Installation and Servicing Instructions

CLAS HE SYSTEM

Gas fired condensing wall hung combination boilers
G.C.N : 41-116-26 (18 kW) G.C.N : 41-116-22 (24 kW) G.C.N : 41-116-23 (30 kW)
CLAS HE SYSTEM 18 CLAS HE SYSTEM 24 CLAS HE SYSTEM 30
Country of destination GB, IE

overview

INDEX Overview General Information...3 Advice for the Installer...4. CE Labelling....4 Data Plate Symbols....4 Safety Regulations....5 Product description Control Panel....6 Display....6 Overall View....7 Overall Dimension....7 Minimum Clearances...7 Technical Information....8 Installation Reference Standards....9 Installing the Boiler.... 12 Gas Connection.... 13 Water Connection.... 13 Instructions for Opening the Casing and Performing an Internal Inspection... 13 Connecting the Flue.... 15 Fitting the Coaxial Flue ( 60/100 Horizontal).. 16. Fitting the 5 Flue ( 80/125 Horizontal / Vertical).. 17 Fitting the Coaxial Flue ( 60/100 Vertical).. 18 Fitting the Twin Pipe ( 80/80)... 19 Electrical Connections... 23 Peripheral Unit Connection... 23 Room Thermostat Connection... 24 Outdoor Sensor Connection... 24 Electrical Diagram.... 25 Wiring diagram for connection to an open vented cylinder. 26 Wiring diagram for connection to an MTS unvented cylinder.. 27 Commissioning Initial Preparation.... 28 Electricity Supply.... 28 Filling the Heating System... 28 Filling of the DHW System... 28. Gas Supply..... 28 Water Treatment.... 28 First Igniton Operation... 29 Ignition procedure... 30 Test Function and Combustion Analysis.. 32 AUTO Function.... 33 Boiler Protection Devices Boiler Protection Devices... 34 Anti-Frost Device.... 34 Table summarising error codes... 34 Settings - Adjustment - Problem Identification Menus Accessing the Menus... 35 Maintenance General Comments.... 43 General Access.... 44 Electrical Unit... 45 Hydraulic Unit.... 47 Main Heat Exchanger... 52 Burner Unit.... 53 Fan Unit.... 56 Gas Valve.... 57. Annual Maintenance.... 58 Benchmark Commissioning Checklist... 59 Benchmark Service Interval Record... 60 Spare Parts Short List... 61
These instructions are suitable for CLAS HE SYSTEM boilers : Do not forget the Log Book! The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturers instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.
To The Installer As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the Householder. Please ensure that your customer is aware of the importance of keeping the Log Book safe as a record of the installation and the appliance service history. Please ensure that your customer is aware of the correct operation of the system, boiler and controls. MTS recommend the use of protective clothing, when installing and working on the appliance i.e. gloves.
CUSTOMER CARE MTS, as a leading manufacturer of domestic and commercial water heating appliances is committed to providing high quality products and a high quality after sales service. Advice on installation or servicing can also be obtained by contacting the MTS Technical and Customer Service Departments at High Wycombe. TECHNICAL DEPARTMENT CUSTOMER SERVICE DEPARTMENT Tel: 8180 Tel: 9888 Fax: Fax: GUARANTEE The manufacturers guarantee is for 2 years from the date of purchase. The guarantee is invalidated if the appliance is not installed in accordance with the recommendations made herein or in a manner not approved by the manufacturer. To assist us in providing you with an efficient after sales service, please return the guarantee registration card enclosed with the boiler without delay. CAUTION In the United Kingdom, installation, start-up, adjustments and maintenance, must be performed by a competent person only, in accordance with the current Gas Safety (Installation & Use) Regulations and the instructions provided. In the Republic of Ireland, the installation and initial start up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 Domestic Gas Installations, the current Buidling Regulations, reference should also be made to the current ETCI rules for electrical installation. All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI directly on:- 0485. Improper installation may cause damage or injury to individuals, animals and personal property for which the manufacturer will not be held liable. To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a competent person. If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a competent person.

product description

Control panel
Legend : 1. Display 2. Reset button 3. Orange indicator Comfort fonction 4. Pressure gauge 5. Heating temperature regulation knob 6. button _ 7. Menu/Ok button (Programming key) 8. Esc button 9. button + 10. Time clock (Optional) 11. ON/OFF button 12. Blue indicator burner ON 13. Yellow indicator Auto function 14. Auto button (To activate Thermoregulation)

Overall view

1. Flue Connector 2. Manual Vent 3. Burner 4. Detection Electrode 6. C.H. Return Temperature Probe 7. C.H. Flow Temperature Probe 8. Gas Valve 11. Trap 12. C.H. Pressure Relief Valve 13. Electrical Box 15. Circuit Filter 17. Circulation Pump with Air Release Valve 19. Water Pressure Sensor 20. Silencer 21. Modulating Fan 22. Ignition Electrodes 23. Ignitor 24. Thermal Fuse 25. Combustion Analysis Test Point

Overall Dimensions

120 180
Minimum clearances In order to allow easy access to the boiler for maintenance operations, The boiler must be installed in accordance with the clearances stated below.
A. entral Heating Flow C C. Gas Inlet D. Cold Mains Connection E. Central Heating Return

Technical Data

GENERAL NOTE
Model CLAS HE System CE Certification (pin) Boiler type Max/min nominal calorific flow rate (Pci) Max/min nominal calorific flow rate (Pcs) Max/min power output (80C-60C) Max/min power output (50C-30C) Combustion efficiency (of flue gas) Nominal calorific flow rate efficiency (60/80C) Hi/Hs Nominal calorific flow rate efficiency (30/50C) (condensation) Hi/Hs Efficiency at 30% at 30C (condensation) Hi/Hs Efficiency at 30% at 47C Hi/Hs Minimum calorific flow rate efficiency (60/80C) Hi/Hs Efficiency rating (dir. 92/42/EEC) Sedbuk Band / Rating Loss when stopped (T = 50C) Loss of burner gas when operating Available air pressure NoX class (5 = less than 70mg/kWh Flue gas temperature (G20) (80C-60C) CO2 content (G20) (80C-60C) CO content (0%O2) (80C-60C) O2 content (G20) (80C-60C) Maximum flue gas flow (G20) (80C-60C) Excess air (80C-60C) Expansion chamber inflation pressure Maximum heating pressure Expansion chamber capacity Maximum water capacity within the appliance (75C-35C) Min/max heating temperature (high temperature range) Min/max heating temperature (low temperature range) Domestic hot water max/min temperature Specific flow rate of domestic hot water (T=30C) Quantity of hot water T=25C Quantity of hot water T=35C Hot water comfort rating (EN13203) Hot water minimum flow rate Domestic hot water max/min pressure Power supply frequency/voltage Total electrical power absorbed Minimum ambient temperature for use Protection level for the electrical appliance Weight Dimension (L x H x D)* *Height includes valve cover Qn Qn Pn Pn kW kW kW kW % % % % % % stars Band / % % % Pa class C % ppm % Kg/h % bar bar L L C C C l/mn l/mn l/mn stars l/mn bar V/Hz W C PI kg mm

24 0085BR0347

B23-C13-C33-C43-C53-C83 18.0/4.5 20.0/5.0 17.6/4.3 19.2/4.8 97.8 97.5/87.8 106.6/96.0 109.0/98.2 98.3/88.5 95.3/85.8 **** A / 90.1 0.2 2.9,0 < 85 4,5 29,6,5 100/300 35/82 20/45 36/60 22.0/5.5 24.4/6.1 21.6/5.2 23.5/6.0 97.9 98.0/88.2 107.0/96.4 108.0/97.3 101.0/90.9 95.0/85.5 **** A / 90.3 0.2 2.9,0 < 100 4,5 41,6,5 100/300 35/82 20/45 36/60 12,0 14,4 10,3 *** <2 10/0,3 230/5 X5D 32 230/+5 X5D 32 28.0/6.5 31.1/7.2 27.4/6.2 30.0/6.9 97.9 98.0/88.2 107.0/96.4 108.0/97.3 98.2/88.4 95.6/86.1 **** A / 90.3 0.1 2.9,0 < 100 4,5 49,6,5 100/300 35/82 20/45 36/60 15,0 18,0 12,9 *** <2 10/0,3 230/+5 X5D 35

ELECTRICAL

DOMESTIC HOT WATER CIRCUIT

HEATING CIRCUIT

EMISSIONS

POWER SPECIFICATIONS

440/820/385 440/820/385 440/820/455

installation

Reference Standards In the United Kingdom, the installation and initial start-up of the boiler must be by a CORGI registered installer in accordance with the installation standards currently in effect, as well as with any and all local health and safety standards i.e. CORGI. In the Republic of Ireland the installation and initial start-up of the appliance must be carried out by a Competent Person in accordance with the current edition of I.S.813 Domestic Gas Installations and the current Building Regulations, reference should also be made to the current ETCI rules for electrical installation. The installation of this appliance must be in accordance with the relevant requirements of the Local Building Regulations, the current I.E.E. Wiring Regulations, the by-laws of the local authority, in Scotland, in accordance with the Building Standards (Scotland) Regulation and Health and Safety document No. 635, Electricity at Work Regulations 1989 and in the Republic of Ireland with the current edition of I.S. 813 and the Local Building Regulations (IE). C.O.S.H.H. Materials used in the manufacture of this appliance are nonhazardous and no special precautions are required when servicing. Codes of Practive Installation should also comply with the following British Standards Code of Practice: BS 7593:1992 BS 5546:1990 BS 5440-1:2000 BS 5440-2:2000 BS 5449:1990 BS 6798:2000 BS 6891:1989 BS 7671:2001 BS 4814:1990 BS 5482:1994 Treatment of water in domestic hot water central heating systems Installation of hot water supplies for domestic purposes Flues Air supply Forced circulation hot water systems Installation of gas fired hot water boilers of rated input not exceeding 70kW Installation of low pressure gas pipes up to 28mm IEE Wiring Regulations Specification for expansion vessels Installation of L.P.G. building within the vicinity and consideration must also be given to adjacent boundaries, openable windows should also be taken into consideration when siting the flue. The minimum acceptable clearances are shown below:

Fig. 1

- A Directly below an opening, window, etc 300 mm - B Horizontally to an opening, window, etc 300 mm - C Below gutters, soils pipes or drain pipes 75 mm - D Below eaves200 mm - E From vertical drain pipe or soil pipe 75 mm - F From internal or external corner 300 mm - G Above ground, roof or balcony level 300 mm - H From a surface facing the terminal2500 mm - I From a terminal facing a terminal2500 mm - J Vertically from a terminal on the same wall 1500 mm - K Horizontally from an terminal on the same wall 300 mm - L Fixed by vertical flue terminal

See table on page 21 4

See table

180 mm 118

Fig. 2

118 mm

Warning The exhaust gas ducts must not be in contact with or close to inflammable material and must not pass through building structures or walls made of inflammable material. When replacing an old appliance, the flue system must be changed. Important Ensure that the flue is not blocked. Ensure that the flue is supported and assembled in accordance with these instructions.
Installation without extension

150 mm

Fig. 3 Installation with extension slope * pente Level
pente 5 per metre slope* 5 mmmm par mtre
Fitting the Coaxial Flue ( 60 / 100 Horizontal) Contents: 1x Silicone O-Ring (60mm) 1x Elbow (90) 2x Wall Seals (Internal & External) 1x Flue Pipe including Terminal (1 metre - 60/100) 2x Flue Clamps 4x Screws 2x Seals Once the boiler has been positioned on the wall, fit the rubber flue seal into the internal flue turret (see Fig.2.), Insert the elbow into the socket and rotate to the required position. note: It is possible to rotate the elbow 360 on its vertical axis. Using the flue clamp, seals and screws supplied (Fig 4) secure the elbow to the boiler. The 1 metre horizontal flue kit (3318073) supplied is suitable for an exact X dimension of 753mm. Measure the distance from the face of the external wall to the face of the flue elbow (X - Fig 2), this figure must now be subtracted from 753mm, you now have the total amount to be cut from the plain end of the flue. Draw a circle around the outer flue and cut the flue to the required length taking care not to cut the inner flue, next cut the inner flue ensuring that the length between the inner and outer flue is maintained. (Fig 4).
e.g. X = 555mm 753-555 = 198mm (Length to be cut from the plain end of the flue). Once cut to the required length, ensure that the flue is free from burrs and reassemble the flue. If fitting the flue from inside of the building attach the grey outer wall seal to the flue terminal and push the flue through the hole, once the wall seal has passed through the hole, pull the flue back until the seal is flush with the wall. Alternatively, the flue can be installed from outside of the building, the grey outer seal being fitted last. Should the flue require extending, the flue connections are push fit, however, one flue bracket should be used to secure each metre of flue. Note: See table for maximum and minimum flue runs.

Screws Seal

Fig. 4
Fitting the 5 Flue ( 80 / 125 Horizontal/vertical) Once the boiler has been positioned on the wall, it is necessary to insert the 80/125 adaptor (Fig. 5) for both horizontal and vertical flue runs into the boiler flue socket (not supplied with flue kit - Part No 3318095). Push the adaptor onto the boilers flue connection, grease the seals then add extensions or elbows as required, secure the adaptor, using the clamp and screws provided.
Useable length of vertical flue 575 mm*
Total length of vertical kit 1240 mm

180 mm

To fit extensions or elbows it is first necessary to ensure that the lip seal is fitted correctly into the inner flue, once verified, it is simply necessary to push them together, no clamps are necessary to secure the flue components. Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the maximum flue length is 10 metres, for each additional 90 elbow 1 metre must be subtracted from the total flue length, and for each 45 0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45 bend can be seen in Fig.6 and a 90 bend in Fig. 7). Note: DO NOT cut the vertical flue kit.

Fig. 5

Fig. 6

Fig. 7

Fitting the Coaxial Flue ( 60 / 100 Vertical) Note: See table for maximum and minimum flue runs. Contents: 1x Silicone O-Ring (60mm) 1x Conical Adaptor (60/100mm) 1x Vertical Flue Kit (80/125mm) 3x Screws The vertical flue kit is supplied with a specially designed weather proof terminal fitted, it can be used either with a flat roof or a pitched roof. The Vertical flue kits useable lengths with the pitched roof flashings are indicated in Fig. 7. Before proceeding to fit the flue, ensure that the maximum flue length has not been exceeded (See the tables) and that all elbows and bends have been taken into consideration, the maximum flue length is see table, for each additional 90 elbow 1 metre must be subtracted from the total flue length, and for each 45 0.5 metres must be subtracted from the total flue length (the height of the vertical adaptor and a 45 bend can be seen in Fig. 8). Mark the position of the flue hole in the ceiling and/or roof (see Fig. 7 for distance from wall to the centre of the flue). Cut a 130mm diameter hole through the ceiling and/or roof and fit the flashing plate to the roof. DO NOT cut the vertical flue kit. To connect the vertical flue kit directly to the boiler, place the vertical starter kit (Part No. 3318079) (see Fig. 7) onto the exhaust manifold and secure with the clamp, fit the vertical adaptor onto the vertical starter kit (note: there is no need to use a clamp to secure this as it is a push fit connection), the vertical flue kit must then be inserted through the roof flashing, this will ensure that the correct clearance above the roof is provided as the terminal is a fixed height. Should extensions be required, they are available in 1 metre (Part No. 3318077), 500mm (Part No. 3318078) and 160mm lengths, they must be connected directly to the vertical starter kit before connecting the adaptor to allow the vertical flue kit to be fitted. In the event that extension pieces need to be shortened, they must only be cut at the male end and it must be ensured that the inner and outer flue remain flush. When utilising the vertical flue system, action must be taken to ensure that the flue is supported adequately to prevent the weight being transferred to the appliance flue connection by using 1 flue bracket per extension. When the flue passes through a ceiling or wooden floor, there must be an air gap of 25mm between any part of the flue system and any combustible material. The use of a ceiling plate will facilitate this. Also when the flue passes from one room to another a fire stop must be fitted to prevent the passage of smoke or fire, irrespective of the structural material through which the flue passes.

H05V2V2-F

Important! The appliance is supplied with a fly-lead already connected, this must be connected to a 240V supply fused at 3 Amp and must facilitate completed electrical isolation of the appliance, by use od a fused double pole isolator having a contact separation of at least 3mm in all poles or alternatively by means of a 3A fused three pin plug and unswitched shuttered socket outlet both complying with BS1363. The use of multiplugs, extension leads or adaptors is strictly prohibited. It is strictly forbidden to use the piping from the hydraulic, heating and gas systems for the appliance earthing connection. The boiler is not protected against the effects caused by lightning. If the mains fuses need to be replaced, use 2A rapid fuses.
Caution! For the connection and positioning of the wires belonging to optional peripheral units, please refer to the installation manuals of these units.
Room Thermostat / Remote Clock Connection To connect a room thermostat, it is necessary to: 1. Open the control panel 2. Loosen the cable clamp using a screwdriver and insert the wires leading from the room thermostat 3. Connect the wires to the terminals as indicated in the figure below, removing the link 4. If a remote time clock is to be fitted, using a volt free switching time clock connect the switching wires from the time clock following points 1 - 3 above 5. If using an external time clock and room thermostat, these must be connected in series as shown in diagram C, 6. Ensure that they are well connected and not subject to stress when the control panel is closed

TP/ TA1 TA2

CARTE CHAUDIERE AMPC-GAL1
Transmetteur BUS (Optionnel)
Connector TA on PCB (low voltage switching)
The boiler can be connected to a central heating system that uses two zone valves to allow connection to an indirect storage cylinder. There are two wiring diagrams shown, one for the connection to an Unvented Cylinder and one for connection to an open vented cylinder. In both cases the boiler connection is shown as TA1. When connecting the boiler to an external cylinder do not run 240V cables and the cables for the room terminal together, use separate cables to prevent induced voltage on the low voltage switching circuit. The use of a Y Plan system is not possible with the CLAS Note: HE SYSTEM boiler due to the low voltage switching of the appliance unless suitable relay controls are used. Important!! Ensure that a balancing valve is fitted on the cylinder return and balanced correctly at commissioning stage.

The function is automatically deactivated after 10 minutes or by pressing the Reset button. Note: the appliance can be forced to minimum or maximum power from menu 7 (see the section on the display - setting diagnostics menu). WARNING! By activating the pigging function, the temperature of the water sent to the installation is limited to 88C; caution is therefore required with regard to low-temperature installations. Maximum gas flow combustion analysis Activate the test function at the maximum heating power t--
Only a 4 mm allen key must be used. Do not use a screwdriver
Set the content by turning the screw about a 1/4 of a turn then wait after each change for approximately 1 minute for the CO2 value to stabilise, then repeat. Once the settings and analyses are complete, exit test mode, and reposition the blanking cover and its seal correctly.
AUTO function This is a function which enables the boiler to automatically adapt its operation routine (the temperature of the heating elements) in line with the outdoor conditions, in order to achieve and maintain the requested room temperature conditions. Depending on the peripheral units connected and the number of zones controlled, the boiler adjusts its flow temperature automatically. The various corresponding parameters should therefore be set (see adjustments menu). To activate the function, press the Auto button. Example 1: Single zone system (high-temperature) with on/off room Thermostat: In this case the following parameters must be set: - Activation of temperature adjustment using sensors - Select 1 = Basic temperature adjustment - Boost Time (optional) The wait time for the flow temperature increase in steps of 4C may be set. The value varies according to the type of system and installation. If the Boost Time value = 00 the function is not activated. Example 2: Single zone system (high-temperature) with on/off room Thermostat + outdoor sensor: In this case the following parameters must be set: - Activation of temperature adjustment using sensors - Select 3 = outdoor sensor only - Temperature adjustment curve selection - Select the relevant curve according to the type of system, installation, heat insulation used in the building, etc. - Perform a parallel curve shift if necessary, increasing or decreasing the set-point temperature (this may also be modified by the user, using the heating temperature adjustment knob, which, with the Auto function activated, is used to shift the curve in a parallel manner). Example 3: Single zone system (high-temperature) with REMOCON remote Control +

maintenance

Important Maintenance is an essential part of the safe and efficient operation of the boiler and ensures its durability. It should be performed according to the instructions given in current legislation. Perform combustion analysis regularly in order to check the operating efficiency of the boiler and to make sure any polluting substances released are within the boundaries set by current legislation. Before beginning maintenance work: - Disconnect the appliance from the electricity supply by turning the external bipolar switch to the OFF position; - Close the gas valve and the central heating and domestic hot water system valve. After the work has been completed the initial settings will be restored. General comments It is recommended that the following inspections be carried out on the boiler at least once a year: 1. Check the seals in the water part and, if necessary, replace the gaskets and restore the seal to perfect working order. 2. Check the seals in the gas part and, if necessary, replace the gaskets and restore the seal to perfect working order. 3. Visually check the overall condition of the boiler. 4. Visually check the combustion and, if necessary, disassemble and clean the burner. 5. Cleaning the primary heat exchanger 6. Make sure the following heating safety devices are operating correctly: - temperature limit safety device. 7. Make sure that the following gas part safety devices are operating correctly: - absence of gas or flame safety device (ionisation). 8. Perform a general inspection of the boiler operation. 9. Remove oxide from the detection electrode using an emery cloth. 10. These checks are not exhaustive. Further mechanical, electrical and combustion maintenance checks may be required. Operational test After having carried out the maintenance operations, fill the heating circuit at a pressure of approximately 1.5 bar and release the air from the system. - Begin operating the boiler. - If necessary, release the air from the heating system again. - Check the settings and make sure all the command, adjustment and monitoring parts are working correctly. - Check the flue system is sealed and operating correctly. Draining procedures The heating system must be drained using the following procedure: - Switch off the boiler, make sure the external bipolar switch is in the OFF position and shut off the gas valve; - Loosen the automatic air relief valve; - Open the system drain off cock and collect the escaping water in a container; - Empty the water from the lowest points of the system (where applicable). If the system is to be left inactive in areas where the room temperature may fall below 0C during winter, we recommend that anti-freeze liquid is added to the water in the heating system in order to avoid the need for repeated draining; when this liquid is used make sure it is compatible with the stainless steel used for the bodywork of the boiler. We recommend the use of anti-freeze products which contain PROPYLENE GLYCOLS as these inhibit corrosion and that they are used in conjunction with the anti-scaling and anti-corrosion function, in the quantities suggested by the manufacturer, at the mimimum temperature. Regularly check the pH level of the water/anti-freeze mix in the boiler circuit and replace it when the value measured is lower than the limit prescribed by the manufacturer. DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE. The manufacturer will not be held liable for any damage caused by the appliance or the system due to the use of inappropriate anti-freeze substances or additives. WARNING Before handling, empty all components which may contain hot water, bleed where necessary. Descale the components in accordance with the instructions provided on the safety data leaflet supplied with the product used, make sure the room is well ventilated, wear protective clothing, avoid mixing different products, and protect the appliance and surrounding objects. Seal all openings used to take a gas pressure reading or to make any gas adjustments. Make sure that the nozzle is compatible with the supplied gas. If a smell of burning is detected or smoke is seen leaking from the appliance, or there is a smell of gas, disconnect it from the electricity supply, shut off the gas valve, open the windows and call for technical assistance. Cleaning the primary exchanger Cleaning the smoke side The inside of the primary exchanger is accessed by removing the burner. Wash with water and detergent using a non-metallic rifletype brush, rinse with water. Cleaning the trap The trap is accessed by emptying the condensate bowl located in the bottom section. Wash with water and detergent. Replace the condensate collection bowl in its housing. NB: In the event of prolonged use of the appliance, the trap must be filled before being used again. A lack of water in the siphon is dangerous and may cause smoke to be released into the atmosphere.

MAINTENANCE GUIDE

1. GENERAL ACCESS
MAINTENANCE GUIDE: CLAS HE SYSTEM 1.3 GENERAL ACCESS

GENERAL ACCESS

Tools Time 3 min
Unclip the cover to remove

Remove the two screws

Remove the front panel

Lower the electrical box

Remove the combustion chamber front panel by releasing the clips

2. ELECTRICAL UNIT

MAINTENANCE GUIDE: CLAS HE SYSTEM

2 ELECTRICAL UNIT

2.1 CONTROL BOX ACCESS

CONTROL BOX ACCESS

Tools Time 4 min
Remove the front panel as above and pivot the electrical box 2.2 FUSE
Remove the two screws and unlock the four clamps to gain access to the control box

Tools Time 5 min

Open the control box as above

Remove the fuse

Page. 7 of 21

MAIN PCB

Tools Time 7 min
After opening the control box, disconnect the electrical plug connectors
Unscrew the two screws and remove the PCB

DISPLAY PCB

Lower the door and remove the two control knobs
Unscrew the four screws and pull the assembly towards you
Disconnect the electrical plug connectors, unlock the four clamps, and remove the PCB

Page. 8 of 21

3. HYDRAULIC UNIT

3 HYDRAULIC UNIT

RIGHT HAND HYDRAULIC BLOCK ASSEMBLY

LEGEND

1. 2. 3. 4. 5. 6. Auto air vent Primary water pressure switch Pump Central heating filter Central heating return Central heating drain valve

DRAINING

1 Turn the drain valve anti-clockwise to open and drain the water from the boiler. 3.3 AUTOMATIC AIR VENT

AUTOMATIC AIR VENT

Drain boiler (see 3.2). Remove the clip and lift the AAV from the assembly

Page. 9 of 21

PRIMARY WATER PRESSURE SENSOR
Drain boiler (see 3.2). Remove the fixing clip, unplug the electrical connector and lift the sensor from the assembly 3.5 PUMP

Tools Time 10 min

Drain boiler (see 3.2). Remove the clip and the two screws
Disconnect the pipe and then move the pump to the right disengage

Remove the pump

Remove the sensor (see 3.4)

Page. 10 of 21

Remove the AAV (see 3.3)
MAINTENANCE GUIDE: CLAS HE SYSTEM 3.6 CH FILTER

CH FILTER

Drain boiler (see 3.2). Remove the clip 3.7

Remove the filter

LEFT HAND HYDRAULIC BLOCK ASSEMBLY
1. Left hand hydraulic block 2. Safety valve & By-pass assembly 3. Central heating flow

SAFETY VALVE

Drain boiler (see 3.2). Disconnect the discharge pipe

Remove the first clip on the left and pull the safety valve towards you

Page. 11 of 21

MAINTENANCE GUIDE GUIDE: CLAS HE SYSTEM MAINTENANCE

3.9 BY-PASS ASSEMBLY

BY-PASS ASSEMBLY
Drain boiler (see 3.2). Remove the second clip and pull the assembly toward you
Push on the by-pass to disengage it

3.10 CONDENSE TRAP

CONDENSE TRAP
Unscrew the condense trap from the condense body

Page. 12 of 21

MAINTENANCE GUIDE: CLAS HE SYSTEM 3.11 TEMPERATURE SENSORS & OVERHEAT THERMOSTAT

3.11 TEMPERATURE SENSORS

TEMPERATURE SENSORS & OVERHEAT THERMOSTAT
IMPORTANT ! Do not use conducting paste for the contact sensors because it will alter the resistance value.

OT NTC1 NTC2

: White wires NTC1 : Black wires : Black wires NTC2 : Grey wires : Grey wires
Unplug the electrical connectors
Remove the clip and and the Remove the clip the temperature sensor temperature sensor or overheat thermostat together
TEMPERATURE RESISTANCE (kOmh) TEMPERATURE (C) RESISTANCE (kOmh) 50 4
IMPORTANT!!!! Do not use conducting paste for the contact sensors because it will alter the resistance value.

3.12 MANUAL AIR VENT

MANUAL AIR VENT
Drain boiler (see3.2). Remove the clip and lift the manual air vent from the exchanger

Page. 13 of 21

MAINTENANCE GUIDE: CLAS HE SYSTEM 3.13 MAIN HEAT EXCHANGER

MAIN HEAT EXCHANGER

Tools Time 20 min
Drain boiler (see 3.2). Remove the four clips and disconnect the Isolate the gas supply. Remove two pipes between the the four screws and disconnect exchanger and pump and the gas pipe from the gas valve between the exchanger and left hand hydraulic block
Remove the four screws to free the heat exchanger
Pull the heat exchanger towards you
Remove the clip and lift the manual air vent
Twist the thermal fuse to remove

52 Page. 14 of

4 BURNER UNIT
1. 2. 3. 4. 5. Burner Fan Silencer Gas inlet Air inlet 6. 7. 8. 9. 10. Gas valve Mixing tube Detection electrode Ignition electrode Spark generator

Page. 15 of 21

SPARK GENERATOR
Unplug the ignition electrode from the spark generator 4.2 ELECTRODES
Remove the screw and the spark generator

ELECTRODES

Unplug the electrodes
Remove the screws and pull the electrodes towards you.

Page. 16 of 21

MAINTENANCE GUIDE: CLAS HE SYSTEM 4.3 BURNER

Customer Name Address Boiler Make and Model Boiler Serial Number Commissioned by (print name) Company Name Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certicate*: Building Regulations Notication Number (if applicable) CORGI ID Number Telephone Number Telephone Number
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating Time and Temperature Control to Hot Water Heating Zone Valves Hot Water Zone Valves Thermostatic Radiator Valves Automatic Bypass to System Boiler Interlock Room Thermostat and Programmer/Timer Programmable Room Thermostat Load/Weather Compensation Optimum Start Control Combination Boiler Not Required Not Required Not Required Not Required Provided
Cylinder Thermostat and Programmer/Timer Fitted Fitted Fitted Fitted

ALL SYSTEMS

The system has been ushed and cleaned in accordance with BS7593 and boiler manufacturers instructions What system cleaner was used? What inhibitor was used? Quantity litres Yes
CENTRAL HEATING MODE Measure and Record:
Gas Rate Burner Operating Pressure (if applicable) Central Heating Flow Temperature Central Heating Return Temperature m3/hr mbar OR OR Gas Inlet Pressure ft3/hr mbar C C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? If yes, has a water scale reducer been tted? What type of scale reducer has been tted? DOMESTIC HOT WATER MODE Measure and Record: Gas Rate Burner Operating Pressure (at maximum rate) Cold Water Inlet Temperature Hot water has been checked at all outlets Water Flow Rate Yes Temperature m3/hr mbar OR OR Gas Inlet Pressure (at maximum rate) ft3/hr mbar C C l/min Yes Yes No No

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturers instructions and/or BS5546/BS6798 Yes

ALL INSTALLATIONS

If required by the manufacturer, record the following CO2 % OR CO ppm OR CO/CO2 Ratio Yes Yes Yes Yes The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturers instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturers literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Commissioning Engineers Signature Customers Signature
(To conrm satisfactory demonstration and receipt of manufacturers literature)

*All installations in England and Wales must be notied to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certicate will then be issued to the customer.
Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

SHORT LIST

136 135

111 616

CL SY AS ST HE EM

0616 0625

BURNER ASSEMBLY IGNITION ELECTRODE IGNITION ELECTRODE IONIZATION ELECTRODE IONIZATION ELECTRODE GASKET D:85-66.5-2.5 ELECTRODE GASKET

Description

Manf. Pt.N

Manf. date

from to
COMBUSTION CHAMBER LINING KIT DOOR GASKET GAS SECTION GAS VALVE FAN ASSY HYDRAULIC BLOCK OVERHEAT THERMOSTAT 100C TEMPERATURE PROBE + CLIP LOW PRESSURE SWITCH AUTO AIR VENT WITH O-RING PRESSURE RELIEF VALVE PUMP 6M 2V ELECTRICAL BOX IGNITER PRINTED CIRCUIT BOARD PRINTED CIRCUIT BOARD (DISPLAY) PRESSURE GAUGE

60000297 60000623

60000537 60000622

Ind 03 - 05/06/2007

61312668 60000591
61002105-65104448 65104234

420010097204 - 06/2008

Commercial subsidiaries: MTS (GB) Limited MTS Building Hughenden Avenue High Wycombe Bucks HP13 5FT Telephone: (01494) 755600 Fax: (01494) 459775 Internet: www.mtsgroup.com/uk E-mail: info@uk.mtsgroup.com Technical Advice: 8180 Customer Service: 9888
Professional Team Limited Suites 9 & 10 Plaza 256 Blanchardstown Corporate Park 2 Ballycoolin Dublin 15 Telephone: (01) Fax: (01) Internet: www.mtsgroup.com/ie E-mail: info@ie.mtsgroup.com Technical Advice: (01) Customer Service: (01) 437 0121