MHS Boilers ELCO GENUS PREMIUM HP 45 Installation and operation manual

ELCO Genus Wall Mounted Condensing Boiler
Operating & Maintenance Manual
MHS Boilers Ltd.
3 Juniper West, Fenton Way
Southfields Business Park
Basildon
ESSEX SS15 6SJ
Tel. [phone] Fax [phone]
WWW.MHSBOILERS.COM
L352

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INDEX
Overview .................................................................................................................
Advice for the installer ............................................................................................
CE labelling ..............................................................................................................
Safety regulations ..................................................................................................
Product description ...............................................................................................
Control Panel ...........................................................................................................
Display ...................................................................................................................
Overall view ...........................................................................................................
Overall dimension ..................................................................................................
Technical Information .............................................................................................
Installation ..............................................................................................................
Before installing the appliance ...............................................................................
Minimum clearances ..............................................................................................
Gas Connection .....................................................................................................
Water connection ...................................................................................................
View of the boiler connections .................................................................................
Residual Head of the boiler ....................................................................................
Excessive pressure device ....................................................................................
Cleaning the heating system ..................................................................................
Appliances with underfloor heating ........................................................................
Water circuit diagram ...............................................................................................
System water characteristics .................................................................................
Discharge of condensation ....................................................................................
Indirect cylinder connection ...................................................................................
Connecting the flue ................................................................................................
Types of boiler - flue exhaust connection ..............................................................
Table of flue gas exhaust duct lengths ..................................................................
Type of air suction/flue gas exhaust ducting ..........................................................
Electrical connection ................................................................................................
Peripheral unit connection .....................................................................................
Electrical diagram ..................................................................................................
Commissioning ......................................................................................................
Ignition procedure ..................................................................................................
Initial procedures ....................................................................................................
Electricity supply ....................................................................................................
Filling the hydraulic circuit ......................................................................................
Gas supply .............................................................................................................
First Ignition ...........................................................................................................
Dearation cycle ......................................................................................................
Cleaning function and combustion analysis ...........................................................
Checking the gas setting ........................................................................................
Cleaning function ...................................................................................................
4
4
5
5
9
9
10
11
12
13
14
14
15
15
16
16
16
17
17
18
19
20
20
21
21
21
22
23
24
25
26
27
27
27
27
27
28
28
29
29
29
29

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Maximum gas flow combustion analysis ................................................................
Minimum gas flow combustion analysis .................................................................
Adjustment the Maximum Heating power ...............................................................
Soft Light adjustment .............................................................................................
Ignition Delay adjustment .......................................................................................
Table summarising changes ..................................................................................
Gas changeover .....................................................................................................
AUTO function .......................................................................................................
Boiler protection devices ......................................................................................
Safety shut-off ........................................................................................................
Shutdown ...............................................................................................................
Table summarising error codes ..............................................................................
Anti-freeze function ................................................................................................
Settings - adjustment - problem identification menus .......................................
Maintenance.............................................................................................................
Instruction for opening the casing and performing an internal inspection ...............
General comments .................................................................................................
Information for the user ..........................................................................................
Data Plate Symbol ..................................................................................................
Certificate ……………………………………………………………………………….
Notes ……………………………………………………………………………………..
29
31
31
32
32
33
33
33
35
35
35
37
38
39
48
48
49
51
51
52
53

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Overview
Advice for the installer
The installation and first ignition of the boiler must be performed by qualified personnel in
compliance with current national regulations regarding installation, and in conformity
with any requirements established by local authorities and public health organisations.
After the boiler has been installed, the installer must ensure that the end user receives the
declaration of conformity and the operating manual, and should provide all necessary
information as to how the boiler and the safety devices should be handled.
This appliance is designed to produce hot water for domestic use. It should be connected to a
heating system and a distribution network for domestic hot water, both of which must be
compatible with its performance and power levels.
The use of the appliance for purposes other than those specified is strictly forbidden.
The manufacturer cannot be held responsible for any damage caused by improper, incorrect and
unreasonable use of the appliance or by the failure to comply with the instructions given in this
manual. Installation, maintenance and all other interventions must be carried out in full conformity
with the governing legal regulations and the instructions provided by the manufacturer.
The boiler is delivered in a carton.
Once you have removed the entire packaging, make sure the appliance is intact and that no parts
are missing. If this is not the case, please contact your supplier.
Keep all packaging material (clips, plastic bags, polystyrene foam, etc.) out of reach of children as
it may present a potential hazard. In the event of afault and/or malfunction, turn the appliance off,
turn off the gas cock and do not attempt to repair it yourself.
Contact a qualified professional instead.
Before any maintenance or repair work is performed on the boiler, make sure you have
disconnected it from the electricity supply by switching the external bipolar switch to the “OFF”
position. All repairs, which should only be performed using original spare parts, should be carried
out by a qualified professional.
Failure to comply with the above instructions could compromise the safety of the appliance and
invalidate all liability on the part of the manufacturer. In the event of any maintenance or other
structural work in the immediate vicinity of the ducts or flue gas exhaust devices and their
accessories, switch the appliance off by switching the external bipolar switch to the “OFF” position
and shutting off the gas valve.
When the work has been completed, ask a qualified technician to check the efficiency of the
ducting and the devices. Turn the boiler off and turn the external switch “OFF” to clean the exterior
parts of the appliance. Clean using a cloth dampened with soapy water.
Do not use aggressive detergents, insecticides or toxic products. If the appliance is used in full
compliance with current legislation, it will operate in a safe, environmentally-friendly and
cost-efficient manner. If using kits or optional extras, make sure they are authentic.

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CE labelling
The CE mark guarantees that the appliance conforms to the following directives:
-90/396/CEE relating to gas appliances
-2004/108/CEE relating to electromagnetic compatibility
-92/42/CEE relating to energy efficiency
-2006/95/CEE relating to electrical safety
Safety regulations
The Genus HP boiler is CE approved and applies to the following European standards:
−92 / 42 / EEC Boiler efficiency directive − 90 / 396 / EEC Gas appliance directive − 73 / 23/
EEC Low voltage directive − 89 / 336 / EEC EMC directive
−EN 656 Gas-fired central heating boilers –Type B boilers of nominal heat input exceeding 70
kW but not exceeding 300 kW
−EN 15420 Gas-fired central heating boilers - Type C boilers of nominal heat input exceeding 70
kW, but not exceeding 1000 kW
−EN 15417 Gas-fired central heating boilers - Specific requirements for condensing boilers with a
nominal heat input greater than 70 kW but not exceeding 1000 kW
−EN 13836 Gasfiredcentral heating boilers - Type B boilers of nominal heat input exceeding 300
kW, but not exceeding 1000 kW
−EN 15502-1 Gas-fired central heating boilers - Part 1: General requirements and tests
−EN 55014-1 Electromagnetic compatibility - Requirements for household appliances, electric
tools and similar apparatus Part 1: Emission
−EN 55014-2 Electromagnetic compatibility - Requirements for household appliances, electric
tools and similar apparatus Part 2: Immunity - Product family standard
−EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic
current emissions (equipment input current 16 A per phase)
−EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3: Limitation of voltage changes,
voltage fluctuations and flicker in public low-voltage supply systems, for equipment with rated
current 16 A per phase and not subject to conditional connection
−EN 60335-1 Household and similar electrical appliances -Safety - Part 1: General requirements

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−EN 50165 Household and similar electrical appliances -Safety - Part 2-102: Particular
requirements for gas, oil and solid-fuel burning appliances having electrical connections
The following Codes of Practice are also applicable: -
BS 6644 : 2011 Specification for gas fired hot water boilers of rated inputs between 70kW (net)
and 1.8MW (net) (2nd and 3rd family gases).
BS 6880:1988 Code of Practice for low temperature hot water heating systems of output greater
than 45kW. Parts 1, 2 & 3.
BS 6891:2005 + A2:2008 Specification for installation of low-pressure gas pipework of up to
35mm (R11/4) in domestic premises (2nd family gases).
BS 7593:2006 Code of Practice for treatment of water in domestic hot water central heating
systems.
BS 7671:2008 Requirements for electrical installations. IEE Wiring Regulations. Seventeenth
Edition
BS EN 12828 2003 Heating systems in buildings –Design for water based heating systems.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
IGE/UP/1 or 1A Gas Tightness Testing & Purging of Commercial Industrial Gas Installations
IGE/UP/2 Gas installation pipework, boosters and compressors on Industrial and Commercial
premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises.
IG/UP/10 edition 3 Installation of gas appliances in Industrial and Commercial premises.
Part 1: Flued appliances.

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Through their unique construction, the Genus HP range of central heating units are renowned for
their:
- High thermal output
- Environmental-friendliness (they meet the most stringent environmental conditions)
- Low weight and compact size
- Durability
- Low noise level
- Broad control range
- Can be supplied in a wide range of models
Through active and market oriented research, MHS Boilers Ltd is in a position to offer
solutions for the most challenging heating requirements.
The supplier
MHS Boilers Ltd is proud to supply and technically support the Genus HP of boilers throughout
the United Kingdom. For advice or more information please contact your local sales
representative or our head office via 01268 546700 or via our website www.mhsboilers.com
This document
The present documentation has been prepared with the following target groups in mind:
- The technical consultant
- The installer
- The maintenance technician
- The user
MHS Boilers Ltd has opted to make the technical documentation as comprehensive as possible
in the form of this book, in order to ensure that these target groups have all the information they
need. As the supplier we would be happy to help you in connection with any additional
information that you may require.

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This document covers the following aspects relating to the boilers:
- General description
- Technical specifications
- Requirements for design and installation
- Maintenance instructions
The operating instructions for the user have been affixed to the appliance itself.
Service
For commissioning and assistance in maintenance matters, please contact the Technical
Services Department via 01268 546700.
General restrictions
MHS Boilers Ltd products should always be used, installed and maintained in accordance with
the statutory requirements, specifications and standards applicable to these installations. All the
data, information and suggestions concerning its products provided by MHS Boilers Ltd are
based on careful study. However, the use, installation and operation of the same are outside the
control of MHS Boilers Ltd and neither MHS Boilers Ltd nor any other organisations associated
with it, accept any liability for the same.

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Product description
Control Panel

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Display

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Overall view

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Overall dimensions

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Technical Information
GENERAL NOTE
Model GENUS Premium HP
45
65
85
100
CE Certification (pin)
CE-0063BT3414
Boiler type
C13-C33-C43-C53-C83-B23
POWER SPECIFICATIONS
Max/min nominal calorific flow rate (Pci) Qn
kW
41,0 / 12,3
58,0 / 17,7
80,0 / 20,0
88,3 / 22,1
Max/min nominal calorific flow rate (Pcs) Qn
kW
45,6 / 13,7
64,4 / 19,7
88,9 / 22,2
98,2 / 24,6
Max/min power output (80°C-60°C) (Central
Heating) Pn
kW
39,8 / 11,8
58,8 / 17,6
78,0 / 19,8
86,2 / 21,9
Max/min power output (50°C-30°C) (Central
Heating) Pn
kW
43,6 / 13,2
63,9 / 19,4
84,5 / 21,8
94,1 / 24,1
Max/min power output (40 °C - 30 °C) Pn
kW
43,7 / 13,2
64,4 / 19,4
84,9 / 21,9
95,2 / 24,2
Combustion efficiency (of flue gas)
%
97,2
97,2
97,2
97,2
Nominal calorific flow rate efficiency (60/80°C)
Hi/Hs
%
97,0 / 96,2
98,8 / 99,4
97,5 / 98,9
97,5 / 98,9
Nominal calorific flow rate efficiency (30/50°C)
Hi/Hs
%
106,4 / 107,5
107,4 / 109,5
105,6 / 109,1
106,5 / 109,1
Nominal calorific flow rate efficiency (30/40 °C)
Hi/Hs
%
106,5 / 107,4
108,2 / 109,8
106,1 / 109,3
107,7 / 109,3
Efficiency at 30% at 30°C Hi/Hs
%
107,4
109,8
107,6
107,6
Efficiency at 30% at 47°C Hi/Hs
%
104,8
105,3
104,9
104,9
Efficiency rating (dir. 92/42/EEC)
star
****
****
****
****
Sedbuk Rating
band
Loss when stopped (ΔT = 50°C)
%
0,24
0,24
0,25
0,25
Loss of burner gas when operating
%
2,8
2,8
2,8
2,8
EMISSIONS
Available air pressure
Pa
130
150
140
140
NoX class (Less than 70 mg/kWh)
class
5
5
5
5
Flue gas temperature (G20) (80°C-60°C)
°C
68/63
68/63
68 / 63
68 / 63
CO2 content (G20) (80°C-60°C)
%
9,0 / 8,4
9,0 / 8,4
9,0 / 8,4
9,0 / 8,4
CO2 content (G30) (80°C-60°C)
10,6 / 10,0
10,6 / 10,0
10,6 / 10,0
10,6 / 10,0
CO2 content (G31) (80°C-60°C)
9,8 / 9,2
9,8 / 9,2
9,8 / 9,2
9,8 / 9,2
CO content (0%O2) (80°C-60°C)
ppm
88
109
98
91
O2 content (G20) (80°C-60°C)
%
4,8
4,8
4,8
4,8
Maximum flue gas flow (G20) (80°C-60°C)
kg/h
74,3
108,4
147,2
162,6
Excess air (80°C-60°C)
%
27
27
27
27
HEATING
CIRCUIT
Residual head on DT = 20°C
mCa-l/h
2,2
1,1
Maximum heating pressure
bars
4 / 1
4 / 1
6 / 1 600/100
6 / 1 600/100
Min/max heating temperature (high temp range)
°C
35 / 82
35 / 82
35 / 82
35 / 82
Min/max heating temperature (low temp range)
°C
20 / 45
20 / 45
20 / 45
20 / 45
DHW
Domestic hot water min/max temperature
°C
40 / 60
40 / 60
40 / 60
40 / 60
ELECTRICAL
Power supply frequency/voltage
V/Hz
230/50
230/50
230/50
230/50
Total electrical power absorbed
W
148
198
123
130
Minimum ambient temperature for use
°C
+5
+5
+5
+5
Protection level for the electrical appliance
IP
X4D
X4D
X4D
X4D
Max condensate production
l/h
5.0
7.4
12.8
14.4
Condensate pH
3,2
3.2
3.2
3.2
Weight
kg
45
50
80
83
Dimension (W x H x D)
440/910/510
440/910/510
585/465/1010
585/465/1010
The installation and first ignition of the boiler must be performed by qualified personnel
in compliance with current national regulations regarding installation, and in conformity
with any requirements established by local authorities and public health organisations.

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Installation
Before installing the appliance.
Genus HP Premium is designed to work individually or in cascade (max 4 devices). Is necessary
that all requirements are met by the rules and regulations for equipment equivalent to the total
installed power generators. In particular, the local installation, security devices and flue exhausts
evacuation system should be adjusted to the total potential of the cascade. The requirements for
installation in this manual concerning the installation of a single device. To install the cascade
read the installation manual included in Kit.
Before installing the appliance
The boiler heats water toa temperature below boiling. It should be connected to a heating system
and to a domestic water mains supply, both of which must correspond in size to the performance
and its power of the appliance. Before connecting the boiler, it is first necessary to perform the
following operations:
- Carefully wash the system piping in order to remove any screw thread or welding residues, or
any dirt which might prevent the boiler from operating correctly.
- Make sure that the boiler is set up for operation with the type of gas available (read the
information on the packaging label and on the boiler data plate).
- Make sure that there are no obstacles inside flue exhaust and that it does not contain any
discharge from other appliances, unless the flue is meant to serve more than one user (in
accordance with current legal requirements).
- Where there is already a connection to existing flue exhausts, check that these exhausts have
been perfectly cleaned and are without residues, because any disconnection could obstruct the
passage of fumes and create potentially dangerous situations.
- Make sure that, where unsuitable flue exhausts are attached, they have been ducted.
- In areas with particularlyhard water, lime scalemay build up on the components inside theboiler
and reduce its overall efficiency.
C-type boilers, with combustion chambers and air supply circuits which are completely sealed
from the air outside, do not have any limitations concerning the ventilation and size of the room in
which they are installed. So that the normal operation of the boiler is not compromised, the place
in which it is installed must be suitable with regardto the operating limit temperature value andthe
appliance should be protected so that it does not come into direct contact with atmospheric
agents.
WARNING No inflammable items should be left in the vicinity of the boiler. Make sure the
installation site and any systems to which the appliance must be connected are fully
compliant with the current applicable legislation. If dust and/or aggressive vapours are
present in the room in which it is to be installed, the appliance must operate
independently of the air inside the room.

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Minimum clearances
In order to allow easy access for boiler maintenance operations, installation distance must be
suitable.
Position the boiler according to the established technical rules, using a spirit level.
Gas connection
The boiler was designed to usegases belonging to the categories as shown in the following table.
Make sure, using the labels on the packaging and the data plate on the appliance itself, that the
boiler is in the correct country and that the gas category for which the boiler was designed
corresponds to one of thecategories available in the country where it will be used. Thegas supply
piping must be created and measured out in compliance with specific legal requirements and in
accordance with the maximum power of the boiler; you should also make sure that the shut-off
valve is the right size and that it is connected correctly. Before carrying out the installation, it is
recommended that the fuel pipes are cleaned thoroughly in order to remove any residues which
could prevent the boiler from operating correctly. Check that the supplied gas corresponds to the
type of gas for which the boiler was designed (see the data plate located on the appliance itself).
It is also important to check that the pressure of the gas (methane or LPG) you will be using to
feed the boiler is suitable, because if it is insufficient the power of the generator may be reduced,
causing inconvenience for the user.
COUNTRY
MODEL
CATEGORIES
UK
Genus Premium HP 45
Genus Premium HP 65
Genus Premium HP 85
Genus Premium HP 100
II2H3P

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Water Connections
View of the boiler connections
Residual Head of the boiler

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Excessive pressure device
The excessive pressure device outlet must be connected to a drainage siphon which can be
checked visually in order to prevent maintenance procedures causing harm to people, animals or
property (the manufacturer shall not be held responsible for any such damage).
Cleaning the heating system
Where the boiler is used in conjunction with an older system, various substances and additives
may be present in the water and these could have an adverse effect on the operation and
durability of the new boiler. Before replacing the old boiler, you must arrange for the system to be
cleaned thoroughly in order to eliminate any residue or dirt which could compromise the correct
operation of the water heater. Make sure the capacity of the expansion vessel is suited to the
amount of water contained in the system.
Warning! It is advisable to install a suitably sized hydraulic separator (available as an
accessory) between the boiler circuit and the heating circuit.

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Warning!
It is advisable to install a filter on the system’s return pipe to prevent impurities or sludge from
damaging the appliance. It is mandatory to add this filter when replacing return pipes on existing
appliances. The manufacturer shall not be held liable for any damages to the appliance due to
failure to install said filter.
Appliances with under floor heating
For appliances with under floor heating, fit a safety thermostat onto the under floor heating outlet.
For the electrical connection of the thermostat see the section on “Electrical connections”. If the
outlet temperature is too high, the boiler will stop both domestic hot water and the heating
production and the error code 1 16 “under floor thermostat open” will appear on the display. The
boiler will restart when the thermostat is closed during automatic resetting. If the thermostat
cannot be installed, the under floor heating equipment must be protected by a thermostatic valve,
or by a bypass to prevent the floor from reaching too high a temperature.

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Water circuit diagram

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System water characteristics
Water should be suitably treated when its hardness exceeds 25° Fr, in order to avoid lime scale
from depositing in the boiler due to hard water, or corrosion due to aggressive water. It is useful
pointing out those even deposits barely a few millimetres thick may cause considerable
overheating of the generator walls due to their low thermal conductivity, thereby causing serious
damage. It is fundamental to treat water used in large-scale systems (i.e. that use high volumes of
water) or when the system is frequently refilled with water. In such cases, if the system is then
partially or totally drained, it must be refilled using treated water again.
Discharge of condensation
High energy efficiency produces some condensation which must be removed. To do so, use a
plastic pipe placed so as to avoid the accumulation of any condensation inside the boiler. This
pipe must be attachedto a discharge siphon which can be checked when required.The standards
governing installation currently in force in the country of installation must be respected, as must
any local authority regulations or those issued by public health bodies. Check the positioning of
the condensate discharge tube:
- it must not be nipped when connected
- it must not form a swan's neck
- ensure that it is cleared using free air in the siphon for the evacuation of condensates, use only
pipes which satisfy the relevant norms. The flow of condensates may reach 2 litres / hour. As the
condensates are acid (pH close to 2), all necessary precautions must be taken before any
operation.
Before the first time the equipment is used, the siphon must be filled with water. To
do this, add approximately 1/4 litre of water via the burnt gas outlet before fitting the
discharge device, or unscrew the siphon positioned underneath the boiler, fill it with water
and refit it
Warning! Insufficient water in the siphon can cause the flue gas to be expelled into
the surrounding ambient air