WarmFlow GS25A, GC29B User Manual

Boiler Manual
Incorporating: User Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record
Model covered by this manual:
G-Series GS25A
Gas premix system boiler
SEDBUK
TR05A140.B1107
TR05A140.B1107
CONTENTS
1 USER INSTRUCTIONS 3
1.1 Boiler controls 3
1.1.1 Control panel layout 3
1.1.2 Operating the appliance 3
1.2 Topping up the system (Error Code H20) 4
1.3 If you smell gas 4
2 GENERAL INFORMATION 5
2.1 General warnings 5
2.2 Information 5
2.3 Product conformity 7
3 TECHNICAL CHARACTERISTICS 8
3.1 Technical data 8
3.2 Dimensions 9
3.3 Internal components 10
3.4 Function diagram 11
3.5 Circulation pump performance curves 12
3.6 Control panel and display 13
3.6.1 Layout 13
3.6.2 Boiler operation 13
3.6.3 Function codes 14
4 INSTALLATION 15
4.1 Reference standards 15
4.2 Unpacking 16
4.3 Installing the boiler 17
4.3.1 Compartment ventilation 17
4.4 Water connections 18
4.4.1 Central heating circuit 19
4.4.2 Filling the central heating system 19
4.5 Condensate drain 20
4.6 Gas connection 21
4.7 Electrical connections 22
4.7.1 General warnings 22
4.7.2 Power supply 23
4.8 Flue connections 24
4.8.1 Flue position 25
4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K) 26
4.8.3 Horizontal coaxial balanced flue – Ø 80/125 27
4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) 28
4.8.5 Vertical coaxial balanced flue – Ø 80/125 29
4.8.6 Twin pipe flue system – Ø 80/80 (Kit H) 30
5 COMMISSIONING 31
5.1 General warnings 31
5.2 Filling the system 32
5.3 Flushing the system 33
5.4 Filling the condensate trap 33
5.5 Starting the boiler 34
5.6 Control parameters 35
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CONTENTS
5.7 Control parameter adjustment 36
5.7.1 Accessing the parameters menu 36
5.7.2 Adjusting the parameters 37
5.8 Gas data 42
5.8.1 Technical reference tables 42
6 MAINTENANCE 43
6.1 General warnings 43
6.2 Boiler inspection 43
6.3 Accessing the boiler 44
6.3.1 Front panel removal 44
6.3.2 Side panel removal 44
6.3.3 Control panel access 44
6.4 Draining the central heating system 45
6.5 Flushing the central heating system 45
6.6 Maintenance operations 46
6.6.1 Primary heat exchanger and burner unit 47
6.6.2 Ignition and ionisation electrodes 48
6.6.3 Safety thermostat 48
6.6.4 Heating sensor 48
6.6.5 Gas valve 49
6.6.6 Circulating pump motor body 49
6.6.7 Electric fan 50
6.6.8 Expansion vessel 50
6.6.9 Modulation circuit board 51
6.6.10 Electric fan circuit board 51
6.6.11 Primary heat exchanger replacement 51
6.7 Wiring diagram 52
6.8 Troubleshooting 53
6.8.1 Error codes 53
6.9 Parts lists 54
6.9.1 Main components 54
7 OPTIONAL CONTROLS 55
7.1 External controls, programmers and room thermostats 55
7.1.1 Appliance connections 55
7.1.2 S-Plan wiring schematic 56
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1 USER INSTRUCTIONS
1.1 Boiler controls
1.1.1 Control panel layout
1. ON/OFF button
2. Central Heating Control knob
3. button
4.
5. button
6. Mains supply terminal board
button
GENERAL INFORMATION
78
ON / OFF
7. Digital LCD display
8. Programmer location (N/A)
Figure 1: Control Panel
1.1.2 Operating the appliance
Operation Instruction
Switching the boiler on
Adjusting the Central Heating temperature
Switching the boiler off
Table 1: Control panel display
Press the ON/OFF button (1)
Turn the Central Heating Control knob (2):
- the temperature setting will appear on the display
Press the ON/OFF button (1)
1 2
3 4 5 6
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GENERAL INFORMATION
1.2 Topping up the system (Error Code H20)
If the water pressure in the central heating circuit falls below 0.3 bar, the boiler will go to lock out (stop working) and Error Code H2O will appear on the display. This could be caused be a leak in the system, if air is bled from a radiator or if a radiator is replaced. The system will then need to be topped up.
To top up the system:
Let the boiler and radiators cool down;
Connect the filling loop (usually located near the boiler);
Open the filling loop valve (or valves);
Fill the system until the pressure gauge (located on the underside of the boiler) reads 1 bar;
Switch the boiler off then on again using the ON/OFF button on the Control Panel;
Check that Error Code H2O is no longer shown on the Control Panel display;
Close the filling loop valve (or valves) and disconnect the filling loop.
The boiler should now fire and continue to work normally.
If a lot of water was required to fill the system (such as after a radiator is replaced) it may be necessary to repeat the process a few times over a period.
1.3 If you smell gas
DO NOT operate any electric switches, telephones or any other equipment that may cause sparks;
Open doors and windows immediately to create a current of air and ventilate the room;
Shut off the main gas supply valve (either at the meter or on the cylinder in the case of bottled gas);
From a safe location, telephone the following 24 hour gas emergency numbers:
Great Britain 0800 111 999 Northern Ireland 0800 002 001 Republic of Ireland 1850 20 50 50
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GENERAL INFORMATION
2 GENERAL INFORMATION
2.1 General warnings
This appliance must only be installed and commissioned by professionally qualified personnel in
accordance with current laws and standards and in line with the manufacturer’s instructions.
In the United Kingdom, the installation must be carried out by a CORGI Registered Installer. To check for
authorised qualified engineers please contact CORGI on 0870 401 2300. The installation must be carried out in accordance with the relevant requirements of:
- The Gas Safety Regulations;
- The appropriate Building Regulations – either the Building Regulations, the Building Regulations
(Scotland) or the Building Regulations (Northern Ireland);
- The Water Fittings Regulations or Water Byelaws in Scotland;
- The current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.
In the Republic of Ireland, the installation must be carried out by a competent person and in accordance
with the current edition of I.E. 813 ‘Domestic Gas Installations’, the current Building Regulations and the current ETCI rules for electrical installations.
The appliance must be used solely for the purpose for which it has been designed and manufactured:
central heating and domestic hot water production. Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through non­compliance with current local and national standards and/or the manufacturer’s instructions.
This instruction manual forms an integral and essential part of the product and must be kept with the
appliance, in a safe place, available for future reference. This manual, along with the Benchmark commissioning booklet, must be left with the end user as per Regulation 29 of the HSC Gas Safety (Installation and Use) Regulations 1998.
The warnings contained in this chapter have been written for the appliance user, the installer and the
service engineer.
This instruction manual must be read carefully as it provides information on the operation and the
operating limits of the appliance.
This appliance is only suitable for use in a sealed central heating system.
2.2 Information
After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children as these items represent a potential hazard and must be disposed of in a responsible manner.
Before carrying out any cleaning or maintenance operations, isolate the appliance from the electricity supply by switching off at the main switch and/or any other isolating device.
Do not obstruct the air intake or flue exhaust terminals.
In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt to
repair the appliance. Contact your commissioning engineer in the first instance or contact the W armflow Customer Care Centre on 028 9262 1515.
Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorised service centre using original spare parts. Non-compliance with this requirement may compromise the safety of the appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its correct operation, it must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions.
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GENERAL INFORMATION
W hen the appliance is no longer required for use, any parts that may constitute potential sources of danger must be rendered harmless.
Only original accessories or optional extras (including electrical parts) may be used with the appliance.
Should there be a smell of gas present in the room where the appliance is installed, DO NOT attempt to activate any
electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to create a current of air and ventilate the room. Shut-off the main gas supply valve (either at the meter or on the cylinder in the case of bottled gas), then telephone the following 24 hour gas emergency numbers:
Great Britain 0800 111 999 Northern Ireland 0800 002 001 Republic of Ireland 1850 20 50 50
Before starting the boiler for the first time, make sure that it is connected to a water supply and central heating system compatible with its performance characteristics.
Check the technical data displayed on the packing and on the data plate located on the inside of the front casing. Also check that the burner is appropriate for the type of gas to be used.
Make sure that the pipes and fittings used for the gas service are perfectly tight and that there are no gas leaks.
Prior to start-up, the central heating pipes should be flushed to remove any residues that could compromise the operation of the appliance.
The appliance can be regarded as being electrically safe when it has been connected to an effective earth system installed in accordance with the requirements of current safety standards. This fundamental safety requirement must be checked and verified. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an ineffective or non-existent earth system.
The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the appliance data plate (positioned on the inside of the front casing). In particular, make sure that the cable ratings are adequate for the power absorbed.
Do not use adapters; multiple sockets or extension leads to connect the appliance to the mains power supply.
The appliance must be connected to the mains power supply through an appropriate electrical isolator in accordance
with the current wiring regulations.
W hen using an electrical appliance, a few fundamental rules must be observed:
Do not touch the appliance with damp or wet parts of the body or when barefoot;
Do not pull on the electric wires;
Do not leave the appliance exposed to atmospheric elements (rain, sun, etc,) unless these conditions have been expressly provided for;
Do not allow the appliance to be used by children or anyone unfamiliar with its operation.
The user must not replace the power supply cable.
If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified
electrician.
When the appliance is no longer required for use, switch off the main power supply to deactivate all the electrical components (circulating pump, burner, etc.)
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GENERAL INFORMATION
2.3 Product conformity
Warmflow declares that all its products are manufactured to a high specification and in compliance with the relevant standards.
All Warmflow gas boilers are CE certified and possess technical and functional characteristics that comply with the following directives and standards:
GAS APPLIANCES DIRECTIVE 90/396 CEE for CE compliance
LOW VOLTAGE DIRECTIVE 73/23 CEE
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89/336 CEE
BOILER EFFICIENCY DIRECTIVE 92/42 CEE
UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT 70 kW
EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT 70 kW
UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS: SPECIFIC REQUIREMENTS FOR CONDENSING BOILERS WITH NOMINAL HEAT INPUT 70 kW
Warmflow will not be responsible for the consequences of non-observance of the instructions contained within this manual where actions not specifically described herein are undertaken.
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TECHNICAL CHARACTERISTCS
3 TECHNICAL CHARACTERISTICS
3.1 Technical data
Model
Appliance Type C13, C33, C43, C53, C63, C83 Appliance Category II2H3+ Heat Input max
Heat Input min Heat Output max (50/30°) kW 26.67 Efficiency 100% (full load 50/30°) % 106.7 Efficiency 30% (partial load 50/30°) % 106.3 Heat Output max - 80/60°C (Non condensing) kW 24.6 Heat Output min - 80/60°C (Non condensing) kW 8.73 Efficiency 100% (full load 80/60°) % 98.4 Efficiency 30% (partial load 80/60°) % 100.1 GAS DIRECTIVE 92/42/ECC - Efficiency marking stars 4 SEDBUK band A
Central Heating (CH) Circuit
CH water temperature setting (min-max) °C 30-80 Max. CH working temperature °C 80 Expansion vessel capacity litres 8 Max. CH working pressure bar 2.5 Min. CH working pressure bar 0.3
Dimensions
Width mm 410 Height mm 730 Depth mm 285 Weight (net) kg 46
Hydraulic Connections
CH Flow connection Ø 3/4" (22mm tail supplied) CH Return connection Ø 3/4” (22mm tail supplied) Gas connection Ø 3/4” (22mm tail supplied)
Flue Systems
Horizontal Concentric flue system Ø mm 60/100 Max. Flue length m 5 Horizontal Concentric flue system Ø mm 80/125 Max. Flue length m 7 Vertical Concentric flue system Ø mm 60/100 Max. Flue length m 5 Vertical Concentric flue system Ø mm 80/125 Max. Flue length m 7 Twin Pipe flue system Ø mm 80/80 Max. Flue length m 50
Gas Supply
Natural gas (Methane) G20 Inlet pressure mbar 20 Gas consumption m3/h 2.65 Butane G30 Inlet pressure mbar 30 Gas consumption kg/h 1.97 Propane G31 Inlet pressure mbar 37 Gas consumption kg/h 1.94
Electrical Specifications
Power supply V/Hz 230/50 Electrical power consumption W 170 Electrical protection IP X4D
kW 25 kW 9
GS25A
Table 2: Technical data
TR05A140.B1107
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730
3.2 Dimensions
48.5 313 48.5
TECHNICAL CHARACTERISTCS
111.5187111.5
730
ON / OFF
HR
G
HF
14849 182 31
105
285
132
285
LEGEND
HR HEATING RETURN 22mm
HF HEATING FLOW 22mm
G
SC CONDENSATE DRAIN 25mm
GAS 22mm
110137163
Figure 2: Dimensions
TR05A140.B1107
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25
3.3 Internal components
TECHNICAL CHARACTERISTCS
17 16
13 12
11
14 10
22 24
23
16
1
18
8
4
5
2
3
7
9
4 5 1 2
12 6
6
9
19
19 11 14
20
15 21
Figure 3: Internal components
LEGEND
1. PRIMARY CONDENSING HEAT EXCHANGER
2. PREMIX BURNER UNIT (GAS MANIFOLD + BURNER)
3. HEAT EXCHANGER CONDENSATE DRAIN CONNECTION
4. IONISATION ELECTRODE
5. IGNITION ELECTRODE
6. FAN
7. VENTURI
8. IGNITION TRANSFORMER
9. ELECTRONIC GAS VALVE
10. 3 BAR PRESSURE RELIEF VALVE – HEATING CIRCUIT
11. AUTOMATIC AIR VENT VALVE
12. HEATING SAFETY THERMOSTAT
13. HEATING SENSOR
14. PUMP WITH AIR VENT
15. WATER PRESSURE SWITCH
16. FLUE HOOD
17. FLUE SAFETY THERMOFUSE
18. EXPANSION VESSEL
19. ROOM SEALED CHAMBER BULKHEAD
20. CONDENSATE TRAP
21. WATER PRESSURE GAUGE
22. SYSTEM DRAIN VALVE
23. CONDENSATE DRAIN PIPE
24. AUTOMATIC BYPASS
25. PRIMARY HEAT EXCHANGER MANUAL AIR VENT VALVE
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3.4 Function diagram
17
13
12
2
4
18
1
6
9
11
14 10 22
TECHNICAL CHARACTERISTCS
LEGEND
16
8
5
3 7
19
20
23
21
15
SC
G HFHR
1. PRIMARY CONDENSING HEAT EXCHANGER
2. PREMIX BURNER UNIT (GAS MANIFOLD &
BURNER)
3. HEAT EXCHANGER CONDENSATE DRAIN PIPE
4. IONISATION ELECTRODE
5. IGNITION ELECTRODE
6. FAN
7. VENTURI
8. IGNITION TRANSFORMER
9. ELECTRONIC GAS VALVE
10. 3 BAR PRESSURE RELIEF VALVE - HEATING
CIRCUIT
11. AUTOMATIC AIR VENT VALVE
12. HEATING SAFETY THERMOSTAT
13. HEATING SENSOR
14. PUMP WITH AIR VENT
15. WATER PRESSURE SWITCH
16. FLUE HOOD
17. FLUE SAFETY THERMOFUSE
18. EXPANSION VESSEL
19. ROOM SEALED CHAMBER
20. CONDENSATE TRAP
21. WATER PRESSURE GAUGE
22. AUTOMATIC BYPASS
23. CONDENSATE DRAIN PIPE
24. SYSTEM DRAIN VALVE
Figure 4: Function diagram
HR HEATING RETURN 22mm
HF HEATING FLOW 22mm
G
SC
GAS 22mm
CONDENSATE DRAIN 25mm
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TECHNICAL CHARACTERISTCS
3.5 Circulation pump performance curves
70
60
Head (kPa)
50
40
30
I
20
III
II
10
0
0
III
II
I
200
Available head at maximum speed Available head at second speed
Available head at minimum speed
Appliance Loss
Figure 5: Pump performance curves
800400 600
1000
14001200 1600
Flow l/h
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TECHNICAL CHARACTERISTCS
S
3.6 Control panel and display
The appliance MUST be supplied with a permanent live in order for the boiler’s protective functions to
operate. These functions include frost protection, post-ventilation, pump overrun and pump & 3-way valve inactivity protection. On first connection to the power supply, the appliance must be switched on using the ON/OFF button on the control panel to activate all of the above protective features. The appliance can then be switched off but the protective features will remain active.
3.6.1 Layout
1. ON/OFF button
2. CH Control knob
3. DISPLAY button
4.
SERVICE button
5. MODE button
6. Mains supply terminal board
7. Digital LCD display
8. Programmer location (N/A)
3.6.2 Boiler operation
ON / OFF
1 2
Figure 6: Control Panel
78
3 4 5 6
Mode / Control Input Display will show:
Boiler switched off
Press ON/OFF button (to switch the boiler on)
CH controls call for heat
CH Control knob turned
SERVICE button pressed & held for 7 seconds
Boiler protection function activated (automatically)
Boiler locked out
Table 3: Control panel display
OFF
Primary circuit temperature in ºC
Icon – lit when appliance switched on
Primary circuit temperature in ºC
Icon – flashes whilst CH mode is active
CH set point temperature in ºC – displayed for 3 seconds
Function Code 07 – flashes whilst activated (see Section 3.6.3)
Function Code 08 – flashes whilst activated (see Section 3.6.3)
Error Code – flashes whilst locked out (see Section 6.8.1)
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TECHNICAL CHARACTERISTCS
S
3.6.3 Function codes
Code Function Description
Operates the boiler at maximum CH output for 15 minutes
07 Commissioning Mode
08
CH Frost Protection Mode
Table 4: Function codes
without modulation.
Activated by pressing and holding the
Deactivated by switching the appliance off.
Operates the boiler at minimum CH output in Heating Only Mode.
Activated when the CH sensor detects below 5°C. Deactivated when the CH sensor detects above 30°C.
button for 7 seconds.
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INSTALLATION INSTRUCTIONS
4 INSTALLATION
4.1 Reference standards
In the United Kingdom, the installation of this appliance must be carried out by a CORGI Registered Installer. To check for authorised qualified engineers contact CORGI on 0870 401 2300. The installation must be carried out in accordance with the relevant requirements of the:
- Gas Safety Regulations;
- The appropriate Building Regulations – either the Building Regulation, the Building Regulations
(Scotland) or the Building Regulations (Northern Ireland);
- The Water Fittings Regulations or Water Byelaws in Scotland;
- The current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice.
In the United Kingdom, the following Codes of Practice apply:
BS 5440: Part 1 Flues BS 5440: Part 2 Air Supply BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 6700 Installation of cold water supplies for domestic purposes BS 6798 Installation of gas-fired hot water boilers BS 6891 Gas Installation BS 7074 Expansion Vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems BS 7671 IEE wiring regulations
In the Republic of Ireland, the installation must be carried out by a competent person and in accordance with the current edition of I.E. 813 ‘Domestic Gas Installations’, the current Building Regulations and the current ETCI rules for electrical installations.
Failure to install a gas appliance correctly and in accordance with the above standards could result in
prosecution.
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INSTALLATION INSTRUCTIONS
4.2 Unpacking
The materials (cardboard) used for packing the appliance are fully recyclable.
It is recommended that the packing material is only removed when the appliance is ready to be installed.
The manufacturer will not be held responsible for damage caused by incorrect storage of the product.
Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that
these items represent a potential hazard.
A. With the packed appliance on
the floor (see Figure 7), remove the staples and open out the four flaps on the end of the box;
B. Stand the boiler up on its end as shown, supporting it from underneath;
C. Lift off the box and remove all packaging.
STORAGE & HANDLING
Please note that prior to installation, the boiler should be stored in the horizontal position with no more than 5 boilers to a stack;
Ensure that the boilers are stored in dry conditions and be aware that the carton is a two-man lift.
A
C
B
Figure 7: Unpacking instructions
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4.3 Installing the boiler
INSTALLATION INSTRUCTIONS
The appliance must only be
installed on a flat vertical solid wall capable of supporting its weight.
The boiler should be fitted within the
building unless otherwise protected by a suitable enclosure i.e. garage or outhouse.
If the boiler is sited in an unheated
enclosure, a permanent live supply must be provided in order for the frost protection function to operate. The appliance can still be switched off using the ON/OFF button on the control panel.
If the boiler is installed in a room
containing a bath or shower, it must have a room sealed flue and reference must be made to the relevant requirements.
In order to allow access to the interior of the boiler for maintenance purposes, it is important that the necessary clearances indicated in Figure 8 are respected.
For ease of installation, the boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall.
To install the boiler, proceed as follows (see Figure 9):
1 Use a spirit level to mark a horizontal
line on the wall where the boiler is to be fitted.
2 Position the top of the template along
the line. Mark the centres of fixing locations and the positions of the water and gas pipes.
3 Remove the template and install the
gas supply pipe and the central heating pipes using the fittings supplied with the boiler.
4 Install the hanging bracket then fix the
boiler to the wall and connect the pipes.
A
B
Figure 8: Access clearances
X
L
H
MI NIMU M DIST ANCE I N mm
X Y L H
Mo de l
X Y L H
RK R 29
X Y L H
10 0045 06060
10 0041 0606 0
A B
A B
200 30 0
10 0041 06060
20 0 30 0
Y
A B
20 0 30 0
Figure 9: Mounting procedure
4.3.1 Compartment ventilation
Where the appliance is installed in a compartment, no air vents are required.
BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
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INSTALLATION INSTRUCTIONS
105
Figure
10
: Location of connections
22
4.4 Water connections
In order to comply with the Terms &
Conditions of warranty, the system must be hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators.
The CH pipes must be adequately
earthed. However, the appliance must also be provided with an adequate earth. Pipe work is NOT suitable for this purpose.
Isolation valves must be installed on
the CH circuit in order to facilitate all maintenance and service operations where the boiler needs to be drained. The boiler is supplied with a fittings kit (see Figure 11) complete with isolation valves and copper tails.
To prevent vibration and noise coming from the system, do not use pipes of reduced diameter, short radius elbows or severe restrictions.
14849 182 31
HR G HF
Ø 22 mm
HF
Ø 15 mm
G
Ø 22 mm
HR
Figure 11: Fittings kit
LEGEND
HR HEATING RETURN 22mm
HF HEATING FLOW 22mm
G
CD
GAS 22mm
CONDENSATE DRAIN 25mm
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