WarmFlow GS25A, GC29B User Manual

Page 1

Boiler Manual

Incorporating: User Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record

High Efficiency Condensing Gas Boilers

Model covered by this manual:

G-Series GS25A

Gas premix system boiler

SEDBUK

TR05A140.B1107

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TR05A140.B1107

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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

5. button

6. Mains supply terminal board

button

GENERAL INFORMATION

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

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730

3.2 Dimensions

48.5 313 48.5

TECHNICAL CHARACTERISTCS

111.5187111.5

730

ON / OFF

14849 182 31

105

285

132

285

LEGEND

HR HEATING RETURN 22mm

HF HEATING FLOW 22mm

SC CONDENSATE DRAIN 25mm

GAS 22mm

110137163

Figure 2: Dimensions

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3.3 Internal components

TECHNICAL CHARACTERISTCS

17 16

13 12

14 10

22 24

4 5 1 2

12 6

19 11 14

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

14 10 22

TECHNICAL CHARACTERISTCS

LEGEND

3 7

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

GAS 22mm

CONDENSATE DRAIN 25mm

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TECHNICAL CHARACTERISTCS

3.5 Circulation pump performance curves

Head (kPa)

III

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

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

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

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

3.6.3 Function codes

Code Function Description

Operates the boiler at maximum CH output for 15 minutes

07 Commissioning Mode

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.

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.

Figure 8: Access clearances

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

200 30 0

10 0041 06060

20 0 30 0

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

: Location of connections

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

Ø 15 mm

Ø 22 mm

Figure 11: Fittings kit

LEGEND

HR HEATING RETURN 22mm

HF HEATING FLOW 22mm

GAS 22mm

CONDENSATE DRAIN 25mm

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INSTALLATION INSTRUCTIONS

4.4.1 Central heating circuit

The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account.

The boiler is supplied with the following components built in:Pressure relief valve – complies with BS 6759 and set is to operate at 3 bar. The outlet connection of the pressure

relief valve must be connected via a tundish to a safe visible discharge. The manufacturer will not be held responsible for flooding caused by the operation of the pressure relief valve in the case of system overpressure where adequate drainage has not been provided.

Pressure gauge – indicates the system pressure. Expansion vessel – conforms to BS 7074:1 and has a volume of 8 litres. If the total system volume requires more than 8

litres of expansion capacity, an additional expansion vessel will be required. Bypass – incorporated within the boiler. However, where all radiators are fitted with thermostatic radiator valves, it is

recommended an additional automatic system bypass is fitted.

Lockshield valve

Note: A drain tap should be in stalled at the lowest point of the heating circuit and beneath the ap pliance

Radiator valve

Boiler

Heating return

System drain tap

Automatic air vent

Filling point (see fig. 2)

DHW outlet

Pressure reducing

valve reccomended for inlet supplies in excess pf 3.5 bar

Mains water inlet

Figure 12: Central heating system layout

4.4.2 Filling the central heating system

All fittings used in filling the system must be suitable for mains pressure applications. Filling of the system must be carried out in an approved manner (in the UK, refer to Guidance G24.2 and Recommendation R24.2 of the Water Regulation Guide) and in accordance with the instructions in Section 5.2.

The system should be filled via a temporary filling loop connection as shown in Figure 13. After filling, the flexible hose of the filling loop must be disconnected. The filling loop should be installed such that it can be easily reconnected in order to top up the system if any water is lost (e.g. due to leakage or after replacing a radiator).

Drain cocks (to BS 2879) must be fitted to the lowest points in the system to allow it to be completely drained.

A corrosion inhibitor must be added to the CH circuit in order to guarantee the life of the appliance. In hard water areas, a combined corrosion inhibitor and softener must be used.

The system pre-charge pressure (cold) should be 1 bar.

Figure 13: Filling loop layout

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Figure

: Condensate drain configuration

4.5 Condensate drain

INSTALLATION INSTRUCTIONS

Sink

Boiler

Termination to an internal soil and vent pipe

Boiler

450mm min

External termination via internal discharge branch e.g. sink waste - downstream

Pipe must terminate above

water level but below

surrounding surface

Failure to install the condensate discharge pipe work correctly will affect the reliable operation of the boiler.

The condensate discharge pipe must not rise at any point along its length. There must be a fall of at least

2.5° (50mm per metre) along the entire run.

The boiler condensate trap is fitted with a 1 metre length of 25mm flexible pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

Ensure the discharge of condensate complies with any national or local regulations in force.

The discharge pipe should be run in a proprietary plastic drain pipe material. Metal pipe work is NOT suitable for use in condensate discharge systems.

The pipe should be a minimum of 21.5 mm diameter and must be supported using suitably spaced clips to prevent sagging. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used.

Boiler

External termination to a drain or gully

Boiler

Pipe must terminate above water level but below surrounding surface

External termination to a purpose made soak-away

Holes in the soak-away must face away from the building

Any condensate discharge pipe work external to the building (or in an unheated area, e.g. garage) must be insulated to protect against frost. It is also recommended that the pipe diameter is increased to 32mm. Any pipe run external to the building must not exceed 3 metres in length.

If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WCs are flushed or sinks emptied then back pressure may force water out of the boiler trap and cause appliance lockout.

500mm min

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INSTALLATION INSTRUCTIONS

4.6 Gas connection

The connection to the gas supply must be carried out by professionally qualified personnel in

accordance with relevant standards.

When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The

use of hemp, PTFE tape and similar materials is not allowed.

In areas prone to Copper Sulphide build-up in gas supply pipes (such as in Northern Ireland) an in-line

filter should be installed upstream of the appliance.

Before installing the boiler, check that:

■ The pipe work is appropriately sized for the flow rates required and the pipe lengths installed, and must be fitted with all the safety and control devices required by current standards;

■ The gas supply line must be a minimum of a 22 mm diameter pipe with a direct supply from meter to boiler and comply with current standards and regulations;

■ Check the internal and external seals of the gas supply system;

■ A gas shut-off valve must be installed upstream of the appliance;

■ An in-line filter is installed, where necessary, and is free from blockage;

■ Before starting up the boiler, make sure that the type of gas corresponds to that for which the appliance has

been configured (see gas type label inside the boiler). Conversion of the appliance from natural gas to LPG must only be carried out by qualified personnel;

■ Check that the gas supply pressure is between the values stated on the rating plate (see gas type label inside the boiler);

■ Prior to installation, it is good practice to ensure that there are no machining residues on the gas supply pipe.

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INSTALLATION INSTRUCTIONS

4.7 Electrical connections

4.7.1 General warnings

The connection to the mains power supply must be carried out by professionally qualified personnel,

registered in accordance with current legislation.

Always check to make sure that the appliance has an effective earth system. This requirement is only

satisfied if it has been properly connected to an effective earth system installed in accordance with the requirements of current safety standards. This basic safety measure must be connected, checked and verified by professionally qualified personnel. 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 earth system.

■ The boiler is designed to operate with a 230 V, 50 Hz supply. The connection to the mains electricity supply must be via a fused spur and the appliance must be protected by a 3A fuse. Make sure that the positions of the live and neutral wires correspond to the wiring diagram (Figure 15);

■ Ensure the domestic power supply is checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the rating plate. In particular, make sure that the cable sizes are adequate for the power absorbed by the appliance;

When 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.

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INSTALLATION INSTRUCTIONS

4.7.2 Power supply

The connection to the mains power supply must be carried out by professionally qualified personnel,

registered in accordance with current legislation.

Connect the power supply to the terminal board inside the control panel as follows:

a. Ensure the supply is isolated; b. Remove the front casing panel of the boiler (refer to Section 6.3 for guidance); c. Remove terminal block cover A (see Figure 15); d. Connect the wires to terminal block B as follows (see Figure 15);

• Connect the earth wire (coloured green/yellow) to the terminal marked with the earth symbol “ “;

• Connect the neutral wire (coloured blue) to the terminal marked with the letter “ N ”;

• Connect the permanent live wire (coloured brown) to the terminal marked with the letter “ L ”;

e. Replace terminal block cover A.

The appliance MUST be supplied with a permanent live in order for the boiler’s protective functions to

operate correctly. 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.

The terminals marked Ta and Se are for external zero-voltage controls including room thermostats, time clocks, zoned system controls and weather compensating controls. Connection of these controls is covered in Section 7.

SeSeTaNL

A B

blue

ON / OFF

green/yellow

brown

Figure 15: Power supply connections

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INSTALLATION INSTRUCTIONS

4.8 Flue connections

In order to ensure that the appliance functions correctly

and efficiently, only Warmflow-approved flue components may be used with this appliance.

Traditional flue components cannot be used for

conveying exhaust fumes from condensing boilers.

Coaxial Balanced Flues

Where a horizontal balanced flue system is installed, the flue must be positioned level, not sloping upwards or downwards.

0.5

40ON50

60708 0

0.5

40ON50

60708 0

C33

C13

0.5

80706 0

50ON40

C53

The exhaust duct and air intake ducts have been designed so as to minimise the build-up of condensate in the flue and protect against the effect of the weather or the ingress of foreign bodies.

Twin Pipe Flues

For the exhaust discharge duct of a twin pipe system, the entire length of the duct must slope upwards towards the exterior in order to facilitate the flow of condensate back to the combustion chamber, which has been specifically designed to collect and drain the acidic condensate;

For the air intake duct of a twin pipe system, the entire length of

50ON40

C43 C83

Figure 16: Appliance and flue types

0.5

40ON50

60708 0

0.5

80706 0

the duct must slope downwards towards the exterior to prevent the entry of rainwater, dust or foreign bodies.

Reference Information – Type C Appliances

Exhaust flues for gas-fired appliances are classified at European level according to the method used for drawing combustion air to and discharging exhaust fumes from the appliance. This classification applies to gas-fired appliances in general.

The combustion circuit (air intake, combustion chamber, heat exchanger and fumes exhaust discharge) of Type C Appliances is sealed off from the room in which the appliance is installed, i.e. room sealed. The combustion air intake and the fumes exhaust discharge are connected directly to the outside.

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INSTALLATION INSTRUCTIONS

300 min

4.8.1 Flue position

The flue system MUST be installed in accordance with the recommendation contained in BS 5440:1.

The boiler MUST be installed so that the terminal is exposed to the external air.

It is important that the position of the terminal allows free passage of air across it at all times.

If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway.

In certain weather conditions a terminal may emit a plume of steam. Positions where this would cause a nuisance should be avoided.

It is ESSENTIAL TO ENSURE, in practice, that products of combustion discharging from the terminal

cannot re-enter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/air conditioning systems. If this should occur, the appliance MUST BE TURNED OFF IMMEDIATELY.

Where the lowest part of the terminal is fitted less than 2m (6.6ft) above a balcony, above ground, or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed guard.

B.C

F F

TERMINAL ASSEMBLY

H,I

TOP VIEW REAR FLUE

PROPERTY BOUNDARY LINE

Figure 17: Flue terminal positions – BS5440:1

A Directly below an opening window, air vent or any other ventilation opening 300 mm B Below gutter, drain pipes or soil pipes 75 mm C Below eaves 200 mm D Below balcony or carport roof 200 mm E From vertical drain pipes or soil pipes 150 mm F From internal or external corners 300 mm G Above adjacent ground, roof or balcony level 300 mm H From a surface or boundary facing the terminal 600 mm I From a terminal facing the terminal 1200 mm J From opening (door, window) in the carport into dwelling 1200 mm K Vertically from a terminal on the same wall 1500 mm L Horizontally from a terminal on the same wall 300 mm M Above an opening, air brick, opening window etc 300 mm N Horizontally to an opening, air brick, opening window, etc. 300 mm

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INSTALLATION INSTRUCTIONS

4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K)

FOR CONDENSING BOILERS ONLY

Ø 60/100

MAXIMUM FLUE LENGTH = 5 m *

The flue length is the total length of the flue excluding the first bend.

The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).

Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m

* If a flue length of above 5 metres is required, use the Ø 80/125 system.

Figure 18: Ø 60/100 Horizontal Kit K

163

100

48.5 313 48.5

Figure 19: Ø 60/100 Horizontal Kit K dimensions

132

111.5187111.5

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INSTALLATION INSTRUCTIONS

Figure

20: Ø

80/125 Horizontal Kit

4.8.3 Horizontal coaxial balanced flue – Ø 80/125

FOR CONDENSING BOILERS ONLY

Ø 80/125

MAXIMUM FLUE LENGTH = 7 m *

The flue length is the total length of the flue excluding the first bend.

The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).

Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m

* If a flue length of above 7 metres is required, use the Twin Pipe system.

163

125

48.5 313 48.5

Figure 21: Ø 80/125 Horizontal Kit dimensions

132

111.5187111.5

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INSTALLATION INSTRUCTIONS

4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V)

Figure 22: Ø 60/100 Vertical Kit V

FOR CONDENSING BOILERS ONLY

Ø 60/100

MAXIMUM FLUE LENGTH = 5 m *

The flue length is the total length of the flue excluding the first bend.

The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).

Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m

* If a flue length of above 5 metres is required, use the Ø 80/125 system.

max. 5.00 mt.

Ø60

Ø100

163

Ø60

Ø100

131

Figure 23: Ø 60/100 Vertical Kit V dimensions

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INSTALLATION INSTRUCTIONS

4.8.5 Vertical coaxial balanced flue – Ø 80/125

Figure 24: Ø 80/125 Verical Kit

FOR CONDENSING BOILERS ONLY

Ø 80/125

MAXIMUM FLUE LENGTH = 7 m *

The flue length is the total length of the flue excluding the first bend.

The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).

Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m

* If a flue length of above 7 metres is required, use the Twin Pipe system.

max. 5.00 mt.

Ø60

Ø100

163

Ø60

Ø100

131

Figure 25: Ø 80/125 Verical Kit dimensions

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INSTALLATION INSTRUCTIONS

4.8.6 Twin pipe flue system – Ø 80/80 (Kit H)

FOR CONDENSING BOILERS ONLY

Ø 80/80

MAXIMUM FLUE LENGTH = 50 m

The flue length is the total length of both the intake and exhaust sections excluding the first bend of each.

The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).

Ø 80 x 90° bend = 1.5 m Ø 80 x 45° bend = 1.2 m

Figure 26: Ø 80/80 Twin Pipe Kit H

163 137

111.5 187 111.5

131

106

122

48.531348.5

Figure 27: Ø 80/80 Twin Pipe Kit H dimensions

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COMMISSIONING INSTRUCTIONS

5 COMMISSIONING

5.1 General warnings

The following operations must be carried out by professionally qualified personnel, registered in

accordance with current legislation. Reference should be made to BS 5449:5 - Commissioning.

The boiler leaves the factory pre-set and tested for burning Natural Gas (Methane). Nevertheless, when

starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler.

Once the system has been filled and the necessary adjustments made, remember to tighten the screws

of the gas valve test point and make sure that there are no gas leaks from the test point and from any pipe fittings upstream of the gas valve.

■ Preliminary operations

Switching the boiler on for the first time means checking that the installation, regulation and operation of the appliance are correct. The commissioning engineer MUST check, referring to the previous sections of this manual, the following:-

• That the data on the data plate corresponds to that of the mains supply networks (gas, electricity, water);

• That the power supply voltage to the boiler complies with the data plate (230 V – 50 Hz) and that the live, neutral

and earth wires are correctly connected. Also, that the earth connection is sound and that the appliance is effectively earthed;

• That the gas supply is correctly sized for the flow rate required by the boiler and that it is fitted with all the safety and control devices as lay down by current regulations;

• That all mechanical connections are sound and have not become loose during transportation and handling;

• That the seals on the gas supply pipe from the mains are sound, and that the meter does not register any flow of

gas;

• That the flue system (air intake and exhaust ducts) is installed correctly and in line with current law and national and local standards;

• The all permanent combustion air and ventilation openings as required by current law for the type of appliances installed are provided and are not blocked;

• That the condensate drainage system(s) are installed correctly and in line with current law and national and local standards;

• That the condensate drainage system, including outside the boiler (condensate collection devices), allows the condensate to flow freely to the drain. Check that no exhaust fumes could discharge into the drainage system;

• That there are no flammable materials or liquids in the immediate vicinity of the boiler.

The commissioning engineer must then:-

• Flush out the central heating circuit (see Section 5.3);

• Turn the gas supply on and purge according to BS6891.

• Test for gas soundness (let-by and tightness).

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5.2 Filling the system

Use only a WRAS approved filling loop

for connection and filling of the primary system. This should be disconnected when not in use (see Section 4.4.2).

COMMISSIONING INSTRUCTIONS

AIR VENT VALVE

AIR VENT VALVE PLUG

Check the properties of the water supply

and use appropriate treatment agents if the mains water has a hardness rating more than 17.5 °Ck.

Use only clean tap water to fill the

system.

Once the water pipes have been connected, close the gas feed valve and fill the system as follows:

• Slacken the air vent valve plug to allow air to

escape from the system (see Figure 28);

• Open the main domestic water supply valve;

• Open the external filling loop;

• Unscrew the pump plug to remove any

trapped air, check that the pump is free then re-tighten it when water starts to flow out;

• Unscrew the manual air vent valve located in

the top left hand corner of the primary heat exchanger until air begins to escape. When water begins to flow out, screw the valve tightly closed.

• Open the air vents on the radiators and

monitor the air evacuation process. When water starts to flow out of the radiators, close the air vents;

PUMP

PUMP PLUG

Figure 28: Air vent and pump bleed plugs

• Use the pressure gauge M (see Figure 29) to

monitor the system pressure. Close the external filling loop when the system pressure reaches 1 bar and check that Error Code H2O is NOT displayed on the control panel display (see Section 3.6);

• If, after the above operations, there is a

reduction in the system pressure, re-open the external filling loop until the pressure gauge reads 1 bar. Check that Error Code H2O is NOT displayed on the control panel display;

• On completion of filling, ensure that the external filling loop is disconnected.

Figure 29: Pressure gauge and boiler drain

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COMMISSIONING INSTRUCTIONS

5.3 Flushing the system

Failure to flush and add inhibitor to the system will invalidate the warranty.

The system must be thoroughly drained and flushed out using flushing agents/descalers that comply

with BS7593. When refilling the system, appropriate corrosion inhibitors and softening agents must be added.

a. Fill the boiler as per the filling instructions; b. Using a drain cock on the lowest point of the system, allow the water to drain from both the system and boiler; c. To flush the system correctly, turn off all radiators, open the filling loop and drain cock simultaneously and allow

the water to flow through the boiler;

d. For each radiator on the system in turn, open the radiator valves, allowing water to flow through, then turn that

radiator off. Repeat for all the radiators on the system;

e. Close the drain cock, re-open all radiators and fill the system following the instructions in Section 5.2; a. Continue to fill the system until the pressure gauge reaches 1 bar.

5.4 Filling the condensate trap

The condensation trap MUST be pre-filled when starting the boiler for the first time in order to prevent flue gases from escaping via the drain.

The filling operation is carried out as follows (see Figure 30):

• Remove plug T and fill the trap S three quarters full with water;

• Replace plug T and connect the drainpipe P.

The trap should be cleaned after a few months of boiler operation, as deposits/residues drawn out of

the heat exchanger may impair the operation of the trap.

Figure 30: Condensate Trap

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5.5 Starting the boiler

COMMISSIONING INSTRUCTIONS

Once the system has been flushed and filled, proceed as follows:

• Check that the exhaust flue is free of obstructions and correctly connected to the boiler;

• Check that all isolation valve are open (CH circuit and gas)

• Switch on the power supply to the boiler and ensure that the system controls are calling for heat;

• Switch the boiler on using the ON/OFF button on the Control Panel (see Section

3.6) and ensure any system controls are calling for heat. After a few seconds the circulating pump will start to run;

• The automatic ignition system will then attempt to fire the burner. The system will make 3 attempts and then go to lock-out if unsuccessful. It may be necessary to repeat the process a few times in order to eliminate all the air from the gas supply line. To repeat the process, wait approximately three minutes then reset the appliance by switching the boiler off then on using the

ON/OFF button on the Control Panel;

Gas Type CO2 Concentration / %

Natural Gas (Methane) – G 20

LPG (Butane) – G 30 10.9

LPG (Propane) – G 31 11.0

Table 5: Correct gas analyser readings

9.4

• With the boiler ignited, if the system still emits noises, the above process must be repeated until all the air has been removed;

• Check the pressure in the heating circuit using the pressure gauge (see Section 5.2). If the pressure has fallen, re-open the filling loop until the pressure gauge reads 1 bar. Check that Error Code H2O is NOT displayed on the Control Panel display. On completion, close the filling loop;

• Unscrew the plug and insert an analyser in the exhaust sampling point PF (see Figure 31 – twin pipe flue system depicted) to check the CO2 value. The value should correspond to those in Table 5;

• If the CO2 value does not correspond to those in the table, adjust screw V on the venturi (see Figure 31) clockwise to reduce the CO2 value or anticlockwise to increase it.

Figure 31: Flue sampling and commissioning points

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5.6 Control parameters

COMMISSIONING INSTRUCTIONS

PARAMETER

NUMBER

PARAMETER NAME

1 Boiler type

2 Fuel type

3 CH flow temperature

4 CH pump mode

PARAMETER

VALUE

01 02

FUNCTION

Non-storage boiler

Storage boiler (type 1) Storage boiler (type 2)

Natural gas

LPG

Standard (30-80°C) for radiators

Reduced (25-40°C) for under floor

Runs when controls call for heat.

Runs continuously when appliance is on.

5 - - Not applicable to this appliance

Short cycling prevention

(CH delay timer)

7 CH pump overrun timer

00-90

(default = 36)

00-90

(default = 36)

Expressed in steps of 5 seconds

(Default = 36 x 5 sec = 180 sec)

Expressed in steps of 5 seconds

(Default = 36 x 5 sec = 180 sec)

8 - - Not applicable to this appliance

9 - - Not applicable to this appliance

10 - - Not applicable to this appliance

11 - - Not applicable to this appliance

12 - - Not applicable to this appliance

13 - - Not applicable to this appliance

14 Burner type

02 03

Atmospheric

Premix 25 kW

Premix 29-34 kW

Premix 50 kW

15 - - Not applicable to this appliance

16 - - Not applicable to this appliance

17 Minimum fan speed

18 Maximum fan speed

19 Minimum fan speed (in CH mode)

20 Maximum fan speed (in CH mode)

21 Ignition sequence fan speed

22 Fan speed display mode

33-202

(default = 66)

33-202

(default = 162)

33-202

(default = 66)

33-202

(default = 162)

33-202

(default = 110)

00 01

Expressed in Hertz (Hz)

(Default = 66 Hz)

Expressed in Hertz (Hz)

(Default = 162 Hz)

Expressed in Hertz (Hz)

(Default = 66 Hz)

Expressed in Hertz (Hz)

(Default = 162 Hz)

Expressed in Hertz (Hz)

(Default = 110 Hz)

Off

On (displays fan speed for 10 minutes)

Table 6: Control Parameters

NOTES

Factory default values highlighted in bold. Parameters 1 and Parameter 14 highlighted in grey only need to be adjusted when replacing the Modulation PCB. When the

PCB is replaced and Parameter 14 is set to values 01, 02 or 03 the PCB will automatically set Parameters 17 through 22 to the factory default values stated above.

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COMMISSIONING INSTRUCTIONS

5.7 Control parameter adjustment

5.7.1 Accessing the parameters menu

OFF

Step 1: Switch the appliance off using the ON/OFF button.

Step 2:

Press and hold both the & buttons. Switch the appliance on using the

ON/OFF

button.

Release the & buttons.

Step 3:

Press and hold the

Use the button to cycle up through the parameters.

Step 4:

Release the

Press and release the

button.

button again.

The value of the selected parameter will be displayed.

Follow the instructions in the following section (Section

5.7.2) to adjust parameter values.

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Page 39

5.7.2 Adjusting the parameters

COMMISSIONING INSTRUCTIONS

Parameter 1 – Boiler type

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Non-storage boiler; 01 = Storage boiler (type 1); 02 = Storage boiler (type 2). Press and release the

button. The parameter number (1) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button.

Parameter 2 – Fuel type

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Natural gas (Methane) 01 = LPG Press and release the

button. The parameter number (2) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button.

Parameter 3 – CH flow temperature

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

00 = Standard (30 – 80°C) for radiators 01 = Reduced (25 – 40°C) for under-floor heating Press and release the

button. The parameter number (3) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button.

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COMMISSIONING INSTRUCTIONS

Parameter 4 – CH pump mode

Access the parameters menu as described in Section 5.7.1.

Use the & buttons to adjust the parameter value: 00 = Runs when controls call for heat

01 = Runs continuously when appliance is on Press and release the

button. The parameter number (4) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

Parameter 5

Not applicable to this appliance

Parameter 6 – Short-cycling prevention (CH delay timer)

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum)

90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the

button. The parameter number (6) will appear on the display.

To store your changes, switch the appliance off then on again using the ON/OFF button.

Parameter 7 – CH pump overrun timer

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum)

90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the

button.

The parameter number (7) will appear on the display.

To store your changes, switch the appliance off then on again using the ON/OFF button.

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COMMISSIONING INSTRUCTIONS

Parameters 8 through 13

Not applicable to this appliance

Parameter 14 – Burner type

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

00 = Atmospheric burner (all outputs); 01 = Premix burner – 25 kW; 02 = Premix burner – 29-34 kW; 03 = Premix burner – 50 kW; Press and release the

button.

The parameter number (14) will appear on the display.

To store your changes, switch the appliance off then on again using the ON/OFF button.

Parameters 15 and 16

Not applicable to this appliance

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Page 42

164

COMMISSIONING INSTRUCTIONS

Parameter 17 – Minimum fan speed

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 66 = 66 Hz Press and release the

button. The parameter number (17) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

Parameter 18 – Maximum fan speed

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

Minimum value determined by Parameter 17 202 = 202 Hz (maximum) Note: Factory preset to 162 = 162 Hz Press and release the

button. The parameter number (18) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

164

Parameter 19 – Minimum fan speed (in CH mode)

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 66 = 66 Hz Press and release the

button. The parameter number (19) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

Parameter 20 – Maximum fan speed (in CH mode)

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

Minimum value determined by Parameter 17 202 = 202 Hz (maximum) Note: Factory preset to 162 = 162 Hz Press and release the

button. The parameter number (20) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

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110

COMMISSIONING INSTRUCTIONS

Parameter 21 – Ignition sequence fan speed

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

Minimum value determined by Parameter 17 Maximum value determined by Parameter 18 Note: Factory preset to 110 = 110 Hz Press and release the

button. The parameter number (21) will appear on the display. To store your changes, switch the appliance off then on again using

the ON/OFF button.

Parameter 22 – Fan speed display mode

Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value:

00 = Off 01 = On (Fan speed displayed for 10 minutes) Press and release the

button. The parameter number (22) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button.

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COMMISSIONING INSTRUCTIONS

5.8 Gas data

5.8.1 Technical reference tables

Gas Type CO2 Concentration / %

Natural Gas (Methane) – G20 9.4 LPG (Butane) – G30 10.9 LPG (Propane) – G31 11.0

Table 7: Reference Carbon Dioxide concentrations

Gas Type Minimum Fan Speed / Hz Maximum Fan Speed / Hz

Natural Gas (Methane) – G20 66 162 LPG (Butane) – G30 60 149 LPG (Propane) – G31 60 149

Table 8: Reference fan speeds

Lower Wobbe index (15ºC; 1013 mbar)

MJ/Nm3 45.67 80.58 70.69

Natural Gas

G20

Liquid Butane Gas

G30

Liquid Propane Gas

G31

Nominal Supply Pressure mbar 20 30 37

Consumption (15ºC; 1013 mbar) Consumption (15ºC; 1013 mbar)

m3/h 2.64 - -

kg/h - 1.97 1.94

Table 9: Reference gas data

Portata termica kW

Heating Power kW

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

G30 G31

G20

Fan Frequency Hz

Frequenza Hz

Figure 32: Heating Output vs Fan Frequency

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MAINTENANCE INSTRUCTIONS

6 MAINTENANCE

6.1 General warnings

All maintenance operations must be carried out by professionally qualified personnel.

The frequency of boiler maintenance must comply with current law and should, in any case, be carried

out annually.

In order to guarantee the long life of the appliance, and in accordance with the current gas safety

regulations, only use original spare parts.

Before carrying out any type of maintenance operation, disconnect the appliance from the mains

electricity supply and close the gas valve.

6.2 Boiler inspection

In order to ensure that the boiler operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year.

The following must be checked annually:

■ The condition of the gas seals – replace where necessary;

■ The condition of the water seals – replace where necessary;

■ The condition of the combustion chamber and flame;

■ The combustion parameters – if necessary adjust in line with Sections 5.6 & 5.7;

■ The condition of the burner – remove any oxidation and clean if necessary;

■ The seal of the room sealed chamber is undamaged and positioned correctly;

■ The condition of the primary heat exchanger – clean if necessary;

■ The maximum and minimum modulation fan speeds and the modulation process itself – adjust if necessary;

■ The condition and operation of the ignition and gas safety systems – if necessary remove and clean any scaling

from the ignition and flame detection electrodes, paying particular attention to replace them at the correct distance from the burner (see Section 6.6.2);

■ The heating safety systems: temperature and pressure limit devices – replace where necessary;

■ The system pre-charge pressure (should be 1 bar when cold) – if necessary refer to Section 5.2;

■ The integrity and operation of the flue system – correct where necessary;

■ That the mains electricity supply is safe and correctly rated (refer to Section 4.7) – correct where necessary;

■ The electrical connections inside the control panel – correct where necessary;

■ That the condensate drainage system is working correctly, including any parts of the system outside the boiler

such as condensate collection devices along the length of the flue and/or any acid neutralising devices – correct where necessary;

■ That the condensate flows freely and that no exhaust fumes are present within the appliance or drainage system – correct where necessary.

TR05A140.B1107

Page 46

MAINTENANCE INSTRUCTIONS

Figure

: Control panel access

6.3 Accessing the boiler

All maintenance operations require one or more of the boiler casing panels to be removed.

6.3.1 Front panel removal

• Remove the fixing screws at the lower edge of

the front panel;

• Grasp the lower part of the panel and pull it

outwards and then upwards (see Figure 33).

Figure 33: Front panel removal

6.3.2 Side panel removal

• The side panels can only be removed after the

front panel has been removed;

• Remove the fixing screws at the front and lower

edge of the side panel;

• Grasp the bottom of the panel, move it

sideways and then upwards (see Figure 34).

6.3.3 Control panel access

• Remove the front panel (refer to 6.3.1 above);

• Grasp the left and right control panel support

brackets and pull them outwards, at the same time rotating the panel downwards (see Figure

35);

• Unscrew the four cover securing screws and

remove the control panel rear cover.

Figure 34: Side panel removal

TR05A140.B1107

Page 47

MAINTENANCE INSTRUCTIONS

6.4 Draining the central heating system

If the ENTIRE SYSTEM needs to be drained:

• Switch on the boiler, select Heating Only

Mode and allow the boiler to fire. Refer to Section 3.6 for how to operate the appliance;

• Isolate the electricity and gas supplies to the

boiler and wait for the boiler to cool down;

• Connect a hosepipe to the system drain

point and locate the other end of the hose in a suitable drain;

• Open the boiler drain valve, located on the

bottom of the pump manifold (see Figure

36);

• Open the air vents on the radiators, starting

with the highest and moving down the system to the lowest;

• W hen the system has been drained, close

the radiator air vents and the boiler drain valve.

Figure 36: Boiler drain valve

If ONLY THE BOILER needs to be drained:

• Switch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to Section 3.6 for how to

operate the appliance;

• Isolate the electricity and gas supplies to the boiler and wait for the boiler to cool down;

• Close the isolating valves on the heating circuit flow and return pipes;

• Connect a hosepipe to the system drain point and locate the other end of the hose in a suitable drain;

• Open the drain valve located at the bottom of the boiler on the pump manifold (see Figure 36);

6.5 Flushing the central heating system

Refer to the detailed instructions in Section 5.3.

TR05A140.B1107

Page 48

MAINTENANCE INSTRUCTIONS

6.6 Maintenance operations

Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY,

WATER and GAS supplies to the boiler. Warmflow will not be held responsible for damage to any of the boiler’s components caused by non-compliance with this instruction.

Section 6.3 gives instructions on accessing the boiler, removing casing panels, and accessing the control panel.

Expansion vessel

Primary heat exchanger

Burner unit

Ignition transformer

Ionisation electrode

Heating sensor

Safety thermostat

Electric fan

Circulating pump

Condensate trap

Ignition electrode

Gas valve

Figure 37: Key components

TR05A140.B1107

Page 49

MAINTENANCE INSTRUCTIONS

6.6.1 Primary heat exchanger and burner unit

• Isolate the electricity, water and gas supplies to

the appliance;

• Disconnect the electrical connections of the

electric fan;

• Disconnect and remove the pipe linking the gas

valve to the venturi;

• Disconnect and remove the gas feed pipe from

the gas valve;

• Unplug the ignition and ionisation electrode

wires from the ignition control unit;

• Unscrew the ring nut at the bottom of the room

sealed chamber and remove the gas valve;

• Unscrew the nuts securing the burner unit

(consisting of a fan, manifold and burner) to the primary heat exchanger;

• Remove the burner unit, taking particular care

not to remove the ceramic fibre board from the end of the heat exchanger;

• Check that the burner is not affected by

deposits, scaling or excessive oxidation. Check that all the holes in the burner are free;

• Clean the electrodes carefully without altering

their positions with respect to the burner;

• Clean the burner cylinder using a non-metal

brush and without damaging the ceramic fibre;

• Check the integrity of the seal on the cover of

the burner;

• Clean the heat exchanger using a suitable

detergent for stainless steel, distributing the product on the spirals of the exchanger using a brush. Do not wet the ceramic fibre board. Wait a few minutes then remove the deposits using a non-metal brush. Remove the residues under running water;

• Remove the condensate drain pipe and clean

under running water;

• Unscrew the joint to the condensate trap,

remove the trap and wash under running water;

• With the cleaning completed, re-assemble the

components following the above procedure in reverse order;

• Finally, check the boiler to make sure that all

gas and exhaust joints are tight.

Figure 38: Primary heat exchanger and burner unit

Stainless steel exchanger coils

Burner

Ignition

electrode

Primary heat exchanger

Premix burner unit

Ionisation electrode

Flue manifold

Ceramic fibre

Figure 39: Primary heat exchanger

TR05A140.B1107

Page 50

MAINTENANCE INSTRUCTIONS

Figure

: Safety thermostat and heating sensor

6.6.2 Ignition and ionisation electrodes

• Isolate the electricity, water and gas supplies to the

appliance;

• Unplug the electrode wires;

• Slacken the fixing screws;

• Remove the electrodes. When refitting the

electrodes, check that the seals are not damaged and replace if necessary;

• Reconnect the wires and reassemble the

components following the above procedure in reverse order;

• Switch on the power supply and restart the

appliance;

If the boiler does not restart, check the

positions of the electrodes. The ignition electrode should be positioned with a 10mm gap between it and the burner. The ionisation electrode must not be touching the burner surface.

Ionisation

electrode

Ignition

electrode

6.6.3 Safety thermostat

• Isolate the electricity, water and gas supplies to the

appliance;

• Disconnect the connecting wire;

• Unscrew the fixing screws and remove the

thermostat;

• Replace the thermostat and re-assemble the

components following the above procedure in reverse order;

6.6.4 Heating sensor

• Isolate the electricity, water and gas supplies to the

appliance;

• Unplug the connecting wires;

• Replace the sensor (expecting some water loss)

and reconnect the wires;

• Refill the system (see Sections 5.2) and check for

any leaks.

Figure 41: Ignition and ionisation electrodes

Heating sensor

Safety thermostat

TR05A140.B1107

Page 51

MAINTENANCE INSTRUCTIONS

6.6.5 Gas valve

• Isolate the electricity, water and gas supplies to the

appliance;

• Disconnect and remove the gas pipe connecting the

gas valve to the venturi;

• Disconnect the gas feed pipe and valve ring nut at

the bottom of the room sealed chamber;

• Remove the couplings of the existing valve and fit to

the new valve using new cork gaskets;

• Replace the gas valve and reassemble the

components following the above procedure in reverse order, replacing all the gas seals;

• Switch on the gas supply and check for any gas

leaks using soapy water or leak detector spray;

• Switch on the electricity and water supplies, switch

on and fire the appliance and repeat the checks for leaks.

Gas valve

Couplings

6.6.6 Circulating pump motor body

• Isolate the electricity, water and gas supplies to the

appliance;

• Drain the central heating circuit of the boiler (see

Section 6.4);

• Use a 5 mm Allen key to unscrew the four screws

securing the motor body to the impeller body;

• Remove the motor body and check the condition of

the gasket. Replace if necessary;

• Replace the pump motor body and reassemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies;

• Refill the system (see Sections 5.2) and check for

any leaks.

Figure 43: Gas valve

Pump impeller body

Figure 44: Circulating pump

Pump motor body

TR05A140.B1107

Page 52

MAINTENANCE INSTRUCTIONS

6.6.7 Electric fan

• Isolate the electricity, water and gas supplies to the

appliance;

• Remove and dismantle the entire burner unit (see

Section 6.6.1);

• Use an 8 mm spanner to unscrew the four nuts

securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer and diaphragm (see Figure 45);

• Remove the air intake duct, unscrew the two fixing

screws from the venturi and remove the electric fan, paying particular attention not to damage the cork gasket.

• Replace the electric fan and reassemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies and

check the soundness of the joint by measuring the CO2 levels;

Figure 45: Fan assembly

Venturi

Fan

6.6.8 Expansion vessel

• Isolate the electricity, water and gas supplies to the

appliance;

• Drain the central heating circuit of the boiler (see

Section 6.4);

• Use a 19 mm spanner to unscrew the vessel pipe

coupling;

• Unscrew the fixing screws and remove the upper

mounting bracket. Remove the expansion vessel from the front of the boiler;

• Replace the expansion vessel and reassemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies;

• Refill the system (see Sections 5.2) and check for

any leaks.

Fixing bracket

Expansion vessel

Vessel pipe

Figure 46: Expansion vessel

TR05A140.B1107

Page 53

Figure

: Circuit boards

6.6.9 Modulation circuit board

MAINTENANCE INSTRUCTIONS

• Isolate the electricity, water and gas supplies to the

appliance;

• Access the control panel (see Section 6.3);

• Disconnect all the connectors, remove the control

knobs from the front of the panel, unscrew the fixing screws and remove the modulation circuit board;

• Replace the circuit board and reassemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies;

• Program the boiler control parameters following the

instructions in Sections 5.7.

6.6.10 Electric fan circuit board

• Isolate the electricity, water and gas supplies to the

appliance;

• Access the control panel (see Section 6.3);

• Disconnect the two connectors from the fan circuit

board, unscrew the two fixing screws and remove the board;

• Replace the circuit board and reassemble the

components following the above procedure in reverse order.

Modulation circuit board

Electric fan circuit board

Modulation circuit board

Electric fan circuit board

Figure 50: Circuit boards

6.6.11 Primary heat exchanger replacement

• Isolate the electricity, water and gas supplies to the appliance;

• Drain the central heating circuit of the boiler (see Section 6.4);

• Remove and dismantle the entire burner unit (see Section 6.6.1);

• Remove the gas valve (see Section 6.6.5);

• Remove the condensate drainpipe;

• Remove the flow and return pipe work;

• Remove the support brackets and pull out the heat exchanger;

• Remove the sensors and pipes from the old exchanger and fit them to the new one;

• Replace the heat exchanger and reassemble the components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies;

• Refill the system (see Sections 5.2) and check for any leaks;

• Fire the boiler and check for any flue gas leaks.

TR05A140.B1107

Page 54

6.7 Wiring diagram

PRINTED CIRCUIT BOARD DIGITECH - SM20019 COD. 16766077

MAINTENANCE INSTRUCTIONS

PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 18767002

M2M1

EXHAUST FAN type RG128/1300-3612

POWER SUPPLY

M10

yellow/green

Key

IG Main Switch PA Air Pressure switch TS Safety thermostat

CVI-M

EV2

EV1

red

orange

light-blue

brown

light-blue

brown

2 3 4 5 6

light-blue

orange

brown

light-blue

brown

VK 4105 G

Telephone control

EXTERNAL CONTROLS

Remote control

light-blue

brown

10000 OhmSRIG

black

white/black

orange

light-blue

brown

Storage cylinder timer

(option)

fusibile 2A

brown

black

Zone valve management +

option remote controller board

Pacq

brown

light-blue

TF Thermofuse 102°C SR Heating sensor

EV Fan ER Ionisation electrode EA Ignition electrode Tra Ignition transformer C Circulating pump Pacq Water pressure switch

remote controller zone valve

Zone valve contact closure

M10

321

1234561234567

123456678

M4M6

Figure 51: Internal wiring

TR05A140.B1107

Page 55

MAINTENANCE INSTRUCTIONS

6.8 Troubleshooting

6.8.1 Error codes

CODE PROBLEM POSSIBLE CAUSE REMEDY

IF BOILER FAILS TO FIRE

a. CHECK MAINS SUPPLY b. CHECK INLET PRESSURE c. CHECK AND ADJUST MECHANICAL

MINIMUM AND IGNITION SEQUENCE SETTINGS

d. REPLACE PART e. REPLACE PART

f. CORRECT MAINS WIRING g. CHECK ELECTRODE WIRING h. REPLACE PART

E01

NO FLAME (FLAME FAILURE DURING STARTUP)

a. NO GAS b. GAS INLET PRESSURE TOO HIGH c. MECHANICAL MINIMUM OR IGNITION SEQUENCE

GAS PRESSURES TOO LOW

d. IGNITION ELECTRODE BROKEN OR EARTHED e. GAS VALVE MALFUNCTION

IF BOILER FIRES NORMALLY

f. MAINS LIVE AND NEUTRAL WIRES REVERSED g. IONISATION ELECTRODE CABLE DISCONNECTED h. IONISATION ELECTRODE MALFUNCTION

E02

E03

H20

E05

E16

E22

E35

SAFETY THERMOSTAT TRIPPED (95°C)

FLUE THERMOFUSE TRIPPED

LOW SYSTEM PRESSURE

HEATING SENSOR FAULT

FAN FAULT

PARAMETER PROGRAMMING REQUEST

IONISATION ELECTORDE FAULT

a. THERMOSTAT CABLE DISCONNECTED b. THERMOSTAT MALFUNCTION

a. THERMOFUSE CABLE DISCONNECTED b. THERMOFUSE LOCK OUT (DUE TO HIGH FLUE

TEMPERATURE)

c. THERMOFUSE MALFUNCTION

a. WATER PRESSURE SWITCH CABLE DISCONNECTED b. INSUFFICIENT WATER PRESSURE IN THE SYSTEM c. WATER PRESSURE SWITCH MALFUNCTION

a. SENSOR CABLE DISCONNECTED OR WET b. SENSOR MALFUNCTION OR OUT OF CALIBRATION

(RESISTANCE VALUE 10 kOhms AT 25 °C).

a. CHECK THERMOSTAT WIRING b. REPLACE PART

a. CHECK THERMOSTAT WIRING b. REPLACE THERMOSFUSE,

RESTART AND CHECK APPLIANCE

c. REPLACE PART

a. CHECK SWITCH WIRING b. FILL OR TOP UP THE SYSTEM c. REPLACE PART

a. CHECK SENSOR WIRING b. CHECK SENSOR RESISTANCE.

REPLACE IF INCORRECT

a. BURNT FAN a. REPLACE PART

a. LOSS OF MICROPROCESSOR MEMORY a. REPROGRAM PARAMETERS

a. IONISATION ELECTRODE WET, DAMP OR EARTHED b. IONISATION ELECTRODE MALFUNCTION

c. IONISATION ELECTRODE CABLE MALFUNCTION d. MODULATION PCB MALFUNCTION

a. CHECK COMBUSTION CHAMBER b. CLEAN PART (REPLACE IF FAULT

REMAINS AFTER CLEANING)

c. REPLACE PART d. REPLACE PART

E42

FAN PCB FAULT

a. FAN PCB TO MOD. PCB WIRING MALFUNCTION b. FAN PCB MALFUNCTION

a. REPLACE PART b. REPLACE PART

Table 10: Appliance error codes

TR05A140.B1107

Page 56

MAINTENANCE INSTRUCTIONS

6.9 Parts lists

6.9.1 Main components

CODE DESCRIPTION

40200069 PRIMARY EXCHANGER ISOTHERM. 4+1 3+3 25KW

12240045 PUMP RSL 15/5-3-KU-CLF6 w/OPEN C1+C3

46270044 CONDENSATE TRAP

50360067 ELECTRONIC GAS VALVE

40360068 VENTURI

20370032 FAN PX128/203 230V/50Hz - PX2030

28432074 WASHER/OR CLIPS KIT FOR MULTIPLEX

28590015 WATER PRESSURE SWITCH PC 5411 BRASS

40735016 HTG CLIP SENSOR X PIPE 17/18 mm. BLUE

40735017 THERMO FUSE 102°C RED ISTMQ 1/4" 4X45

16766077 PRINTED CIRCUIT BOARD BMBC c/DISPLAY

18767002 PRINTED CIRCUIT BOARD KOND DT

44860006 SAFETY THERMOSTAT 95C° X EL.TB 1NT

28860014 WATER PRESSURE GAUGE M3A-ABS 40 0-4 G1/8C/D+C

18880019 TRANSFORMER AC1 230VAC 25HZ 39/3200Y

48950013 EXPANSION VESSEL LT.7 3/8"

12960039 3 BAR PRESSURE RELIEF VALVE -HTG CIRCUIT

Table 11: Short parts list

TR05A140.B1107

Page 57

OPTIONAL CONTROLS

7 OPTIONAL CONTROLS

7.1 External controls, programmers and room thermostats

All external controls used with this appliance MUST BE ZERO-VOLT SWITCHING ONLY!

If mains voltage, i.e. a switched live, is fed to the control terminals THE APPLIANCE WILL NOT

FUNCTION and could be SEVERELY DAMAGED!

7.1.1 Appliance connections

To fit a programmer, room thermostat or other external controls:

• Isolate the electricity, water and gas supplies to the appliance;

• Remove the front casing panel of the boiler (refer to 6.3 for guidance);

• Remove terminal block cover A of the control panel;

• Remove the link between the two terminals marked Ta on terminal block B;

• Connect the two wires from the programmer, room thermostat or controls to the terminals marked Ta;

• Replace terminal block cover A.

SeSeTaNL

Figure 52: Connection of external controls

External Controls:

- Programmer

- Room thermostat

- S-Plan system

TR05A140.B1107

Page 58

TR05A140.B1107

Figure 53: S-Plan wiring schematic

7.1.2 S-Plan wiring schematic

Heating Zone Hot Water Cylinder

Room

Thermostat

Permanent Live

Cylinder

Thermostat

OPTIONAL CONTROLS

Add more valves

& programmers

Neutral

as required

Boiler

Terminal Block

2-port

zone valves

Zone valve

microswitches

Zero-volt Switching Circuit

Page 59

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Page 61

INSTALLATION, COMMISSIONING & SERVICING RECORD

INSTALLER & COMMISSIONING ENGINEER DETAILS

Installer Details

Company Name Installation Date

Address

CORGI Registration No. CORGI ID Serial No.

Commissioning Engineer Details (if different from Installer)

Company Name Installation Date

Address

CORGI Registration No. CORGI ID Serial No.

APPLIANCE & CONTROL DETAILS

Boiler

Make & Model

Serial No. SEDBUK Efficiency

Location

New System or Replacement boiler

Controls

To comply with Building Regulations, each section must have a tick in one or more boxes

Requirement Measures Provided

1. Time and Temperature Control to Heating

2. Time and Temperature Control to Hot Water

3. Heating Zone Valves Fitted Not Required

4. Thermostatic Radiator Valves Fitted

5. Automatic Bypass to System Fitted Not Required

Room Thermostat and Programmer / Timer

Cylinder Thermostat and Programmer / Timer

Programmable Room Thermostat

Combi Boiler

6. Boiler Interlock Provided

TR05A140.B1107

Page 62

INSTALLATION, COMMISSIONING & SERVICING RECORD

COMMISSIONING PROCEDURE INFORMATION

For All Boilers

Has the system been flushed in accordance with the boiler manufacturer’s instructions? Yes No

What cleanser was used?

Has an inhibitor been added? Yes No

Which inhibitor was used?

For central heating mode, measure and record:

Heat Input kW

Burner Operating Pressure mbar

Central Heating Flow Temperature ºC

Central Heating Return Temperature ºC

For Combination Boilers Only

Has a water scale reducer been fitted? Yes No

What type of scale reducer has been fitted?

For domestic hot water mode, measure and record:

Heat Input kW

Maximum Burner Operating Pressure mbar

Maximum Operating Water Pressure bar

Cold Water Inlet Temperature ºC

Hot Water Outlet Temperature ºC

Water Flow Rate at Maximum Setting l/min

For Condensing Boilers Only

Has the condensate drain been fitted in accordance with the manufacturer’s instructions? Yes No

For All Installations

Does the heating and hot water system comply with the appropriate Building Regulations? Yes

Has the appliance and associated equipment been installed and commissioned in accordance with the manufacturer’s instructions?

Have you demonstrated the operation of the appliance and system controls to the customer? Yes

Have you left all the manufacturer’s literature with the customer? Yes

Competent Person’s Signature Customer’s Signature

TR05A140.B1107

(To confirm demonstrations of equipment and receipt of appliance instructions)

Yes

Page 63

INSTALLATION, COMMISSIONING & SERVICING RECORD

Service 1 Date: Service 2 Date:

Engineer Name Engineer Name Company Name Company Name Tel. No. Tel. No. CORGI ID Serial No. CORGI ID Serial No. Comments Comments

Signature

Service 3 Date: Service 4 Date:

Engineer Name Engineer Name Company Name Company Name Tel. No. Tel. No. CORGI ID Serial No. CORGI ID Serial No. Comments Comments

Signature

Service 5 Date: Service 6 Date:

Engineer Name Engineer Name Company Name Company Name Tel. No. Tel. No. CORGI ID Serial No. CORGI ID Serial No. Comments Comments

Signature

Service 7 Date: Service 8 Date:

Engineer Name Engineer Name Company Name Company Name Tel. No. Tel. No. CORGI ID Serial No. CORGI ID Serial No. Comments Comments

Signature

Service 9 Date: Service 10 Date:

Engineer Name Engineer Name Company Name Company Name Tel. No. Tel. No. CORGI ID Serial No. CORGI ID Serial No. Comments Comments

Signature

TR05A140.B1107

Page 64

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Page 66

WARMFLOW Engineering Company Limited

Lissue Industrial Estate, Moira Road, Lisburn BT28 2RF Tel: 028 9262 1515 Fax: 028 9262 0869

Warmflow Customer Care Centre

UK 028 9262 1515 ROI 048 9262 1515 Email [email protected]

THE TECHNICAL DATA AND MEASUREMENTS ARE PROVIDED FOR INFORMATION PURPOSES ONLY AND ARE NOT BINDING. THE COMPANY RESERVES THE RI GHT TO APPLY VARIATIONS WI THOUT PRIOR NOTIFICATION. NEITHER WILL THE COMPANY BE HELD RESPONSIBLE FOR ANY INACCURACIES IN THIS HANDBOOK DERIVING FROM PRINTI NG OR TRANSLATION ERRORS. E+OEALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED, MEMORISED IN ANY FILING SYSTEMS OR TRANSMITTED IN ANY FORM WHATSOEVER, INCLUDING ELECTRONIC, MECHANICAL, PHOTOCOPIES, RECORDINGS OR ANY OTHER MEANS W ITHOUT THE COMPANY’S PRIOR WRITTEN APPROVAL.

TR05A140.B1107