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Ultimate 3 25r

Glow-worm ENERGY 12r, ENERGY 15r, ENERGY 18r, ENERGY 25r, ENERGY 30r Installation And Maintenance Instructions Manual

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Installation and main­tenance instructions
ENERGY
12r 15r 18r 25r 30r
GB, IE
Contents
Contents
1 Safety .................................................................... 3
1.1 Action-related warnings ......................................... 3
1.2 Risk caused by inadequate qualifications.............. 3
1.3 Intended use .......................................................... 3
1.4 General safety information .................................... 3
1.5 Regulations (directives, laws, standards).............. 5
2 Notes on the documentation .............................. 6
2.1 Observing other applicable documents ................. 6
2.2 Storing documents................................................. 6
2.3 Validity of the instructions...................................... 6
3 Product description............................................. 6
3.1 Benchmark............................................................. 6
3.2 Compartment Ventilation ....................................... 6
3.3 Functional elements............................................... 6
3.4 Information on the identification plate.................... 7
3.5 CE label ................................................................. 7
4 Set-up.................................................................... 7
4.1 Transporting the unit .............................................. 7
4.2 Unpacking the product........................................... 7
4.3 Checking the scope of delivery.............................. 7
4.4 Dimensions............................................................ 8
4.5 Minimum clearances.............................................. 8
4.6 Using the mounting template................................. 8
4.7 Wall-mounting the product..................................... 8
4.8 Removing/installing the front casing...................... 9
4.9 Removing/installing the side section ..................... 9
5 Installation.......................................................... 10
5.1 Preparing for installation ...................................... 10
5.2 Installing the heating pump.................................. 10
5.3 Heating water supply in the open heating
system ................................................................. 11
5.4 Connecting the heating flow and heating
return ................................................................... 11
5.5 Gas connection.................................................... 11
5.6 Connecting the condensate discharge pipe ........ 12
5.7 Electrical installation ............................................ 13
6 Operation............................................................ 15
6.1 Using diagnostics codes ...................................... 15
6.2 Displaying the status codes................................. 15
6.3 Using check programmes .................................... 16
7 Start-up ............................................................... 16
7.1 Carrying out the initial start-up............................. 16
7.2 Checking the type of gas ..................................... 16
7.3 Checking the factory setting ................................ 16
7.4 Checking and treating the heating water/filling
and supplementary water .................................... 16
7.5 Filling the condensate trap .................................. 17
7.6 Switching on the product ..................................... 18
7.7 Filling the heating installation .............................. 18
7.8 Checking and adjusting the gas settings ............. 18
7.9 Checking leak-tightness ...................................... 19
7.10 Checking the heating mode................................. 19
8 Adapting the unit to the heating
installation.......................................................... 19
8.1 Burner anti-cycling time ....................................... 19
9 Handing the product over to the end user ...... 20
9.1 Informing the operator about the maintenance
intervals ............................................................... 20
10 Inspection and maintenance ............................ 20
10.1 Using original seals.............................................. 20
10.2 Observing inspection and maintenance
intervals ............................................................... 20
10.3 Procuring spare parts .......................................... 20
10.4 Checking the CO₂ content ................................... 20
10.5 Setting the CO₂ content ....................................... 20
10.6 Removing the gas-air mixture unit ....................... 21
10.7 Cleaning the heat exchanger............................... 22
10.8 Checking the burner ............................................ 22
10.9 Checking the ignition electrode ........................... 22
10.10 Cleaning the condensate siphon ......................... 22
10.11 Installing the gas-air mixture unit ......................... 22
10.12 Draining the product ............................................ 22
10.13 Completing inspection and maintenance work .... 23
10.14 Checking the product for leak-tightness .............. 23
11 Troubleshooting ................................................ 23
11.1 Rectifying faults ................................................... 23
11.2 Calling up the fault memory ................................. 23
11.3 Deleting the fault memory.................................... 23
11.4 Preparing the repair work .................................... 23
11.5 Replacing defective components......................... 23
11.6 Checking the product for leak-tightness .............. 24
12 Decommissioning the product ......................... 24
13 Customer service............................................... 24
Appendix ............................................................................25
A Inspection and maintenance work –
Overview............................................................. 25
B Check programmes – Overview ....................... 25
C Overview of diagnostics codes........................ 26
D Status codes – Overview .................................. 29
E Overview of fault codes .................................... 30
F Wiring diagram................................................... 32
G Wiring diagram, 30 kW ...................................... 33
H Position of the opening in the air/flue pipe ..... 34
H.1 Positioning of the opening of a fan-supported
flue gas pipe ........................................................ 34
H.2 Horizontal terminal positioning ............................ 35
I Commissioning Checklist................................. 36
J Pipe lengths for the air/flue pipe ...................... 40
J.1 Length L of the C13 type air/flue pipe.................. 40
J.2 Length L of the C33 type air/flue pipe.................. 40
J.3 Length L of the C43 type air/flue pipe.................. 40
K Technical data.................................................... 41
Index ...................................................................................45
Safety 1
0020177748_03 ENERGY Installation and maintenance instructions 3
1 Safety
1.1 Action-related warnings
Classification of action-related warnings
The action-related warnings are classified in accordance with the severity of the possible danger using the following warning signs and signal words:
Warning symbols and signal words
Danger!
Imminent danger to life or risk of severe personal injury
Danger!
Risk of death from electric shock
Warning.
Risk of minor personal injury
Caution.
Risk of material or environmental damage
1.2 Risk caused by inadequate qualifications
– Set-up – Dismantling – Installation – Start-up – Inspection and maintenance – Repair – Decommissioning
▶ Observe all instructions that are included
with the product.
▶ Proceed in accordance with current tech-
nology.
▶ Observe all applicable directives, stand-
ards, laws and other regulations.
1.3 Intended use
There is a risk of injury or death to the user or others, or of damage to the product and other property in the event of improper use or use for which it is not intended.
The product is intended as a heat generator for open or closed heating installations and for domestic hot water generation with a ven­ted or unvented domestic hot water cylinder.
Depending on the unit type, the products referred to in these instructions must only be installed and operated in conjunction with the
air/flue pipe accessories listed in the other applicable documents.
Intended use includes the following:
– observance of accompanying operating,
installation and servicing instructions for the product and any other system compon­ents
– installing and fitting the product in accord-
ance with the product and system approval
– compliance with all inspection and main-
tenance conditions listed in the instruc­tions.
Intended use also covers installation in ac­cordance with the IP code.
Any other use that is not specified in these in­structions, or use beyond that specified in this document shall be considered improper use. Any direct use in industrial or commercial processes is also deemed to be improper.
Caution.
Improper use of any kind is prohibited.
1.4 General safety information
1.4.1 Risk of injury due to the heavy weight of the product
▶ Make sure that the product is transported
by at least two people.
1.4.2 Risk of death from escaping gas
What to do if you smell gas in the building:
▶ Avoid rooms that smell of gas. ▶ If possible, open doors and windows fully
and ensure adequate ventilation.
▶ Do not use naked flames (e.g. lighters,
matches).
▶ Do not smoke. ▶ Do not use any electrical switches, mains
plugs, doorbells, telephones or other com­munication systems in the building.
▶ If it is safe to do so, close the emergency
control valve or the main isolator.
▶ If possible, close the gas isolator cock on
the product.
▶ Warn other occupants in the building by
yelling or banging on doors or walls.
▶ Leave the building immediately and ensure
that others do not enter the building.
1 Safety
▶ Notify the gas supply company or the Na-
tional Grid +44 (0) 800 111999 by tele­phone once you are outside of the build­ing.
1.4.3 Risk of death from escaping flue gas
If you operate the product with an empty con­densate trap / siphon, then flue gas may es­cape into the room air.
▶ In order to operate the product, ensure that
the condensate trap / siphon is always full.
1.4.4 Risk of death due to blocked or leaking flue gas routes
Installation errors, damage, tampering, unau­thorised installation sites or similar can cause flue gas to escape and result in a risk of pois­oning.
What to do if you smell flue gas in the prop­erty:
▶ Open all accessible doors and windows
fully to provide ventilation.
▶ Switch off the product. ▶ Check the flue gas routes in the product
and the flue gas diversions.
1.4.5 Risk of poisoning and burns caused by escaping hot flue gases
▶ Only operate the product if the air/flue pipe
has been completely installed.
▶ With the exception of short periods for
testing purposes, only operate the product when the front casing is installed and closed.
1.4.6 Risk of death due to explosive and flammable materials
▶ Do not use the product in storage rooms
that contain explosive or flammable sub­stances (such as petrol, paper or paint).
1.4.7 Risk of death from electric shock
There is a risk of death from electric shock if you touch live components.
Before commencing work on the product:
▶ Disconnect the product from the power
supply by switching off all power supplies at all poles (electrical partition with a con-
tact gap of at least 3 mm, e.g. fuse or cir­cuit breaker).
▶ Secure against being switched back on
again.
▶ Wait for at least 3 minutes until the capa-
citors have discharged.
▶ Check that there is no voltage.
1.4.8 Risk of death due to lack of safety devices
The schematic drawings included in this doc­ument do not show all safety devices re­quired for correct installation.
▶ Install the necessary safety devices in the
system.
▶ Observe the applicable national and inter-
national laws, standards and guidelines.
1.4.9 Risk of corrosion damage due to unsuitable combustion and room air
Sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia com­pounds, dust or similar substances may lead to corrosion on the product and in the flue system.
▶ Ensure that the supply of combustion air is
always free of fluorine, chlorine, sulphur, dust, etc.
▶ Ensure that no chemical substances are
stored at the installation site.
▶ If you are installing the product in
hairdressing salons, painter's or joiner's workshops, cleaning businesses or similar locations, choose a separate installation room in which the room air is technically free of chemical substances.
1.4.10 Risk of material damage caused by
frost
▶ Do not install the product in rooms prone
to frost.
1.4.11 Risk of being burned or scalded by
hot components
▶ Only carry out work on these components
once they have cooled down.
Safety 1
0020177748_03 ENERGY Installation and maintenance instructions 5
1.4.12 Risk of material damage caused by using an unsuitable tool
▶ Use the correct tool to tighten or loosen
threaded connections.
1.4.13 Risk of material damage caused by deformed pipes
Caution. Risk of material damage caused
by changes to the pipes that have already been connected.
▶ Only bend connection pipes if
they have not yet been connec­ted to the product.
1.5 Regulations (directives, laws,
standards)
▶ Observe the national regulations, stand-
ards, guidelines and laws.
2 Notes on the documentation
2 Notes on the documentation
2.1 Observing other applicable documents
▶ You must observe all the operating and installation in-
structions included with the system components.
2.2 Storing documents
▶ Pass these instructions and all other applicable docu-
ments on to the system operator.
2.3 Validity of the instructions
These instructions apply only to:
Product article number
Article number
Gas Council Number
ENERGY 12r -A (H-GB)
0010015660 41-019-21
ENERGY 15r -A (H-GB)
0010015661 41-019-22
ENERGY 18r -A (H-GB)
0010015662 41-019-23
ENERGY 25r -A (H-GB)
0010015663 41-019-24
ENERGY 30r -A (H-GB)
0010015664 41-019-25
3 Product description
3.1 Benchmark
Glow-worm is a licensed member of the Benchmark Scheme.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regu­lations. The Benchmark Checklist can be used to demon­strate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commission­ing and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Benchmark is managed and promoted by the Heating and Hotwater Industry Council.
For more information visit www.centralheating.co.uk
3.2 Compartment Ventilation
The boilers are very high efficiency appliances.
As a consequence the heat loss from the appliance casing during operation is very low.
Compartment ventilation is not required as the products are only certified, and can only be fitted with a concentric flue system.
3.3 Functional elements
4
5
6
3
11
10
9
7
8
1
2
1 Supply air test point
(for the upper air/flue connection)
2 Flue gas analysis point
(for the upper air/flue connection)
3 Fan/gas-air mixture
4 Flue pipe
5 Flue gas analysis point
(for the rear air/flue connection)
6 Gas valve assembly
7 Ignition transformer
8 Heat exchanger
9 Air intake pipe
10 Condensate trap
11 Electronics box
Set-up 4
0020177748_03 ENERGY Installation and maintenance instructions 7
3.4 Information on the identification plate
The identification plate is mounted on the underside of the product in the factory.
Information on the identification plate
Meaning
Barcode with serial number
Serial number For quality control purposes; 3rd and 4th
digits = year of production
For quality control purposes; 5th and 6th digits = week of production
For identification purposes; 7th to 16th digits = product article number
For quality control purposes; 17th to 20th digits = place of manufacture
ENERGY ..r Product designation
2H, G20 – 2.0 kPa (20 mbar)
Factory setting for type of gas and gas connection pressure
Cat. Approved gas category
Condensing techno­logy
Efficiency class of the boiler in accord­ance with EC Directive 92/42/EEC
Type: Xx3(x) Permissible flue gas connections
PMS Maximum water pressure in heating
mode
PMW Maximum water pressure in hot water
handling mode
V/Hz Electrical connection
W Max. electrical power consumption
IP Level of protection
Heating mode
Pn Nominal heat output range in heating
mode
Pnc Nominal heat output range in heating
mode (condensing technology)
P Nominal heat output range in hot water
handling mode
Qn Nominal heating load range in heating
mode
Qnw Nominal heating load range in hot water
handling mode
T
max.
Max. flow temperature
NOx NOx class for the product
Code (DSN) Specific product code
Read the instructions.
GC no. Gas council number
3.5 CE label
The CE label shows that the products comply with the basic requirements of the applicable directives as stated on the identification plate.
The declaration of conformity can be viewed at the manufac­turer's site.
4 Set-up
4.1 Transporting the unit
Important: With regard to the regulations of 1992 concern-
ing the manual handling of loads, the unit exceeds the weight that can be lifted by a single person.
4.1.1 General
▶ Hold the load as close as possible to your body. Avoid
rotational movements. Instead, reposition your feet.
▶ If the unit is being lifted by two persons, ensure your
movements are coordinated during lifting.
▶ Avoid bending your upper body – do not lean forwards or
to the side.
▶ Wear suitable non-slip protective gloves in order to pro-
tect your hands against sharp edges. Ensure that you are carrying the load securely.
▶ If required, get somebody to assist you in this.
4.1.2 Unloading the box from the delivery van
▶ It is recommended that two people lift the unit together. ▶ Lift the box using the straps provided. ▶ Use safe lifting techniques – keep your back straight and
bend your legs at the knee.
▶ Hold the load as close as possible to your body. ▶ If the unit is being lifted by two persons, ensure your
movements are coordinated during lifting.
▶ If required, get somebody to assist you in this.
4.2 Unpacking the product
1. Remove the product from its box.
2. Remove the protective film from all of the product's components.
4.3 Checking the scope of delivery
▶ Check that the scope of delivery is complete and intact.
4.3.1 Scope of delivery
Num­ber
Description
1
Heat generator
1
Hanging bracket
1 Flue gas adaptor
1
Gas isolator cock
1 Gas pipe
1 Condensate drain hose
4 Set-up
Num­ber
Description
1
Installation template
1 Enclosed documentation
4.4 Dimensions
112
183,5 71
375
7833,5
602
220
150
32,5
100
157,5
280
1
2
3
4
5
6
1 Condensate discharge
2 Gas connection
3 Heating return
4 Heating flow
5 Connection on the back
of the air/flue pipe
6 Connection on the top
of the air/flue pipe
4.5 Minimum clearances
CC
A
B
D
Minimum clearance
A 150 mm (top air/flue gas connection)
20 mm (air/flue gas connection on the rear)
B 150 mm
C 5 mm
(70 mm if the side panels ought to be removed)
D 600 mm
It is not necessary to maintain a clearance between the product and components made of combustible materials that go beyond the minimum clearances.
4.6 Using the mounting template
▶ Use the mounting template to ascertain the locations at
which you need to drill holes.
4.7 Wall-mounting the product
Note
If you are using the rear air/flue connection, in­stall the air/flue pipe before you wall-mount the product.
1. Check whether the wall has sufficient load-bearing ca­pacity to bear the operational weight of the product.
2. Check if the supplied fixing material may be used for the wall.
Conditions: The load-bearing capacity of the wall is sufficient, The fixing material may be used for the wall
▶ Wall-mount the product as described.
Set-up 4
0020177748_03 ENERGY Installation and maintenance instructions 9
Conditions: The load-bearing capacity of the wall is not sufficient
▶ Ensure that wall-mounting apparatus on-site has a suf-
ficient load-bearing capacity. Use individual stands or primary walling, for example.
▶ Do not wall-mount the product if you cannot provide
wall-mounting apparatus with a sufficient load-bearing capacity.
Conditions: The fixing material may not be used for the wall
▶ Wall-mount the product as described using the permitted
fixing material provided on-site.
4.8 Removing/installing the front casing
4.8.1 Removing the front casing
B
D
C
A
1. Undo the two screws .
2. Gently press the front casing backwards in the centre and pull it downwards on the lower edge so that the retaining clip is released.
3. Pull the front casing forwards at the bottom edge.
4. Lift the front casing upwards from the retainers.
4.8.2 Installing the front casing
1. Place the front casing on the upper retainer.
2. Press the front casing onto the product so that the re­tainer bracket clicks into place.
3. Secure the front casing by tightening both screws.
4.9 Removing/installing the side section
4.9.1 Removing the side section
Caution. Risk of material damage caused by mech-
anical deformation.
Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for ex­ample, and potentially result in leaks.
▶ Always remove only one side section –
never both side sections at the same time.
Note
If there is sufficient lateral clearance (at least 70 mm), you can remove the side section to fa­cilitate maintenance or repair work.
C
D
A
B
E
1. Tilt the electronics box forward.
2. Hold on to the side section so that it cannot fall, and unscrew both screws, one from the top and one from the bottom.
3. Tilt the side section to the outside and take it out to­wards the top.
4.9.2 Installing the side section
1. Push the side section into the recesses in the back wall.
2. Tilt the side section towards the product.
3. Screw the two screws into the side section, one at the top and one at the bottom.
4. Fold up the electronics box.
5 Installation
5 Installation
5.1 Preparing for installation
Danger! Risk of scalding and/or damage due to
incorrect installation leading to escaping water.
Mechanical stresses in the connection pipes may lead to leaks.
▶ Install the connection pipes such that they
are free from mechanical stress.
Caution. Risk of material damage caused by corro-
sion
Due to non-diffusion-tight plastic pipes in the heating installation, air gets into the heating water. Air in the heating water causes corro­sion in the heat generator circuit and in the product.
▶ If you use non-diffusion-tight plastic pipes
in the heating installation, ensure that no air gets into the heat generator circuit.
Caution. Risk of material damage caused by
residues in the pipelines.
Welding remnants, sealing residues, dirt or other residues in the pipelines may damage the product.
▶ Flush the heating installation thoroughly
before installing the product.
Caution. Risk of material damage due to heat trans-
fer during soldering.
▶ Only solder connectors if the connectors
are not yet screwed to the service valves.
Caution. Risk of material damage caused by
changes to the pipes that have already been connected.
▶ Only bend connection pipes if they have
not yet been connected to the product.
Caution. Risk of damage caused by incorrect gas
installation.
Excess test pressure or operating pressure may cause damage to the gas valve.
▶ Check the leak-tightness of the gas valve
using a maximum pressure of 11 kPa (110 mbar).
▶ Make sure that the existing gas meter is capable of
passing the rate of gas supply required.
▶ Install the following components:
– Drain cocks at the lowest points in the heating install-
ation (→ current version of "BS 2879")
– A heating pump in the heating flow – A bypass that is at least 1.5 m away from the product – A stopcock in the gas pipe – Where applicable, a flow regulator valve to adjust the
flow rate
Pressure loss from the product
0
50
100
150
200
250
300
350
400
0 200 400 600 800 1000 1200 1400
30r
25r
18r 15r 12r
A
B
1
2
A Flow rate [l/h]
B Pressure loss [mbar]
1 Pressure loss 12r, 15r,
18r
2 Pressure loss 25r, 30r
The flow rate must not fall below the value in the diagram.
5.2 Installing the heating pump
▶ Only use pumps that have an in-rush current ≤ 10/15 A. ▶ When designing/selecting the pump, note the pressure
loss of the product.
▶ Install the pump in the heating flow. ▶ Install the pump upstream and downstream of the pump
isolation valves.
▶ Set the pump so that the temperature difference between
the flow and return is no more than 20 °C when the max­imum flow temperature is set.
– The flow rate specified in the technical data is
reached.
Installation 5
0020177748_03 ENERGY Installation and maintenance instructions 11
5.3 Heating water supply in the open heating system
▶ Connect the product to a supply/expansion tank as
shown in the figure. – The tank must not be more than 27 m (90 ft) above
the product.
– The open vent pipe must be installed with an upward
gradient and must not be blocked.
– Supply line diameter: ≥ 15 mm – The relative positions of the pump, supply and open
vent pipe must be as shown in the figure.
Conditions: Combined supply and open vent pipe
▶ Install the line in accordance with "BS 5449".
– Diameter: ≥ 22 mm
5.4 Connecting the heating flow and heating return
2
1
1 Heating return connec-
tion
2 Heating flow connection
1. Establish the heating connections in accordance with
the applicable standards.
2. Check whether the connections (→ Page 19) are leak-
tight.
5.5 Gas connection
1
1. Establish the gas connection (1) in accordance with the
applicable standards.
2. Purge the gas line before start-up.
3. Check the entire gas line properly for leak-tightness.
5 Installation
5.6 Connecting the condensate discharge pipe
1
2
▶ Follow the instructions listed here and observe the legal
and local regulations on condensate discharge.
▶ Use PVC or any other material that is suitable for drain-
ing the non-neutralised condensate.
▶ If you cannot guarantee that the materials from which the
drain pipework is made are suitable, install a system for neutralising the condensate.
▶ Ensure that the connection between the condensate dis-
charge pipe and the drain hose is not air-tight.
Note
The condensate drain pipework must have a continuous fall (45 mm per metre) and should whenever possible terminate at a suitable drain point within the heated envelope of the building that will remain frost free under long periods of low external temperatures.
▶ During installation remove all burrs from inside of cut pipe
work and avoid excessive adhesive which may trap small pockets of water close to the pipe wall which can freeze and build into a larger ice plug.
▶ For any installation the condensate must be free flowing
and not be possible for air back-pressure to prevent wa­ter flow.
▶ As with other pipe work insulate the condensate dis-
charge pipe to minimise any risk of freezing and beware when crossing cavities that the fall is maintained and the pipe sleeved.
You can find further information in specification "BS 6798" for installing and maintaining gas-fired boilers with a nominal heat input below 70 kW.
5.6.1 Condensate drainage systems
5.6.1.1 Internal soil and vent pipe
Ø19mm
min
5.6.1.2 External soil and vent pipe
L = 3m max
Ø19mm
min
Ø30mm
5.6.1.3 External termination into a gulley or hopper
L = 3m max
Ø19mm
min
Ø30mm
Installation 5
0020177748_03 ENERGY Installation and maintenance instructions 13
5.6.1.4 Internal termination into combined sink waste
Ø30mm
Ø19mm
min
5.6.1.5 Internal termination downstream of sink waste
Ø30mm
Ø19mm
min
5.6.1.6 External termination into soakaway
400mm min
300mm
min
25mm
min
500mm min
Ø100mm
L = 3m max
Ø19mm
min
Ø30mm
5.6.1.7 External termination into rain water down pipe
Ø19mm
min
Ø30mm
5.7 Electrical installation
Danger! Risk of death from electric shock!
The power supply terminals L and N remain live even if the product is switched off:
▶ Switch off the power supply. ▶ Secure the power supply against being
switched on again.
Only qualified electricians may carry out the electrical install­ation.
5.7.1 Opening the electronics box
A
B
B
▶ Follow the instructions in the specified sequence.
5 Installation
5.7.2 Closing the electronics box
▶ Follow the instructions in the reverse order.
5.7.3 Cable route
1
2
1 24-V eBUS cable route 2 230-V eBUS cable route
5.7.4 Carrying out the wiring
30 mm max.
1. Shorten the connection cables to the appropriate lengths to prevent them from causing damage inside the electronics box.
2. Screw the plug to the connection cable.
3. Plug the plug into the slot provided on the PCB.
5.7.5 Establishing the power supply
1
1. Observe all valid regulations.
2. Ensure that the rated mains voltage is 230 V.
3. Set up a fixed connection and install a partition with a contact opening of at least 3 mm (e.g. fuses or power switches).
4. Provide one common electricity supply for the boiler and for the corresponding controller:
– Power supply: Single-phase, 230 V, 50 Hz – Fuse protection: ≤ 3 A
5. Open the electronics box. (→ Page 13)
6. Observe the routing of the power supply cable (1) in the electronics box in order to guarantee that there is no strain.
≤ 30 mm
NL
X1 230V~
RT
7. Carry out the wiring. (→ Page 14)
8. Close the electronics box.
9. Make sure that access to the mains connection is al­ways available and is not covered or blocked.
5.7.6 Connecting controllers to the electronic
system
X2
X22
X41
–
+
24V=
RT BUS
Burner
off
X106
BUS24 V
BUSRTB.off
B ur ner
off
R T
24V
=
-
+
B U S
1
4
32
1 Safety thermostat for
floor-standing heating
2 24 V controller
3 eBUS controller or radio
receiver unit
4 Outside temperature
sensor, wired
1. Open the electronics box. (→ Page 13)
Operation 6
0020177748_03 ENERGY Installation and maintenance instructions 15
2. Carry out the wiring. (→ Page 14)
3. Connect the individual components depending on the type of installation.
Conditions: If installing a multi-circuit controller.
▶
Change the pump's operating mode d.18 from Eco (in­termittently operating pump) to Comfort (continuously operating pump).
Conditions: When connecting a controller (230 V).
≤ 30 mm
NL
X1 230V~
RT
▶ Connect the controller to the main plug. ▶ Remove the bridge from the plug 24V=RT.
Conditions: 230 V 3-wire connection
▶ Ensure that the controller is designed for a maximum
rated current of 7 A.
▶ Connect the controller to the main plug X1.
– Terminal assignment: L ‑ line, N ‑ neutral conductor,
‑ earth
▶ Draw the operator's attention to the fact that the follow-
ing features are present with this type of installation.
◁ The frost protection function is deactivated. If the
product is installed in a room where there is a risk of frost and it has not been protected by a room ther­mostat, install an additional frost protection thermo­stat.
◁ The pump programmes are not active. ◁ If the product is switched off, the display is switched
off.
◁ Each time the unit is started, the fan runs for
20 seconds.
◁ Residual heat in the heating return may result in the
product blocking the burner for 10 minutes.
4. Close the electronics box.
6 Operation
6.1 Using diagnostics codes
You can use the parameters marked as adjustable in the table of diagnostics codes to adapt the product to the system and customer requirements.
Overview of diagnostics codes (→ Page 26)
6.1.1 Activating diagnostics codes
1.
Press and hold the button for seven seconds.
◁
is shown in the display.
2.
Press the buttons to set the value.
◁ The access code (96) is reserved for the competent
person.
◁ The access code (35) is reserved for the customer
service.
3.
Press the button to confirm.
◁
is shown in the display.
6.1.2 Setting a diagnostics code
1.
Press the or button to select the diagnostics code.
2.
Press the button to confirm.
◁ The value and/or status of the diagnostics code is
shown in the display.
3.
Press the or button to set the value.
4. If you allow the value to flash for three seconds, the setting is automatically confirmed.
◁
is shown in the display for 1 second.
Note
You can manually confirm the setting at any time by pressing and holding the button for less than 3 seconds.
5. Proceed accordingly for all parameters that need to be changed.
6.
Press and hold the button for 3 seconds to finish configuring the diagnostics codes.
◁ The display switches to the basic display.
6.2 Displaying the status codes
The status codes display the product's current operating status.
Status codes – Overview (→ Page 29)
6.2.1 Activating the status codes display
1.
Hold the button down for more than 7 seconds.
◁ S.XX is shown on the display, followed by the heat-
ing flow temperature, the internal system pressure and the cylinder temperature (depending on the ver­sion).
2.
Press the button to exit this menu.
◁ The display switches to the basic display.
7 Start-up
6.3 Using check programmes
By activating various check programmes, you can trigger various special functions on the product.
Check programmes – Overview (→ Page 25)
6.3.1 Activating check programmes
1.
Press and hold the button for more than five seconds.
◁
is shown in the display.
2.
Press and hold the button for five seconds.
◁
is shown in the display.
3.
Press the button to select the check programme.
4.
Press the button to confirm.
◁ The selected check programme is started.
5.
Press the button to finish the check programme.
6.
Press and hold the button for three seconds to finish the check programmes.
Note
If you do not press any button for 15 minutes, the current programme is automatically can­celled and the basic display is shown.
6.3.2 Activating the check programme for the maximum output function
▶
Press and hold the and buttons simultaneously for more than five seconds.
7 Start-up
7.1 Carrying out the initial start-up
Initial start-up must be carried out by a customer service technician or an authorised competent person using the first­commissioning-checklist. The first-commissioning-checklist in the appendix (→ Page 36) of the installation instructions must be filled out and stored carefully along with the unit's documentation.
▶ Carry out the initial start-up using the first-commission-
ing-checklist in the appendix.
▶ Fill out and sign the first-commissioning-checklist.
7.2 Checking the type of gas
Make sure that the product is set up correctly by checking the type of gas. This ensures optimum combustion quality.
▶ Check the type of gas as part of routine product mainten-
ance work when replacing components or carrying out work on the gas route.
7.3 Checking the factory setting
The product's combustion has been factory tested and is preset for operation with the gas group indicated on the iden­tification plate.
The product is only authorised to be operated with natural gas.
▶ Check the information about the type of gas indicated on
the identification plate and compare this with the type of gas available at the installation location.
Conditions: The product design is not compatible with the local gas group
▶ Do not start up the product.
Conditions: The product design is compatible with the local gas group
▶ Proceed as described below.
7.4 Checking and treating the heating water/filling and supplementary water
Caution. Risk of material damage due to poor-qual-
ity heating water
▶ Ensure that the heating water is of suffi-
cient quality.
▶ Before filling or topping up the installation, check the
quality of the heating water.
Checking the quality of the heating water
▶ Remove a little water from the heating circuit. ▶ Check the appearance of the heating water. ▶ If you ascertain that it contains sedimentary materials,
you must desludge the installation.
▶ Use a magnetic rod to check whether it contains mag-
netite (iron oxide).
▶ If you ascertain that it contains magnetite, clean the in-
stallation and apply suitable corrosion-protection meas­ures, or fit a magnetic filter.
▶ Check the pH value of the removed water at 25 °C. ▶ If the value is below 6.5 or above 8.5, clean the system
and treat the heating water.
▶ Ensure that oxygen cannot get into the heating water.
Checking the filling and supplementary water
▶ Before filling the installation, measure the hardness of the
filling and supplementary water.
Treating the filling and supplementary water
▶ Observe all applicable national regulations and technical
standards when treating the filling and supplementary water.
Provided the national regulations and technical standards do not stipulate more stringent requirements, the following applies:
You must treat the heating water in the following cases:
– If the entire filling and supplementary water quantity dur-
ing the operating life of the system exceeds three times the nominal volume of the heating installation, or
– If the guideline values listed in the following table are not
met, or
Start-up 7
0020177748_03 ENERGY Installation and maintenance instructions 17
– if the pH value of the heating water is less than 6.5 or
more than 8.5.
Total heating output
Water hardness at specific system volume
1)
≤ 20 l/kW
> 20 l/kW ≤ 50 l/kW
> 50 l/kW
kW
ppm
CaCO₃
mol/m³ppm
CaCO₃
mol/m³ppm
CaCO₃
mol/
m³
< 50 < 300 < 3 200 2 2 0.02
> 50 to ≤ 200
200 2 150 1.5 2 0.02
> 200 to ≤ 600
150 1.5 2 0.02 2 0.02
> 600 2 0.02 2 0.02 2 0.02
1) Nominal capacity in litres/heating output; in the case of multi­boiler systems, the smallest single heating output is to be used.
Caution. The use of unsuitable heating water may
cause aluminium corrosion and a result­ing lack of leak-tightness.
In contrast to steel, grey cast iron or copper, for example, aluminium reacts with alkaline heating water (pH value > 8.5) to produce substantial corrosion.
▶ When using aluminium, make sure that
the pH value of the heating water is between 6.5 and a maximum of 8.5.
Caution. Risk of material damage if the heating
water is treated with unsuitable additives.
Unsuitable additives may cause changes in the components, noises in heating mode and possibly subsequent damage.
▶ Do not use any unsuitable frost and cor-
rosion protection agents, biocides or seal­ants.
No incompatibility with our products has been detected to date with proper use of the following additives.
▶ When using additives, follow the manufacturer's instruc-
tions without exception.
We accept no liability for the compatibility of any additive or its effectiveness in the rest of the heating system.
Additives for cleaning measures (subsequent flushing required)
– Adey MC3+ – Adey MC5 – Fernox F3 – Sentinel X 300 – Sentinel X 400
Additives intended to remain permanently in the installation
– Adey MC1+ – Fernox F1
– Fernox F2 – Sentinel X 100 – Sentinel X 200
Additives for frost protection intended to remain permanently in the installation
– Adey MC ZERO – Fernox Antifreeze Alphi 11 – Sentinel X 500
▶ If you have used the above-mentioned additives, inform
the end user about the measures that are required.
▶ Inform the end user about the measures required for frost
protection.
7.5 Filling the condensate trap
C
2
3
1
A
B
1. Unclip the lower section of the condensate trap (1) from the upper section of the condensate trap (2).
2. Remove the float (3).
3. Fill the lower section of the condensate trap with water up to 10 mm below the upper edge of the condensate discharge pipe.
4. Re-insert the float (3).
Note
Check whether the float is present in the condensate trap.
5. Clip the lower section of the condensate trap (1) into the upper section of the condensate trap (2).
7 Start-up
7.6 Switching on the product
▶ Switch on the product via the main switch installed on-
site.
7.7 Filling the heating installation
1. Flush the heating installation through.
2. Fill the heating installation with the maximum possible volume flow.
7.8 Checking and adjusting the gas settings
Only a qualified competent person is authorised to imple­ment the settings on the gas valve assembly.
Each destroyed tamper-proof seal must be replaced.
The CO₂ adjusting screw must be sealed.
Never modify the factory setting of the gas pressure regu­lator of the gas valve assembly.
7.8.1 Checking the gas flow rate
The gas flow rate has been set during production and does not require adjustment. With the front casing fitted check the gas flow rate of the boiler as follows:
▶ Start up the product with the check programme P.01. ▶ In addition, ensure that maximum heat can be dissipated
into the heating system by turning up the room thermo­stat.
▶ Wait at least 5 minutes until the boiler has reached its
operating temperature.
▶ Ensure that all other gas appliances in the property are
turned off.
▶ Measure the gas flow rate at the gas meter. ▶ Compare the measured values with the corresponding
values in the table.
Qnw from the data plate
H gas in m³/h
Nom. +5% −10%
15.3 1.62 1.70 1.46
18.4 1.95 2.05 1.76
24.7 2.61 2.74 2.35
25.7 2.72 2.86 2.45
28.6 3.03 3.18 2.73
30.6 3.24 3.40 2.92
35.7 3.78 3.97 3.40
Conditions: Gas flow rate not in the permissible range
▶ Check all of the piping and ensure that the gas flow rates
are correct.
▶ Only put the product into operation once the gas flow
rates have been corrected.
Conditions: Gas flow rate in the permissible range
▶ End the check programme P.01. ▶ Allow the boiler to cool down by allowing pump overrun to
operate for a minimum of 2 minutes.
▶ Record the boiler maximum gas flow rate onto the
Benchmark gas boiler commissioning checklist.
7.8.2 Checking the gas connection pressure (gas flow pressure)
1
2
1. Ensure that the gas inlet working pressure can be
obtained with all other gas appliances in the property working.
2. Close the gas stopcock (1).
3. Undo the sealing screw on the test nipple (2).
4. Connect a manometer to the test nipple (2).
5. Open the gas stopcock (1).
6. Start up the product with check programme P.01 (sys-
tem with eBUS control) or P.03 (installation without eBUS control).
7. In addition, ensure that maximum heat can be dissip-
ated into the heating system by turning up the room thermostat.
8. With the boiler operating at full load check that the gas
inlet working pressure at the reference test point (2) complies with the requirements.
Permissible connection pressure
Great Bri­tain
Natural gas G20
1.7 … 2.0 kPa
(17.0 … 20.0 mbar)
9. Should the pressure recorded at the reference test point
in the boiler be lower than indicated check if there is any blockage in the pipework or if the pipework is un­dersized.
Conditions: Gas flow pressure not in the permissible range
Caution. Risk of material damage and operating
faults caused by incorrect gas connec­tion pressure.
If the gas connection pressure lies outside the permissible range, this can cause oper­ating faults in and damage to the product.
▶ Do not make any adjustments to the
product.
▶ Do not start up the product.
▶ If you cannot correct the failure, notify the gas supply
company and proceed as follows:
▶ End check programme P.01. ▶ Allow the boiler to cool down by allowing pump overrun
to operate for a minimum of two minutes.
▶ Close the gas stopcock. ▶ Remove the pressure gauge and retighten the sealing
screw (2) for the measuring nipple.
▶ Open the gas stopcock (1). ▶ Check the test nipple for gas tightness. ▶ Close the gas stopcock (1). ▶ Install the front casing.
Adapting the unit to the heating installation 8
0020177748_03 ENERGY Installation and maintenance instructions 19
▶ Disconnect the product from the electrical installation. ▶ You must not start up the boiler.
Conditions: Gas flow pressure in the permissible range
▶ End the check programme P.01. ▶ Allow the boiler to cool down allowing pump overrun to
operate for a minimum of two minutes.
▶ Close the gas stopcock (1). ▶ Remove the pressure gauge and retighten the sealing
screw (2) for the measuring nipple.
▶ Open the gas stopcock (1). ▶ Check the test nipple for gas tightness. ▶ Remove the front casing. ▶ Reset boiler controls for normal operation. ▶ Record the appliance gas inlet working pressure (kPa
resp. mbar) in the Benchmark gas boiler commissioning checklist.
7.8.3 Checking the leak-tightness of the flue gas installation and flue gas recirculation
1. Check the flue gas installation is intact in accordance
with the latest gas safe technical bulletin and informa­tion supplied in the installation instructions.
2. For extended flue gas installations check for flue gas
recirculation using the air analysis point.
3. Use a flue gas analyser.
4. If you discover CO or CO2in the supply air, search for
the leak in the flue gas installation or for signs of flue gas recirculation.
5. Eliminate the damage properly.
6. Check again whether the supply air contains any CO or
CO2.
7. If you cannot eliminate the damage, do not start up the
product.
7.8.4 Checking the CO₂ content
1. Start up the product with the check programme (P.01)
and set the value. – Setting value for the programme P.01: 100 Check programmes – Overview
2. Wait until the value that is read is stable.
– Waiting period for reading a stable value: 5 min
1
3. Unscrew the cover from the flue gas analysis point (1).
4. Measure the CO₂ content at the flue gas analysis point
(1).
5. Compare the measured value with the corresponding
value in the table.
Checking the CO₂ content
Great Britain
front casing on / front casing off
Natural gas
G20
9.2 ±1 %
◁ The value is OK. ▽ The value is not OK; you cannot start up the
product.
▶ Inform Customer Service.
7.9 Checking leak-tightness
▶ Check the gas pipe, the heating circuit and the hot water
circuit for leak-tightness.
▶ Check that the air/flue pipe has been installed correctly.
Conditions: Room-sealed operation
▶ Check whether the vacuum chamber has been closed
tightly.
7.10 Checking the heating mode
1. Activate the heating mode on the user interface.
2. Turn all thermostatic radiator valves on the radiators until they are fully open.
3. Allow the product to operate for at least 15 minutes.
4. Purge the heating installation.
5. Activate the display for the current operating status. (→ Page 15)
Status codes – Overview (→ Page 29)
◁ If the product is working correctly, the display shows
S.04.
8 Adapting the unit to the heating
installation
You can reset/change the system parameters (section "Us­ing diagnostics codes").
Overview of diagnostics codes (→ Page 26)
8.1 Burner anti-cycling time
To prevent frequent switching on and off of the burner and thus prevent energy losses, an electronic restart lockout is activated for a specific period each time the burner is switched off. The burner anti-cycling time is only active for the heating mode. Hot water handling mode during a burner anti-cycling time does not affect the time function element.
8.1.1 Setting the burner anti-cycling time
▶ Set the diagnostics code. (→ Page 15)
Overview of diagnostics codes (→ Page 26)
9 Handing the product over to the end user
8.1.2 Resetting the remaining burner anti-cycling time
▶ Press and hold the reset button for more than
three seconds.
◁
is shown in the display.
9 Handing the product over to the end
user
▶ When you have finished the installation, attach the sticker
supplied (in the end user's language) to the product cover.
▶ Explain to the end user how the safety devices work and
where they are located.
▶ Inform the end user how to handle the product. ▶ In particular, draw attention to the safety information
which the end user must follow.
▶ Inform the end user that they must have the product
maintained in accordance with the specified intervals.
▶ Instruct the end user about measures taken for routing
the combustion air supply and flue system.
9.1 Informing the operator about the maintenance intervals
▶ Inform the operator that they must have the product
maintained in accordance with the specified intervals.
10 Inspection and maintenance
10.1 Using original seals
If you replace components, use only the enclosed original seals; additional sealing materials are not required.
10.2 Observing inspection and maintenance intervals
▶ Adhere to the minimum inspection and maintenance in-
tervals. The inspection may require maintenance to be carried out earlier, depending on the results.
– Inspection and maintenance work (→ Appendix)
10.3 Procuring spare parts
The original components of the product were also certified by the manufacturer as part of the declaration of conformity. If you use other, non-certified or unauthorised parts during maintenance or repair work, this may void the conformity of the product and it will therefore no longer comply with the applicable standards.
We strongly recommend that you use original spare parts from the manufacturer as this guarantees fault-free and safe operation of the product. To receive information about the available original spare parts, contact the contact address provided on the reverse of these instructions.
▶ If you require spare parts for maintenance or repair
work, use only the spare parts that are permitted for the product.
10.4 Checking the CO₂ content
1. Start up the product with the check programme (P.01) and set the value.
– Setting value for the programme P.01: 100 Check programmes – Overview
2. Wait until the value that is read is stable. – Waiting period for reading a stable value: 5 min
1
3. Unscrew the cover from the flue gas analysis point (1).
4. Measure the CO₂ content at the flue gas analysis point (1).
5. Compare the measured value with the corresponding value in the table.
Checking the CO₂ content
Great Britain
front casing on / front casing off
Natural gas
G20
9.2 ±1 %
◁ The value is OK. ▽ The value is not OK; you cannot start up the
product.
▶ Set the CO₂ content.
10.5 Setting the CO₂ content
Conditions: The CO₂ content must be adjusted
1
A
B
▶ Remove the sticker. ▶ Turn the screw (1) to set the CO₂ content (value with
front casing removed).
◁ To increase the CO₂ content: Turn anti-clockwise ◁ To decrease the CO₂ content: Turn clockwise
▶ Only carry out the adjustment in increments of 1/8 turn
and wait approximately 1 minute after each adjustment until the value stabilises.
Inspection and maintenance 10
0020177748_03 ENERGY Installation and maintenance instructions 21
▶ Compare the measured value with the corresponding
value in the table.
Setting the CO₂ value
Great Britain
front casing on / front cas­ing off
Natural gas
G20
CO₂ at full load
9.2 ±0.2 %
Set for Wobbe index W₀
14.09 kW⋅h/m³
O₂ at full load
4.5 ±1.8 vol. %
CO at full load
≤ 250 ppm
CO/CO₂
≤ 0.0027
▽ If the setting is not in the specified adjustment range,
you must not start up the product.
▶ Inform Customer Service.
▶ Check whether the requirements regarding air pollution
control and/or CO have been complied with.
▶ Install the front casing.
10.6 Removing the gas-air mixture unit
Note
The gas-air mixture unit consists of three main components:
– Ventilator
– Gas valve
– Burner cover
1. Switch off the product via the main switch.
2. Close the gas isolator cock.
3. Remove the front casing. (→ Page 9)
A
B
1
4. Remove the air intake pipe (1).
D
C
B
2
3
A
5. Remove the screw (2).
6. Push the clip upwards.
7. Remove the flue pipe (3).
A
D
C
B
8. Remove the plug from the gas valve and from the fan.
9. Remove the gas-air mixture unit.
10. Remove both burner seals from the burner cover.
1
11. Remove the burner (4).
10 Inspection and maintenance
10.7 Cleaning the heat exchanger
1. Check the heat exchanger for damage and dirt.
2. If required, clean and replace the heat exchanger.
3. Protect the folded down electronics box against sprayed water.
1
4. Clean the ribs of the heat exchanger (1) with water.
◁ The water runs out via the condensate tray.
10.8 Checking the burner
▶ Check the surface of the burner for damage. If you see
any damage, replace the burner.
10.9 Checking the ignition electrode
1
2
3 4 5
1. Disconnect the connection (2) and the earthing cable (1).
2. Remove the fixing screws (3).
3. Carefully remove the electrode from the combustion chamber.
4. Check that the electrode ends (4) are undamaged.
5. Check the electrode distance. – Clearance for the ignition electrodes: 3.5 … 4.5 mm
6. Make sure that the seal (5) is free from damage.
▽ If necessary, replace the seal.
10.10 Cleaning the condensate siphon
2
3
1
A
B
1. Unclip the lower section of the siphon (1) from the up­per section of the siphon (2).
2. Remove the float (3).
3. Flush out the lower section of the siphon with water.
4. Reinsert the float (3).
Note
Check whether the float is present in the condensate siphon.
5. Clip the lower section of the siphon (1) into the upper section of the siphon (2).
10.11 Installing the gas-air mixture unit
1. Install the burner.
2. Install two new burner seals in the burner hood.
3. Install the gas-air mixture unit.
4. Tighten the screws on the gas-air mixture unit. – Ideally to 7 Nm if a torque spanner is available.
5. Install the flue pipe.
6. Install the air intake pipe.
10.12 Draining the product
1. Close the service valves of the product.
2. Start check programme P.05 (→ Page 16). Check programmes – Overview (→ Page 25)
3. Open the drain valves.
Troubleshooting 11
0020177748_03 ENERGY Installation and maintenance instructions 23
10.13 Completing inspection and maintenance work
1. Check the gas connection pressure (gas flow pressure).
(→ Page 18)
2. Check the CO₂ content.
10.14 Checking the product for leak-tightness
▶ Check that the product is leak-tight. (→ Page 19)
11 Troubleshooting
11.1 Rectifying faults
▶ If fault codes (F.XX) are present, refer to the table in the
appendix for advice or use the check programme(s). Overview of fault codes (→ Page 30) Check programmes – Overview (→ Page 25)
If several faults are present at the same time, the fault codes are displayed alternately followed by the time at which the respective fault occurred.
▶
Hold the button down for more than 3 seconds.
▶ If you are unable to clear the fault code and it reappears
despite several reset attempts, contact customer service.
11.2 Calling up the fault memory
The last ten fault codes are stored in the fault memory (to­gether with the time at which the respective fault occurred).
▶
Press and hold the button for more than seven seconds.
Overview of fault codes (→ Page 30)
▶
Press the button to exit this menu.
11.3 Deleting the fault memory
▶ Delete the fault memory (d.94).
Overview of diagnostics codes (→ Page 26)
11.4 Preparing the repair work
1. Decommission the product.
2. Disconnect the product from the electrical installation.
3. Remove the front casing.
4. Close the gas stopcock.
5. Close the service valves in the heating flow and in the
heating return.
6. Close the service valve in the cold water pipe.
7. Drain the product if you want to replace water-bearing
components of the product.
8. Make sure that water does not drip on live components
(e.g. the electronics box).
9. Use only new seals and O-rings. Do not use any addi-
tional components.
11.5 Replacing defective components
11.5.1 Replacing the burner
1. Remove the gas-air mixture unit. (→ Page 21)
2. Remove the burner seal.
3. Remove the burner.
4. Install the new burner complete with new seal on the heat exchanger.
5. Install the gas-air mixture unit. (→ Page 22)
11.5.2 Replacing the gas-air mixture unit
1. Remove the gas-air mixture unit. (→ Page 21)
2. Install the new gas-air mixture (→ Page 22).
11.5.3 Replacing the heat exchanger
1. Remove the side section. (→ Page 9)
2. Remove the gas-air mixture unit. (→ Page 21)
E
1
2
D
B
C
A
3. Remove the flow pipe (1).
4. Remove the return pipe (2).
B
A
5. Remove the gas pipe.
12 Decommissioning the product
B
3
4
A
6. Undo the clip underneath the condensate tray (4).
7. Undo the two screws (3).
A
5
C
B
8. Lift the heat exchanger up slightly and remove it to­gether with the condensate tray.
9. Remove the ignition transformer (5).
10. Replace all the seals.
11. Install the new heat exchanger in reverse order.
11.5.4 Replacing the main PCB
C
C
D
B
C
C
D
B
A
A
1. Open the electronics box. (→ Page 13)
2. Pull all of the plugs out from the PCB.
3. Undo the clips on the PCB.
4. Remove the PCB.
5. Install the new PCB in such a way that it clicks into the groove at the bottom and into the clip at the top.
6. Plug in the PCB plugs.
7. Close the electronics box.
11.5.5 Replacing the PCB for the user interface
B
C
C
D
A
A
1. Open the electronics box. (→ Page 13)
2. Pull the plug out of the PCB.
3. Undo the clips on the PCB.
4. Remove the PCB.
5. Install the new PCB in such a way that it clicks into the groove at the bottom and into the clip at the top.
6. Plug in the PCB plug.
7. Close the electronics box.
11.6 Checking the product for leak-tightness
▶ Check that the product is leak-tight. (→ Page 19)
12 Decommissioning the product
▶ Switch off the product. ▶ Disconnect the product from the power mains. ▶ Close the gas isolator cock. ▶ Close the cold water stop valve. ▶ Drain the product. (→ Page 22)
13 Customer service
For contact details for our customer service department, you can write to the address that is provided on the back page, or you can visit www.glow-worm.co.uk.
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 25
Appendix
A Inspection and maintenance work – Overview
The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na­tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed in the table.
No. Work
Inspection
(annual)
Mainten-
ance
(must be
carried out
at regular
intervals)*
1
Check the air/flue pipe for leak-tightness and to ensure that it is fastened correctly. Make sure that it is not blocked or damaged and has been installed in accordance with the relevant Installa­tion Manual.
X X
2
Check the general condition of the product. Remove dirt from the product and from the vacuum chamber.
X X
3
Visually inspect the general condition of the entire heating cell and, in particular, check for signs of corrosion, soot or other damage. If you notice any damage, carry out maintenance work.
X X
4
Check the gas connection pressure at maximum heat input. If the gas connection pressure is not within the correct range, carry out maintenance work.
X X
5
Check the CO₂ content (the air ratio) of the product and, if necessary, adjust it. Keep a record of this.
X X
6
Disconnect the product from the power mains. Check that the electrical plug connections and other connections are seated correctly and correct these if necessary.
X X
7
Close the gas isolator cock and the service valves.
X X
8
Drain the product on the water side.
X
9
Remove the gas-air mixture unit.
X
10
Check the seals in the combustion area. If you see any damage, replace the seals. Replace the burner seal each time it is opened and accordingly each time maintenance is carried out.
X
11
Clean the heat exchanger.
X
12
Check the burner for damage and replace it if necessary.
X
13
Check the condensate siphon in the product, clean and fill if necessary.
X X
14
Install the gas-air mixture unit. Caution: Replace the seals.
X
15
Open the gas isolator cock, reconnect the product to the power mains and switch the product on.
X X
16
Open the service valves, fill the product/heating installation.
X
17
Perform a test operation of the product and heating installation, including hot water generation, and purge the system once more if necessary.
X X
18
Visually inspect the ignition and burner behaviour.
X X
19 Check the CO₂ content (the air ratio) of the product again.
X
20
Check the product for gas, flue gas, hot water and condensate leaks, and repair if necessary.
X X
21
Record the inspection/maintenance work carried out.
X X
*Note: For those appliances which are not part of an annual service agreement/policy, maintenance must be carried out at least every 5 years.
B Check programmes – Overview
Note
Since the programme table is used for various products, some programmes may not be visible for the product in question.
Display Meaning
P.01 Start up the burner at the adjustable heat input:
The product is operated after a successful ignition with the set heat input between "0" (0% = Pmin) and "100" (100% = Pmax).
The function is activated for 15 minutes.
Appendix
Display Meaning
P.02 Start up the burner at ignition load:
The product is operated at ignition load after successful ignition.
The function is activated for 15 minutes.
P.03 The product runs in heating mode with the maximum heat input set using diagnostics code d.00.
P.04 Maximum output function:
If there is a hot water request, the product runs in hot water handling mode with maximum heat input.
If there is no hot water request, the product runs in heating mode with the heating partial load that is set using diagnostics code d.00.
The function is activated for 15 minutes.
P.05 Filling the product:
The diverter valve is moved to the mid-position. The burner and pump are switched off (to fill or drain the product).
If the pressure is lower than 0.05 MPa (0.5 bar) and then is above 0.07 MPa (0.7 bar) for longer than 15 seconds, the automatic purging function is activated.
The function is activated for 15 minutes.
P.06 Purging the heating circuit:
The diverter valve is moved to the heating position.
The function is activated in the heating circuit for 15 minutes.
The pump runs and stops at regular intervals.
If required, this function can be manually switched off.
P.07 Purging the hot water circuit:
The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute.
The pump runs and stops at regular intervals.
If required, this function can be manually switched off.
P.10 Safety cut-out check
Automatic purging function
Purging the product:
If the pressure is lower than 0.05 MPa (0.5 bar) and then is above 0.07 MPa (0.7 bar) for longer than 15 seconds, the automatic purging function is activated.
The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute.
This function cannot be manually switched off.
C Overview of diagnostics codes
Setting level Values
Unit Increment, select, explanation
Default set­ting
Own setting
Min. Max.
d.00 Heating maximum output – – kW The maximum heating output varies
depending on the product.
→ Section "Technical data"
→ Section
"Technical
data"
Adjustable
d.01 Pump overrun in heating mode
1 60 min 1 5 Adjustable
d.02 Burner anti-cycling time in heating mode
2 60 min 1 20 Adjustable
d.04 Water temperature in the cylinder
Current value ℃ – – Not
adjustable
d.05 Determined heating flow set target temperature
Current value
℃ – – Not
adjustable
d.07 Set target temperature for the domestic hot water cylinder
Current value ℃ – – Not
adjustable
d.08 Status of the 230 V ther­mostat
Current value – 0 = Room thermostat open (no heat
requirement)
1 = Room thermostat closed (heat requirement)
– Not
adjustable
d.09 Heating flow set target temperature that is set on the eBUS room thermostat
Current value – – – Not
adjustable
d.10 Status of the internal pump in the heating circuit
Current value – off / on – Not
adjustable
d.11 Status of the heating cir­cuit's shunt pump
Current value – off / on – Not
adjustable
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 27
Setting level Values
Unit Increment, select, explanation
Default set­ting
Own setting
Min. Max.
d.13 Status of the hot water circuit's circulation pump
Current value – off / on – Not
adjustable
d.16 Status of the 24 V room thermostat
Current value – off = Heating off
on = Heating on
– Not
adjustable
d.17 Heating control – – – off = Flow temperature
on = Return temperature (adjustment for underfloor heating. If you have ac­tivated the return temperature control, the automatic heating output determ­ination function is not active.)
0 Adjustable
d.18 Pump overrun operating mode
1 3 – 1 = Comfort (continuously operating
pump) 3 = Eco (intermittent pump mode –
for the dissipation of the residual heat after hot water generation at an ex­tremely low heat demand)
1 Adjustable
d.20 Maximum hot water set target temperature
50 60 ℃ 1 50 Adjustable
d.23 Status of the heating de­mand
Current value – off = Heating off (Summer mode)
on = Heating on
– Not
adjustable
d.24 Status of the pressure monitor
0 1 – off = Not switched
on = Switched
– Not
adjustable
d.25 Status of the requirement to reheat the cylinder or for the hot water warm start from the eBUS thermostat
Current value – off = Function deactivated
on = Function activated
– Not
adjustable
d.27 Function of relay 1 (multi­functional module)
1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (omitted)
8 = eBUS remote control
9 = Legionella protection pump
10 = Solar valve
1 Adjustable
d.28 Function of relay 2 (multi­functional module)
1 10 – 1 = Circulation pump
2 = External pump
3 = Cylinder charging pump
4 = Extractor hood
5 = External solenoid valve
6 = External fault message
7 = Solar pump (omitted)
8 = eBUS remote control
9 = Legionella protection pump
10 = Solar valve
2 Adjustable
d.31 Automatic filling device 0 2 – 0 = Manual
1 = Semi-automatic
2 = Automatic
0 Adjustable
d.33 Fan speed target value Current value rpm Fan speed = Display value x 100 – Not
adjustable
d.34 Value for the fan speed Current value rpm Fan speed = Display value x 100 – Not
adjustable
d.40 Heating flow temperature Current value ℃ – – Not
adjustable
d.41 Heating return temperat­ure
Current value ℃ – – Not
adjustable
d.43 Heating curve 0.2 4 – 0.1 1.2 Adjustable
d.45 Value for the base point of the heating curve
15 30 – 1 20 Adjustable
Appendix
Setting level Values
Unit Increment, select, explanation
Default set­ting
Own setting
Min. Max.
d.47 Outside temperature Current value ℃ – – Not
adjustable
d.50 Correction of the min­imum fan speed
0 3000 rpm 1
Fan speed = Display value x 10
600 Adjustable
d.51 Correction of the max­imum fan speed
-2500 0 rpm 1
Fan speed = Display value x 10
-1000 Adjustable
d.58 Solar circuit reheating 0 3 – 0 = Boiler's Legionella protection
function deactivated
3 = Hot water activated (target value min. 60 °C)
0 Adjustable
d.60 Number of blocks by the temperature sensor
Current value – – – Not
adjustable
d.61 Number of successful ignitions
Current value – – – Not
adjustable
d.62 Night set-back 0 30 – 1 0 Adjustable
d.64 Average burner ignition time
Current value s – – Not
adjustable
d.65 Maximum burner ignition time
Current value s – – Not
adjustable
d.66 Activation of the warm start function for hot water
– – – off = Function deactivated
on = Function activated
1 Adjustable
d.67 Remaining burner anti­cycling time (setting under d.02)
Current value min – – Not
adjustable
d.68 Number of unsuccessful ignitions at 1st attempt
Current value – – – Not
adjustable
d.69 Number of unsuccessful ignitions at 2nd attempt
Current value – – – Not
adjustable
d.71 Maximum heating flow set target temperature
45 80 ℃ 1 75 Adjustable
d.75 Maximum cylinder reheat­ing time
20 90 min 1 45 Adjustable
d.77 Max. cylinder reheating – – kW 1
→ Section "Technical data"
– Adjustable
d.78 DHW max. flow temperat­ure
50 80 ℃ 1 – Adjustable
d.80 Running time in heating mode
Current value h – – Not
adjustable
d.81 Running time in DHW mode
Current value h – – Not
adjustable
d.82 Number of burner igni­tions in heating mode
Current value – Number of ignitions = Display value x
100
– Not
adjustable
d.83 Number of burner igni­tions in DHW mode
Current value – Number of ignitions = Display value x
100
– Not
adjustable
d.84 Maintenance in 0 3000 h Number of hours = Display value x 10 300 Not
adjustable
d.85 Increase in the min. out­put (heating and DHW mode)
– – kW 1
→ Section "Technical data"
– Adjustable
d.90 Status of the eBUS room thermostat
Current value – off = Not connected
on = Connected
– Not
adjustable
d.93 Setting the product code 0 99 – 1 – Adjustable
d.94 Delete fault list 0 1 – off = No
on = Yes
– Adjustable
d.95 Software versions – – – 1 = Main PCB
2 = Interface PCB
– Adjustable
d.96 Reset to factory setting – – – 0 = No
1 = Yes
– Adjustable
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 29
Setting level Values
Unit Increment, select, explanation
Default set­ting
Own setting
Min. Max.
d.128 Heating minimum target value
10 75 ℃ 1 10 Adjustable
d.129 Hot water minimum tar­get value
35
(com-
bina-
tion
unit)
45
(pure
boiler)
60 ℃ 1 35 Adjustable
D Status codes – Overview
Status code Meaning
Displays in heating mode
S. 0 Heating mode: No requirement
S.01 Heating mode: Advance fan operation
S.02 Heating mode: Pump pre-run
S.03 Heating mode: Burner ignition
S.04 Heating mode: Burner on
S.05 Heating mode: Pump/fan overrun
S.06 Heating mode: Fan overrun
S.07 Heating mode: Pump overrun
S.08 Heating mode: Temporary shutdown after heating procedure
Display in hot water handling mode with cylinder
S.20 Hot water handling mode: Requirement
S.21 Hot water handling mode: Advance fan operation
S.22 Hot water handling mode: Pump pre-run
S.23 Hot water handling mode: Burner ignition
S.24 DHW mode: Burner on
S.25 DHW mode: Pump/fan overrun
S.26 DHW mode: Fan overrun
S.27 DHW mode: Pump overrun
S.28 Hot water handling mode: Temporary shutdown of the burner
Other displays
S.30 Room thermostat is blocking heating mode.
S.31 No heating demand: Summer mode, eBUS controller, waiting period
S.32 Fan waiting time: Fan speed outside of the tolerance values
S.34 Frost protection active
S.39 Underfloor heating contact open
S.42 Flue non-return flap closed
S.46 Frost protection mode (Comfort): Minimum load
S.53 Product in waiting period/operation block function due to low water pressure (flow/return spread too large)
S.54 Waiting period: Low water pressure in the circuit (flow/return spread too large)
S.88 Product purging active
S.91 Maintenance: Demo mode
S.96 Automatic test programme: Return temperature sensor, heating demands blocked.
S.98 Automatic test programme: Return temperature sensor, heating demands blocked.
S.99 Internal automatic test programmes
S.108 Purging the combustion chamber, fan in operation
S.109 Product's standby mode activated
Appendix
E Overview of fault codes
Fault code Meaning Possible cause
F.00 Fault: Flow temperature sensor NTC plug not plugged in or has come loose, multiple plug on the PCB not
plugged in correctly, interruption in cable harness, NTC sensor defective
F.01 Fault: Return temperature sensor NTC plug not plugged in or has come loose, multiple plug on the PCB not
plugged in correctly, interruption in cable harness, NTC sensor defective
F.10 Short circuit: Flow temperature sensor NTC sensor defective, short circuit in the cable harness, cable/casing
F.11 Short circuit: Return temperature sensor NTC sensor defective, short circuit in the cable harness, cable/casing
F.12 and F.91
Short circuit: Cylinder temperature sensor
NTC sensor defective, short circuit in the cable harness, cable/casing
F.13 Short circuit: Domestic hot water cylinder
temperature sensor
NTC sensor defective, short circuit in the cable harness, cable/casing
F.20 Safety switch-off: Overheating temperat-
ure reached
Incorrect earth connection between cable harness and product, flow or return NTC defective (loose connection), black discharge via ignition cable, ignition plug or ignition electrode
F.23 Safety switch-off: Temperature difference
too great (NTC1/NTC2)
Pump blocked, insufficient pump output, air in product, flow and return NTC sensors connected the wrong way round
F.24 Safety switch-off: Temperature rise too
fast
Pump blocked, insufficient pump output, air in product, system pressure too low, non-return valve blocked/incorrectly installed
F.25 Safety switch-off: Flue gas temperature
too high
Break in plug connection for optional flue gas safety cut-out (STB), break in cable harness
F.27 Safety switch-off: Fault in flame detection Moisture on the electronics, electronics (flame monitor) defective, gas solen-
oid valve leaking
F.28 Fault: Ignition unsuccessful when startingupGas meter defective or gas pressure monitor has triggered, air in gas, gas
flow pressure too low, thermal isolator device (TAE) has triggered, incorrect gas restrictor, incorrect spare gas valve, fault on the gas valve, multiple plug on PCB incorrectly plugged in, break in cable harness, ignition system (ig­nition transformer, ignition cable, ignition plug, ignition electrode) defective, ionisation current interrupted (cable, electrode), incorrect earthing of product, electronics defective
F.29 Fault: Flame loss Gas supply temporarily stopped, flue gas recirculation, incorrect earthing of
product, ignition transformer has spark failure
F.32 Fan frost protection function active: Fan
speed outside the tolerance values
Plug on fan not correctly plugged in, multiple plug on PCB not correctly plugged in, break in cable harness, fan blocked, Hall sensor defective, elec­tronics defective
F.49 eBUS fault: Voltage too low Short circuit on eBUS, eBUS overload or two power supplies with different
polarities on the eBUS
F.61 Fault: Gas valve control system Short circuit/short to earth in cable harness for the gas valve, gas valve
defective (coils shorted to earth), electronics defective
F.62 Fault: Gas valve switch-off control Delayed switch-off of gas valve, delayed extinguishing of flame signal, gas
valve leaking, electronics defective
F.63 Fault: EEPROM Electronics defective
F.64 Fault: Electronics/sensor/analogue-to-
digital converter
Flow or return NTC short circuited, electronics defective
F.65 Fault: Electronics temperature too high Electronics overheating due to external influences, electronics defective
F.67 Value sent back by ASIC is incorrect
(flame signal)
Implausible flame signal, electronics defective
F.68 Fault: Unstable flame (analogue input) Air in gas, gas flow pressure too low, incorrect air ratio, incorrect gas re-
strictor, ionisation flow interruption (cable, electrode)
F.70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number not
reset, wrong or missing output range coding resistance
F.71 Fault: Flow/return temperature sensor Flow temperature sensor signalling constant value: Flow temperature sensor
incorrectly positioned on supply pipe, flow temperature sensor defective
F.72 Fault: Deviation in the water pressure
sensor/return temperature sensor
Flow/return NTC temperature difference too great → flow and/or return tem­perature sensor defective
F.77 Fault: Condensate or smoke No response, flue non-return flap defective
F.78 Interruption to DHW outlet sensor at
external controller
UK link box is connected, but hot water NTC not bridged
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 31
Fault code Meaning Possible cause
F.83 Fault: Dry fire When the burner starts, the temperature change registered at the flow or
return temperature sensor is non-existent or too small: Insufficient water in the product, the flow or return temperature sensor is not in the correct position on the pipe
F.84 Fault: Flow/return temperature sensor Values not consistent, difference < -6 K
Flow and return temperature sensors signalling implausible values: Flow and return temperature sensors have been inverted, flow and return temperature sensors have not been correctly installed
F.85 Fault: Temperature sensor The flow and/or return temperature sensors have been installed on the same
pipe/incorrect pipe
Temperature sensor not connected or is connected incorrectly
F.86 Fault: Underfloor heating contact Underfloor heating contact open, sensor disconnected or defective
F.87 Fault: Electrodes Electrodes not connected or they are connected incorrectly, short circuit in
the cable harness
F.88 Fault: Gas valve Gas valve not connected or it is connected incorrectly, short circuit in the
cable harness
Connection No communication between the PCB
and the user interface
Electronics defective
Appendix
F Wiring diagram
X14
L
N
X12
X51
X51
X20
16
1 9
3
15
4
5
6
13
X51
X20
X40 X51
X30
X21
X41
X22
X14
L
N
–
+
24V=
RT BUS
Burner
off
RT
X1
X106
X32
X12
X35
X1
RT
X21
L
N
L
N
1
5
eBUS
Burner off
X106
M
4
3
2
1
N
L
24V
230V~
24V
230V~
2
7
9
1
4
3
5
6
10
11
12
8
1 Main PCB
2 Interface PCB
3 Control system
4 Temperature sensor on the heating flow
5 Temperature sensor on the heating return
6 Fan
7 Gas valve assembly
8 Heating pump
9 Monitoring electrode
10 Room thermostat
11 Main power supply and connection for 230 V control
12 Ignition electrode
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 33
G Wiring diagram, 30 kW
X14
L
N
X12
X51
X51
X20
16
1 9
3
15
4
5
6
13
X51
X20
X40 X51
X30
X21
X41
X22
X14
L
N
–
+
24V=
RT BUS
Burner
off
RT
X1
X106
X32
X12
X35
X1
RT
X21
L
N
L
N
1
5
eBUS
Burner off
X106
M
4
3
2
1
N
L
24V
230V~
24V
230V~
2
7
9
1
4
3
5
6
10
11
12
8
1 Main PCB
2 Interface PCB
3 Control system
4 Temperature sensor on the heating flow
5 Temperature sensor on the heating return
6 Fan
7 Gas valve assembly
8 Heating pump
9 Monitoring electrode
10 Room thermostat
11 Main power supply and connection for 230 V control
12 Ignition electrode
Appendix
H Position of the opening in the air/flue pipe
G
N
N
MM
A
I
I
O
H
H
C
B
L
J
Q
Q
Q
Q
Q
K
P
D, E
F
I
S
R
T
H.1 Positioning of the opening of a fan-supported flue gas pipe
Installation site
Minimum dimen­sions
A
Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm
B Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm
C Horizontally to an opening, air bricks, opening windows, etc., that can be opened. 300 mm
D
Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater pipes
75 mm
E Below eaves 200 mm
F Below balconies or car port roofs 200 mm
G From vertical wastewater pipes or down pipes 150 mm
H From external or internal corners 200 mm
I Above floors, roofs or balconies 300 mm
J From a surface facing a terminal 600 mm
K From a terminal facing a terminal 1,200 mm
L From an opening in the car port (e.g. door, window) which leads into the dwelling 1,200 mm
M Vertical from a terminal on the same wall 1,500 mm
N Horizontal from a terminal on the same wall 300 mm
O From the wall on which the terminal has been installed 0 mm
P From a vertical structure on the roof 300 mm
Q Above the roof area 300 mm
R Horizontal from adjacent windows on pitched or flat roofs 600 mm
S Above adjacent windows on pitched or flat roofs 600 mm
T Below adjacent windows on pitched or flat roofs 2,000 mm
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 35
H.2 Horizontal terminal positioning
BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows:
a) at least 2 m from an opening in the building directly opposite, and
b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely to cause a nuisance to a neighbour or discharge over a walkway or patio.
For IE see current issue of IS 813.
For boilers covered within this manual.
1) Dimensions D, E, F and G:
These clearances may be reduced to 25 mm without affecting the performance of the boiler. In order to ensure that the con­densate plume does not affect adjacent surfaces the terminal should be extended as shown below.
Balcony/eaves
Gutter
Adequately secured air/flue gas pipe
The flue pipe must protrude beyond any overhang
2) Dimension H:
This clearance may be reduced to 25 mm without affecting the performance of the boiler. However, in order to ensure that the condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred.
For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed away from the building fabric.
Appendix
I Commissioning Checklist
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Benchmark Commissioning and Servicing Section
It is a requirement that the boiler is installed and commissioned to the
completed in full.
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 37
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
CONTROLS
Optimum start control
Fitted
Fitted
Fitted
Fitted
ALL SYSTEMS
Yes
Yes
CENTRAL HEATING MODE
OR
mbar OR mbar
COMBINATION BOILERS ONLY
Yes
Yes
DOMESTIC HOT WATER MODE
OR
mbar OR mbar
Yes Temperature
CONDENSING BOILERS ONLY
Yes
ALL INSTALLATIONS
AND
²
Ratio
AND
²
Ratio
Yes
Yes
Yes
Yes
Appendix
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
SERVICE RECORD
SERVICE 01
AND
²
%
AND
²
%
SERVICE 02
AND
²
%
AND
²
%
SERVICE 03
AND
²
%
AND
²
%
SERVICE 04
AND
²
%
AND
²
%
SERVICE 05
AND
²
%
AND
²
%
SERVICE 06
AND
²
%
AND
²
%
SERVICE 07
AND
²
%
AND
²
%
SERVICE 08
AND
²
%
AND
²
%
SERVICE 09
AND
²
%
AND
²
%
SERVICE 10
AND
²
%
AND
²
%
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 39
PRIOR TO CO AND COMBUSTION RATIO CHECK
The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas
supply pressure/rate checked as required prior to commissioning.
As part of the installation process, especially where a flue has been fitted by persons other than the
boiler installer, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been
exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
The flue gas analyser should be of the correct type, as specified by BS 7967
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the
manufacturer. The installer must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.
NOTE
THE AIR GAS RATIO VALVE IS FACTORY
SET AND MUST NOT BE ADJUSTED DURING COMMISSIONING UNLESS THIS ACTION IS RECOMMENDED FOLLOWING
CONTACT WITH THE MANUFACTURER.
If any such adjustment is recommended and
further checking of the boiler is required the
installer/service engineer must be competent
to carry out this work and to use the flue gas
analyser accordingly.
If the boiler requires conversion to operate with
a different gas family (e.g. conversion from
natural gas to LPG) separate guidance will be
provided by the boiler manufacturer
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe into air inlet test point and allow readings to stabilise.
NOTE - where no air inlet test point is provided then a flue integrity check
with the analyser is not possible. The installer should verify that flue
integrity has been visually checked in accordance with the “Prior to
CO and combustion ratio check” box above before proceeding to the
“Check CO and combustion ratio at maximum rate” stage below.
SET BOILER TO MINIMUM RATE
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum
rate contact Technical Helpline for advice.
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE
With boiler still set at minimum rate, insert analyser probe into flue gas sampling
point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is not
specified in the manual, consult boiler manufacturer for guidance.
CHECK CO AND COMBUSTION RATIO AT MAX. RATE
With boiler still set at maximum rate, insert analyser probe into flue gas
sampling point. Allow readings to stabilise before recording.
NOTE - If no flue gas sampling point is present and the correct procedure is
not specified in the manual, consult boiler manufacturer for guidance.
SET BOILER TO MAXIMUM RATE
In accordance with boiler instructions, set boiler to operate at max. rate
(full load condition). Allow sufficient time for combustion to stabilise.
NOTE - Do not insert analyser probe during this period to avoid
possible “flooding” of sensor.
Is CO less than 350ppm and CO/CO
2
ratio
less than 0.004
Is
O
2
20.6%
and
CO
2
< 0.2%
Is CO less than 350ppm and CO/CO
2
ratio
less than 0.004
BOILER IS OPERATING SATISFACTORILY
no further actions required.
Ensure test points are capped, boiler case is correctly replaced and
all other commissioning procedures are completed.
Complete Benchmark Checklist, recording CO and combustion ratio
readings as required.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED.
VERIFY FLUE INTEGRITY
Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of
the flue is therefore required.
Check that flue components are assembled, fixed
and supported as per boiler/flue manufacturer’s
instructions.
Check that flue and flue terminal are not obstructed.
Is
CO
less than
335ppm
and
CO/CO
2
ratio less
than 0.004
Is
O
2
20.6%
and
CO
2
< 0.2%
Check all seals around the appliance burner,
internal flue seals, door and case seals.
Rectify where necessary.
TURN OFF APPLIANCE AND CALL
MANUFACTURER’S TECHNICAL HELPLINE
FOR ADVICE.
THE APPLIANCE MUST NOT BE
COMMISSIONED UNTIL PROBLEMS ARE
IDENTIFIED AND RESOLVED. IF
COMMISSIONING CANNOT BE FULLY
COMPLETED, THE APPLIANCE MUST BE
DISCONNECTED FROM THE GAS SUPPLY IN
ACCORDANCE WITH THE GSIUR.
NOTE: Check and record CO and combustion ratio
at both max. and min. rate before contacting the
manufacturer.
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
Appendix
J Pipe lengths for the air/flue pipe
J.1 Length L of the C13 type air/flue pipe
Applicability: C13 type air/flue pipe
Diameter of the air/flue pipe
Dia. 60/100 (L) Dia. 80/125 (L)
C13 type air/flue pipe
C13 type air/flue pipe
ENERGY 12r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 15r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 18r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 25r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 30r -A (H-GB)
≤ 10 m ≤ 19 m
J.2 Length L of the C33 type air/flue pipe
Applicability: C33 type air/flue pipe
Diameter of the air/flue pipe
Dia. 60/100 (L) Dia. 80/125 (L)
C33 type air/flue pipe
C33 type air/flue pipe
ENERGY 12r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 15r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 18r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 25r -A (H-GB)
≤ 10 m ≤ 25 m
ENERGY 30r -A (H-GB)
≤ 10 m ≤ 19 m
J.3 Length L of the C43 type air/flue pipe
Applicability: C43 type air/flue pipe
Diameter of the air/flue pipe
Dia. 60/100 (L) Dia. 80/125 (L)
C43 type air/flue pipe
C43 type air/flue pipe
ENERGY 12r -A (H-GB)
≤ 10 m ≤ 10 m
ENERGY 15r -A (H-GB)
≤ 10 m ≤ 10 m
ENERGY 18r -A (H-GB)
≤ 10 m ≤ 10 m
ENERGY 25r -A (H-GB)
≤ 10 m ≤ 10 m
ENERGY 30r -A (H-GB)
≤ 10 m ≤ 10 m
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 41
K Technical data
Technical data – Heating
ENERGY 12r -A (H-GB) ENERGY 15r -A (H-GB) ENERGY 18r -A (H-GB)
Max. flow temperature adjustment range (default setting: 75 °C)
10 … 80 ℃ 10 … 80 ℃ 10 … 80 ℃
Maximum permissible pressure
0.3 MPa
(3.0 bar)
0.3 MPa
(3.0 bar)
0.3 MPa
(3.0 bar)
Nominal water flow (ΔT = 20 K)
530 l/h 655 l/h 788 l/h
Nominal water flow at Pmin (ΔT = 20 K)
195 l/h 195 l/h 215 l/h
Nominal water flow (ΔT = 30 K)
353 l/h 436 l/h 525 l/h
Nominal water flow at Pmin (ΔT = 30 K)
130 l/h 130 l/h 145 l/h
Approximate value for the condensate volume (pH value between 3.5 and 4.0) at 50/30 °C
1.23 l/h 1.53 l/h 1.84 l/h
ENERGY 25r -A (H-GB) ENERGY 30r -A (H-GB)
Max. flow temperature adjustment range (default setting: 75 °C)
10 … 80 ℃ 10 … 80 ℃
Maximum permissible pressure
0.3 MPa
(3.0 bar)
0.3 MPa
(3.0 bar)
Nominal water flow (ΔT = 20 K)
1,094 l/h 1,313 l/h
Nominal water flow at Pmin (ΔT = 20 K)
260 l/h 300 l/h
Nominal water flow (ΔT = 30 K)
729 l/h 876 l/h
Nominal water flow at Pmin (ΔT = 30 K)
170 l/h 200 l/h
Approximate value for the condensate volume (pH value between 3.5 and 4.0) at 50/30 °C
2.55 l/h 3.06 l/h
Technical data – G20 power/loading G20
ENERGY 12r -A (H­GB)
ENERGY 15r -A (H­GB)
ENERGY 18r -A (H­GB)
ENERGY 25r -A (H­GB)
Maximum heat output
12 kW 15 kW 18 kW 25 kW
Effective output range (P) at 40/30 °C
4.8 … 13.0 kW 4.8 … 16.2 kW 5.3 … 19.5 kW 6.5 … 27.0 kW
Effective output range (P) at 50/30 °C
4.7 … 12.8 kW 4.7 … 15.9 kW 5.2 … 19.1 kW 6.4 … 26.5 kW
Effective output range (P) at 80/60 °C
4.5 … 12.3 kW 4.5 … 15.2 kW 5.0 … 18.3 kW 6.1 … 25.4 kW
Domestic hot water heat output (P)
4.4 … 15.0 kW 4.4 … 18.0 kW 4.9 … 25.2 kW 6.0 … 30.0 kW
Maximum heat input – heating (Q max.)
12.3 kW 15.3 kW 18.4 kW 25.5 kW
Minimum heat input – heat­ing (Q min.)
4.5 kW 4.5 kW 5.0 kW 6.1 kW
Maximum heat input – hot water (Q max.)
15.3 kW 18.4 kW 25.7 kW 30.6 kW
Minimum heat input – hot water (Q min.)
4.5 kW 4.5 kW 5.0 kW 6.1 kW
ENERGY 30r -A (H­GB)
Maximum heat output
30 kW
Effective output range (P) at 40/30 °C
7.6 … 32.4 kW
Effective output range (P) at 50/30 °C
7.4 … 31.8 kW
Appendix
ENERGY 30r -A (H­GB)
Effective output range (P) at 80/60 °C
7.1 … 30.5 kW
Domestic hot water heat output (P)
7.0 … 35.0 kW
Maximum heat input – heating (Q max.)
30.6 kW
Minimum heat input – heat­ing (Q min.)
7.1 kW
Maximum heat input – hot water (Q max.)
35.7 kW
Minimum heat input – hot water (Q min.)
7.1 kW
Technical data – General
ENERGY 12r -A (H­GB)
ENERGY 15r -A (H­GB)
ENERGY 18r -A (H­GB)
ENERGY 25r -A (H­GB)
Gas category
I
2H
I
2H
I
2H
I
2H
Diameter of the gas pipe
1/2 inch 1/2 inch 1/2 inch 1/2 inch
Diameter of the heating connec­tions
3/4 inch 3/4 inch 3/4 inch 3/4 inch
Expansion relief valve connector (min.)
15 mm 15 mm 15 mm 15 mm
Condensate drain pipework (min.)
21.5 mm 21.5 mm 21.5 mm 21.5 mm
G20 gas supply pressure
2.0 kPa
(20.0 mbar)
2.0 kPa
(20.0 mbar)
2.0 kPa
(20.0 mbar)
2.0 kPa
(20.0 mbar)
Gas flow at P max. – hot water (G20)
1.6 m³/h 1.9 m³/h 2.7 m³/h 3.2 m³/h
Gas flow at P max. – heating mode (G20)
1.3 m³/h 1.6 m³/h 1.9 m³/h 2.7 m³/h
Gas flow at P min. (G20)
0.480 m³/h 0.480 m³/h 0.533 m³/h 0.648 m³/h
CE number (PIN)
CE-0063CP3646 CE-0063CP3646 CE-0063CP3646 CE-0063CP3646
Flue gas mass rate in heating mode at P min.
2.08 g/s 2.08 g/s 2.31 g/s 2.81 g/s
Flue gas mass rate in heating mode at P max.
5.5 g/s 6.9 g/s 8.3 g/s 11.5 g/s
Flue gas mass rate in hot water handling mode at P max.
6.9 g/s 8.3 g/s 11.6 g/s 13.8 g/s
Flue gas temperature (80 °C/60 °C) at P max.
55 ℃ 55 ℃ 60 ℃ 77 ℃
Flue gas temperature (80 °C/60 °C) at P min.
55 ℃ 55 ℃ 55 ℃ 55 ℃
Flue gas temperature (50 °C/30 °C) at P max.
43 ℃ 48 ℃ 51 ℃ 62 ℃
Flue gas temperature (50 °C/30 °C) at P min.
32 ℃ 32 ℃ 34 ℃ 35 ℃
Flue gas temperature in hot water handling mode
71 ℃ 71 ℃ 69 ℃ 68 ℃
Flue gas temperature when over­heating
105 ℃ 105 ℃ 105 ℃ 95 ℃
Nominal efficiency at 50/30 °C
104.0 % 104.0 % 104.0 % 104.0 %
Nominal efficiency at 40/30 °C
106.0 % 106.0 % 106.0 % 106.0 %
NOx class
5 5 5 5
Product dimensions, width
375 mm 375 mm 375 mm 375 mm
Product dimensions, height
602 mm 602 mm 602 mm 602 mm
Net weight
22 kg 22 kg 22 kg 22 kg
Weight when filled with water
26 kg 26 kg 26 kg 26 kg
Appendix
0020177748_03 ENERGY Installation and maintenance instructions 43
ENERGY 30r -A (H­GB)
Gas category
I
2H
Diameter of the gas pipe
1/2 inch
Diameter of the heating connec­tions
3/4 inch
Expansion relief valve connector (min.)
15 mm
Condensate drain pipework (min.)
21.5 mm
G20 gas supply pressure
2.0 kPa
(20.0 mbar)
Gas flow at P max. – hot water (G20)
3.8 m³/h
Gas flow at P max. – heating mode (G20)
3.2 m³/h
Gas flow at P min. (G20)
0.756 m³/h
CE number (PIN)
CE-0063CP3646
Flue gas mass rate in heating mode at P min.
3.27 g/s
Flue gas mass rate in heating mode at P max.
13.8 g/s
Flue gas mass rate in hot water handling mode at P max.
16.1 g/s
Flue gas temperature (80 °C/60 °C) at P max.
86 ℃
Flue gas temperature (80 °C/60 °C) at P min.
56 ℃
Flue gas temperature (50 °C/30 °C) at P max.
60 ℃
Flue gas temperature (50 °C/30 °C) at P min.
37 ℃
Flue gas temperature in hot water handling mode
75 ℃
Flue gas temperature when over­heating
104 ℃
Nominal efficiency at 50/30 °C
104.0 %
Nominal efficiency at 40/30 °C
106.0 %
NOx class
5
Product dimensions, width
375 mm
Product dimensions, height
602 mm
Net weight
22 kg
Weight when filled with water
27 kg
Technical data – Electrics
ENERGY 12r -A (H-GB) ENERGY 15r -A (H-GB) ENERGY 18r -A (H-GB)
Electric connection
230 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz
Built-in fuse (slow-blow)
T2/2A, 250V T2/2A, 250V T2/2A, 250V
Max. electrical power consump­tion
65 W 65 W 66 W
Standby electrical power con­sumption
2 W 2 W 2 W
Level of protection
IPX4D IPX4D IPX4D
ENERGY 25r -A (H-GB) ENERGY 30r -A (H-GB)
Electric connection
230 V / 50 Hz 230 V / 50 Hz
Built-in fuse (slow-blow)
T2/2A, 250V T2/2A, 250V
Max. electrical power consump­tion
75 W 60 W
Appendix
ENERGY 25r -A (H-GB) ENERGY 30r -A (H-GB)
Standby electrical power con­sumption
2 W 2 W
Level of protection
IPX4D IPX4D
Index
0020177748_03 ENERGY Installation and maintenance instructions 45
Index
A
Air/flue pipe, installed ............................................................ 4
B
Burner anti-cycling time ....................................................... 19
C
Calling up the fault memory................................................. 23
CE label .................................................................................7
Check programmes ....................................................... 16, 25
Checking the burner ............................................................ 22
Cleaning the condensate siphon.........................................22
Cleaning the heat exchanger ..............................................22
CO₂ content
Checking.................................................................. 19–20
Competent person.................................................................3
Completing inspection work ................................................ 23
Completing maintenance work ............................................ 23
Condensate discharge pipe................................................. 12
Controller............................................................................. 14
Corrosion............................................................................... 4
D
Decommissioning................................................................24
Decommissioning the product ............................................. 24
Diagnostics codes ...............................................................15
Documents ............................................................................ 6
Draining the product ............................................................ 22
E
Electricity ...............................................................................4
F
Fault codes ..........................................................................23
Filling the condensate trap .................................................. 17
Filling the heating installation .............................................. 18
Flue gas route .......................................................................4
Front casing, closed .............................................................. 4
Frost ...................................................................................... 4
G
Gas family check ................................................................. 16
Gas flow rate ...................................................................... 18
H
Handing over to the end user .............................................. 20
I
Identification plate ................................................................. 7
If you smell flue gas............................................................... 4
If you smell gas ..................................................................... 3
Inspection work ............................................................. 20, 25
Installation site....................................................................... 4
Installing the front casing....................................................... 9
Installing the side section ...................................................... 9
Intended use.......................................................................... 3
L
Leak-tightness ......................................................... 19, 23–24
M
Mains connection ................................................................ 14
Maintenance work .........................................................20, 25
Minimum clearance ...............................................................8
P
Power supply .......................................................................14
Preparing the repair work ....................................................23
Preparing, repair work ......................................................... 23
Q
Qualification...........................................................................3
R
Regulations ...........................................................................5
Removing the air intake pipe...............................................21
Removing the burner ...........................................................21
Removing the flue pipe........................................................ 21
Removing the gas-air mixture unit....................................... 21
Removing the side section .................................................... 9
Replacing the burner ........................................................... 23
Replacing the heat exchanger.............................................23
Replacing the main PCB ..................................................... 24
Resetting the burner anti-cycling time ................................. 20
S
Safety device .........................................................................4
Schematic drawing ................................................................ 4
Setting the burner anti-cycling time ..................................... 19
Spare parts ..........................................................................20
Switching on the product .....................................................18
T
Tool .......................................................................................5
Transport ...............................................................................3
Transporting .......................................................................... 7
Treating the heating water .................................................. 16
U
Unloading the box ................................................................. 7
Unpacking the product .......................................................... 7
User interface, replacing the PCB ....................................... 24
V
Voltage .................................................................................. 4
W
Wall-mounting the product .................................................... 8
Weight ................................................................................... 8
0020177748_03
Manufacturer/Supplier
Vaillant Group UK LTD
Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ Telephone 01773 824639 ‒ Technical helpline 0330 100 7679 After sales service 0330 100 3142
www.glow-worm.co.uk
0020177748_03 ‒ 16.11.2017
© These instructions, or parts thereof, are protected by copyright and may be repro­duced or distributed only with the manufacturer's written consent.
We reserve the right to make technical changes.
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