Buccaneer GT Combination Boiler
Falcon GTE Combination Boiler
Installation, Assembly and Servicing
Oil or Gas Fired Boilers
Assembly and Installation Instructions for Ideal Buccaneer and Falcon Oil or Gas Fired heating combination boilers should be read in
conjunction with the Boiler Assembly Instructions enclosed and any other technical publication supplied with the burner.
CAUTION: To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken when handling
edges of sheet steel components.
BUC5034
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1.1 Technical Specifications of Combination Boilers
Boiler:
MLS Calorifier:
Maximum operating pressure
Maximum operating temperature
Maximum safety temperature of
boiler (as per TRD 702)
Boiler thermostat setting
Safety thermostat setting
:
:
4 bar
100ºC
Primary circuit (heating water)
- Maximum operating temperature
- Maximum operating pressure
Secondary circuit (domestic hot water)
- Maximum operating temperature
- Maximum operating pressure
:
:
95ºC
12 bar
:
:
:
120ºC
30 - 85ºC
110ºC
:
:
95ºC
10 bar
Bucaneer GT - Domestic Hot Water Production
MLS tank capacity
3
4
5
litres
litres/h
150
640
235
228
150
780
260
256
150
780
260
284
Continuous flow rate (1) (2)
Maximum flow rate over 10mn (1) (2) (3)
Weight (Boiler and tank)
litres/10mn
kg
Falcon GTE - Domestic Hot Water Production
MLS tank capacity
4 (150/250)
5 (150/250)
150/250
780/950
260/380
395.5
litres
litres/h
litres/10mn
kg
150/250
780/950
260/380
354
Continuous flow rate (1) (2)
Maximum flow rate over 10mn (1) (2) (3)
Weight (boiler and tank) 150 litre
Weight (boiler and tank) 250 litre
kg
384
425.5
(1) Domestic cold water at 10ºC
(2) Storage temperature : 60ºC
- Domestic hot water at 45ºC - Primary at 80ºC
20ºC
(3) Boiler temperature
:
80ºC - Ambient temperature
:
Tank Details
Note: With IDEAL boilers, the setting limits the temperature of the primary circuit at the beginning to 75ºC (adjustment is possible from
50ºC to 95ºC).
Tank Type
MLS 150/III
MLS 250/II
Primary circuit (central heating water)
Water capacity of coil
Exchange surface of coil
Secondary circuit (sanitary water)
Water capacity
litres
m2
5.9
7.2
1.2
0.92
litres
kg
150
100
250
130
Delivery weight
3
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GENERAL
1.2 Main Dimensions
Buccaneer GT Combination Boiler
A
1" 1/4
74
B
141
335
195
530
F O flue
gas
nozzle
thread
heating
outlet
1" 1/4
thread
heating
35
35
G
return
348
138
3
/
4" dhw outlet
Optional
delivered
burner
3
/4" dhw loop return
(optional)
1
/2"
tapped
draining
outlet
3
/4" dcw inlet
60
600
150
1030
300
300
GT
A
B
E
O F
G
3
4
5
686 471 1009 125 18
813 598 1009 125 18
940 725 1009 125 18
BUC5000
Falcon GTE Combination Boiler
A
205
355
214
111
150
B
346
560
O 150
flue gas
nozzle
Heating outlet
R 1 1
4"
/
110
10
Heating
return
R 1 1
/4"
20
20
Rp 3
to be plugged
/4"
45
Burner
centre line
R 3
R 3
/
4" outlet
4" dhw loop
Optional
delivered
burner
/
return (optional)
R 3
/4" dcw inlet
60
150 1030 (150l), 1274 (250l)
1180 (150l), 1424 (250l)
600
300
300
(
1
)
A
dju
s
t
a
ble
f
ee
t
:
b
as
ic
h
e
igh
t
10 mm wi
t
h
9
-
15 mm
F
a
dju
s
t
m
e
nt
r
a
nge
.
R
p
:
T
a
pped
eaded
R
:
T
h
r
GTE
A
B
C
D
E
G
H
I
J
4
5
4
5
/
/
/
/
150
150
250
250
I
I
I
I
853
980
853
980
592
719
592
719
90
90
738
738
788
788
475
475
515
515
270
270
310
310
65
65
1537
1537
1587
1587
1158
1158
1208
1208
1303
1303
1353
1353
130
130
105
105
BUC5025
4
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INSTALLATION
2.
INSTALLING THE BOILER
2.1 Boiler Location
Sufficient space shall be left clear around the boiler.
The figure stated in metres in the drawings below are the minimum recommended dimensions for providing easy access around the
boiler.
Buccaneer GT
Falcon GTE
1357
0
.
5
m
m
5
.
0
1030
600
m
5
.
GTE
4/150 I
5/150 I
4/250 I
5/250 I
L1
H
0
1180 1537
1424 1587
1
m
BUC5038
BUC5001
2.2 Ventilation
WARNING
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entire volume of the boiler
room. The ventilation shall comply with any applicable national or
local regulations.
Please note that boilers installed in or close to
rooms in which the atmosphere is polluted with
chlorine or fluorine compounds may be subject
to high corrosion.
For example: hairdressing salons, industrial
premises (solvents), cooling equipment etc.
2.3 Assembly
The upper section of the MLS 150 tank (only) is provided with marks
allowing precise positioning of IDEAL boilers from the Buccaneer
GT or Falcon GTE range (see leaflet provided with these units).
Boilers installed in such locations shall not be
covered by the warranty.
2.4 Levelling
Levelling of the unit is carried out using the 4 bolts H 10 x 20 (packed
in the instruction bag) screwed into the base.
BUC5002
5
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INSTALLATION
2.5 Hydraulic Connections
WARNING
Installation must be carried out following the regulations in force,
trade practices and the recommendations contained in this leaflet.
If the distribution pipework is in copper, a sleeve
in steel, cast iron or insulating material must be
placed between the hot water outlet of the unit
and this pipework so as to avoid any corrosion at
the level of the branch pipe.
WARNING
There must be no obstructions, complete or
partial, between the boiler and the safety valves.
Notes:
-
The safety unit and its connection to the tank must be at
least of the same diameter as the tanks sanitary cold water
supply pipework (minimum 3/4").
WARNING
-
-
-
The safety unit's outlet pipe must have sufficient, continuous
slope and its section must be at least equal to that of the
orifice for the safety unit outlet (so as to avoid slowing down
the water flow when there is an excess of pressure).
Heating installations must be designed and
assembled so that central heating water and any
products introduced into it cannot find their way
into the drinking water system. A removable
connection must be installed for filling the heating
circuit according to current regulations.
The level of the safety unit must be below that of the cold
water inlet so it can be drained. If this is not the case, install
a draining pipe at the lowest point of the tank (see drawing
in Section 2.8).
To ensure hot water as soon as the taps are opened, a
circulation loop between the mains supply and the re-
circulation pipes of the unit can be installed.
•
•
Before making the hydraulic connections for the central
heating circuit, it is essential to flush the water system to
eliminate any dirt which may damage certain parts (safety
valve, pumps, flap valves . . .)
2.7 Important
Recommendations
for
Be careful to isolate hydraulically the primary and secondary
circuits using stop valves. This will facilitate matters during
maintenance.
Connecting the Boiler to the Heating
Circuit and the Drinking Water Supply
Inclusion of these valves means that maintenance of the
unit and its parts can be carried out without having to empty
it. They also mean that the tank can be carried out without
having to empty it. They also mean that the tank can be
isolated whilst a watertight pressure test is carried out if the
test pressure is above the pressure admitted by the tank.
The installation shall be made in keeping with applicable regulations
and codes of practice and the recommendations contained in these
instructions.
The expansion vessel shall be connected to the boiler without any
valve or stop valve between the boiler and the expansion vessel.
The heating system shall be designed and installed in a way as to
prevent the water from the heating circuit and any substances added
to it from flowing back into the drinking water circuit located before
it. The installation shall not be directly connected to the drinking
water system.
2.6 Connection of the Domestic Hot Water
Circuit
The domestic hot water units can operate under a maximum service
pressure of 10 bar. Generally, they operate at 7 bar.
As a general rule, a check valve shall be fitted on the cold water
supply pipe.
•
Before connecting the domestic hot water circuit, the
pipework must be flushed to wash out any metal or other dirt
which could damage certain parts (safety units, pump, valves
. . .).
VERY IMPORTANT: under safety rules, a sealed safety valve
calibrated to 7 bar shall be fitted on the cold water intake pipe
of the hot water tank. We recommend membrane type hydraulic
safety devices with the NF mark.
•
The connection between the safety valve and the unit must
not contain any section parts. Also, the flow pipe for the
safety valve must not be obstructed. If the supply pressure
exceeds 5.5 bar, a pressure reducer must be included
"upstream" of the tank. It is advisable to site the pressure
reducer "downflow" of the water meter so as to have the
same pressure in all the pipes.
During normal valve operation some drops of water are lost each
time the water is heated. This apparent leak is not only normal, but
is actually a sign that the valve is operating correctly.
The safety valve shall always be placed on the cold water supply
pipe and no valve or tap shall be fitted between the safety valve
and the tank.
•
•
Include a drain valve in the boiler as well as a "syphon funnel"
for the safety unit.
In order to ensure the continuous circulation of hot water in the
installation and be able to draw hot water as soon as a tap is opened,
a circulation loop may be installed between the drawing points and
the tank recirculation tube. A non return valve shall be fitted on this
loop.
Connection to the cold water supply must be carried out
according to the drawing in section 2.8. Components must
conform to the standards and regulations in force. A stop
valve is installed into the cold water supply.
6
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INSTALLATION
2.8 Example of Installation
The boiler-to-tank connection kit is placed between points A and B between the boiler and the heating circuit.
Example: Buccaneer GT
7
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ASSEMBLY
3
ASSEMBLY
3.1 BUCCANEER GT COMBINATION BOILER
Tools required:
- Phillips head screwdriver
- Wide flat screwdriver
- 13mm spanner
Packaging: the tables below show the numbers of the packages
which make up the boiler. The packages are listed in the order in
which they are opened for assembly.
Boiler
3
4
5
Boiler
Body
IC1
IC2
IC3
Jacket
Pack
IC4
IC5
IC6
Control Panel -
Standard
IC7
IC7
IC7
Domestic Hot
Water Sensor
AD127
BH 59
BH 46
AD127
BH 59
BH 46
AD127
BH 59
BH 46
Domestic Hot
Water Tank
- MLS 150
Hydraulic
Boiler-to-Tank
Connection Kit
1.
2.
See the assembly instruction supplied with burner.
See the technical instructions for sensor connection. The assembly of any optional devices purchased with the boiler is described
in the instructions supplied with the relevant device or in the control panel instructions. The list of available optional devices is
provided in the applicable price list.
8
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ASSEMBLY
1 Package IC1, IC2, IC3
À
Á
A
BUC5010
Â
Ã
2
1
2
2
1
1
2
1
3.
Unscrew 1/2" plastic plug A from the rear section of the boiler
Assembling the base and draining tube
body.
1.
Lay a sheet of paper in front of the boiler body, take the
boiler body off the pallet and place it standing on the furnace
door.
Fit the base onto the feet of the boiler and clip it onto the
rear section.
4.
5.
Screw the draining pipe onto the rear section. Make the
connection watertight with hemp or filler.
2.
Remove the adjustable feet assembled on the base and
replace them with the four protective plastic plugs supplied
in connection kit package BH 46.
Set the boiler body on its feet.
9
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ASSEMBLY
2
Assembling the boiler onto the tank
-
Place the boiler on the tank so that it is
positioned on the first two marks on the
front of the tank.
-
Assemble the boiler as instructed in
views 3 - 13 of Buccaneer GT boiler
Assembly Instructions.
14
15
*
Installing the pipes
Assembling the tank front panel
-
Connect the pipes between boiler and tank (package
BH 46) - see the instructions on page13.
-
Fit the tank front panel after inserting the thermometer bulb
in the thimble tube of the inspection plug of the tank.
10
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ASSEMBLY
3.2 FALCON GTE COMBINATION BOILER
Tools required:
- Phillips head screwdriver
- Wide flat screwdriver
- 13mm spanner
Packaging: the tables below show the numbers of the packages
which make up the boiler. The packages are listed in the order in
which they are opened for assembly.
Boiler
GTE 4 150
GTE 5 150
GTE 4 250
GTE 5 250
Boiler Body
delivered loose
- front section
- intermediate section
- rear section
1
2
1
1
3
1
1
2
1
1
3
1
- set of assembly rods
- accessory package
-
-
-
-
IL 4
IL 5
IL 4
IL 5
BUC5039
BUC5040
Mounted boiler
body with
accessories
IL 24
IC 7
IL 25
IC 7
IL 24
IC 7
IL 25
IC 7
Control Panel -
Standard
Casing
IL 14
IL 15
IL 14
IL 15
Domestic Hot
Water Tank
150
250
BH 59
-
BH 59
-
-
-
BH 9
BH 9
Front Panel of tank
-
-
BH 47
BH 46
BH 47
BH 46
Hydraulic Connection
Kit
BH 46
AD 127
BH 46
AD 127
Domestic Hot
Water Sensor
AD 127
AD 127
The assembly of any optional devices purchased with the boiler is described in the instructions supplied with relevant device or in the
control panel instructions.
The list of available optional devices is provided in the applicable price list.
1.
Refer to the assembly instructions supplied with the burner.
11
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ASSEMBLY
37
38
Assemble the boiler as instructed in figures 1 - 16
*
BUC5041
Assembling the boiler on the hot water tank
-
Place the boiler on the tank if required with a handling
tool (if required).
Installing the tubes
-
Assembly the boiler as instructed in figures 17 - 33 of
boiler assembly instructions for Falcon GTE.
-
Connect the tubes between boiler and tank (package BH
46) as directed in the instructions on page 13.
39
Assembling the tank front panel
-
Insert the thermometer bulb in the thimble tube of the
inspection plug of the tank (For 250 litre system - separate
package BH 47) and fit the tank front panel.
12
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ASSEMBLY
3.3 Hydraulic Boiler to Tank Connections Kit (BH46)
Assembly
Connection kit BH46, provides connections from the tank to the IMPORTANT
boiler.
-
-
-
-
Ensure access to pump speed control and vent screw V
Ensure flexible connectors are run to prevent air pockets
The 1/2" plug 11 fitted to Tee 1 can be replaced by a drain cock
To ensure best venting of the assembly and continued good
operation of the installation, an automatic vent (P) not supplied,
should be fitted on Tee 9 (1/2")
Screw the Tee with union nut 1 and plug 2 on tank outlet D
Fit the pump 3 to union nut 4 and Tee 1 inserting O rings 5
Screw Tee 7 to boiler return B
Screw Tee with tappings 9 with plug 11 to boiler flow A
Screw valve Tee 10 with plug 11 to tank inlet C
Connect elbow flexible 12 (1200mm) between 7 & 4 and flexible
13 (1120mm) between 9 & 10 inserting O rings 14.
Assemble flexible clip 16 and fitting 17 then clip them in the
7.5mm hole E on the boiler rear panel.
The kit consists of
-
-
-
-
A pump with cable 3
Insulated flexible connector 13, length 1120mm
Insulated flexible connector with elbow 12, length 1200mm
A bag containing:
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
An antisyphon valve 10
Connecting union 4
Tee with union nut 1
Tee 7
Tee with tappings 9
3 X 1/2" plugs 11
3 X 1 1/2" O rings 5
5 X 3/4" O rings 14
4 X plastic plugs 15
-
-
Fit flexible 13 in clip 16.
-
Flexible clip 16 with fixing 17
The pump cable allows simple connection to the boiler control
box. See Electrical section for further information.
13
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ASSEMBLY
4.
CONTROLS
The boiler connections shall be performed by a
qualified professional only.
4.1 Description
Strict compliance with these operating and
connecting instructions is a precondition for the
correct operation of the boiler
9
6
10
7
2
3
6
5
3
7
9
4
8
TEST STB
30
AUT
oc
6,3 AT
BUC5037
8
4
1
5
9.
Location for MB1 module (also refer to the instructions
supplied with the device).
1.
2.
On / Off switch.
Burner switch: turning the heating off (summer position
)
10.
Location for an optional time counter.
or on (winter position ) by turning off/on the burner and the
pump (domestic hot water production continues).
Boilers with the domestic hot water facility:
For an MB1 domestic hot water priority module the switch
is disabled by the control device.
A potentiometer for setting the temperature of the
domestic hot water is located on the MB1 module casing
(graduated from 1-8).
3.
Heating pump switch: used to turn the heating pump off
(summer position ) or on (winter position ).
4.2 Operating Principle
For an MB1 module it must be set to the winter position
Boiler thermometer.
.
Control Panel
4.
5.
The boiler temperature is regulated either by the boiler thermostat
or any room thermostat. The safety of the installation is achieved
via the safety thermostat with manual reset.
Three-position switch:
: manual position, used when the boiler is not fitted
with a room thermostat.
Heating Regulation
The boiler temperature is regulated by boiler thermostat 7.
The heating is regulated in different ways (manual mixing valve,
thermostatic valves etc.). It is up to the fitter to explain to the user
how the heating is regulated.
This position may be used to test the burner of installations
fitted with a room thermostat.
AUTO : automatic position, used for normal operation of
boilers. The boiler temperature is regulated by the connected
device.
Domestic Hot Water Regulation (Versions with MB1)
The presence of a filling pump and an antithermosiphon valve on
the primary circuit of the hot water production system means that
the domestic hot water temperature is kept correctly regulated. The
temperature of the domestic hot water is set by means of a
potentiometer located on the MB1.
TEST STB : momentary use to test the safety thermostat.
Safety thermostat with manual reset (factory setting 110ºC).
6.
7.
Boiler thermostat with 30 - 85ºC adjustment range.
However, the built-in stop limits the maximum temperature
to 75ºC. The stop may be moved if required.
When the domestic hot water is reheated, the burner and the primary
filling pump are started up, whilst the heating pump is stopped. The
boiler temperature is controlled by the limiting thermostat built into
the MB1 module (the thermostat is factory set to 80ºC). When the
need for hot water is met, the burner is turned off and the filling
pump continues to operate for 4 minutes after the burner stops (the
delay is adjustable from 30 sec to 15 min). In this way, the residual
heat accumulated in the heating elements is used to complete
reheating the tank.
The boiler thermostat must necessarily be set to the
maximum position if a room thermostat is used.
8.
6.3 AT fuse.
14
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ASSEMBLY
The connecting cables may be brought inside the boiler through
the cut-outs provided in the cover of the boiler, which may be used
along with purchased cable channels.
4.3 Electrical Connections
The electrical wiring has been carefully checked in the factory and
the internal connections of the control panel must not be modified
in any event.
Fasten the cables to the rear plate of the control panel by means of
the cable clamps (supplied in the instructions bag), after mounting
them on the plate.
The electrical connections of the boiler shall be made in compliance
with applicable standards and regulations in force.
The pump cable has a connector fitted. Discard the connector.
The unit shall be powered by a circuit with an omnipole switch with
an opening distance greater than 3 mm.
WARNING
VERY IMPORTANT: never place sensor cables
(extra low voltage) and 230 V power supply cables
in the same cable channel or duct.
WARNING
Electrical connections shall be carried out by a
qualified professional only.
All the connections shall be made to the connection strip provided
for that purpose outside the volume of the control panel.
Refer to Boiler Assembly Instructions for Control Panel Installation
4.4 Installation with MB1 Domestic Hot water
Priority and Regulation Mode
Fitting and Connecting the MB1 Module
Fit the MB1 module on the front of the control panel. Proceed as
follows:
1.
Remove the cover: cut the four fixing studs of the cover with
a knife and fold it outward.
2.
Install and connect the MB1 module as directed on pages
16-18.
BUC5042
15
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ASSEMBLY
-
-
Install domestic hot water sensor cable A(e.g. for Buccaneer GT)
as shown and fix it with plastic clips B.
-
-
Connect as directed in the diagram on the following pages.
Insert the bulb of the limiting thermostat in the thimble tube
on the rear of the boiler.
Insert the sensor in the thimble tube of the tank.
Tank Sensor
Boiler Sensor
BUC5043
BUC5044
4.5 MB1 Domestic Hot Water Sensor
Operating and Installation - Package AD127
6
5
7
4
8
3
2
1
MB
The MB1 module allows for regulation of the storage temperature
and ensures priority for the production of hot water for sanitary
systems. When there is a demand for the sanitary hot water to be
reheated, the MB 1 module activates the burner and the tank
charging pump, and stops the circulation of the heating system.
The period during which the heating circulator is switched off
depends on the volume of water being pumped round the system,
the power of the boiler which is connected, and the performance
values of the sanitary hot water preparation unit.
A limiter thermostat, set at the factory to 80ºC, regulates the
temperature of the boiler during the charging of the sanitary system.
The timing device of the pump overrun (4 minutes), after the burner
has been switched off, allows for the residual heat accumulated in
the body of the heating unit to complete the reheating of the
preparation unit.
16
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ASSEMBLY
1.
Instructions for use
Regulating the storage temperature of hot water for sanitary
systems:
4
5
The regulating button A allows for the average temperature of stored
sanitary hot water to be adjusted between 10 and 80ºC, with a hard
point at 6 (about 60ºC).
3
6
2
7
1
8
In the event of prolonged absence:
In order to ensure that the sanitary hot water tank is protected against
frost, set the regulating button A to the position 1 (this setting
corresponds to a temperature of about 10ºC).
A
2.
Adjusting the timing of the charging pump
The timing device for stopping the charging pump allows the pump
to keep operating for 4 minutes (factory setting) after the setting
temperature for the sanitary system has been reached. This allows
the residual heat accumulated in the body of the heating unit to be
used to complete the reheating of the sanitary hot water.
Adjustment: This timing device can be adjusted from 3 to 6 minutes,
with the aid of the potentiometer located on the back of the unit.
TEMPO
MINI
MAXI
Taking the timing device out of operation: To take the timer out
of operation, remove the bridge unit located on the back of the
device, as shown in the drawing opposite.
T
T=0
3.
Adjusting the limiter thermostat
It is possible to change the setting of the limiter thermostat, over a
range from 30 to 90ºC, the original setting being 80ºC. To do this:
90ºC
80ºC
30ºC
-
-
-
-
Take the module out of the boiler console, if applicable;
Remove the setting button, by drawing it towards yourself;
Unhook the PCB;
30
C
90
C
80
C
5
6
7
4
8
3
2
MB
1
Adjust the limiter thermostat in accordance with the reference
settings shown in the diagram opposite, with the aid of a flat
screwdriver;
-
Reassemble the unit by proceeding in the reverse order.
4.
Installation and Connection
For all boilers:
-
Remove the TL bridge, connected to the terminal strip of
the boiler control console, with terminals 1 and 2 to terminals
1 and 3.
-
Withdraw the LP bridge at terminals 4 and 5 in order to do
away with an ECS priority.
Main
Terminal
Strip
-
-
Remove the panel A from the control console of the boiler
(refer to the technical instruction plate).
Connect the connector elements B and C of the module to
the connectors D and E coming from the boiler control
console (blue on blue, red on red).
-
Attach the earthing wire F to an earthing terminal of the
control console.
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ASSEMBLY
-
-
Introduce the bulb G of the limiter thermostat into the boiler
pocket.
Connect the charging pump to the boiler control console,
ensuring that the terminals live (L), neutral (N) and earth (
are properly attached.
)
-
-
Connect the probe bulb to the boiler control console.
Introduce the probe bulb into the pocket of the sanitary hot
water tank.
If the tank is already fitted with a thermostat, it will not be used :
accordingly replace the bulb of this thermostat with the tank probe.
WARNING
IMPORTANT: Under no circumstances may the
wires of the probe (very low voltage) and wires
carrying 230 V supply feed be placed in the same
conduit or cable duct. Make sure that a minimum
interval of 10 cm is maintained between them.
Failure to do so can cause interference and lead
to malfunction of the control system and the
deterioration of the electronic circuits.
Securing the module
Mount the module by the front so as to secure it with the help of the
two screws located on the front section (use a cruciform (Phillips)
screwdriver).
Connections (Installation with MB1 Module)
-
-
-
Move bridge TL from terminals 1-2 to terminals 1-3.
Remove bridge LP from terminals 4-5.
WARNING
If the installation includes an MB1 module and no
room thermostat (TAM), set three position switch
5 (see page 14) to
Connect the power supply, the heating pump and the tank
load pump as shown.
.
-
Connect the tank sensor.
If the installation includes an MB1 module and a
room thermostat (TAM), set three position switch
5 (see page 14) to AUTO.
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ASSEMBLY
4.6 Heating and Domestic Hot Water
Installation (with MB1 module)
WARNING
IMPORTANT: If the installation includes an MB1
module and no room thermostat (TAM), set three
position switch 5 (see page 14) to
.
If the installation includes an MB1 module and a
room thermostat (TAM), set three position switch
5 (see page 14) to AUTO.
ZG F 6,3AT
L
8
(RG)*
(TAM)*
(RG)*
25
BA
11
10
21
23
18
Remove
bridge LP
to benefit
from the
heating
pump
22
9
BA
BA
13
BA
4
5
LP
TF*
BA
(TL)*
TEST
STB
1
2
12
ZT
24
19
20
16
26
q
logic
ZEH 1
3
q
q
TS
TCH
20
24
23
17
16
BA
BA
BA
BA
BA
A
P*
(CH)*
(B)
14
L1
T1
T2
N
B4
S3
BA
19
22
BA
BA
h
ZEH 2
ZG
7
N
BA
A
B
BA
CH
CS
Heating pump
Burner
Connection strip
Time counter
Safety contact
RG
Control unit
Room thermostat
Boiler thermostat
Flue gas thermostat
Limiting thermostat
Safety thermostat
Alarm indicator
ZEH2
Heating pump Summer/
Winter switch
Main switch
Test switch
Optional
TAM
TCH
TF
TL
TS
ZG
ZT
*
F6, 3AT Fuse
L
Connecting strip
Connector
Phase
VA
LP
N
P
Pump logic
Neutral
Filling pump
V3V
ZEH1
Three-way valve
Burner Summer/
Winter switch
BUC5031
4.7 Connecting the Burner
The boiler is fitted with a cable with a 7-pin European connecting
plug which can be plugged into the socket supplied with the burners
(see the instructions supplied with the burner).
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ASSEMBLY
5.
COMMISSIONING
-
Ensure connections are watertight.
-
Vent the tank heat exchanger as follows:
1. Unscrew the auto vent cap (P)* a few turns.
2. Turn the antisyphon valve screw 10 to open position (O)
3. Close the vent (P)* when water flows continuously.
4. Return the antisyphon valve screw 10 to the automatic
position (A)
5. To vent the pump, unscrew the protection cover in the
pump head and turn the pump shaft (V) left and right a
few times.
•
Make sure that safety thermostat 6 is set by unscrewing the
hexagonal cap and pressing the reset button with a
screwdriver.
•
•
Turn On/Off switch 1 to On
.
Turn burner switch 2 to Winter
.
If the boiler is fitted with an MB1 domestic hot water module, this
switch is disabled by the optional unit.
6. Leave the pump running with cold water for a few minutes
to prime the system.
(* Not supplied)
Turn heating pump switch 3 to Winter
.
Note: We advise you never to set the boiler thermostat below mark
4 (40ºC) in order to avoid the risk of combustion products
condensing on the walls of the boiler.
5.1 Starting Up
Initial starting up shall be performed by a qualified professional.
5.2 Commissioning Secondary Circuit
Before turning the boiler on, make sure that the installation is filled
with water.
•
If needed, flush the sanitary circuit (especially if re-starting)
and fill the tank using the sanitary cold water inlet pipe.
Perform the start-up operations in the chronological order given
below, referring to the diagram on page 14.
•
Bleed the secondary circuit (tank and distribution system)
in order to avoid any noise caused by trapped air moving
during re-heating and drawing off. To do this, fill it completely
with water, leaving a hot water tap open; close this tap only
when the flow of water is continuous and noise-free.
•
Set boiler thermostat 7 to the selected position (move the
stop if required).
WARNING
•
•
•
Then bleed in succession all hot water pipes by opening the
corresponding taps.
IMPORTANT: if the boiler is fitted with a room
thermostat, set boiler thermostat 7 to the maximum
position.
Bleed the tank's exchanger circuit using the vent made for
the purpose.
Check all safety units (especially the safety valve or group)
referring to the leaflet supplied with the component.
•
Set the domestic hot water temperature setting potentiometer
to the desired temperature (versions with MB1).
WARNING
•
Check the position of three-position switch 5, which must be
as follows:
During the heating of domestic hot water, some
water may escape through the safety valve or
group as a result of the expansion of water in the
unit. There is no cause for concern as this is
entirely normal. Do no attempt to prevent this from
happening
-
-
either set to manual : boilers without room thermostats
or set to AUTO (automatic): boilers with room
thermostats.
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SERVICING
•
Magnesium anode
6.
MAINTENANCE AND PERIODIC CHECKS
The magnesium anode must be checked at least every two years.
Starting with the first check and taking account of the wear to the
anode, the frequency of the following checks must be decided. The
anode can be checked according to one of the following two
methods:
•
Safety valve or group
WARNING
IMPORTANT: The safety unit must be used
periodically (at least once per month). To do
this, place the safety group in the draining position.
This allows the evacuation of any deposits which
could eventually obstruct the safety group valve.
Non-compliance with this requirement could
result in a deterioration of the unit's tank (see
notice enclosed with the safety unit).
-
Visual check:
The anode must be replaced if its diameter is less than 15mm
(initial diameter = 33mm)
-
Check by measurement:
-
-
Disconnect the earth wire to the anode.
Measure the current between the tank and the anode; if
the current is less than 0.1 mA, the anode must be
replaced.
•
De-scaling:
in hard water regions, it is advisable to ask the installer to
carry out an annual de-scaling of the tank exchanger so that
it will retain its performance.
•
•
The outside of the unit can be cleaned with soapy water.
Replace the inspection cover taking care to place the salt
rod at the bottom and refit the washer:
Operations to be carried out during the de-scaling, visual checks
and replacement of the magnesium anode.
-
-
-
position the lip seal in the inspection hole, being careful
to place its tongue outside the tank.
•
Shut off the cold water supply and drain the tank. To drain it
via the safety unit, put the latter into the drainage position
and open a hot water tap so that air can enter.
position the retaining ring around the seal, placing the
tongue above the ring.
Refit the cover, salt rod at the bottom, on the flange,
tightening the 6 bolts evenly across the diameter of the
cover.
•
•
•
•
Take off the front panel and the probes.
Take off the cover (13 mm spanner).
If necessary, replace the anode.
Remove all the scaling deposits from the bottom of the tank.
The exchanger must be de-scaled in order to guarantee its
proper operation.
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NOTES
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NOTES
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Caradon Plumbing Limited, P.O. Box 103, NationalAve, Kingston upon Hull, HU5 4JN. Telephone:
01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.
Caradon Plumbing Limited
pursues a policy of continuing
improvement in the design and
performance of its products. The
right is therefore reserved to vary
specification without notice.
Technical Training
The Caradon Plumbing Limited Technical Training Centre
offers a series of first class training courses for domestic,
commercial and industrial heating installers, engineers and
system specifiers.
For details of courses please ring:............... 01482 498432
July 2006
156597 A02
Ideal Installer/Technical Helpline: 01482 498 376
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