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Table of Contents
Related Manuals for Malvern 80
Summary of Contents for Malvern 80
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Page 2: Boiler Model
Technical Data BOILER MODEL Heat Input 9.6 kW (32,600 Btu/h) 12.7 kW (43,500 Btu/h) Heat Output 80 - 60ºC 8.1 kW (27,700 Btu/h) 11.0 kW (37,400 Btu/h) Heat Output 60 - 40ºC 8.8 kW (30,000 Btu/h) 11.7 kW (40,000 Btu/h) Setting Pressure, 20mb Line 11.0 mb (4.4 in) - Page 3 BOILER MODEL 70/80 (min/max) Heat Input 15.9 kW (54,300 Btu/h) 22.2-25.5 kW (75,750–87,000 Btu/h) Heat Output 80 - 60ºC 13.7 kW (46,700 Btu/h) 19.1-22.0 kW (65,200–74,800 Btu/h) Heat Output 60 - 40ºC 14.7 kW (50,000 Btu/h) 20.6-23.5 kW (70,000–80,000 Btu/h) Setting Pressure, 20mb Line 12.6 mb (5.1in)
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Page 4: Location Of Boiler
INTRODUCTION These Instructions cover a range of lightweight, BS.5440:1 Flues (for gas appliances of rated wall hung, gasfired, condensing boilers. The input not exceeding 60kW). flue system is roomsealed and fan assisted on BS.5440:2 Air supply (for gas appliances of the flue side. -
Page 5: Gas Supply
Where a room sealed appliance is installed in FLUEING a room containing a bath or shower then the Detailed recommendations for flueing are given appliance electrical switch in BS.5440: 1. appliance control, utilising mains electricity The following notes are intended for general should be so situated that it cannot be touched guidance. -
Page 6: Air Supply
(for cooling purposes) in the cupboard or compartment, at both high and low levels. Terminal Position Minimum Below window or vent 300mm The air vents must either communicate with a Below gutter or pipes 75mm room/internal space, or vent directly outside. Below eaves 200mm Below balcony or roof... -
Page 7: Condensate Drain
storage vessel. Draining taps should be at A pressure gauge with a fill pressure indicator least ½ in. nominal size and be in accordance and a range of 0-4 bar should be fitted close to the expansion vessel in a visible position. with BS.2879. -
Page 8: Installation Of Boiler
left or right outlet, remove appropriate INSTALLATION OF BOILER blanking plate and assemble on rear outlet. Suggested procedure: 1. Site to suit system and terminal limitations. Note: Blanking plate holes should be left with a 2. Mark fixing and flueing positions (Fig. 7). screw, to seal them. -
Page 9: Condensate Connection
Rear Outlet GAS CONNECTION The ½" BSP. gas connection point is shown in Install as above but using the STRAIGHT Fig.2. A minimum of 20mb. (8in. w.g.) must be connector in turning box. Follow the available at the boiler inlet, with the boiler and instructions under Right or Left outlet, points other connected appliances firing. -
Page 10: Electrical Connections
Thermostatic radiator valves can be used but it is essential to fit a bypass to maintain minimum flow conditions. A TRV controlled system would Terminal Connection also be improved by the addition of an anti- cycling device. Earth The boiler waterside is completely copper so all Mains Live good corrosion inhibitors are suitable, Programmer Live... -
Page 11: Commissioning Procedure
Two or three second bursts on the pump at Pour 3/4 of the inhibitor in and fill the system the initial stage will reduce the risk of foam with clean water and vent air from radiators formation. and pipework. (Sealed Systems only: Pour in all the inhibitor, Sloping the pipe runs towards the vent points and fill to required pressure plus 0.3 bar to will greatly aid air removal. - Page 12 The gas valve opens in two steps, the first low- Note: The boiler is fitted with a blocked rate step can be adjusted to the required 5 drain device and syphon trap to safeguard mBar in the following manner. the boiler and help defer the effects from the Fit a U gauge to the outlet pressure testpoint possible freezing of the condensate and remove plug from 'Port B'.
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Page 21: Fault Finding
FAULT FINDING General Information The electrical sequence in the boiler is very straight forward and faults can easily be tracked down if this simple sequence is followed. Systemcontrols-------ControlStat-------FlueStat------OverheatStat------PressureSwitch----------Ignition The lamps on the front panel indicate several of the stages in the ignition sequence. When the system controls and the programmer are calling for heat, power is fed to the boiler initiating the following sequence. -
Page 23: Changing Components
CHANGING COMPONENTS SERVICING THERE ARE NO REPAIRABLE ITEMS, IF NOT Health and Safety Statement : WORKING AN ITEM MUST BE REPLACED. This product contains no asbestos. The boiler is in two major sections, the Case, Routine and the Electrical Tray, The Major Components To ensure continued efficient operation of the Diagram shows where the items are to be appliance it is recommended that it is checked... - Page 24 • Replace the Sequence Controller. Note: The step opening action takes 20 • Reassembly is the reverse. seconds to reset after each operation. • Check the Flame Supervision drop out by lighting the boiler, putting a voltmeter across the Pilot solenoid and then turning off the gas cock.
- Page 25 • Lift the Case straight up about half an inch • Pull the electrical connectors off the Control (12mm). Thermostat. • Gently pull the Case straight forward off the • Pull off the Control Thermostat Knob. • Undo the two M4 screws beneath the Knob. hidden studs at the top of the boiler.
- Page 26 • Remove the Case. • Lower the Electrical Tray. • Undo the left and right screws holding the • Remove the Case. • Remove the front baffle. Front Burner Baffle and remove. If access is • Remove or cover the Burner. restricted also remove the right hand baffle.