MC 5-20 CI 5/20 kW. MC 5-30 CI 5/30 kW.

190171-G(280508)

MC SERIES LOG BOILER

INSTALLATION AND USER INSTRUCTIONS

Boiler Assembly 10

Assembly

Contents 2

MISCELLANEOUS

Boiler Identification 7Boiler Specification 7Boiler / Appliance Contents 8Boiler Dimensions 9

Perodic Maintenance Requirements 12Ash Removal and Upper Chamber Cleaning Instructions 12Rear Spigot Ash Door Cleaning and Removal 12

MAINTENANCE

Fitting and Calibration of the Thermostat 11Use and Operation 11

SETUP AND USE

Overview 3Safety and Approvals 4

Chimney and Flue Requirements 5General Requirements 5Boiler Description 6

INSTALLATION

INTRODUCTION AND REQUIREMENTS

3

Conformity

The MC 5.20 CI and MC 5.30 CI both conform to European Directive:

• EN 303-5

MODÈLE CODEMC 5.20 CIMC 5.30 CI

902 007902 011

Gamme

Thank you for purchasing a boiler from the Perge range of central heating boilers, please take time

to read the following guidance instructions on how to install and use your new boiler. It is important

that these guidelines are followed in order to give optimum performance from your new Perge boiler.

IMPORTANT: FOLLOWING INSTALLATION, PLEASE ENSURE THAT THESE INSTRUCTIONS ARE LEFT WITH THE USER FOR

FUTURE USE AND SERVICING.

To maintain the boilers high thermal efficiency and give trouble free operation, it should be serviced annually by

a suitably qualified heating engineer. THIS IS ALSO A CONDITION OF THE PRODUCT GUARANTEE..

Please contact Perge should you need help in finding an engineer.

All electrical work should be carried by a qualified electrican, in accordance with the latest regulations. Before

attempting any work on the boiler or system controls, ensure the mains supply is disconnected.

The boiler can be connected to most normal heating systems, but should there be any doubt in the application

please call Perge for further information. As it is a continuously burning appliance, it should be connected to a

heat-bleed device (such as a radiator) to disapate any heat produced, due to a system pump failure. It is also

advisable to connect the intergral 'Quench Coil' fitted as standard to all Perge MC series boilers.

This appliance should be installed in accordance with the rules in force and in line with any local requlations;

Building Regulations, Local Bye Laws, Local Water Authority Bye Laws

Installation Of Chimneys and Flues For Solid Fuel Appliances BS 6461 Pt 1 and 2

Forced Circulation Of Hot Water Systems For Domestic Premises BS 5449

4 Safety and Approvals

Safety Notes

Boiler Location Requirements

● It is a legal requirement under England and Wales BuildingRegulations, that the installation of this appliance is in ac-cordance with Local Building Control Approval or is installedby a competent person registered with a Government approvedscheme. HETAS Ltd operate such a scheme and a listing oftheir competent persons on their website www.hetas.co.uk

● Do not store or use petrol or other flammable liquids inthe vicinity of the appliance. Do not burn anything otherthan wood. In the event of a chimney fire, the applianceshould be turned to its minimum setting and the firebrigade informed. Do not relight until fully inspected andpassed by a qualified competent engineer.

● As a heating appliance and the high operating tem-peratures it produces, it should ideally located away frompublic access. Additionally, should children or the elderlyand infirm be liable to come into contact with the appliancea suitable guard should be fitted to prevent access.

IMPORTANTENSURE VENTILATION IS PROVIDED IN ACCORDANCE WITHTHE RULES IN FORCE .

● All permenant ventilation to the room should be keptclear at all times. Seek professional advice if in any doubt.

● Ensure the customer is presented with this manual fol-lowing installation.

● Improper use of this appliance can lead to injury or deathof the user or third party. Therefore, ensure the appliance isinstalled in accordance with this manual any any rules in force.Any faults should be fixed immediately to ensure safe operation. The manufacturer accepts no responsibility for improper useand/or installation of this appliance. This includes maintainingthe installation, operation and conditions specified by themanufacturer

● Ensure the appliance is installed and maintained in accor-dance with these instructions. Failure to do so may result inunsafe operation, and will invalidate any guarantee or warranty.

The appliance and flue should be inspected and cleanedannually. More frequent cleaning may be required ifunseasoned wood is used. Consult a qualifed chimney sweepor heating engineer if in any doubt.

Approved Document B, of the Building Regulations states that boiler houses are classed as 'places of special fire hazard':

● As a 'Places Of Special Fire Hazard' there must be aseparate fire compartment constructed. This means that ifan existing room is altered, such as a utility room orgarage. It should be fireproofed to make it a specialcompartment as well as in the case of a new construction

● The requirements for a designated compartment is thatthe responsible person must carry out a risk assessment forthe location and take into accountthe requirements of theBuilding Regulations Approved Document B1 and B2.

● This compartment should not form a part of one of theexits from the property that would be used as a fire exit.There can be a door from the property to the boiler room,and a door from the boiler room to the outside, but thisshould not be classed as a fire exit.

● As a 'Places of Special Hazard' it has to be treated as aseparate compartment and the materials used for lining ofthe walls and ceilings for fire protection must meet theNational Class 1 or European C-S3, D2.

● Any wall or floor between a garage and a house musthave 30minutes fire resistance with a self closing door, andmust be classed as smoke sealed along its jambs and head.

● Any services that passs through the wall between theboiler house and dwelling should have adequate firestop-ping as per ADB1 Section 7. i.e. If the pipe is non-com-bustible and has an internal diameter of less than 160mm.

● If the boiler house, plant room or store is in thebasement of the property, then this must have its ownseparate natural smoke and heat outlet.

● Combustion needs oxygen to burn, therefore a permenantair supply into the installation location is required. Require-ments are as per Building Regulations Approved Document J.

● The boiler should be located on a level non-combustiblesurface, with suitable load bearing capacity.

● Allow sufficient space aroungd the boiler for access formaintenance and cleaning.

Requirements 5

Chimney / Flue Requirements

Chimney installations and Ventilation should comform to requirements of the Building Regulations and approvedDocument J and all subsequent standards referred to. IF IN DOUBT CONSULT PERGE OR HETAS FOR ADVICE.Twin wall insulated flue should be specified for use with multifuel/wood burning appliances.Existing clay/brick chimneys should be lined with a flexible liner suitable for use with multifuel/wood burning appliances.

If in any doubt as to the suitability of the flue or chimney, consult a flue manufacturer or Perge.

If the appliance is NOT used in conjuntion with an accumulator tank, then it is advisable to fit a 'flue damper / stabiliser' toensure correct operation in all conditions. Refer to the manufacturer for more advice.

A minimum effective flue height of 3 metres is recommended for use. Take into account any bends or elbows when calculatingthis requirement.

A soot door should be provided to aid in cleaning and serving of the boiler installation.

A minimum height of 600mm above the boiler to any bend is required, taking into account that each bend will require an additional flue height to be provided. Any bend should be no greater that 45 degrees.IMPORTANT: A FLUE DRAUGHT OF BETWEEN 130-180 MICROBARS IS REQUIRED WHEN RUNNING AT RATED OUTPUT. ADDITIONAL FLUE PULL SHALL REQUIRE A DRAUGHT STABILISER TO BE FITTED TO PREVENT OVER-FIRING.

General Requirements

Electrical System

All electrical connections and installation to the system or controls should conform to the low voltage directive and guidlineswithin EC 73/23 and EEC-L 77/73

Water

The heating system must be filled with water in accordance with BS 7593:2006. Code of Practice for treatment of water in domestichot-water and central heating systems or the VDI guidelines 2035 sheets 1 and 2 "Avoiding Damage In Hot Water Systems"

Ventilation

Ventilation to the appliance should be provided in accordance with Document J of the Building regulations 2000

Bolier Description

Safety Features

The PERGE MC series boilers are comprised of a two part heat exchanger and combustion chamber.

- Bottom Heat Exchanger (1) consisting of a cermaic lined combustion chamber with parallel heat exchanger tubes embedded in (2) within a high temperature refractory ceramic chamber with removeable fuelbed grate.- Upper Chamber (3) designed to maximise effeciency by incorporating a series of water filled tubes through which flue gases pass.

- Anti-Boiling Quench Coil (4) to prevent overheatingFuelbed Grate / Cleaning Door(5) to allow access forcleaning and ash removal. This also houses theprimary air entrainment control system (6). Access tothe main combustion chamber is made throught theloading door (7), in order to load the chamber/ fu-elbed with logs.A thermostat (8) automatically maintains the boiler water temperature by controlling the primary air entrainment to the combustion chamber (6). *for operating details on the thermostat see p..

4

5

3

2 1

6

7

8

The Perge MC series boiler are a range of wood burning boilers with ceramic combustion chamber technology.The unique design of the Perge MC series boilers are covered by a patent No 8 211 712They can be used for : - Domestic Hot Water Only (in summer) - Central Heating and Domestic Hot Water (in winter) - Heating Only

These boilers can be designed into exisiting system layouts and/or alongside an accumulator tank, to provide flexibility of heating requirements. -

- Anti-Boiling Quench Coil, which can be connected to main cold water to operate should via a thermostatic valve should the boiler reach boiling point.This feature comes as standard on the MC series boiler, but is an optional feature for use in open vented systems.

6 Boiler Information

Boiler Identification

Boiler Specification

kW.

kW.

%

microbar

microbar

°C

° C

k W

m m

mm.

mm.

Kg.

Bars

Bars

Bars

mm.

mm.

Heat Output Max.

Min.

Maximum Efficiency

Flue Pull Min.

Max

Water Thermostat Setting Mini.

Maxi.

Heat Output (at maximum effeciency).

Loading Chamber Opening Dimension

Maximum Log Length

Combustion Chamber Dimension (W x H x D)

Product Weight

Pression d’épreuve

Maximum Operating Pressure

Anti-Boiling Coil Pressure

Anti-Boiling Coil Connection Dimensions

Flow / Return Connection Dimensions

20

5

81,15

130

180

80

90

15

308 x 308 500

500

340 x 535 x 495

425

4,5

3

2

15/21

100 180

40/49 F.

26/34 M.

30

5

78,15

130

180

80

90

18

308 x 308 500

500

340 x 535 x 495

445

4,5

3

2

15/21

100 180

40/49 F.

26/34 M.

MC 5-20 CI MC 5-30 CIMODEL

A Data Plate for each boiler is fitted to the top rear of the appliance, benea the top cover. This is required when callingregarding a spares or technical enquiry.

Miscellaneous 7

Appliance Contents

- 2 Door Handles

0,82

m.

0,26 m.

- 1 Removable Grate (withfront/back plates)

()

1,12 m.

- 1 screw pack φ5x13

- 1 Themrostat ()

- 1 Top Panel / 2 x Insulation

- 1 ftop ront panel (black)

- RHS Side Panel(orange/black) with insulation

- 1 LHS side panel with insulation. Plus boiler

thermometer

Box 1 : Contains the main boiler / combustion chamber engine.The following accessories are located within the boiler combustion chamber :

- 1 Top Rear Panel / 1 x Insulation

- 1 central rear panel and insulation

- 1 cleaning brush

- 1 Ash Tray

Box 2 : The follwing components arepacked within Box 2 of 2 :

- 1 Vertical Flue Spigot

1 Lower Rear Panel

- 1 Baffle Plate

- 2 SecondaryAir Channels

- 2 side support brackets

- 1 Raking Bar (Ash)

- 1 Raking Bar (Tubes)

8 Miscellaneous

Boiler Dimensions

MISCELLANEOUS 9

1326

097

2 11251165

Heating Circuit Flow Connections φ 1"1/2 F.

193

Anti-Boiling Quench Coil connections

Hot Water Flow Connection φ 1"M.

Return Heating Circuit φ 1"1/2 F.

Hot Water Return Connections and DrainPoint φ 1"M.135 135

MC 5-20/5.30(Rear)

Assemblage desdeux échangeurs (par 4 boulons)

Phial Location Points

Lifting Hook

Thermostat

Collecteur deraccordement entre leséchangeurs haut et bas

600

1118

1270

165 165

910

MC 5-20/5.30(Top Section)

MC 5-20/5.30(Front)

5377

8

Vertical Flue Spigot(located with two screws)

1010

φ 180 mm. int.

MC 5-20/5.30()

Prior to installation, it is important to decide on the right location for your boiler:- Locate your boiler so that you are able to easily access stored wood fuel- Ensure there is sufficient access to load and clean the boiler- Ensure the boiler is located in a dry, weather resistant atmosphere- Allow a minimum 60cm around the boiler for access and servicing

!

Boiler Assembly

10 Assembly

5-Fit the top front panel from in-side the top section of the boiler and fix to the black section of the side panels with two screws .

5

6

4

6-Locate the top panel/insulation onto the boiler.

4- Insert the thermometer phial-bulb through the opening and insert into one of three location tubes. It is advisable to smear the bulb in contact paste prior to location.- Locate the thermometer body into the side panel location.

7-Remove the red plastic protection plug and screw in the water temper-ature regulator, ensuring it is sealed prior to fitting (7b) connect he link chain to the primary air damper.

7

7b

8-Fit the two door handles, by screw-ing ontot he relevant door section.

8

8

3-Position the rear panel assembly :1 top rear panel (3a) 1 central rear panel (3b) 1 lower rear panel (3c) Secure these onto the side panels using the 12 screws supplied

See page 11 for installation of the temperature regulator.

3b

3c

3a

1-Attach the two support brackets (1) with the screws supplied φ4(A)

-Attach the two sec-ondary air channels with

the screws supplied(1b)

A

A

1

11b

1b

2-Attach the two insulated side panels onto the side support bracket lugs (B)

B

B

B

2

2

Fitting and Calibration Of The Thermostat (Calorstat)

Technical 11

Position the control lever so that the chain is line with the primary air damper.The regulator is factory set for Vertical operation : For a horizontal setting place the regulator control to read 30, then remove and rotate clockwise half a turn before refitting.

To set the chain position, set the control knob to read 80 degrees centigrade.When the thermometer indicates 80 degress centigrade. Connect the chain to the damper to give an opening gap of 1mm - 2mm. This will ensure correct operation of the primary air control.

- Water temperature Display.

Primary Air Damper

Loading Door Handle

- It is important to ensure that all installation requirements are met.- Prior to initial use of the boiler, it is IMPORTANT that the boiler is fired at a reduced operating temperature in order to drive any moisture from the combustion chamber ceramic refractory. In order to do this the boiler should be run for the first 3 days firing at a reduced fuel load. This should be sticks and paper and small sticks initially, at a maintained temperature of 40 degrees centigrade over an eight hour period. This can then be progressively increased over a period of 4-5 days. Failure to carry out this instruction, may lead to cracking of the combustion chamber ceramic and invalidate the manufacturers guarantee

It is also recommended that the outer panels are not fitted until this time, to allow any impurities to be burnt off the boiler casing.

Water temperature regulator.Ash Door Handle

- Logs should not be loaded above the level indicated in the combustion chamber.-

.

- Only use dry well seasoned wood, for fuelling the boiler. Ideally a moisture content of 20% is required.

Tray for removal of Ash

Secondary Air Entrainment Slots(Factory Set).

- Upper Combustion Chamber Baffle (Ensure thiscomponent is correctly fitted before use).

Operation of the boiler

Note: If the bottom grate regulators are fitted, this will reduce the boiler output if required.

PERGE uk LTDNew StreetLeekStaffordshire ST13 6EBTel: 01538 382387www.perge.co.uk info@perge.co.uk

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Ash Removal and Upper Heat Tube Cleaning Instruction

- Open the lower ash door, and rake any fallendebris/ash into the tray provided, and dispose ofaccordingly.

Ash Tray

RearFace

Brush

Upper BafflePlate

Ash Removal Tool

Tube CleaningTool

Remove the rear ash t rap col lector p late anddispense any ash that may have col lected.Remove with two screws, and replace.

Ash Door (Rear Spigot Connection) (2 times per month)

Removable Grate

Rear Ash Trap

12 OPERATION AND MAINTENANCE

After cleaning en-sure the upper baf-fle plate is replacedcorrectly.

A B

Periodic Maintenance

It is important for both efficient and safe operation of the boiler that the following operations are carried out. Detailed below areinstructions on the removal of ash form the boiler and cleaning of the upper heat tubes and combustion chamber

Ash Removal (fig. A) As Required When required the ash can be removed form the bottom grate by using theash removal tool. A tray is provided for safe and coveniant removal.

Upper Heat Tubes (fig. B) 1 to 2 months

Air Controls

Operation Frequency Comments

Check that all air entrainment holes / plates are free from debris or blockageRegularly

Servicing of the boiler and flue installation Annually

The boiler and installation should be checked and fully serviced eachyear by a suitablly wualified heating engineer. This is a safetyrequirement, and forms part of the product warranty

Open the loading door and remove the upper baffle plate.Using the tools provided first rake the upper tubes andclean with the brush provided. Also remove any depositsfrom the sides of the combustion chamber.