Ariston INTESA TP30 User Manual, Installation & Servicing Instructions
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Ariston INTESA TP30 User Manual, Installation & Servicing Instructions

Ariston INTESA TP30 User Manual, Installation & Servicing Instructions

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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
- Italy
spa
Country of destination: GB - IE
Supplied By www.heating spares.co Tel. 0161 620 6677

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  • Page 1: Users Guide

    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 - Italy Country of destination: GB - IE Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS USERS GUIDE 1. GENERAL INFORMATION 2. OPERATING INSTRUCTIONS 3. BOILER SHUTDOWN SITUATIONS 4. TIME CLOCK INSTALLATION AND SERVICING INSTRUCTIONS 10. SERVICING INSTRUCTIONS GENERAL INFORMATION 10.1 Replacement of Parts 10.2 To Gain General Access General Instructions 10.2.1 Removing the Front Panel Overall View 10.2.2 Removing the Sealed Chamber Front Panel 10.2.3 Removing the Side Panels...

  • Page 3: General Information

    USERS GUIDE 2. Operating Instructions 1. General Information This is a combined appliance for the production of central heat- Installation, start-up, adjustments and maintenance must be ing (C.H.) and domestic hot water (D.H.W.). This appliance must performed by a competent person only, in accordance with be used only for the purpose for which it is designed.
  • Page 4 3. Boiler Shutdown Situations Winter and Summer Operating Modes The boiler is equipped with safety devices that intervene in cer- tain situations and shut it off. Most of these situations are commu- In the ‘winter operating mode’, the boiler will nicated by means of the LED’s and at times the user may be able produce both Central Heating and Domestic to remedy them.

  • Page 5: Supplied By Www.heating Spares.co Tel. 0161 620 6677

    3. Boiler Shutdown Situations 4. Time clock Shutdown Due To Insufficient Circulation f the boiler is off, one possible cause for this state is an insuffi- cient pressure of water in the system. Check the system pressure on the pressure gauge “D”...

  • Page 6: Operating Instructions

    INSTALLATION AND SERVICING INSTRUCTIONS 5. GENERAL INFORMATION General Instructions This manual is an integral and essential part of the product. It Check the following at least once a year: should be kept with the appliance so that it can be consulted by Check the seals for the water connections;...

  • Page 7: General Information

    General Information Overall View Legend: Flue connector Air intake for twin pipe flue systems Combustion chamber hood Heat exchanger Safety thermostat Combustion chamber Combustion chamber insulation panel Detection electrode 10. Ignition electrodes 11. Pump pressure switch 12. Main circuit temperature probe 13.

  • Page 8: Installation

    INSTALLATION Siting the Appliance Reference Standards The technical information and instructions provided herein below The appliance may be installed in any room or indoor area, are intended for the installer / Servicing Technician so that the although particular attention is drawn to the requirements of the unit may be installed and serviced correctly and safely.

  • Page 9: Overall Dimensions

    Installation Overall Dimensions OUNTING THE PPLIANCE After removing the boiler from its packaging, remove the template from the separate box containing the connection kit. Note: Pay particular attention to any test water that may spill from the appliance. . 6.1 QT002A Legend: A = Central Heating Flow (3/4”)

  • Page 10: Electrical Connection

    Installation Gas Connection 6.5.1. Drill the wall and plug using those supplied with the con- The local gas region contractor connects the gas meter to the nections kit, position the bracket and secure with the wall service pipe. bolts supplied. Note: It is highly recommended that a spir- If the gas supply for the boiler serves other appliances ensure it level be used to position the appliance to ensure that it is that an adequate supply is available both to the boiler and the...
  • Page 11 Installation Note: The installer should ensure that there are no leaks as fre- quent filling of the heating system can lead to premature scaling of the main exchanger and failure of hydraulic com- ponents. Domestic Water: The domestic water must be in accordance with the relevant rec- ommendation of BS 5546:1990.

  • Page 12: Flue Connection

    Installation Flue Connections IMPORTANT! For all flue systems, a restrictor may need to be insert- YSTEM ed into the exhaust manifold, the size of the restrictor The provision for satisfactory flue termination must be made in accordance with BS 5440-1. and details of fitting requirements are shown in Table The appliance must be installed so that the flue terminal is exposed 6.1 (Page 18).
  • Page 13 Installation face of the flue elbow (X - F 6.8), add 22 mm to this measure- ment, you now have the total length of flue required (including the terminal), this figure must now be subtracted from 860mm, you now have the total amount to be cut from the plain end of the flue. Cut the flue to the required length ensuring that the distance between the inner and the outer flue is maintained (F 6.10).
  • Page 14 Installation The Vertical flue kits maximum and minimum useable lengths 6.13 with both flat and pitched roof flashings are indicated in (Figs. 6.14 & 6.15). Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded and that all elbows and bends have been taken into consideration, the maximum flue length is 4 metres, for each additional 90 elbow 1 metre must be subtracted...
  • Page 15 Installation According to Table 6.1 (Page 18) decide if condensation will form within the flue. If yes, there are two options; 1) Where condense will form but can be negated with insulated flue, install the insulated flue with a fall of 5mm in every metre away from the boiler.
  • Page 16 Installation For flue runs with the intake and exhaust pipes under the same atmospheric conditions (Type 4) the maximum length is 43 metres (80) and 28 metres (100), for runs with the terminals under different atmospheric conditions (Type 5) the exhaust ter- minal must extend 0.5 metres above the ridge of the roof (this is not obligatory if the exhaust and air intake pipes are located on the same side of the building).
  • Page 17 Installation . 6.19 Type 1 Type 2 Type 3 Type 5 Type 4 Note: Drawings are indicative of flueing options only. AIR INTAKE MUST NOT BE FITTED ABOVE THE EXHAUST AIR INTAKE EXHAUST AIR INTAKE 6.20 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 18 Installation TP 23 Table 6.1 Exhaust Use the Do not use the Maximum Risk of Condensation Forming Type ø 41 mm Restrictor Flue Restrictor Length Coaxial Systems Between Between NOT APPLICABLE NOT APPLICABLE ø 60/100 345 mm - 1 m 1 m - 4 m Risk of Condensation Forming With: Exhaust...

  • Page 19: Control Panel

    Installation 6.10 Control Panel I H G To dismantle the front casing panel it is necessary to: 1 - Remove the two screws “B”; 2 - Move the front casing panel up and lift forward. EGEND A - On/Off button B - Central heating temperature adjustment C - Domestic hot water temperature adjustment D - Heating system pressure gauge...

  • Page 20: Fitting The Time Clock

    Installation 6.12 Fitting the Time Clock To fit the mechanical time clock supplied with the boiler, it is nec- essary to proceed as follows: 1) Remove the fastening screws ‘A’ from beneath the boiler; 2) Rotate the control panel forward, if necessary, it is possible to lift the control panel up and rotate it to a fully horizontal posi- tion;...
  • Page 21 Installation 6.12 Fitting the Time Clock (continued) MECHANICAL DIGITAL TIME CLOCK TIME CLOCK 5 4 3 GREY GREY BLACK BLACK . 6.21 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 22: Room Thermostat Connection

    Installation 6.13 Room Thermostat Connection To connect a room thermostat, it is necessary to: 1. - Open the control panel as indicated in 6.11. SECTION 2.- Remove the link “A” from the terminal block on the reverse of the control panel. 3.
  • Page 23 Installation 6.14 LECTRICAL YSTEM IAGRAMS CN104 FUSE CN103 CN104 FUSE CN103 CN102 CN102 CN100 CN100 CN101 CN101 . 6.23 A - Jumper: Q - Motorised diverter valve Relay R - Gas Valve Relay Don’t move (jumper is factory set in position B) S - Circulation Pump Relay Anti-cycling Device Adjustment for Heating T - Fan Relay...

  • Page 24: Water Circuit Diagram

    Installation 6.15 Water Circuit Diagram Legend: . 6.24 Heat Exchanger Overheat Thermostat Burner Detection Electrode Ignition Electrodes Main Circuit Temperature Probe Pressure Gauge Low Water Pressure Switch 10. Safety Valve 11. Domestic Hot Water Temperature Probe 12. Secondary Exchanger 13. Gas Valve 14.

  • Page 25: Commissioning

    COMMISSIONING Initial Preparation Initial Start-up Preliminary electrical system checks to ensure electrical safety HE CHECKS TO BE RUN BEFORE INITIAL START UP ARE AS FOLLOWS must be carried out by a competent person i.e. polarity, earth con- 1. Make sure that: tinuity, resistance to earth and short circuit.

  • Page 26: Combustion Analysis

    Commissioning Combustion Analysis Boiler Safety Systems The flue connector has two apertures, readings can be taken for the The boiler is fitted with the following devices (see S 6.10 ECTION temperature of the combustion by-products and of the combustion for references). air, as well as of the concentrations of O and CO , etc.

  • Page 27: Draining The System

    Commissioning Draining the System 7.10 Instructing The End User Draining the Heating System Hand over the copy of the End User Instructions supplied The heating system must be drained as follows: with the appliance, together with these instructions, and - Turn off the boiler; explain how to use the timeclock and room thermostat if fit- - Attach a hose pipe and open the drain valve;...

  • Page 28: Gas Adjustments

    8. GAS ADJUSTMENTS Model CATEGORY II2H3+ Methane Gas Liquid Butane Gas Liquid Propane Gas Lower Wobbe Index (15°C;1013mbar) TP 23 MJ/m 45.67 80.58 80.58 TP 30 Nominal Delivery Pressure mbar Minimum Delivery Pressure mbar TP 23 Main Burner: n. 14 jets (ø) 1.25 0.72 0.72...
  • Page 29 Gas Adjustments 5. To set the minimum power, disconnect a supply terminal “F1” from the modureg and adjust screw “F” (ensure that the 10mm nut is held in position). Turn the screw clockwise to increase the pressure and anti-clockwise to decrease the pressure (displayed on the pressure gauge) corresponding to the minimum power (see TABLE A page 28).
  • Page 30 Gas Adjustments ABLE 2.80 2.09 Kg/h 2.06 Kg/h 1.16 0.87 Kg/h 0.85 Kg/h 28 mbar 37 mbar 10.3 28.1 mbar 35.6 mbar 5.0 mbar 6.8 mbar 14 x 1.25 14 x 0.72 14 x 0.72 3.49 2.60 Kg/h 2.56 Kg/h 1.48 1.10 Kg/h 1.09 Kg/h...

  • Page 31: Maintenance

    MAINTENANCE It is recommended that the following inspections be carried out on the boiler at least once a year: Check the seals for the water connections; replace any faulty seals. Check the gas seals; replace any faulty gas seals. Visual check of the entire unit. Visual check of the combustion process or analysis of combustion by-products (see section 3.6) and cleaning of the burner if needed.

  • Page 32: Servicing Instructions

    10. SERVICING INSTRUCTIONS To ensure efficient safe operation, it is recommended that the . 10.3 boiler is serviced annually by a competent person. Before starting any servicing work, ensure both the gas and electrical supplies to the boiler are isolated and the boiler is cool.

  • Page 33: Removing The Side Panels

    Servicing Instructions 10.2.2 Removing the sealed chamber front cover 10.2.3 Removing the side panels 1. Remove the screws “C” (F . 10.6); 1. Remove the four screws “D” for each side panel (F .10.8); 2. Lift the sealed chamber front cover from the locating pins 2.

  • Page 34: Access To The Combustion Chamber

    Servicing Instructions 10.3 Access to the Combustion Chamber 10.3.3 Removing the electrodes Before carrying out this procedure, unscrew and slide the burn- 10.3.1 Removing the combustion cover er forward (see previous section). 1. Remove the screws “E” (F . 10.10); 1.

  • Page 35: Removing The Main Heat Exchanger

    Servicing Instructions 10.3.4 Removing the main heat exchanger . 10.21 1. Drain the boiler of water; 2. Remove the side panels (see 10.2.3) 3. Remove the overheat thermostat sensor “I” (F . 10.17); 4. Remove the clip “J” (F . 10.18); 5.

  • Page 36: Removing The Fan

    Servicing Instructions 10.3.6 Removing the fan 10.4 Access to the Gas Valve 1. Disconnect electrical connections “O” and silicone pipe “P” 10.4.1. Removing the spark generator .10.25); 2. Remove screw “Q” and remove the fan collar clamp “R” (F 1. Disconnect ignition leads “T” by pulling upward 10.26);...

  • Page 37: Removing The Gas Valve

    Servicing Instructions 10.4.2 Removing the gas valve 10.5 Access to the Water Circuit Important! Before removing the gas valve, ensure the gas sup- Important! Before any component is removed, the boiler ply is turned off. must be drained of all water. 1.

  • Page 38: Removing The Pump Pressure Switch

    . 10.38 10.5.3 Removing the safety valve 1. Disconnect the discharge pipe work from below the boiler; 2. Unscrew and remove the valve “A1” (F . 10.41). 10.5.2 Removing the pump pressure switch 1. Remove the pump pressure switch electrical connections “Z” 10.39);...

  • Page 39: Removing The Pressure Gauge

    Servicing Instructions 10.5.5 Removing the pump 10.5.6 Removing the pressure gauge 1. Remove the electrical connection “ C1” (F . 10.44); 1. Remove the U-clip “E1” (F . 10.47) 2. Remove the allen screw “D1” (F . 10.45); 2. Push the pressure gauge through the control panel from the 3.

  • Page 40: Removing The Expansion Vessel

    Servicing Instructions 10.5.7 Removing the expansion vessel 10.5.8 Removing the overheat thermostat 1. Release nuts “F1” and remove the gas pipe (F . 10.49); 1. Disconnect the overheat thermostat electrical connections “I1” 2. Release nut “G1” (F . 10.50); . 10.53); 2.

  • Page 41: Removing The D.h.w. Flow Switch

    Servicing Instructions 6.5.12 Removing the divertor valve actuator 10.5.10 Removing the D.H.W. temperature sensor (N.T.C.) 1. Unplug the electrical connector “L1” (F . 6.60); 1. Pull off the electrical connector and unscrew the sensor probe 2. Release the retaining clip “M1” and remove the divertor using a suitable spanner (F .

  • Page 42: Access To The Control System

    Servicing Instructions 10.6 Access to the Control System 10.6.2 Removing the P.C.B. 1. Isolate electricity; Important! Isolate the electrical supply to the boiler before 2. Remove the inspection cover from the reverse of the control accessing the control panel. panel; 3.

  • Page 43: Fault Finding

    11. FAULT FINDING 11.1 Fault Finding Guide (Flow-charts) These fault finding guides are not exhaustive. However, it is pos- To ensure that the external controls do not interfere with the fault sible to detect and correct many defects by using the standard finding, disconnect the wires from the terminal block on the rear fault finding diagrams described in this chapter, ensure these of the control panel and provide a solid link between the termi-...
  • Page 44 Fault Finding Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 45 Fault Finding 0.55mbar (23kW) 0.90mbar (30kW) 0.55mbar (23kW) 0.90mbar (30kW) Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 46 Fault Finding Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 47 12. SHORT SPARE PARTS LIST 31 32 36 37 40 41 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 48 Short Spares Parts List Part Number Description 65101294 995903 Pump Pressure Switch 997088 Safety Valve (3 Bar) 65101390 Pressure Gauge 995948 D.H.W. Flow Switch 997147 3 Way Valve Motor 996615 Pump Motor 996123 Gasket (Pump Motor) 995865 Auto Air Vent 65100716 Air pressure Switch 65100719...
  • Page 49 Fault Finding Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 50: Technical Information

    13. TECHNICAL INFORMATION TP 23 MFFI TP 30 MFFI CE Certification 0694BO0090 0694BO0090 Heat Input max/min kW 25.6/11.0 36.6/15.5 Heat Output max/min kW 24.8/9.7 30.6/12.1 Efficiency of Nominal Heat Input 92.9 83.4 Efficiency at 30% of Nominal Heat Input 91.1 80.9 Heat Loss to the Casing (∆T=50°C) Flue Heat Loss with Burner Operating...

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47-166-3247-116-33Intesa tp23

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