After Sales Service Guide

After Sales Service Guide ZENA MS wall-hung gas boilers 300029718-001-A 28/09/2012

Use of this guide is reserved for qualified professionals Any intervention on the appliance and heating equipment must be carried out by a qualified engineer. Abide by prevailing local regulations. For Belgium: Any work on the gas block must be carried out by a factory technician. Caution danger Symbols used Risk of injury and damage to equipment. Attention must be paid to the warnings on safety of persons and equipment Specific information Information must be kept in mind to maintain comfort Reference Reference to other paragraphs in the guide 2

1. PRESENTATION - SPECIFICATIONS Contents: page 6 2. OPERATING PRINCIPLE Contents: page 16 3. PRODUCT EVOLUTION Contents: page 32 4. TROUBLESHOOTING DIAGRAMS Contents: page 38 5. INSTALLATION - COMMISSIONING Contents: page 54 6. CONTROLS AND SETTINGS Contents: page 76 7. ELECTRICAL DIAGRAMS Contents: page 112 1 2 3 4 5 6 7 3

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PRESENTATION SPECIFICATIONS 1 5

CONTENTS 1. Presentation................................................................ 7 1.1 The various models..................................................................... 7 1.2 Performance (in accordance with RT 2005 for France).......................................... 9 1.3 Strong points.......................................................................... 9 1.4 Control panel options................................................................... 10 1.5 Boiler options......................................................................... 11 2. Specifications.............................................................. 12 2.1 Technical specifications................................................................. 12 2.2 Characteristics of domestic hot water production............................................. 12 2.3 Location of the data plate............................................................... 13 2.4 Characteristics of the heating pumps...................................................... 13 1 6

1. Presentation 1.1 The various models Boiler Type of connection Model Useful output range (kw) Chimney MS 24 9.3-24 Heating only Flue gas outlet* MS 24 FF 9.3-24 Chimney CMV (1) MS 24 MI 9.3-24 MS 24 MI VMC (1) 9.3-24 Heating and micro-storage domestic hot water production Flue gas outlet* MS 24 MI FF 9.3-24 1 Chimney MS 24 BIC 10.4-23.3 Heating + DHW Boiler with integrated DHW tank (40 litres) Flue gas outlet* MS 24 BIC FF 10.4-24 * Horizontal forced flue: Diameter 60/100 mm or Vertical forced flue: Diameter 80/125 mm + adapter (1) for France only 7

Boiler Type of connection Model Useful output range (kw) Chimney MS 24 / BS80 (MS 24 + BMR 80) 9.3-24 Heating + DHW BS80 calorifier The DHW calorifier can be placed to the left or right of the boiler. Flue gas outlet* MS 24 FF/ BS80 (MS 24 FF+ BMR 80) 9.3-24 Chimney MS 24 / BS 130 (MS 24 + SR 130) 9.3-24 Heating + DHW BS130 calorifier DHW tank placed under the boiler. Flue gas outlet* MS 24 FF / BS 130 (MS 24 FF+ SR 130) 9.3-24 1 * Horizontal forced flue: Diameter 60/100 mm or Vertical forced flue: Diameter 80/125 mm + adapter 8

1.2 Performance (in accordance with RT 2005 for France) Generator type: Energy used: Natural gas (All models) or Propane (except MS 24 MI VMC) - MS 24 (FF): Heating only Combustion evacuation: Chimney, Flue gas outlet or - MS 24 MI (FF, VMC): Heating and domestic hot water. Boiler with CMV. < 10 litres of additional storage integrated in the secondary circuit. Min. return temperature: 20 C - MS 24 BIC (FF) : Heating and domestic hot water (Boiler with Min flow temperature: 30 C integrated DHW tank > 10 litres) EC certificate reference: Boiler type: Low temperature atmospheric gas boiler MS... : 51BT3644/45DR/ED03 Burner: Atmospheric with no fan (Chimney versions); Atmospheric with fan (FF MS... FF : 51BT3642/43DR/ED03 Versions). MS... VMC : 51CL4020/21DR/ED03. 1.3 Strong points Compact, user-friendly boiler thanks to its accessibility and the easy dismantling of all its components: all components can be accessed from the front. Combustion chamber: - Primary exchanger (heating body) in copper pipes with fins, coated with aluminium silicone paint, enhancing its resistance to heat. - Atmospheric gas burner with stainless steel burner trains. Electronic ignition and flame control by ionization, Modulating gas valve with dual safety solenoid valve, Control panel: - Electronic control panel with easy to use, direct access digital display, - Display of the error code on the digital display console to facilitate troubleshooting, - The control panel is used as standard to manage a direct circuit and a DHW circuit, - Optional regulation of the heating circuit by adding a programmable or non-programmable room temperature thermostat (wire- or radio-controlled) and/or an outside temperature sensor, - Anti-blocking function for the pump and the reversal valve. Compact water unit (Hydroblock): - In brass for the MS 24, MS 24 FF versions - In composite material for the MS 24 MI, MS 24 MI FF, MS 24 VMC, MS 24 BIC and MS 24 BIC FF versions - 2-speed heating pump with automatic air vent - Automatic bypass - Motorised heating / DHW reversal valve fitted to the return - Low water pressure switch - Boiler and disconnector drain valve - Heating circuit safety valve (3 bar) - Safety valve on the DHW circuit (7 bar - For MS 24 BIC and MS 24 BIC FF boilers) - Pressure gauge - The filters on the heating and DHW circuits are housed in detachable cartridges - Stainless steel plate exchanger for DHW production (MI and BIC versions) - Turbine flow switch for measuring the DHW flow rate (MI and BIC versions) 6-litre expansion vessel (Heating circuit) - all versions excepted BIC BIC Versions: 7,5-litre expansion vessel (Heating circuit) Extraction fan and air pressure switch (FF Versions) Downdraught thermostat (Chimney versions, Version VMC*) Full antifreeze protection (heating and DHW circuits) High energy efficiency: - *** efficiency class for the FF versions - ** efficiency class for the chimney and VMC versions - N0x 3 class in accordance with pr EN297 A3 for the chimney versions, in accordance with EN483 for the FF versions. The IPX5D protection rating allows the boiler to be installed in a kitchen or bathroom. 1 * Version VMC: for France only. 9

1.4 Control panel options AD137 / AD200 / AD247 / AD248 AD269 8801Q029 Programmable, wire-controlled room thermostat - Package AD137 / AD247 Wireless settable ambient thermostat - Package AD200 / AD248 Programmable, wire-controlled room thermostat 230 V - Package AD269 Non settable ambient thermostat - Package AD140. AD140 8801Q003det MCX_Q0009 Domestic hot water sensor - Package AD250 The DHW sensor is used for the priority control of the temperature and the programming of domestic hot water production by an accumulation tank. 1 MS_Q0005 Outside sensor - Package HX31 The outside temperature sensor can be used on its own or in combination with the room thermostats to regulate the heating according to the outside temperature. 10

1.5 Boiler options BMR80 SR 130 MCR_QG0010 MS_Q0029 MS_Q0006 8666QG043A MS_Q0030 DHW expansion vessel (For MS 24 BIC - MS 24 BIC FF)- Package HX26 Capacity : 2 litres. Used to prevent water loss caused by expansion when reheating the DHW tank. DHW calorifiers: - BMR80: Package EE53. Wall-hung DHW tank - 80 litres - Connection kit BMR80 / MS24 : Package HX33. - SR130: Package EE22. Floor-standing DHW tank - 130 litres - DHW sensor included. - Connection kit SR130 / MS24 : Package HX32. Hyrdaulic connection kit for a solar circuit with directional thermostatic valve - Package HX23 (For MI versions only) This kit contains all the pipes needed to connect the boiler to a solar DHW tank, including the directional thermostatic valve and the cold water isolating valve. It makes it possible to combine a solar system with a boiler with microstorage domestic hot water production, thus handling regulation of the solar DHW system according to the needs of the user. Filling kit with pressure gauge - Package HX27. To be connected between the heating flow valve at one end and the domestic cold water inlet on the boiler's hydraulic connection plate at the other. MS_Q0004 Propane conversion kit - for: MS 24, MS 24 FF, MS 24 MI, MS 24 MI FF - Package HX28 - for: MS 24 BIC, MS 24 BIC FF - Package HX29 For the other hydraulic connection options, refer to the current product catalogue. 1 Stove fittings accessories, specific to MS boilers DY908 G000256 DY736 G000258 Horizontal terminal Alu Diameter 60/100 mm - Package DY908 Horizontal terminal Alu Diameter 80/125 mm, Length 730 mm - Package CX119 Vertical terminal Alu Diameter 80/125 mm - Package DY735 (Black) or DY736 (Red) Condensates adapter/recuperator - From diameter 60/100 to 80/125 mm (Alu) - Package DY909 Condensate collector - Diameter 60/100 mm (Alu) - Package DY910 DY909 DY910 G000255 G000259 Bi-flow boiler connection kit - Package HX30 DY911 3 CE pipe connection kit Diameter 60/100 mm - Package DY911 G000257 11

2. Specifications 2.1 Technical specifications 1 Boilers Generator type (1) for France only - (2) For VMC versions: No operation on propane. MS 24 24/BS... 24 FF 24 FF/BS... MS 24 (FF): Heating only MS 24 (FF)/BS:Heating and DHW with separate domestic hot water tank 24 MI 24 MI VMC (1) 24 MI FF 24 BIC 24 BIC FF Heating and domestic hot water: Boiler with 10 litres of additional storage integrated in the secondary circuit Heating and integrated domestic hot water tank Nominal useful output Pn (heating and DHW modes) kw 24 24 24 24 23.3 24 LHV efficiency % 91.2 92.9 91.2 92.9 91.0 92.9 at 100% Pn - 70 C % 90.2 90.4 90.2 90.4 89.8 90.6 at 30% Pn - 40 C Nominal water flow rate at Pn, T = 20 K m 3 /h 1.03 1.03 1.03 1.03 1.00 1.03 Stand-by losses to T = 30 K W 183 59 183 59 199 99 Minimum useful output (heating and DHW modes) kw 9.3 9.3 9.3 9.3 10.4 10.4 Manometric height available for the heating circuit mbar 175 175 175 175 230 220 Water content l 3 3 3.5 3.5 5 5 Gas flow rate at Pn - Natural gas H or L m 3 /h 2.78/3.23 2.73/3.17 2.78/3.23 2.73/3.17 2.73/3.17 2.73/3.17 - Propane Kg/h 2.04 2.00 2.04 (2) 2.00 2.00 2.00 Required depressurisation at the nozzle mbar 0.5-0.5-0.5 - Mass flue gas flow rate at Pn Kg/h 0.014 0.020 0.014 0.020 0.021 0.017 Electrical specifications Power supply voltage V AC 230 230 230 230 230 230 Auxiliary electrical power (Ex circulating pump) at Pn W 5 55 5 55 5 60 Electrical power circulating pump at Pn / Pmin W 75 / 75 75 / 75 75 / 75 75 / 75 75 / 75 75 / 75 Electrical protection index IPX5D IPX5D IPX5D IPX5D IPX5D IPX5D Other characteristics Weight (empty) kg 28 32 29 33 51 61 2.2 Characteristics of domestic hot water production Conditions of validity of the table: Ambient temperature 20 C, Cold water temperature 10 C, Primary hot water temperature 85 C. Boilers (1) for France only MS 24 MI 24 MI FF 24 MI VMC(1) 24 BIC 24 BIC FF 24 / BS80 24 FF / BS80 24 / BS130 24 FF / BS130 Tank capacity (Domestic hot water) l - 40 40 80 130 Power exchanged kw 24 23.3 24 24 24 Flow in 10 min. at T =30 K l/10 mm - 180 180 210 260 Flow per hour at T =35 K l/h 590 573 590 590 590 Specific flow at T=30 K (in accordance with EN 13203-1) l/min 12.0 17.7 17.7 21.0 26.0 Auxiliary electrical power (In DHW mode) W 80 80 80 80 80 Losses through the outer casing at T = 45 K W - 69 69 62 73 Cooling constant Cr Wh/24h L K - 0.67 0.67-0.27 12

2.3 Location of the data plate MS 24 BIC (FF) MS 24 (FF) - MS 24 MI... (FF) The data plate provides important information on the boiler: serial number, model, gas category, etc... 2.4 Characteristics of the heating pumps The following graphs show the manometric height at various outputs. If flow noises can be heard in the heating circuit, reduce the speed of the pump. First of all, vent the heating system. If the circulation in the radiators is too low or the radiators do not heat up completely, increase the speed of the pump (Bleed the radiators). Pump GRUNDFOS UPSO 15-50 (2-speed pump) MS 24 MI - MS 24 MI FF - MS 24 MI VMC 1 H: Manometric height available with the pump, at T=20 K. Q: Water flow l/h MS 24 - MS 24 FF - MS 24 BIC - MS 24 BIC FF 13

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OPERATING PRINCIPLE 2 G000271 15

CONTENTS 1. Description................................................................. 17 1.1 Control panel......................................................................... 17 1.2 Main parts........................................................................... 18 2. Operating principle diagram.................................................. 22 2.1 Boiler MS 24......................................................................... 22 2.2 Boiler MS 24 MI - MS 24 MI VMC......................................................... 23 2.3 Boiler MS 24 FF....................................................................... 24 2.4 Boiler MS 24 MI FF.................................................................... 25 2.5 Boiler MS 24 BIC...................................................................... 26 2.6 Boiler MS 24 BIC FF................................................................... 27 2.7 Description of the boiler operating......................................................... 28 2 16

1. Description 1.1 Control panel Info mode Alternating display: É Description of the keys: Press button for 5 seconds: The Info mode is active. The display shows the code A..., alternating with the value of the parameter. Operating mode selection key : - Stop (Display: OFF) / Antifreeze protection active - DHW heating only: Only domestic hot water production is ensured, the heating is switched off. (Display: Boiler temperature + ) - Heating only (Display:Boiler temperature + ) - Heating and domestic hot water (Display: Boiler temperature + + ) Reinitialisation (RESET) Press the Reset button for 2 seconds Press the (+/-) keys on side to get an instant display of the following information: This function is active for 3 minutes. To interrupt the "INFO" function in advance, press the button again. The display shows ESC. Info mode: Parameter display: Info mode (see opposite) A00 Domestic hot water temperature ( C) If there is no DHW preparation, the display shows 99. / : Heating temperature setting A01 Outside temperature (if the optional outside temperature sensor is connected). / : Setting the domestic hot water temperature If the sensor is not connected, a full stop is displayed. Display: A02 Current modulation value ( 100% = 230 ma on natural gas G20/G25-100% = 310 ma on propane G31). Operating in heating mode A03 Percentage of maximum boiler output (%) in heating Operating in DHW mode mode. Flame present A04 Heating temperature setting ( C) Igniter fault ERROR Reinitialisation A05 If an outside temperature sensor is connected, display of the heating gradient (Kt:See section 6, chapter 6.2). Current boiler temperature ( C) No water / Pressure lower than 0.5 bar A06 Domestic hot water set point temperature ( C) Display,Depending on the situation: A07 Not used. - Measured temperature - Set temperature A08 Domestic hot water flow (l/min x 10) - For versions MI and BIC only - Operating modes - Failure code A09 Last error which occured. 2 17

1.2 Main parts MS 24 MS 24 FF 1 Control panel (in tilted position) 2 Low water pressure switch 3 Gas valve (with diaphragm) 4 Gas pressure measurement point 5 Ignition/ionization electrode 6 Atmospheric gas burner with stainless steel burner trains 7 Boiler temperature sensor 8 105 C safety thermostat 9 Air pressure switch (FF versions only) 10 MS 24 FF : Air/flue gas connection Ø 60/100 mm MS 24 : Flue gas nozzle Ø 125 mm 11 Venturi (FF versions only) 12 Extractor fan (FF versions only) 13 Combustion chamber 14 Primary exchanger (Water / flue gases) 15 Flame inspection window 16 Expansion vessel 6 litres 17 2-speed heating pump with automatic air vent 18 Heating / DHW inversion valve 19 Disconnector 2 20 Filling valve 21 Pressure gauge 22 Heating circuit safety valve Model shown: MS 24 FF 18

MS 24 MI FF 1 Control panel (in tilted position) 2 Low water pressure switch 3 Gas valve (with diaphragm) 4 Gas pressure measurement point 5 Ignition/ionization electrode 6 Atmospheric gas burner with stainless steel burner trains 7 Boiler temperature sensor 8 105 C safety thermostat 9 Air pressure switch 10 Air/flue gas connection Ø 60/100 mm 11 Venturi 12 Extractor fan 13 Combustion chamber 14 Primary exchanger 15 Flame inspection window 16 Expansion vessel 6 litres 17 Stainless steel plate exchanger for the production of micro-storage DHW 18 2-speed heating pump with automatic air vent 19 Heating / DHW inversion valve 20 Disconnector 21 Filling valve (Blue) 22 Pressure gauge 23 Heating circuit safety valve 24 Domestic hot water outlet temperature sensor 2 19

MS 24 MI MS 24 MI VMC 1 Control panel (in tilted position) 2 Low water pressure switch 3 Gas valve (with diaphragm) 4 Gas pressure measurement point 5 Ignition/ionization electrode 6 Atmospheric gas burner with stainless steel burner trains 7 Boiler temperature sensor 8 105 C safety thermostat 9 Draught diverter 10 Flue gas nozzle Ø 125 mm 11 Combustion chamber 12 Primary exchanger 13 Expansion vessel 6 litres 14 Stainless steel plate exchanger for the production of microstorage DHW 15 2-speed heating pump with automatic air vent 16 Heating / DHW inversion valve 17 Disconnector 18 Filling valve (Blue) 19 Pressure gauge 20 Heating circuit safety valve 21 Domestic hot water outlet temperature sensor 2 Model shown: MS 24 MI 20

MS 24 BIC FF MS 24 BIC 2 Model shown: MS 24 BIC FF 1 Control panel (in tilted position) 14 Flame inspection window 2 Pressure gauge 15 Primary exchanger (Water / flue gases) 3 Heating / DHW inversion valve 16 Stainless steel plate exchanger for DHW production 4 Gas valve (with diaphragm) 17 DHW tank 5 2-speed heating pump with automatic air vent 18 Tank temperature sensor 6 Disconnector 19 Safety valve on the DHW circuit 7 Atmospheric gas burner with stainless steel burner trains 20 DHW load pump 8 Air pressure switch (FF versions only) 21 Flow switch (domestic water) 9 Venturi (FF versions only) 22 Expansion vessel 7.5 litres (Heating circuit) 10 Extractor fan (FF versions only) 23 Boiler temperature sensor 11 105 C safety thermostat 24 Heating circuit safety valve 12 Ignition/ionization electrode 25 Low water pressure switch 13 Combustion chamber 21

2. Operating principle diagram 2.1 Boiler MS 24 1 Automatic bypass 2 Low water pressure switch 3 Heating / DHW inversion valve 4 Reversal valve motor 5 Gas valve (with diaphragm) 6 Gas ramp (with injection nozzles) 7 Boiler temperature sensor 8 Ignition/ionization electrode 9 105 C safety thermostat 10 Primary exchanger (Water / flue gases) 11 Draught diverter cut-off 12 Flue gas thermostat - 70 C 13 Atmospheric gas burner with stainless steel burner trains 14 Expansion vessel 6 litres 15 2-speed heating pump with automatic air vent 16 Non-return valve 17 Drain cock (Boiler) 18 Pressure gauge 19 Heating circuit safety valve 2 20 Disconnector Heating flow Primary flow to DHW tank Gas inlet Domestic cold water inlet (Filling valve) Heating return 22

2.2 Boiler MS 24 MI - MS 24 MI VMC 1 2-speed heating pump with automatic air vent 2 Non-return valve 3 Heating / DHW inversion valve 4 Reversal valve motor 5 Pressure gauge 6 Filter (Heating circuit) 7 Disconnector 8 Filling valve (boiler) 9 Filter (Domestic cold water inlet) 10 Flow switch (domestic water) 11 Domestic hot water outlet temperature sensor 12 Non-return valve (on automatic bypass) 13 Low water pressure switch 14 Drain cock (boiler) 15 Heating circuit safety valve 16 Plate heat exchanger (Water / Water) 17 Gas valve (with diaphragm) 18 Gas ramp (with injection nozzles) 19 Heating flow temperature sensor 20 Ignition/ionization electrode 21 105 C safety thermostat 22 Primary exchanger (Water / flue gases) 23 Draught diverter cut-off 24 Flue gas thermostat MS 24 MI : 70 C MS 24 MI VMC : 57 C 25 Atmospheric gas burner with stainless steel burner trains 26 Expansion vessel 6 litres 2 Heating flow Domestic hot water outlet Gas inlet Domestic cold water inlet (Filling valve) Heating return 23

2.3 Boiler MS 24 FF 1 Automatic bypass 2 Low water pressure switch 3 Heating / DHW inversion valve 4 Reversal valve motor 5 Gas valve (with diaphragm) 6 Gas ramp (with injection nozzles) 7 Heating flow temperature sensor 8 Ignition/ionization electrode 9 105 C safety thermostat 10 Primary exchanger (Water / flue gases) 11 Flue gas header 12 Extractor fan 13 Venturi 14 Positive pressure outlet 15 Negative pressure outlet 16 Air pressure switch 17 Atmospheric gas burner with stainless steel burner trains 18 Expansion vessel 6 litres 19 2-speed heating pump with automatic air vent 20 Non-return valve 21 Drain cock (Boiler) 22 Pressure gauge 2 23 Heating circuit safety valve 24 Disconnector Heating flow Primary flow to DHW tank Gas inlet Domestic cold water inlet (Filling valve) Heating return 24

2.4 Boiler MS 24 MI FF 1 2-speed heating pump with automatic air vent 2 Non-return valve 3 Heating / DHW inversion valve 4 Reversal valve motor 5 Pressure gauge 6 Filter (Heating circuit) 7 Disconnector 8 Filling valve (boiler) 9 Filter (Domestic cold water inlet) 10 Flow switch (domestic water) 11 Domestic hot water outlet temperature sensor 12 Non-return valve (on automatic bypass) 13 Low water pressure switch 14 Drain cock (boiler) 15 Heating circuit safety valve 16 Plate heat exchanger (Water / Water) 17 Gas valve (with diaphragm) 18 Gas ramp (with injection nozzles) 19 Heating flow temperature sensor 20 Ignition/ionization electrode 21 105 C safety thermostat 22 Primary exchanger (Water / flue gases) 23 Flue gas header 24 Extractor fan 25 Venturi 26 Positive pressure outlet 27 Negative pressure outlet 28 Air pressure switch 29 Atmospheric gas burner with stainless steel burner trains 30 Expansion vessel 6 litres 2 Heating flow Domestic hot water outlet Gas inlet Domestic cold water inlet (Filling valve) Heating return 25

2.5 Boiler MS 24 BIC 2 1 Filter (Heating circuit) 19 Tank temperature sensor 2 Pressure gauge 20 Anode 3 Heating / DHW inversion valve 21 DHW load pump 4 Gas valve (with diaphragm) 22 Flow switch (domestic water) 5 2-speed heating pump with automatic air vent 23 Drain cock (DHW tank) 6 Non-return valve 24 Safety valve on the DHW circuit 7 Disconnector 25 Expansion vessel DHW circuit (Option) 8 Filling valve (boiler) 26 Heating circuit safety valve 9 Gas ramp (with injection nozzles) 27 Drain cock (boiler) 10 Draught diverter cut-off 28 Low water pressure switch 11 Flue gas thermostat 29 Non-return valve (on automatic bypass) 12 105 C safety thermostat 30 Plate heat exchanger (Water / Water) 13 Primary exchanger (Water / flue gases) 14 Ignition/ionization electrode Heating flow 15 Atmospheric gas burner with stainless steel burner trains Domestic hot water outlet 16 Heating flow temperature sensor Gas inlet 17 DHW tank (Stainless steel) Domestic cold water inlet (Filling valve) 18 Expansion vessel 7.5 litres (Heating circuit) Heating return 26

2.6 Boiler MS 24 BIC FF 1 Filter (Heating circuit) 21 DHW tank (Stainless steel) 2 Pressure gauge 22 Expansion vessel 7.5 litres (Heating circuit) 3 Heating / DHW inversion valve 23 Tank temperature sensor 4 Gas valve (with diaphragm) 24 Anode 5 2-speed heating pump with automatic air vent 25 DHW load pump 6 Non-return valve 26 Flow switch (domestic water) 7 Disconnector 27 Drain cock (DHW tank) 8 Filling valve (boiler) 28 Safety valve on the DHW circuit 9 Gas ramp (with injection nozzles) 29 Expansion vessel DHW circuit (Option) 10 Flue gas header 30 Heating circuit safety valve 11 Air pressure switch 31 Drain cock (boiler) 12 Negative pressure outlet (Not used) 32 Low water pressure switch 13 Positive pressure outlet 33 Non-return valve (on automatic bypass) 14 Venturi 34 Plate heat exchanger (Water / Water) 15 Extractor fan Heating flow 16 105 C safety thermostat Domestic hot water outlet 17 Primary exchanger (Water / flue gases) Gas inlet 18 Ignition/ionization electrode Domestic cold water inlet (Filling valve) 19 Atmospheric gas burner with stainless steel burner trains Heating return 20 Heating flow temperature sensor 2 27

2.7 Description of the boiler operating 2 Description of the ignition phase - The regulator controls the opening of the gas valve: the modulator opens the valve at 50 ma (G20/G25) or 70 ma (G31) - The regulator simultaneously controls the appearance of sparks on the ignition electrode. - During the safety time, the modulating valve opens with a gradient of 36 ma/s (G20/G25) or 48 ma/s (G31). Safety time: 5 seconds. - If a flame is detected after 3 seconds, the regulator continues to supply current to the modulator until the maximum value of 230 ma (G20/G25) or 310 ma (G31), with a gradient of 112 ma/s. - The regulator then moves on to the next operation: - heating function (if no DHW requirement). The regulator releases modulation after 20 seconds (between 50 and 230 ma (G20/G25) or 70 and 310 ma (G31), in accordance with A: Ignition flow the heating set point. B: Flame detection - full load DHW function (230 ma on G20/G25 or 310 ma on C: Switching to DHW or heating mode G31) then flame modulation phase in accordance with the DHW set point. - If no flame is detected, the boiler switches to safety shutdown after 3 re-ignition attempts and displays the error code E01. Description of the operating modes The OFF key is used to select one of the following operating modes: Stop / Antifreeze protection: (Display: OFF). Antifreeze protection only is activated, no other requests are taken into account. DHW heating only: Only domestic hot water production is ensured, the heating is switched off. The antifreeze protection function is activated.(display: Heating flow temperature + ) If the CTN sensor on the DHW circuit breaks down, hot water production continues nevertheless. The temperature will be controlled by the heating sensor. Heating only: heating is handled (The antifreeze protection function is activated). (Display: Heating flow temperature + ) + Heating and domestic hot water: the boiler provides domestic hot water and the heating is on. (The antifreeze protection function is activated) (Display: Heating flow temperature + + ) Antifreeze protection (Heating circuit and Domestic hot water circuit) The boiler's electronic controller has an antifreeze protection function which trips the burner to reach a boiler temperature close to 30 C when the boiler temperature is lower than 5 C. The antifreeze protection function is activated if: - The boiler is electrically powered up, - The gas supply is available, - The pressure switch measures a pressure in the circuit higher than or equal to 0.5 bar, - The boiler is not in safety lockout. Post-circulation of the heating pump (In heating mode): When the boiler is no longer required (e.g. room thermostat), postcirculation of the pump runs for 180 seconds. Post-circulation of the heating pump (In DHW mode): When there is no DHW request, post-circulation of the pump runs for 30 seconds. For BIC versions: When there is no DHW request, post-circulation of both pumps runs for 30 seconds. Pump anti-block function (unclogging) In heating mode, if there is no heating request, the pump runs automatically for 10 seconds every 24 hours. This function is only available if the boiler is electrically powered up. Reversal valve anti-block function If there is no heating request, the reversal valve runs a full automatic cycle every 24 hours. This function is only available if the boiler is electrically powered up. 28

Safety devices: - Air pressure switch (FF Versions): This device prevents burner operation when the flue gas circuit is blocked or presents an anomaly (flue gas extraction terminal blocked, venturi blocked, fan blocked, venturi-pressure switch connection interrupted). In this case, the boiler shuts down and displays the error code E03. - Flue gas thermostat (all versions excepted FF): This device, for which the sensor is located in the left-hand section of the draught diverter, interrupts gas input to the main burner when the chimney is blocked or if there is no draught. In this case, the boiler shuts down and displays the error code E03. - Safety thermostat: This device, for which the sensor is fitted to the heating flow, interrupts the gas supply to the burner in the event of the water overheating in the primary circuit. In this case, the boiler shuts down and displays the error code E02. - Ignition and flame detection electrode: fitted close to the burner, the ignition / ionisation electrode guarantees safety if there is no gas to the burner or ignition is incomplete. If no flame is detected, the boiler switches to safety shutdown after 3 re-ignition attempts and displays the error code E01. - Low water pressure switch (or hydraulic pressure switch): This device is used to ignite the burner only if the pressure inside the installation is higher than 0.5 bar. Otherwise, the boiler shuts down and shows the error code E10. - Measurement of the gradient of the boiler temperature, measured by the boiler sensor: The burner stops if the boiler temperature gradient exceeds 5 C per second. In this case, the boiler shuts down and displays the error code E25. Cut-off because of the gradient is activated 12 seconds after the flame is detected by the electrode if the boiler temperature exceeds 42 C. The anomaly is temporary but, if the error is duplicated more than 3 times, the boiler shuts down and the error code E25 is displayed steadily on the readout. This may occur if there is air in the heating circuit or if there is no water circulation or insufficient circulation in the primary circuit. - Measurement of the over-temperature in heating mode, measured by the boiler sensor: In heating mode, the burner stops when the boiler temperature exceeds the heating set point temperature by 20 C. In this case, the boiler shuts down and displays the error code E26. The anomaly is temporary but, if the error is duplicated more than 3 times, the boiler shuts down and the error code E26 is displayed steadily on the readout. This may occur if there is no water circulation or insufficient circulation in the primary circuit. - Heating circuit safety valve: This device is calibrated to 3 bar and controlled by the heating circuit. - Safety valve on the DHW circuit: This device is calibrated to 7 bar Scenario with MS 24 MI VMC boilers (for France only): The MS 24 MI VMC boiler is fitted with a special device used to make the connection to a unit that mechanically extracts combustion products. Operating principle: - A thermostat is placed in the draught diverter. - When the burner is ignited and the fan is running normally, the thermostat is swept by the ambient air. - If the ventilation becomes faulty (either because of a fan breakdown, an obstruction in the duct or extraction outlet, or for any other reason), the flow rate of ambient air diminishes and the temperature at which the combusted air and gas are mixed increases immediately; The draught diverter thermostat cuts off the electrical circuit, causing the gas inlet to be locked down. This brings about a boiler safety lockout and the error code E03 is displayed. The appliance is shut down and cannot start up again until after a manual intervention. After checking the ventilation circuit (duct, fan, etc.), it will be possible to reset the boiler. Collective safety device (DSC): This boiler can, where present, be connected to the gas VMC collective safety device (this device is in no event a substitute for the device integrated in the boiler). The mains supply to the boiler (230 V 50 Hz) is done by a specific line, controlled by a safety relay, independent of the boiler and located in the room to be heated. The safety relay itself is managed by the control device (pressure switch, tachometer, etc.) for the collective VMC. If the latter breaks down, the mains supply to the boiler will be interrupted, temporarily shutting off the gas supply to the burner. The appliance is in the OFF position and will start up again automatically after the fault has been cleared. 2 29

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PRODUCT EVOLUTION 3 31

Contents 1. Product launch date......................................................... 33 2. Modifications - Technical information.......................................... 34 3 32

1. Product launch date Appliance Date Details MS 24 MS 24 MI MS 24 FF MS 24 MI FF From: February 2011 Commercialization in FRANCE Commercialization in other countries MS 24 MI VMC From: February 2011 Commercialization in FRANCE MS 24 BIC MS 24 BIC FF From: May 2011 Commercialization in FRANCE Commercialization in other countries 3 33

2. Modifications - Technical information 2.1 IT2581 - New disconnector 2.1.1 Description of the modification Following the change in supplier, the WATTS disconnector will be replaced by a CALEFFI disconnector and a new connecting tubing, on the whole MS boiler range. Previous version - WATTS New version - CALEFFI Forecasted application date in production: February 2012. 2.1.2 Spare parts A new set with pipe + disconnector + gaskets is available and already delivered in spare parts, to replace the old disconnector: 3 Appliance type MS 24 BIC MS 24 BIC FF MS 24 MI VMC MS 24 MI MS 24 MI FF MS 24 MS 24 FF References in spare parts Exploded view Marker Reference Description New version (CALEFFI disconnector) 236 JJD710877800 CALEFFI disconnector + Pipes + Gaskets 234 JJD710795501 Disconnector pipe - CALEFFI 622 JJD710795401 Disconnector pipe - CALEFFI Previous version (WATTS disconnector) 234 JJD710395200 Disconnector pipe - WATTS 622 JJD710395300 Disconnector pipe - WATTS New version (CALEFFI disconnector) 236 236 JJD710876000 CALEFFI disconnector + Pipe + Gaskets 234 234 JJD710755501 Disconnector pipe - CALEFFI Previous version (WATTS disconnector) 234 JJD005659050 Disconnector pipe - WATTS 34

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3 36

TROUBLESHOOTING DIAGRAMS 4 37

Contents 1. Checks to make before carrying out any work................................... 39 2. Error codes................................................................ 40 3. Diagrams.................................................................. 42 4 38

1. Checks to make before carrying out any work Before carrying out any work on the boiler because of a breakdown, the following points must be checked: Check the hydraulic connections Check the hydraulic pressure in the circuit Check that the air has been correctly purged from the installation Check the inflation pressure of the expansion vessel Check that the installation is clean Check the mains supply voltage (Respect live / neutral ) Check that there is no parasitic current on the earthing (Neutral / Earth) Check that the combustion gases are adequately evacuated and that the diameter of the diaphragm is correct, if necessary. See section 5, chapter 4 Check the gas pressure (Gas supply pressure - Nozzle pressure) See section 6, chapter 6 4 39

2. Error codes If a malfunction occurs, the control panel displays an error code. To reset the boiler: Press the R key for at least 2 seconds. If the fault is not cleared: Correct the malfunction of the appliance. Refer to the appropriate synoptic (see below) The boiler stops automatically after the fifth attempt to reset it. To carry out another attempt to reset it, switch the boiler off for a few seconds. Fault that can be reset Error code Type of malfunction Causes / Corrections E01 Gas supply or ignition error. Check the gas supply. Check the condition and connection of the ignition and ionisation electrode cable. Refer to the appropriate synoptic. Check the safety thermostat. Refer to the appropriate synoptic. FF Versions (Air pressure switch): flue gas extraction terminal blocked, venturi blocked, fan blocked, venturi-pressure switch connection interrupted. Correct it. MS 24-24 MI - 24 MI VMC Versions (Flue gas thermostat) : - Chimney blocked: Clean. - No draught: make sure there is some draught. Press the R key for at least 2 seconds. Refer to the appropriate synoptic. E02 Safety thermostat tripped. Overheating alarm. Flue gas thermostat tripped (all versions excepted FF) /Air pressure switch (FF Versions). The burner is off. E03 E04 Malfunction after the flame going out unexpectedly 6 times (loss of flame signal). Breakdown of the CTN heating sensor. E05 Check the CTN heating sensor. If the sensor is damaged: - If running, the boiler shuts down - The fan stops after 10 seconds - The pump continues to run for 3 minutes. This error is cleared automatically when the sensor is replaced. Check the CTN domestic hot water sensor Note: If the CTN sensor on the DHW circuit breaks down, hot water production continues nevertheless. The temperature will be controlled by the heating sensor. The heating function continues to operate. This error is cleared automatically when the sensor is replaced. The hydraulic pressure switch enables burner ignition only if the pressure in the installation is higher than 0.5 bar. Check the water pressure. Refer to the appropriate synoptic. 4 E06 E10 Breakdown of the CTN domestic hot water sensor. The water pressure is too low. E12 The hydraulic pressure switch microswitch always remains open. The hydraulic pressure switch microswitch always remains closed. E13 Refer to the appropriate synoptic. 40

Error code Type of malfunction Causes / Corrections E25 E26 E31 E32 Maximum boiler temperature exceeded. Anomaly because of too high gradient. Maximum boiler temperature exceeded. Anomaly for overheating. Communication error between the boiler and the remote control. Scaling alarm. Presence of limescale in the exchanger. The burner stops if the boiler temperature gradient exceeds 5 C per second. The display shows the error code E25. Cut-off because of the gradient is activated 12 seconds after the flame is detected by the electrode if the boiler temperature exceeds 42 C. The anomaly is temporary but, if the error is duplicated more than 3 times, the boiler shuts down and the error code E25 is displayed steadily. This may occur if there is air in the heating circuit or if there is no water circulation or insufficient circulation in the primary circuit. - Check that the plug in the automatic air vent located on top of the heating pump body is open. - Check that there is sufficient flow rate in the installation. In heating mode, the burner stops when the boiler temperature exceeds the heating set point temperature by 20 C. In this case, the display shows the error code E26. The anomaly is temporary but, if the error is duplicated more than 3 times, the boiler shuts down and the error code E26 is displayed steadily. This may occur if there is no water circulation or insufficient circulation in the primary circuit. Refer to the appropriate synoptic. Descale the appliance (See section 6, chapter 4.3 / 4.4). Press the R key for at least 2 seconds. E35 Flame presence anomaly (Parasite flame) Refer to the appropriate synoptic. E36 Parasite flame or flame anomaly Refer to the appropriate synoptic. Power cut due to fall in voltage (voltage Automatic reset. E96 less than 170 Volts) E97 Mains supply frequency anomaly (Hz) Automatic reset. E98 - E99 Internal error on the PCB Replace the PCB. 4 41

3. Diagrams Before repair work: - Check the good state of the fuses - Ensure that all connectors are engaged, that there are no loose wires, by pulling them gently, nor any trapped or damaged wires. Before and after each intervention : - Check and ensure that the sensor and 230 V cables are separated. Symbols used: XXX FAULT Fault display Check to be made (yes/no) Processing to be carried out or comment END End of processing 4 42

3.1 No DHW production No DHW production. Check if the boiler is in Heating Only or OFF/Frost Protection position: Select the appropriate operating mode: Summer ( ) or Winter ( ). MS 24 (FF) + DHW tank BMR.../ SR...: Check that parameter F03 is correctly set to 03. See section 5, chapter 7.5. Establish a DHW flow rate of > 2 l per min. yes OK? no Rectify the settings Check the condition of the cold water valve, the filters, the flowmeter, the plate exchanger and the reversal valve. Clean / replace the defective part(s). Check whether parameter A08 (1) shows the corresponding value. yes Check the reversal valve and its wiring. no Check the flowmeter and its wiring See section 6, chapter 5.3. OK? no Replace defective parts. yes Replace the PCB. 4 END (1) A08 = l/min x 10 43

3.2 E01: Gas supply or ignition error E01 fault Gas supply or ignition error. To reset the boiler: Press the R key for at least 2 seconds. yes OK? END no See section A - page 49 3.3 E02: Safety thermostat tripped E02 fault Safety thermostat tripped. - Overheating due to a lack of flow rate: All the radiators are closed. - Vent the air in the heating system. Check that the plug in the automatic air vent located on top of the heating pump body is open. - To reset the boiler: Press the R key for at least 2 seconds. yes OK? END no Check the safety thermostat and its wiring. See section 6, chapter 5.4. 4 3.4 E03: Flue gas evacuation defect E03 fault Flue gas thermostat (all versions except FF) or air pressure switch (version FF) tripped. The burner is off. To reset the boiler: Press the R key for at least 2 seconds. yes OK? END no All versions: See section E - page 51. FF Versions : See section C page 50. 44

3.5 E04: loss of flame signal E04 fault Malfunction after the flame going out unexpectedly 6 times. To reset the boiler: Press the R key for at least 2 seconds.. yes OK? END no See section C - page 50. 3.6 E05 or E06: Sensor fault E05 / E06 fault - Breakdown of the CTN heating sensor. - Breakdown of the CTN domestic hot water sensor. Measure the resistance of the sensor on the connector terminals. See section 6, chapter 5.2. yes OK? Check the harness no Replace the defective sensor. 4 yes OK? no Replace the harness. Replace the PCB. END 45

3.7 E10, E12, E13: Hydraulic pressure switch defect (Low water pressure switch) E10 fault: The water pressure is too low E12 fault: Pressure switch contact remains open E13 fault: Pressure switch contact remains closed. - If necessary, top up the water level in the heating system (recommended hydraulic pressure between 1 and 1.5 bar) - Check that the plug in the automatic air vent located on top of the heating pump body is open; - Carry out maintenance on the boiler (Clean the filters, Exchanger...). yes OK? no Check the wiring. OK? no Replace the harness. yes Check continuity on the hydraulic pressure switch terminals (Normally open contact): See section 6, chapter 5.6. Contact open? no Replace the hydraulic pressure switch. yes 4 Replace the PCB. END 46

3.8 E25, E26: Maximum boiler temperature exceeded E25, E26 fault E25: Anomaly because of too high gradient. Water circulation fault. E26: Maximum boiler temperature exceeded. - Check parameters F08 and F09: Recommended value = 100 - Vent the heating installation.check that the plug in the automatic air vent located on top of the heating pump body is open. Unblock the heating pump. Check that the heating pump is operating correctly: See section 6, chapter 5.9. The pump operates? no yes See section B page: 49. Check the power supply to the pump (230 V) at the outlet on the PCB (Terminals 6-7). yes no Replace the PCB. Check pump operation (Power it separately). no OK? yes Replace the pump wiring. Replacing the pump. 4 END 47

3.9 E31: Communication fault E31 fault Communication error between the boiler and the remote control. Check the room thermostat if fitted. If the room thermostat is not in use: check that the bridge is fitted to the connection terminal block. yes OK? END no See section A page: 49. 3.10 E35 or E36: Parasite flame fault E35 / E36 fault Parasite flame or flame anomaly. Check the settings on the gas valve See section 6, chapter 6. 4 yes OK? END no See section D - page 50. 48

3.11 Sections A - Defects E1, E31 or no display. Check that the gas supply is available and that the gas pipe is sufficiently vented. Check live-neutral compliance = 230 V and neutral-earth = 0 V. Check the fuses on the control panel. Replace if necessary. - Reset by pressing the R key for at least 2 seconds. - Press. Choose position or (Press for 2 seconds to change function). Display OK? yes END Check the room thermostat if fitted. If the room thermostat is not in use: check that the bridge is fitted to the connection terminal block. no Replace the PCB. Check that there is no voltage between neutral and earth (< 5 V). < 5 V? yes See section D - page 50. no Appliance or cable defective in the electrical installation: - Replace or repair the electrical problem with the installation - Fit a circuit separation transformer. B Check the cleanliness of the heat exchanger. Carry out maintenance on the boiler. Clean the filters. See section 6, chapter 4; - Reset by pressing the R key for at least 2 seconds. - Press. Choose position or (Press for 2 seconds to change function). Display OK? yes END 4 Check continuity on the hydraulic pressure switch terminals. See section 6, chapter 5.5 no ok? yes no Replace the PCB. Replace the hydraulic pressure switch. 49

C - Check the fan wiring. - Check the power supply to the fan at the oultet on the PCB (230 V AC) See section 6, chapter 5.11. Fan blocks or does not rotate correctly? yes Replace the fan. no Check the settings on the gas valve. yes - Check the venturi pipe - Check the air pressure switch connections. OK? no Refurbish / Replace. END D Check the ionization/ignition electrode: - Position - Visual inspection (state of wear) - Wiring - Check that the voltage on the electrode terminal block on the PCB is 230 V. OK? yes Replace the ignition electrode / ionisation sensor. no Replace the PCB. 4 END 50

E The flue gas thermostat has tripped or is defective. Check continuity on the flue gas thermostat (all versions except FF) or the air pressure switch (versions FF) terminals. continuity? no Replace the harness. yes Check the resistance on the flue gas thermostat or air pressure switch terminals. Resistance > 1.5 Ohm. no Replace the board / electronics circuit. yes Replace the flue gas thermostat (all versions except FF) or the air pressure switch (versions FF). END 4 51

4 52

INSTALLATION COMMISSIONING 5 G000008 53

Contents 1. Location of the appliance..................................................... 55 1.1 Location............................................................................. 55 1.2 Ventilation........................................................................... 55 2. Hydraulic connections....................................................... 56 2.1 Water treatment in the heating circuit...................................................... 56 2.2 Installing the boiler in new installations (installations less than 6 months old)....................... 57 2.3 Installing the boiler in existing installations.................................................. 57 2.4 Hydraulic connections (Heating circuit, DHW circuit).......................................... 58 2.5 Connecting the expansion vessel......................................................... 58 2.6 Connecting a solar DHW tank............................................................ 59 2.7 Expansion vessel DHW circuit (Option) - MS 24 BIC (FF)...................................... 60 3. Gas connection............................................................. 61 3.1 Connecting........................................................................... 61 3.2 Gas categories........................................................................ 61 4. Connecting the flue gas pipe.................................................. 62 4.1 Installation........................................................................... 62 4.2 Concentric air / flue gas connection (FF Versions)............................................ 63 5. Electrical connections....................................................... 66 6. Filling the installation with water............................................... 67 5 7. Check points before commissioning........................................... 68 7.1 Checking the gas supply pressure......................................................... 68 7.2 Check the hydraulic circuit............................................................... 69 7.3 Bleed............................................................................... 69 7.4 Check the electrical connections.......................................................... 69 7.5 Parameter settings - MS 24 (FF) - MS 24 MI (FF / VMC)....................................... 70 7.6 Parameter settings - MS 24 BIC (FF)...................................................... 72 8. Commissioning............................................................. 73 8.1 Commissioning procedure............................................................... 73 8.2 The boiler does not start up.............................................................. 73 8.3 In the event of run-off noise.............................................................. 73 54

1. Location of the appliance 1.1 Location The boiler must be installed in a frost-free environment. Do not place the appliance above a heat source or a cooking appliance. The IPX5D protection rating allows the boiler to be installed in a kitchen or bathroom. In order to avoid damage to the boiler, it is necessary to prevent the contamination of combustion air by chlorine and/or fluoride compounds, which are particularly corrosive. These compounds are present, for example, in aerosol sprays, paints, solvents, cleaning products, washing products, detergents, glues, snow clearing salts, etc. Therefore: - Do not pull in air evacuated from premises using such products: hairdressing salons, dry cleaners, industrial premises (solvents), premises containing refrigeration systems (risk of refrigerant leakage), etc. - Do not stock such products close to the boilers. If the boiler and/or peripheral equipment are corroded by such chloride or fluoride compounds, the contractual guarantee cannot be applied. The warranty does not apply to damage to the boiler caused by these instances. 1.2 Ventilation To ensure adequate accessibility to the appliance and facilitate maintenance, leave enough space around the boiler. The minimum recommended dimensions are shown in the illustration in mm. If the heating appliance is installed in residential premises where people are present all the time, ensure sufficient ventilation pursuant to prevailing regulations. MS 24, MS 24 MI, MS 24 MI VMC, MS 24 BIC Do not block (even partially) the ventilation vents in the room in which the appliance is installed. S1 25 min. 25 min. min. 200 Fresh air inlet: France: In the event of direct air inlet, the cross-section of the fresh air inlet, which is compulsory, must have a minimum surface area of 50 cm 2 (NF P 45.204). Other countries: the cross section of the aeration inlet, which is compulsory in the premises in which the boiler is installed, must comply with the standards in force in the country. Evacuation of polluted air: When the boiler is installed in a kitchen, for example, the evacuation of polluted air from appliances not connected to a discharge flue (e.g. gas cooker) can be handled by the boiler's draught cut-off. To do this, it is sufficient for the top of the boiler casing to be positioned at least 1.8 mm from the floor. If located in a closed cubby hole, ensure ventilation of the cubby hole itself with a minimum total cross section of 600 cm 2. The minimum distance between the front of the boiler and the door or closing panel must be 10 cm. S1 + S2 = 600 cm 2 MS 24... FF If combustion gas evacuation and combustive air intake are done using a concentric pipe (connection type C12 or C32), ventilation of the room in which the appliance is installed is not necessary unless the gas supply comprises one or more mechanical connections (see NF P 45.204). S2 100 mini 730 min. 250 5 55