Trianco Aztec Gold Manual de usuario

TRIANCO

KM 59690

Electric System Boiler

To be retained by the householder

FITTING, OPERATION,

INSTALLATION & SERVICING

INSTRUCTIONS

Notes:

(a) Electrical safety checks should be carried out by a competent person.

(b) It is a requirement of the guarantee and any extended warranty that an annual service is carried out by a competent

person.

Installation Engineer’s Signature ................................................................................................................................

Company Name (if applicable) ................................................................................................................................

Company Address: ................................................................................................................................

................................................................................................................................

Company Tel. No: ................................................................................................................................

HEALTH AND SAFETY

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEERS

Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a

requirement to provide information on substances hazardous to health (COSHH Regulations

1988).

The Company takes every reasonable care to ensure that these products are designed and

constructed to meet these general safety requirements, when properly used and installed.

To fulfil this requirement products are comprehensively tested and examined before despatch.

This appliance may contain some of the items below.

When working on the appliance it is the responsibility of the user/engineer to ensure that any

necessary personal protective clothing or equipment is worn appropriate to parts that could be

considered as being hazardous to health and safety.

INSULATION AND SEALS

Mineral fibre insulation is used on this appliance.

May be harmful if inhaled. May be irritating to the skin, eyes, nose or throat. When handling avoid

inhalation and contact with eyes. Use (disposable) gloves, face masks and eye protection.

After handling wash hands and other exposed parts. When disposing, reduce dust with water

spray, ensure parts are securely wrapped.

GLUES, SEALANTS & PAINT

Glues and sealants are used in the product and present no known hazards when used in the

manner for which they are intended.

PACKAGING

Materials used for the packaging of this appliance are of a recyclable nature.

Warning: plastic bags can cause suffocation. Keep out of reach of children.

Please read these instructions fully before installing this appliance.

If in doubt, seek expert advice.

These instructions should be kept in a place close to the appliance for easy reference.

CONTENTS

BASIC FITTING INSTRUCTIONS 4

Preparation and Siting 4/5

Ventilation 4

Clearances and Access 4

Water System 6

Electrical Supply 6

Wiring Diagrams 6/7

Filling the System 8/9

Underfloor Heating Systems 10

OPERATING INSTRUCTIONS 11

Introduction 11

Boiler Controls 11

Indicator Lights 11

Safety Controls 11

External Controls 11

Cleaning & Maintenance 11

Simple Fault-Finding 12

TECHNICAL SPECIFICATION 12

INSTALLATION NOTES 13

Regulations & Safety 13

Declaration of Conformity 13

Boiler Schematic 14

Boiler Components 15

SERVICE 16

After-Sales Service Information 16

Engineer's Fault-Finding 17

Servicing 18

Parts Replacement 18/19/20

Spares List 21

PREPARATION & SITING

1) Before starting the installation, carefully unpack the

boiler from the carton, ensuring all items are present

and in good condition. The carton should include:

1 x fully-cased boiler

2 x cable strain reliefs

1 x hose connector with manifold fitting

1 x high-limit thermostat for underfloor heating

Notes: Always store the boiler in a dry place prior to

fitting.

Retain all packaging until installation is complete.

Plastic bags can cause suffocation; please keep

out of reach of children.

2) Work out the desired position of the boiler and, using

the dimensions on Fig. 2 for reference, drill 4 x 6mm

holes in the wall to a depth of 38mm. Insert wall plugs

and fixing screws (not supplied) into the wall.

Notes:

a) If the appliance is to be fitted in a confined space or

compartment with a potential ambient temperature of

60°C or above, it is strongly recommended that

adequate ventilation is provided to prevent the

overheating of the boiler controls. Aeration of 110cm2

will be required to the compartment, in both high and

low level positions.

b) Ensure that the area surrounding the boiler is kept free

of items which would impede the good ventilation of

the appliance (e.g. towels, linen).

c) When siting the boiler, take into account the need for

future servicing. Enough space should be provided at

the front of the appliance to enable an engineer to

adequately service and/or replace components.

d) The boiler is not to be fitted in a shower compartment

or bathroom, and is not suitable for external installation,

nor in any area subject to adverse temperature

conditions or moisture.

e) The appliance is designed to be fitted in an upright

position only, with the flow and return connections to

the bottom of the boiler.

f) Ensure adequate clearance is allowed for making the

water connections, as the boiler can be fully serviced

from the front.

FITTING INSTRUCTIONS

The Aztec Gold is a wall-mounted electric central heating boiler designed with smaller locations in mind. The boiler can be fitted

in the smallest of places and requires minimal attention to ensure efficient and reliable operation. The boiler produces hot water

for a fully-sealed system by passing water over electric heating elements which are housed in an insulated stainless steel heat

exchanger.

FIG. 1 - PACK CONTENTS

FIG. 2 - DIMENSIONS & CLEARANCES

FITTING INSTRUCTIONS (cont.)

3) Removing the front panel beforehand, hang the

boiler onto the screws in the wall, ensuring that all

4 keyhole fixing slots are utilised. Tighten screws

to ensure a secure fixing.

4) Fit the 2 x cable strain reliefs into the base of the

boiler.

5) Install the heating system (radiator/towel rails, etc)

in the desired positions as per the manufacturer's

instructions. A drain cock must be fitted at the

lowest part of the system for ease of drainage.

See Fig. 4 for a typical system layout.

IMPORTANT

While the Aztec Gold is entirely suitable for use on

heating systems which utilise plastic pipework, the

first 100mm from the boiler manifold must always

be 15mm copper.

FIG. 3 - STRAIN RELIEF FIXING

FITTING INSTRUCTIONS (cont.)

WATER SYSTEM

Connect the flow and return pipework from the

radiator(s) into the corresponding fittings on the boiler

manifold. Ensure all fittings are made water-tight.

Notes:

a) The pressure relief valve must be piped to a

permanent drain-off on the outside of the

building. The drain must not discharge above

an entrance, window, or any public access

area. It should be clear of any electrical

fittings, and positioned so that any discharge

can be clearly seen. The terminating point of

the drain-off should be bent down at an angle

of 90°.

b) It is recommended that isolation valves are

fitted to the pipework. A bypass, as shown in

Fig. 4, must be fitted if TRVs are used on the

radiators.

c) The flow and return connections are made to

the boiler by 2 x 15mm compression fittings.

ELECTRICITY SUPPLY

First isolating the electricity, pass the electrical supply

cables and any external control cables through the

cable strain reliefs in the base of the boiler, and wire

securely into the terminal block. The terminal block is

located within the casings at the top left-hand side of

the boiler.

Notes:

a) This appliance must be earthed.

b) It is recommended the boiler is fitted with an

external control, such as a room thermostat

or programmer.

c) If the water in the system is to be subject to

freezing conditions during the pipework run,

the appliance should be fitted with a frost

thermostat. This will activate the boiler should

the temperature fall to a level which could

damage the installation.

d) Incoming mains and controls cables should

not be routed close to heating pipes.

e) The diagrams opposite are for reference only.

Refer to manufacturer's instructions for

specific fitting instructions for the room

thermostat or programmer.

f) It is recommended that the boiler is wired via

a 13 amp RCD plug or switched fused spur.

g) Remove the link wire between terminals 3 &

5 when fitting any external controls.

FIG. 5 - BOILER CONNECTION MANIFOLD, SHOWING

PRESSURE RELIEF VALVE, WATER CONNECTIONS AND

PRESSURE GAUGE

FIG. 6 - WIRING FOR EXTERNAL PROGRAMMER & ROOM

THERMOSTAT

Important Note:

Before installation, please ensure that the supply

voltage to the appliance is above 207v. If the voltage

drops below this level, a temporary boiler malfunction

may result.

FITTING INSTRUCTIONS (cont.)

ELECTRICAL SUPPLY (cont.)

FIG. 9 - INTERNAL WIRING DIAGRAMFIG. 9 - INTERNAL WIRING DIAGRAM

FIG. 7 - WIRING FOR PROGRAMMABLE ROOM

THERMOSTAT

FIG. 8 - WIRING FOR EXTERNAL PROGRAMMER, ROOM

THERMOSTAT & FROST THERMOSTAT

FITTING INSTRUCTIONS (cont.)

FILLING THE SYSTEM

A filling point connection is provided on the front face of

the boiler manifold to facilitate the initial filling and

pressurising of the system via a hose connection

(supplied). Alternatively, a permanent filling-loop may be

employed.

Notes:

a) Before filling, ensure that all fittings and joints

have been made.

b) Thoroughly flush out the system to remove any

swarf and residue from the pipework and

radiator(s).

c) There must be no permanent connection between

the boiler and the mains water supply.

Filling Method 1: Temporary Hose (Figs. 10/11)

1) Connect a hose to the fill point on the manifold

using the fittings supplied.

2) Connect the other end of the hose to the mains

water supply, ensuring that all safety valves are

fitted in the run (Fig. 11) to prevent system

water entering the mains supply. Approved hose

unions should be used on all connections.

3) Open the fill point on the manifold (Fig. 10) by

turning the isolating knob anti-clockwise.

4) Ensure all isolation valves to the system are open,

that the bypass valve is closed, and that the

automatic air vent contained within the boiler

casings is open (turn the black cap on the device

fully anti-clockwise).

5) Switch on the mains supply to the boiler and test

the pressure relief valve by continuing to fill until

this device activates and releases water into the

drain.

6) Switch off the mains water supply.

7) Using the pressure gauge on the front face of the

manifold for reference, reduce the water content of

the system until the pressure is indicated as 1.5

bar.

8) Thoroughly vent all parts of the system of air and,

if necessary, readjust pressure back to 1.5 bar.

9) Close off the fill connection on the manifold, remove

the hose and close the automatic air vent.

10) Check all joints are water-tight before operating

the appliance.

FIG. 10 - FILL POINT

FIG. 11 - FILLING METHOD 1

FITTING INSTRUCTIONS (cont.)

Filling Method 2: Filling Loop (Fig. 12)

1) During installation, feed a permanent 15mm

supply to any part of the system via the use of a

WRC-approved filling loop. A fixed-spindle stop

valve should also be fitted to the mains water

supply to the system.

2) Open the supply valves to fill the system, following

all further instructions as per those for filling with a

hose from (4) onwards (page 8).

3) Once complete, close all supply valves.

Notes:

a) The filling method adopted must be in accordance

with the Water Supply Regulations and the Water

Bylaws.

b) Approved hose unions should be used on all

connections of this type.

COMPLETION

1) Replace the front casing of the boiler.

2) Switch on the electricity supply to the boiler and

external controls.

The appliance is now ready for use (Fig. 13).

See overleaf for additional fitting instructions when

using the boiler in conjunction with underfloor heating

systems.

FIG. 12 - FILLING METHOD 2

FIG. 13 - COMPLETED INSTALLATION

FIG. 14 - CONTROL KNOB

When installed on an underfloor heating system without

the use of a mixing valve, the following instructions must

be adhered to.

IMPORTANT NOTE: Ensure the mains supply to the

boiler is disconnected before carrying out any work.

1) Replace the safety high-limit thermostat with the

alternative stat provided within the literature pack

(Fig. 15). See page 19 for more detailed

instructions on how to replace high-limit thermostat.

2) Using the white control knob on the front of the

PCB controller, the temperature must be set to its

lowest setting (30°C) before initial firing.

Important: The temperature should only be

subsequently increased in accordance with

underfloor heating manufacturer's instructions and

BS EN 1264-4.

3) After the temperature has been adjusted to the

preferred level, it may be useful to remove the

control knob from the PCB controller to prevent

further modification. Carefully pull the knob from

the PCB, ensuring its mooring is held securely in

position (Fig. 14).

Notes:

a) The factory-fitted safety high-limit thermostat is set

at 100°C, and is suitable for use with radiator

heating systems. The additional high-limit

thermostat, for exclusive use with underfloor

heating systems, is set at 60°C and must be

fitted. Failure to do so will result in damage to

the floor surfaces.

b) If the high-limit thermostat operates often, the

temperature may be set too high. It is essential

that the temperature is not set to above 50°C

(refer to Fig. 14 for temperature settings).

c) The pump fitted to this appliance is suitable for a

Ø15mm plastic pipework run of up to 100m in

length. Pipework runs greater than this will require

the fitting of an additional pump.

d) Fit the underfloor heating system in accordance

with manufacturer's instructions. Trianco cannot

accept any responsibility for breakdowns or

damage caused by incorrectly-fitted systems.

CONTROL KNOB SETTINGS

FIG. 15 HIGH LIMIT THERMOSTAT REPLACEMENT

1 - ISOLATE ELECTRICAL SUPPLY

2 - REMOVE THE BOILER FRONT CASING

3 - REMOVE CABLES FROM HIGH LIMIT STAT

4 - LOOSEN 2 X RETAINING CLIPS

5 - REMOVE THERMOSTAT & REPLACE IN REVERSE

ORDER

ADDITIONAL FITTING INSTRUCTIONS - UNDERFLOOR HEATING SYSTEMS

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