Trianco TRISTAR OPTIMA JUNIOR K CB User manual

TRISTAR OPTIMA JUNIOR K CB AND SB
WALL MOUNTED GAS BOILERS
INSTALLATION INSTRUCTIONS
TO BE RETAINED BY HOUSEHOLDER
CB MODEL G.C. No: 47-897-0
SB MODEL G.C. No: 41-898-39

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INDEX:
1 Warnings & Safety Advice page 5
1.1 EEC Declaration of Conformity page 5
1.2 Contents of Pack page 5
1. Standards & Regulations page 6
1.4 Description of Appliance page 6
1.5 Use of Antifreeze Products page 6
2 Technical Specification Chart page 7
2.1 Boiler Dimensions page 8
2.2 Wall-Mounting Template page 9
2. Technical Schematic page 10
2.4 Hydraulic Schematic page 11
Installation and Assembly page 12
.1 Siting and Access page 12
.2 Unit Assembly page 12
. Hydraulic Connections page 12
.4 Filling the System page 1
.5 Circulating Pump page 1
.6 System Pressure Checks page 1
.7 Condensate Trap page 14
.8 Condensate Pipe page 14
.9 Hard Water Areas page 14
.10 Underfloor Heating page 14
.11 Pipework Connection Manifold page 15
4 Access to Inside of Boiler page 16
5 Electrical page 17
5.1 Access to Electrical Panel page 17
5.2 Controls Connection Plug page 17
5. Controls & Wiring page 18
5.4 Y-Plan Wiring page 19
5.5 S-Plan Wiring page 19
5.6 Wiring Schematic page 20
6 Flue System page 21
6.1 Horizontal Flue Kit Assembly page 22
6.2 High-Level Flue Kit Assembly page 22
6. Vertical Flue Kit Assembly page 22
6.4 Horizontal Flue Kit Components page 2
6.5 High-Level Flue Kit Components page 2
6.6 Vertical Flue Kit Components page 2
6.7 90° Concentric Bend Components page 24
6.8 45° Concentric Bend Components page 24
6.9 500mm Pipe Components page 24
6.10 Rear-Outlet Horizontal Schematic page 25
6.11 Rear-Outlet High-Level Schematic page 25
6.12 R/H Horizontal Flue Schematic page 26
6.1 R/H High-Level Flue Schematic page 26
6.14 L/H Horizontal Flue Schematic page 27
6.15 L/H High-Level Flue Schematic page 27
6.16 Vertical Balanced Flue Schematic page 28
6.17 Alternate Flueing Examples page 29
7 Boiler Controls page 0
7.1 Starting the Boiler page 0
7.2 Use of the Controls page 0
7. MODE Function - Adjustable page 1
7.4 MODE Function - Information page
7.5 Frost Thermostat page 4
7.6 Comfort Function page 4
7.7 Resetting the Boiler page 4
7.8 System Pressure page 4
7.9 Antilock Function page 4
8 Maintenance and Cleaning page 4
9 Useful Operating Tips page 4
10 Combustion Analysis page 5
10.1 Preparation page 5
10.2 Analysis at Maximum Output page 5
10. Analysis at Minimum Output page 5
11 LPG Conversion page 6
12 Servicing and Maintenance page 7
12.1 Service Procedure page 7
12.2 Burner & Heat Exchanger Servicing page 8
1 Fault-Finding page 9
1 .1 Fault Codes page 40
14 Additional System (SB) Connections page 41
14.1 Controls Connection Plug page 41
14.2 Diverter Valve Connection page 41

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This booklet, along with the accompanying user
manual, should be kept by the householder and
should always stay with the boiler, even when the
appliance is transferred to another system.
Please read these instructions carefully, as they
provide important directions for the safe installation,
use and maintenance of the appliance.
Any use of the boiler not sanctioned by these
instructions is strictly prohibited and will invalidate the
guarantee.
Installation, commissioning and servicing of the boiler
must only be carried out by a CO GI-trained and
registered engineer.
Any person(s) who carries out other remedial work,
e.g. electrical fault-finding, must have suitable
engineering qualifications.
The appliance contains no asbestos or other
substances which contravene the COSHH
egulations (Control of Substances Hazardous to
Health egulations, 1988).
Flue systems must not be modified in any way other
than as described in the installation manual.
Do not store or use any combustible materials close
to, or within the appliance.
In the case of structural work or maintenance close to
the pipework, flue system, appliance or accessories,
switch off the boiler prior to the commencement of
such work. Only reactivate the boiler once these have
been thoroughly checked by suitably-qualified
personnel.
The appliance must be serviced annually by a
CO GI-registered engineer, unless the requirements
of the installation demand more frequent service.
Do not obstruct the clean air supply to the boiler, or
the flue terminal.
When installing the appliance, do not mount it on
chairs, ladders, stools or any other unstable surface.
To clean the appliance casing, switch off the boiler
and isolate the power supply. Wipe with a damp cloth.
Do not use detergents, harsh liquids, or other toxic
products.
Before operating the appliance, please ensure that all
gas and water supply valves are open, and that the
system has been correctly filled with water.
The system must be flushed of all deposits before
filling.
Installation is the purchaser’s responsibility.
Any repair should be carried out using original spares.
Failure to do so may invalidate the guarantee and
jeopardise the safety of the boiler. Trianco is not held
liable for the malfunction of any of these components
It is forbidden to climb on the appliance.
Always turn off the gas cock before carrying out any
work on components which carry gas.
If you smell gas:
- do not operate any electrical appliances
- extinguish any fires
- close the main gas valve upstream of the meter
- open all windows and doors to ventilate the room
- telephone the gas company
If you smell combustion fumes from the boiler:
- switch off the boiler
- open all windows and doors to ventilate the room
- call your local authorised engineer
Before carrying out any work on the
boiler, always switch off the power to
the appliance at the mains isolation.
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler
Efficiency Directive, Electromagnetic Compatibility
Directive, and the Low Voltage Directive.
PIN CE 0694 BM 3593
Category UK II2H 3P
Appliance Type C13, C83, B23, B33
The boiler carton should include:
- Boiler
- Pipework connection manifold
- Wall mounting bracket and templates
- Instruction/guarantee pack
- Bag of screws/fixings
- Diverter valve connection (SB model only)
- External controls connection (SB model only)
1 WARNINGS & SAFETY ADVICE
1.1 E.C. DECLARATION OF CONFORMITY
1.2 CONTENTS OF PACK

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This boiler must only be installed by a CO GI-
registered engineer and be in accordance with any
local building regulations. Where no specific
instruction is given, reference should be made to the
relevant British Standards Codes of Practice.
The installation must also comply with the following
regulations and standards:
The Building egulations Part L
I.E.E. Wiring egulations
Gas Safety (Installation and Use) equirements
Local Water Undertaking bylaws.
BS 6891 – Gas Installations
BS 5482 – Installation of LPG
IS 813 – Installation of Gas Appliance
(Ireland only)
BS 5546 – Installation of Hot Water Supplies for
Domestic Purposes
BS 5449 – Flues and Ventilation
BS 4814 – Specification for Expansion Vessels for
Sealed Hot Water Heating Systems
BS 6798 – Measurement of Emitted Noise
BS 5449 – Forced Circulation Hot Water Central
Heating Systems
BS 7074 – Expansion Vessels and Ancilliary
Equipment for Sealed Water Systems
BS 7593 – Treatment of Water in Domestic Hot
Water Central Heating Systems
BS 7671 – Electrical Wiring egulations
BS EN 1264 Part 4 – Installation of Floor Heating,
Systems and Components.
Incorrect installation may cause harm to people,
animals and property. The manufacturer is not liable
for damage caused by incorrect installation and by
non-observance of these instructions.
The addition of anything which may interfere with the
normal operation of the boiler without the written
permission of Trianco Ltd could invalidate the
appliance guarantee and infringe the Gas Safety
(Installation and Use) egulations.
- Wall-mounted appliance. Siting not dependant
upon room size.
- Multi-function display
- Natural gas models are low-emission
- Automatic ignition
- Modulating Output
- Full safety systems, with flame ionisation
monitoring and temperature sensors
- Concentric flue with CO/CO2 test point
- egulated-speed fan
- Pre-mix burner
- Central heating temperature control
- DHW temperature control (CB Model)
- Three-speed circulating pump with auto vent
- Pressure gauge, relief valve, expansion vessel
- Hot water priority circuit
- Plate-type heat exchanger (CB Model)
- Integral condensate trap
If antifreeze substances are to be used in the system,
always check with the manufacturer that they are
compatible with the aluminium which forms the main
body of the boiler heat exchanger. Due to
its corrosive nature, do not use antifreeze
products which contain ETHYLENE
GLYCOL.
A suitable antifreeze liquid will prevent rust and the
formation of scale.
Periodically check the pH value of the system water,
replacing as necessary when this falls below that
stipulated by the antifreeze manufacturer.
Do not mix different types of antifreeze.
Trianco cannot be held liable for damage caused to
the boiler or water system as a result of the incorrect
use of antifreeze or other additives.
1.5 USE OF ANTIFREEZE PRODUCTS
1.3 STANDARDS AND REGULATIONS 1.4 DESCRIPTION OF APPLIANCE

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2 TECHNICAL SPECIFICATION

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KEY:
A - Heating Flow …………………………. _”
B - Domestic Hot Water (CB only) ...…… _”
C - Gas Inlet ...……………………………. _”
D - Domestic Cold Water Inlet ...……….. _”
E - Heating eturn ..……………………… _”
F - Flue Pipe Collar ………………………ø60/100mm
H - Wall Mounting Holes ………………… ø8mm
L - Condensate Trap Pipe
2.1 BOILER DIMENSIONS
FIG. 1

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2.2 WALL-MOUNTING TEMPLATE
FIG. 2

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KEY:
1 Flue Collar
1 Manual Air Valve
2 Pressure Switch
3 Flow Sensor
4 Ionisation Probe
5 Gas Pipe Mixer
6 Ignition Transformer
7 Ignition Electrode
8 Safety Thermostat
9 Fan
10 Silencer
11 Condensate Trap Pipe
12 Condensate Trap
13 3 bar Pressure elief Valve
14 DHW Sensor
15 Bypass
16 Secondary Heat Exchanger
17 Gas Valve
18 Filling Valve
19 Domestic Water Pressure Switch
20 Drain Tap
21 Pump
22 Automatic Air Valve
23 Three-way Valve
24 Expansion Vessel
25 Condensation Bottom Plate
26 Inspection Cover
27 Primary Heat Exchanger
2.3 TECHNICAL SCHEMATIC
Combi (CB) Model System (SB) Model FIG. 3
1
3
6
13
12
11
10
14
15 16 17 18 19 20 21
22
25
27
28
8
9
4
26
23
24
2
7
5
11
1
6
10
13
12
14
16 21
25
27
28
8
9
7
4
5
3
26
2
16 18 19
22
23

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KEY:
1 Flow Sensor
2 Low Pressure Switch
3 Manual Air Valve
4 Ignition Electrode
5 Nozzle
6 Fan
7 Silencer
8 Condensate Trap Pipe
9 Gas Valve
10 Pressure Gauge
11 Pressure elief Valve
12 Secondary Heat Exchanger
13 DHW Sensor
14 Drain Tap
15 Filling Valve
16 Domestic Water Pressure Switch
17 Three-way Valve
18 Bypass
19 Pump
20 Expansion Vessel
21 Primary Heat Exchanger
22 Burner
23 Overheat Thermostat
24 Ignition Transformer
25 Ionisation Probe
26 Automatic Air Valve
A Heating Flow
B Domestic Hot Water
C Gas Inlet
D Domestic Cold Water Inlet
E Heating eturn
2.4 HYDRAULIC SCHEMATIC
AB C DE
1
4
5
6
7
8
9
11
10
12
13
14
16
15
17
18
19
21
22
20
23
24
25
2
3
26
AC ED
1
4
5
6
7
8
9
11
10
14
15
18
19
21
22
20
24
25
2
26
3
23
Combi (CB) Model
System (SB) Model
FIG. 4

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The appliance must only be installed on sealed
heating systems.
Do not use galvanised radiators or pipework, as this
will lead to the formation of gas in the system.
A suitable antifreeze fluid should be added to the
water in the central heating system.
Do not use add sealing agents to the water in the
central heating system, as deposits may remain in
the boiler heat exchanger.
egard should be given to the siting of the flue
terminal, so as not to cause a nuisance. Further
guidance is given in section , on page 21.
Clearances
The boiler must be installed
in an accessible position,
with attention given to the
need for future servicing and
maintenance.
While the side panels will not
require removal during most
service operations, it is
recommended that a
clearance of 35mm is
provided on either side of
the boiler for convenience.
As the casing and flue temperature will not exceed
85°C, no special provisions are required to protect
flammable building components and nearby furniture,
though all specified clearances must be observed.
Due to low thermal losses from the casings, the
appliance is eminently suitable for installation in a
cupboard or compartment, provided all specified
clearances are observed and the requirements of
BS 6798 and BS 5440 Part 2 are observed.
Combustion Air
The combustion air to the appliance must not contain
any corrosive substances. Substances which are
classed as corrosive include chlorine and fluorine-
based products, solvents, paints adhesives, some
aerosols and household cleaners.
The boiler must be installed in a position complying
with the dimensions set out in section 3.1.
Using the wall template (section 2.2, page 9)
provided, and making sure that the template is level,
mark and drill the holes required for mounting the wall
plate, pipework, manifold connections and flue. Mark
and drill the holes required for the boiler mounting
plate and insert appropriate plugs for the type of wall.
Fix the boiler mounting plate and manifold in position
on the wall. In this way the water connections can be
pre-piped before the boiler is mounted. Lift the boiler
onto the mounting plate and make good all
appropriate connections.
For optimum performance after installation, the boiler
and associated central heating system must be
flushed in accordance with BS 7593 (Treatment of
Water in DHW Central Heating Systems).
Observe all regulations in force, specified by the
Local Water Authority.
The pressure relief valve (item 13, page 10 & item
11, page 11) is set at 3 bar. All pipework, fitting, etc.
used on the system should be suitable for pressures
in excess of this. The pressure relief discharge pipe
should not be less than 15mm in diameter and should
run continuously downward. The termination point
should be bent facing downwards and towards the
wall and not discharge over windows, entrances,
walkways and any other place likely to cause
nuisance to persons and electrical components.
Consideration should be given to the fact that boiling
water and steam will discharge from the pipe upon
activation of the pressure relief valve.
A _” male pipe connection will be required to connect
to the pressure relief valve.
The 10 litre expansion vessel provided with the boiler
is suitable for system volumes of up to 140 litres. An
additional vessel will be required for system volumes
in excess of this. The following formula can be used
to calculate the required expansion vessel size:
V = 0.07 x C
V = Expansion vessel volume (litres)
C = Water system volume (litres)
3 INSTALLATION AND ASSEMBLY
3.1 SITING AND ACCESS
3.2 UNIT ASSEMBLY
3.3 HYDRAULIC CONNECTIONS
FIG. 5

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To fill the system once the pipework has been
connected, first gain access to the inside of the boiler
(see section 4, page 1 ) and open the cap on the
automatic air valve (item 23, page 10). Gradually
open the filling loop valves located on the underside
of the boiler. Once at desired pressure, close the
filling loop and open the manual air valve (item 2,
page 10) to vent the system when full. When
complete, close the manual air valve (fig 7).
All system filling must be done in accordance with
recommended W AS guidelines.
Automatic Air Valve
Manual Air Valve
The boiler operates between working pressures of
1-1.5 bar. This can be checked on the pressure
gauge located on the front control panel. Once all the
air has been vented from the system, close the
manual and automatic air valves. Once the desired
pressure has been reached, close the filling valves.
Before initial firing of the boiler, ensure that the pump
has not become blocked by carrying out the following
operation:
1) emove screw ‘A’ (fig 8).
2) Turn the rotator knob, taking care not to apply
excessive force.
3) eplace screw ‘A’.
Check that the circulator is operating correctly, and if
necessary, bleed of air by turning screw ‘A’ anti-
clockwise. Tighten once complete.
Important: Before proceeding, always ensure that
the water within the pump is not boiling.
Also take care not to damage any other
components with water which may
escape during this process.
The pump is factory-set at setting III. In most
circumstances this is the best setting to achieve
optimum boiler performance and will not require
adjustment. We recommend that this is not altered
unless strictly necessary.
To change the pump speed, rotate knob ‘S’ (see
below) into the required position (I, II, III).
The householder should be informed that the system
pressure should be checked periodically via the
gauge on the front face of the control panel.
To recalibrate the system pressure, slowly open the
filling valves on the underside of the appliance. When
the desired pressure has been reached, close the
valve.
(continued overleaf)
3.4 FILLING THE SYSTEM 3.5 CIRCULATING PUMP
3. SYSTEM PRESSURE CHECKS
FIG.
FIG. 8
A
FIG. 7

14
Circa
1/2 H
H
When the system pressure drops below the minimum
values, the digital readout on the control panel will
display the fault codes ‘E 02’. Once the pressure has
been reset, the boiler should be switched off, then on,
via the ON/OFF button on the control panel.
If during normal operation the pressure drops
repeatedly, this indicates a loss of pressure in the
system beyond expected levels and all valves,
pipework, etc. should be checked for leaks.
The appliance has an in-built condensate trap (item
12, page 10) which eliminates the need for any
external traps. The flexible drain hose is located
behind the pipework on the underside of the boiler.
This should be routed through the cutout in the base.
Connect to the flexible and extend the pipe run away
from the appliance with a continuous fall of 2° (or
20mm in every metre).
Before initial firing of the
boiler, the condensate trap
must be filled with water to
prevent the escape of flue
gases. On the underside of
the boiler, unscrew the
transparent glass of the
drain connection, fill the
trap to halfway with water,
before reassembling.
The condensate pipe may terminate into any four
areas:
1) Into an internal waste system, with the end of the
pipe into a gully below ground level, but above
the water line.
2) Into an external waste system, with the end of the
pipe into a gully below ground level, but above
the water line.
3) Into an internal soil and vent stack.
4) Into an external purpose-made soakaway.
As external condensate pipe runs may be susceptible
to freezing during very cold weather, it is advisable to
terminate the pipe into an internal waste system
where possible.
If there is no alternative to an external pipe run, the
following should be taken into consideration:
1) The pipework should be insulated with weather-
proof material to prevent the condensation from
freezing.
2) The pipe run should take the shortest practical
route.
3) The pipe should terminate as close as is possible
to the ground/drain, while still allowing for the
safe dispersal of the condensation.
A condensate pump can be fitted where the external
ground level is higher than the boiler and there are no
internal drains.
The pipework from the condensate trap to the drain is
not supplied with the boiler.
If the combi (CB) model is to be installed in a hard
water area, a suitable water-treatment device must
be fitted in the mains supply to the boiler.
If in doubt, please contact the local water authority.
These notes are for guidance only. In all cases, refer
to manufacturer’s instructions and BS EN 1264-4 for
best practice when installing underfloor heating
systems.
The use of plastic pipes without protection against
oxygen ingress can cause corrosion of parts within
the system. All pipework must be of a type which
incorporates an oxygen-proof barrier in accordance
with standards DIN 4726 and DIN 4729.
Trianco is not liable for any damage caused to the
appliance, system, or floor areas as a result of non-
compliance with manufacturer’s instructions and the
standards quoted above.
3.7 CONDENSATE TRAP
3.9 HARD WATER AREAS
3.10 UNDERFLOOR HEATING
3.8 CONDENSATE PIPE
FIG. 9

15
The boiler is supplied with a pipework connection
manifold (fig 12), simplifying the connection of the
gas and water supplies.
Mount the boiler as shown and described on the
template provided and the manifold as shown on
fig 11.
Connect the pipework to the manifold, ensuring all
joints are sealed correctly. The correct pipework
placement can be seen on fig 10.
After the system fill, check all joints once more for
leaks.
3.11 PIPEWORK CONNECTION MANIFOLD
A
Heating Flow
B Domestic Hot Water
C Gas Inlet
D Domestic Cold Water Inlet
E Heating Return
FIG. 10
FIG. 11
FIG. 12

16
To gain access to the combustion chamber, proceed
as follows:
1) emove the two screws from the underside of
the control panel (fig 13) and bring forward,
pulling from the top.
2) emove the two screws behind the control panel.
3) Lift the front door upwards and then forward to
remove.
4) emove screws (marked ‘a’ on fig 15) from the
combustion chamber cover and lift off.
5) emove screws (marked ‘b’ on fig 1 ) from the
side panel and lift off.
Note: emoval of the side panel will not be required
during normal maintenace and service procedures.
4 ACCESS TO THE INSIDE OF THE BOILER
FIG. 13
FIG. 14
FIG. 15
FIG. 1

17
Always isolate the power supply to the
appliance before carrying out any work
on the electrical systems and
components.
Wiring to the boiler must conform with all
requirements of the current issue of the IEE Wiring
egulations for fixed wiring to a stationary appliance,
and any local regulations which may apply. Failure to
do so may cause a hazard and will invalidate the
appliance warranty.
This appliance must be earthed.
Connection to the appliance should be via a fused
double-pole isolation switch, with a contact
separation of at least 3mm in all poles, and serving
only the boiler and system controls.
The cables to low power supply peripherals such as
remote controls, room thermostats, probes, etc. must
be double-isolated or follow a different path from
those to the main net.
After installation, or in the event of a fault, the
electrical system should be thoroughly checked for
fuse failure, short circuits, incorrect polarity,
resistance to earth, and earth continuity.
In the event of replacement, use a cable with the
same specification as that fitted.
- Supply – 230V, 50Hz, 150 Watts.
- External fuse – 3 amp.
- Water protection IPX4D.
To gain access to the electrical components, remove
the two screws from the underside of the control
panel (fig 17) and bring forward, pulling from the top.
emove screws (marked ‘A’ on fig 18) from the rear
of the control panel and lift the fixed panel as shown
on fig 19.
On the System (SB) Model only, this item is supplied
separately in a bag within the boiler carton and is
used to connect external controllers to the boiler. See
wiring diagram (section 5. , fig 24) for correct
placement. Using a crimping tool, attach the external
control wiring to the terminals provided and insert into
the plug provided (fig 20).
Connect
as shown
5 ELECTRICAL
5.1 ACCESS TO ELECTRICAL PANEL
5.2 CONTROLS CONNECTION PLUG
FIG. 17
FIG. 18
FIG. 19
FIG. 20

18
Combi (CB) Model
The boiler should be connected to a double-channel
programmer with volts-free switching to allow the
control of the central heating and hot water. A room
thermostat should also be fitted.
Alternatively, a digistat can be fitted in place of these,
controlling the central heating and leaving the hot
water facility on permanently. See fig 21 for digistat
wiring.
In both circumstances, it may also be necessary to fit
a frost thermostat, should there be a possibility of the
water in the pipes freezing.
When using standard controls, the boiler flow
temperature can be set using the heating knob on the
control panel. The hot water control becomes inactive
when the temperature is set via the cylinder
thermostat.
System (SB) Model
The boiler should be connected to a double-channel
programmer with volts-free switching to give the
option of controlling both the central heating and hot
water separately. A room thermostat and cylinder
thermostat should also be fitted.
It may also be necessary to fit a frost thermostat,
should there be a possibility of the water in the pipes
freezing.
The System (SB) model can be wired to both Y-plan
and S-plan control systems (see figs 22 & 23).
When using standard controls, the boiler flow
temperature can be set using the heating knob on the
control panel. The hot water control becomes inactive
when the temperature is set via the cylinder
thermostat.
5.3 CONTROLS & WIRING
FIG. 21
IMPORTANT:
All external controls must be volts-free switching type.

19
5.4 Y-PLAN WIRING
5.5 S-PLAN WIRING
CONNECTION PLUG
- SEE SECTION 5.2, PAGE 1 FOR DETAILS
CONNECTION PLUG
- SEE SECTION 5.2, PAGE 1 FOR DETAILS
FIG. 22
FIG. 23

20
5. WIRING SCHEMATIC
KEY: IG – Main Switch TR – Transformer VD – Diverter Valve (CB Model Only) CI – Pump VG – Gas Valve TA – oom Thermostat TSI – Installation Safety Thermostat TS – High Limit Thermostat PM – Low Pressure Switch NTC1 – Outlet Probe NTC3 – DHW Probe (CB Model Only) TB – Boiler Thermostat FS – DHW Flow Switch MV – Fan ER – Ionisation Probe EA – Ignition Electrode Maximum length of room thermostat cable (2 x 0.75mm2 = 40m)
FIG. 24