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- Page 1 twenty Condensing Boilers Installation & Service Instructions GC No. 41 555 17 41 555 18, 41 555 19 Serial Number: 0087 Note to the Installer: Natural and Propane Gas Please leave these Instructions adjacent to the meter.
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Page 2: Technical Data
Technical Data Boiler Model (min/max) (min/max) Flue, Gas Type & Destination , CAT II U.K. & I.E. , CAT II U.K. & I.E. 2H3P, SEDBUK Rating Heat Input, NET 10.1-16.8 kW (34,410-57,360 Btu/h) 20.0-23.0 kW (68,250-78,400 Btu/h) Heat Input, GROSS 11.2-18.7 kW (38,200-63,730 Btu/h) 22.2-25.5 kW (75,750-87,000 Btu/h) Heat Output 80-60ºC... -
Page 3: Table Of Contents
sealed systems. These systems may be pumped Contents central heating or pumped central heating combined with a pumped indirect domestic hot water circuit. Gravity circuits must NOT be used. Section Page Technical Data The boilers include a pump overrun device so it is Introduction essential that there is an open circuit for water to Boiler Location... -
Page 4: Boiler Location
IMPORTANT. It is important that no external In siting the boiler, the following limitations MUST be observed: control devices are directly connected to this appli- ance - unless covered by these ‘Installation and Servicing Instructions’ or otherwise recommended 1. The position selected for installation MUST allow by the manufacturer. -
Page 5: Air Supply
7. Because the flue gases and terminal are at very Air Supply low temperature it is not necessary to fit a It is NOT necessary to have a purpose provided air Terminal guard to protect against burns. If a vent in the room or internal space in which the boiler guard is required for any other reason the is installed. -
Page 6: Sealed Systems
Sealed Systems Electricity Supply A sealed system should follow the guidelines given Refer to Figs. 3 and 4. in the Code of Practice BS 7074 :1. It should Wiring external to the appliance MUST be in accord- include a safety valve to BS 6750 Pt 1. fitted close ance with the current I.E.E. -
Page 7: Removing Case
Right or Left Outlet Removal of the Case 1. Secure the 50mm flue tube with ELBOW connec- tor on the saddle using the Velcro strap. Refer to Fig. 6 See Fig. 7 1. Lower the electrical cover. This is detached by pulling the cover towards you and carefully 2. -
Page 8: Plumbing
screws, and retain. For Twin Pipe Installations, 2. Pipes must be clipped every 1000mm, minimum. also remove the Left Hand Side Trim. 3. The condensate connection from the Boiler 3. With the bottom of the boiler away from the wall, Mounting Box must be connected to the Boiler hang the top of the back panel onto the Mounting Condensate Drain Trap. -
Page 9: System Design
2. Combined Feed and Vent systems. minimum of 19mm pipe. External runs MUST be made in a minimum of 32mm pipe, starting inside 3. Separate Cold Feed and Vent systems. the building, and if possible insulated to defer The pump may be on the flow or return, but careful problems from freezing. -
Page 10: Commissioning
substantial amounts of air being dispersed through the system as small bubbles. Commissioning General Carry out electrical tests as stated in Electrical Connections if not already done so. The elimination of air from systems is essential to minimise the occurrence of heat exchanger and With all radiator valves fully open, fill the system but general system noise. - Page 11 Continue running for 15 minutes, venting every 5 Note: The boiler is fitted with a syphon minutes. trap that includes a blocked drain device. This is to safeguard the boiler and help The Pilot is factory set. defer the effects from the possible freez- ing of the condensate pipework in ex- The Main gas valve, GV2, gradually raises the pressure to the set point.
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Page 12: Fig 1. Gas Valve
Commission Check List (hydraulic) The key points which must be observed closely, are shown below. With radiator valves and vents open fill the Do not light boiler. system. Run pump for at least 30 minutes. Do not use pump. Do not light gas Stop at 5 minute intervals to vent. -
Page 13: Fig 2. Installation Dimensions
Installation Dimensions Service Access Flue 17 kW 24 kW 120 mm 100 mm 0 to +3 Degrees 56mm Rear Flue Side Flue Side View Front View Concentric Flues Twin flues Service Access Suggested core drill 128mm Suggested core drill 90mm Front 450mm Above 30mm Overall lengths: Minimum 200mm Sides 30mm Below 25mm... -
Page 14: Fig 3. Schematic Wiring
Schematic Wiring Fig.3 Condensing Boiler 10/07/06... -
Page 15: Fig 4. Physical Wiring
Physical Wiring Diagram Fig.4 Condensing Boiler 06/06/01... -
Page 16: Fig 5. Fixing Positions
Fixing Positions 17 kW Wall Fixing Holes For Concentric Use 2 at the top and any other 2 below Core Drill 24 kW 128mm For Twin Pipe Core Drill 90 mm 2 Lower Wall Fixing Holes 17 kW 24 kW Fig.5 Condensing Boiler 06/06/01... -
Page 17: Fig 6. Boiler Panel Assembly
Boiler Panel Assembly Top Trim Twin Pipe Side Trim Boiler Mounting Concentric Flue Boiler Mounting Fan Protection Hoop Pressure Cover Lower Burner Baffle Front Burner Baffle Control Board Chassis Electrical Cover Fig.6 Condensing Boiler 06/06/01... -
Page 18: Fig 7. Concentric Flue & Air Duct
Concentric Flue, positions Fig.7 Twin Flue Positions 100mm Air Duct Flue Duct Twin Pipe Boiler Mounting Box Assembly Flue Spigot Adapter Drain Point Fig.8 Condensate Drain Connection (connects to drain point Connects to optional on Flue Spigot Adapter) condensate drain point on Condensate Drain Trap Condensing Boiler 06/06/01... -
Page 19: Fault Finding
Fault Finding The electrical sequence in the boiler is very straightforward and faults can easily be tracked down if this simple sequence is followed. System Controls - - - - Flue Stat - - - - Overheat Stat - - - - Pressure Switch - - - - Control Board - - - - Ignition The lamps on the front panel indicate several of the stages in the ignition sequence. - Page 20 Fault Diagnosis Condensing Boiler 03/07/03...
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Page 21: Servicing
Servicing CHANGING COMPONENTS THERE ARE NO REPAIRABLE ITEMS, IF NOT WORKING AN ITEM MUST BE REPLACED. Health and Safety Statement : This product contains no asbestos. The boiler is in two major sections, the Case, and the Electrical Tray, The Major Components Routine Diagram shows where the items are to be To ensure continued efficient operation of the... - Page 22 2. Gas Valve 3. Fan Assembly • Lower the Electrical Tray. • Lower the Electrical Tray. • Turn the Gas Cock off. • Remove the Case. • Pull off the electrical connector from the • Undo the wing nut holding the Fan Protec- Gas Valve.
- Page 23 12. Combustion Chamber Insulation 8. Electrode and HT Lead • Lower the Electrical Tray. • Lower the Electrical Tray. • Remove the Case. • Remove the Case • Remove the Front Baffle, then undo the four • Pull off the HT lead from the Control board. •...
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Page 24: Fig 9. Spares
Spares 1st Line Spares: Item Part Number GC Number Primary Heat Exchanger (17 kW) M0142 Primary Heat Exchanger (24 kW) M0593 Secondary Heat Exchanger (17 kW) M0502 Secondary Heat Exchanger (24 kW) M0797 Burner (17 kW) M3726 Burner (24 kW) NG M3727 Burner (24 kW) Propane M5148... -
Page 25: Fig 10. Major Components
Major Components Flue Gas Sampling Point Air Pressure Switch Fan Assembly Flue Hood Gasket Secondary Heat Exchanger Flue Thermostat Inspection Cover Condensate Outlet Fibre Washer ( 2 Places ) Primary Heat Exchanger O/H Stat Ceramic Board Main Injector Burner Condensate Trap Pilot Assembly Pilot Injector... -
Page 26: Fig 11. Example Condensate Disposal
Example Condensate Disposal Methods Note: Internal - minimum 19mm pipe External - minimum 32mm pipe 75mm Running Trap Air Break Strap-On Boss Insulate against freezing 150mm Land Drain 1:20 Fall ( 2.5 Degrees ) Filled with Gravel 750mm deep Soakaway 110mm Soil Pipe or Drain Air Gap Air Gap... - Page 27 The Company reserves the right to change 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.malvernboilers.co.uk Email: service@malvernboilers.co.uk M3821...