the heat e xchanger This will ensure t...

Страница 4: ...ecessary to slow the flow rate from the hot water outlet being used C Turning Off the Central Heating To turn off the Central Heating press the Centr al Heating button F the respective green LED G wil...

Страница 5: ...entral heating control only The time clock is provided with 96 switches called riders each of which covers a time interval of 15 minutes four per hour When a rider is switched from the inside off sett...

Страница 6: ...o 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 v alve Al...

Страница 7: ...etection electrode 10 Ignition electrodes 11 Pump pressure switch 12 Main circuit temperature probe 13 Safety valve 3 bar 14 Domestic hot water temperature probe 15 Secondary exchanger 16 Gas valve 17...

Страница 8: ...lations applicab le in Scotland with respect to the installation of the combined appliance in a room containing a bath or sho wer the location of the boiler in a room containing a bath or sho wer shou...

Страница 9: ...arate box containing the connection kit Note Pay particular attention to any test water that may spill from the appliance 6 5 MOUNTING THE APPLIANCE Place the template in the position the appliance is...

Страница 10: ...iance 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 outle...

Страница 11: ...sealed e xpansion 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 connectio...

Страница 12: ...inity and consideration must be given to adjacent boundaries In cold or humid w eather water vapour may condense on leaving the flue terminal The effect of such pluming must be considered If the ter m...

Страница 13: ...ue Kit Horizontal CONTENTS 1X SILICONE O RING 60mm 1X ELBOW 90O 2X WALL SEALS INTERNAL EXTERNAL 1X ALUMINIUM FLUE PIPE INCLUDING TERMINAL TELESCOPIC 60 100 2X FLUE CLAMPS 8X SCREWS 2X SEALS The telsco...

Страница 14: ...ht Should extensions be required the y are a vailable in 1 metre Part No 705786 500mm Part No 705790 and 160mm lengths Part No 705812 they must be connected directly to the boiler and secured with the...

Страница 15: ...ys be used on the exhaust pipe It is not recommended that the pipe bridge be used for horizontal termination however in the unlikely event that this proves to be a necessity it is extremely important...

Страница 16: ...metres 80 and 51 metres 100 The maximum length is reached by combining the total lengths of both the air intak e and e xhaust pipes Therefore a maxim um length of 40 metres for example will allow a f...

Страница 17: ...17 Installation FIG 6 19 Type 1 Type 5 Type 4 Type 3 Type 2 EXHAUST AIR INTAKE AIR INTAKE AIR INTAKE MUST NOT BE FITTED ABOVE THE EXHAUST FIG 6 20 Note Drawings are indicative of flueing options only...

Страница 18: ...e a minimum fall of 5mm per metre away from the appliance Maximum Length combined length of air intake and exhaust pipes less any equivalent lengths for elbows Note Under some circumstances condense m...

Страница 19: ...the Front Panel B 1 2 3 4 A 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 forward In order to access the inside of the bo...

Страница 20: ...control panel up and rotate it to a fully hor izontal posi tion 3 Using a suitable knife remove the knock out B for the time clock 4 Insert the clock into the control panel 5 Secure the clock in place...

Страница 21: ...21 Installation 6 12 Fitting the Time Clock continued 7 5 4 3 2 1 GREY BLACK RED 3 2 1 GREY BLACK RED MECHANICAL TIME CLOCK DIGITAL TIME CLOCK FIG 6 21...

Страница 22: ...from the P C B 6 Using a volt free switching time clock connect the switching wires from the time cloc k following points 1 4 abo ve Diagram B 7 If using an external time clock and room thermostat th...

Страница 23: ...move jumper is factory set in position B 2 Anti cycling Device Adjustment for Heating Position A 0 mins Position B 2 mins 3 Don t move jumper is factory set in position B 4 Don t move jumper is facto...

Страница 24: ...ch 10 Safety Valve 11 Domestic Hot Water Temperature Probe 12 Secondary Exchanger 13 Gas Valve 14 D H W Flow Switch 15 D H W inlet filter 16 Drain Valve 17 Motorised Diverter Valve 18 Automatic By pas...

Страница 25: ...MB 1 or equivalent is strongly recommended to pre vent corrosion sludge damaging the boiler and system Failure to carry out this procedure may invalidate the appli ance warranty 7 1 Initial Preparatio...

Страница 26: ...e In the event of insufficient water pressure in the heating sys tem a safety device will shutdown the boiler Check the sys tem pressure on the pressure gauge D and if it is less than 0 4 bar refill t...

Страница 27: ...tions and explain how to use the timeclock and room thermostat if fit ted 2 Show the End User how to switch the appliance off quickly and indicate the position of the electr ic supply isolator 3 Infor...

Страница 28: ...2 09 28 1 5 0 0 72 2 06 35 6 6 8 TP 30 Main Burner n 14 jets mm Consumption 15 C 1013mbar m3 h Consumption 15 C 1013mbar Kg h Gas Burner Pressure max min mbar 1 35 3 49 11 5 2 2 0 80 2 60 26 8 5 3 0 8...

Страница 29: ...ght hand potentiometer see below Turn clockwise to increase the pressure or counter clockwise to reduce the pressure Adjust the setting to the required heating pressure v alue displayed on the pressur...

Страница 30: ...49 20 11 5 2 2 1 48 2 60 Kg h 1 10 Kg h 26 8 mbar 5 3 mbar 28 mbar 14 x 0 80 14 x 1 35 2 56 Kg h 1 09 Kg h 34 0 mbar 6 5 mbar 37 mbar 14 x 0 80 TABLE A model 23 model 30 Regulating the heating power f...

Страница 31: ...primary heat exchanger check for overheating in the blade assembly clean the exhaust fan if needed 8 Adjustment of the flow rate of the gas flow rate for lighting partial load and full load 9 Check o...

Страница 32: ...al inspection and replacement of the individual parts are given in the following pages 10 1 Replacement of Parts 10 2 To Gain General Access All testing and maintenance oper ations on the boiler requi...

Страница 33: ...t the sealed chamber front cover from the locating pins FIG 10 7 FIG 10 6 C C FIG 10 7 10 2 3 Removing the side panels 1 Remove the four screws D for each side panel FIG 10 8 2 Pull the panel away fro...

Страница 34: ...ON 10 3 3 4 Remove the jets using a No 7 socket spanner 5 Replace in reverse order 10 3 1 Removing the combustion cover 1 Remove the screws E FIG 10 10 2 Lift off the combustion cover 10 3 Access to t...

Страница 35: ...ght out FIG 10 21 10 3 4 Removing the main heat exchanger Fig 10 17 I FIG 10 18 J J FIG 10 19 K FIG 10 20 FIG 10 21 1 Disconnect the electrical connections L and silicone pipes M from their connection...

Страница 36: ...Remove fan and mounting plate FIG 10 28 10 3 6 Removing the fan FIG 10 25 O O P FIG 10 26 Q R FIG 10 27 S S S FIG 10 28 10 4 1 Removing the spark generator 1 Disconnect ignition leads T by pulling upw...

Страница 37: ...emove the gas valve FIG 10 34 V FIG 10 33 W W FIG 10 34 10 5 Access to the Water Circuit FIG 10 35 X X FIG 10 36 FIG 10 37 Important Before any component is removed the boiler must be drained of all w...

Страница 38: ...re 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 39 Z...

Страница 39: ...FIG 10 44 2 Remove the allen screw D1 FIG 10 45 3 Remove the pump FIG 10 46 FIG 10 44 FIG 10 45 FIG 10 46 10 5 6 Removing the pressure gauge 1 Remove the U clip E1 FIG 10 47 2 Push the pressure gauge...

Страница 40: ...50 FIG 10 51 FIG 10 52 F1 H1 10 5 8 Removing the overheat thermostat 1 Disconnect the overheat thermostat electrical connections I1 FIG 10 53 2 Then remove the ther mostat from its mounting b y relea...

Страница 41: ...IG 10 57 FIG 10 58 FIG 10 59 J1 K1 10 5 11 Removing the D H W flow switch 1 Unplug the electrical connector J1 FIG 10 58 2 Unscrew the screws K1 FIG 10 59 3 Remove the D H W flow switch 6 5 12 Removin...

Страница 42: ...ly to the boiler bef ore accessing the control panel Servicing Instructions 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 Unpl...

Страница 43: ...fault finding diag rams described in this chapter ensure these guides are carried out in the set order 11 1 Fault Finding Guide Flow charts To ensure that the external controls do not interfere with...

Страница 44: ...44 Fault Finding...

Страница 45: ...45 Fault Finding...

Страница 46: ...46 Fault Finding 0 55mbar 23kW 0 90mbar 30kW 0 55mbar 23kW 0 90mbar 30kW...

Страница 47: ...47 Fault Finding...

Страница 48: ...37 30 29 33 31 32 96 101 100 33 50 98 96 99 95 92 89 91 91 97 85 86 88 87 116 115 112 117 58 113 60 61 75 59 58 57 125 126 124 56 56 74 72 73 70 62 68 64 66 67 56 63 70 70 65 70 56 69 123 23 50 53 52...

Страница 49: ...ir pressure Switch 75 65100719 Fan 80 996065 Overheat Thermostat 81 65100521 Clip Overheat Stat 82 65100297 Cable Time Clock 83 999599 Time Clock 86 65100693 Ignition Electrode RH 87 65100694 Ignition...

Страница 50: ...50...

Страница 51: ...51...

Страница 52: ...D H W Flow Rate T 35 C l min D H W Minimum Flow Rate l min Pressure of Domestic Hot Water max min bar Expansion Vessel Capacity l Expansion Vessel Pre load Pressure bar Maximum Water Content of System...

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