Boiler Manual. Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record

Transcription

1 Boiler Manual Incorporating: User Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate ervice Record High Efficiency Condensing Gas Boilers Model covered by this manual: G-eries Gas premix combi boiler GC29A EDBUK

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3 CONTENT 1 UER INTRUCTION Boiler controls Control panel layout Operating the appliance Operating modes Topping up the system (Error Code H20) If you smell gas 4 2 GENERAL INFORMATION General warnings Information Product conformity 7 3 TECHNICAL CHARACTERITIC Technical data Dimensions Internal components Function diagram Circulation pump performance curves Control Panel and display Layout Boiler operation Operating modes Function codes 14 4 INTALLATION Reference standards Unpacking Installing the boiler Compartment ventilation Water connections Domestic hot water circuit Central heating circuit Filling the central heating system Condensate drain Gas connection Electrical connections General warnings Power supply Flue connections Flue position Horizontal coaxial balanced flue Ø 60/100 (Kit K) Horizontal coaxial balanced flue Ø 80/ Vertical coaxial balanced flue Ø 60/100 (Kit V) Vertical coaxial balanced flue Ø 80/ Twin pipe flue system Ø 80/80 (Kit H) 30 5 COMMIIONING General warnings Filling the system Flushing the system 33

4 CONTENT 5.4 Filling the condensate trap tarting the boiler Control parameters Control parameter adjustment Accessing the parameters menu Adjusting the parameters Gas data Technical reference tables 43 6 MAINTENANCE General warnings Boiler inspection Accessing the boiler Front panel removal ide panel removal Control panel access Draining the central heating system Flushing the central heating system Draining the domestic hot water system Maintenance operations Primary heat exchanger and burner unit DHW heat exchanger Ignition and ionisation electrodes afety thermostat Heating sensor Gas valve Electric fan Expansion vessel Circulating pump motor body way diverter valve Modulation circuit board Electric fan circuit board Primary heat exchanger replacement Wiring diagram Troubleshooting Error codes Parts lists Main components MULTIPLEX unit 57 7 OPTIONAL CONTROL External controls, programmers and room thermostats Appliance connections Plan wiring schematic Weather compensating controls Fitting the outside sensor Controlling the appliance 61

5 GENERAL INFORMATION 1 UER INTRUCTION 1.1 Boiler controls Control panel layout ON/OFF button 2. Central Heating Control knob 3. Hot Water Control knob 4. DIPLAY button 5. ERVICE button 6. MODE button 7. Mains supply terminal board 8. Digital LCD display 9. Programmer location ON TIME ON / OFF OFF Figure 1: Control Panel MODE Operating the appliance Operation Instruction witching the boiler on Press the ON/OFF button (1) electing the operating mode (see ection below) Adjusting the Central Heating temperature Adjusting the Hot Water temperature Press the MODE button (6): - either the, or & Icons will appear on the display Turn the Central Heating Control knob (2): - the temperature setting will appear on the display Turn the Hot Water Control knob (3): - the temperature setting will appear on the display witching the boiler off Press the ON/OFF button (1) Table 1: Control panel display Operating modes Heating Only Mode Hot Water Only Mode & Heating & Hot Water Mode 3

6 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; witch 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; hut 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 Northern Ireland Republic of Ireland

7 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 The installation must be carried out in accordance with the relevant requirements of: - The Gas afety Regulations; - The appropriate Building Regulations either the Building Regulations, the Building Regulations (cotland) or the Building Regulations (Northern Ireland); - The Water Fittings Regulations or Water Byelaws in cotland; - The current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British tandards 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 HC Gas afety (Installation and Use) Regulations 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 Warmflow Customer Care Centre on 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. 5

8 GENERAL INFORMATION When 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. hould 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. hut-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 Northern Ireland Republic of Ireland 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. 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. 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.) 6

9 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: GA APPLIANCE 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 GA-FIRED CENTRAL HEATING BOILER TYPE B OF NOMINAL HEAT INPUT 70 kw EN 483 for GA-FIRED CENTRAL HEATING BOILER TYPE C OF NOMINAL HEAT INPUT 70 kw UNI EN 677 for GA-FIRED CENTRAL HEATING BOILER: PECIFIC REQUIREMENT FOR CONDENING BOILER 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. 7

10 TECHNICAL CHARACTERITC 3 TECHNICAL CHARACTERITIC 3.1 Technical data Model GC29A Appliance Type C13, C33, C43, C53, C63, C83 Appliance Category II2H3+ Heat Input max kw 30 Heat Input min kw 10 Heat Output max (50/30 ) kw 31.8 Efficiency 100% (full load 50/30 ) % 106 Efficiency 30% (partial load 50/30 ) % Heat Output max - 80/60 C (Non condensing) kw Heat Output min - 80/60 C (Non condensing) kw 9.73 Efficiency 100% (full load 80/60 ) % 98.1 Efficiency 30% (partial load 80/60 ) % GA DIRECTIVE 92/42/ECC - Efficiency marking stars 4 EDBUK band A Central Heating (CH) Circuit CH water temperature setting (min-max) C 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 Domestic Hot Water (DHW) Circuit DHW temperature setting (min-max) C Max. DHW working pressure bar 6 Min. DHW working pressure bar 0.5 DHW flow rate at T 25 l/min DHW flow rate at T 30 C l/min DHW flow rate at T 35 C l/min Dimensions Width mm 410 Height mm 730 Depth mm 310 Weight (net) kg 47 Hydraulic Connections CH Flow connection Ø 3/4" (22mm tail supplied) CH Return connection Ø 3/4 (22mm tail supplied) Cold Water Mains connection Ø 1/2 (15mm tail supplied) DHW connection Ø 1/2 (15mm tail supplied) Gas connection Ø 3/4 (22mm tail supplied) Flue ystems Horizontal Concentric flue system Ø mm 60/100 Max. Flue length m 3 Horizontal Concentric flue system Ø mm 80/125 Max. Flue length m 8 Vertical Concentric flue system Ø mm 60/100 Max. Flue length m 3 Vertical Concentric flue system Ø mm 80/125 Max. Flue length m 8 Twin Pipe flue system Ø mm 80/80 Max. Flue length m 50 Gas upply Natural gas (Methane) G20 Inlet pressure mbar 20 Gas consumption m 3 /h 3.17 Butane G30 Inlet pressure mbar 30 Gas consumption kg/h 2.37 Propane G31 Inlet pressure mbar 37 Gas consumption kg/h 2.33 Electrical pecifications Power supply V/Hz 230/50 Electrical power consumption W 180 Electrical protection IP X4D Table 2: Technical data 8

11 ON TIME OFF TECHNICAL CHARACTERITC 3.2 Dimensions MODE ON / OFF HR HWO G CWI HF LEGEND HR HEATING RETURN 22mm HF HEATING FLOW 22mm CWI COLD WATER INLET 15mm HWO HOT WATER OUTLET 15mm G GA 22mm C CONDENATE DRAIN 25mm Figure 2: Dimensions 9

12 TECHNICAL CHARACTERITC 3.3 Internal components Figure 3: Internal components LEGEND 1. PRIMARY CONDENING HEAT EXCHANGER 2. PREMIX BURNER UNIT (GA MANIFOLD + BURNER) 3. HEAT EXCHANGER CONDENATE DRAIN CONNECTION 4. IONIATION ELECTRODE 5. IGNITION ELECTRODE 6. FAN 7. VENTURI 8. IGNITION TRANFORMER 9. ELECTRONIC GA VALVE BAR PREURE RELIEF VALVE HEATING CIRCUIT 11. AUTOMATIC AIR VENT VALVE 12. HEATING AFETY THERMOTAT 13. HEATING ENOR 14. PUMP WITH AIR VENT 15. WATER PREURE WITCH 16. FLUE HOOD 17. FLUE AFETY THERMOFUE 18. EXPANION VEEL 19. ROOM EALED CHAMBER BULKHEAD 20. CONDENATE TRAP 21. WATER PREURE GAUGE 22. YTEM DRAIN VALVE 23. CONDENATE DRAIN PIPE 24. AUTOMATIC BYPA 25. DHW ENOR 26. FLOW LIMITER 27. ELECTRONIC FLOWWITCH 28. DHW EXCHANGER WAY VALVE 30. PRIMARY HEAT EXCHANGER MANUAL AIR VENT VALVE 10

13 TECHNICAL CHARACTERITC 3.4 Function diagram C HR HWO G CWI HF Figure 4: Function diagram LEGEND HR HEATING RETURN 22mm LEGEND 1. PRIMARY CONDENING HEAT EXCHANGER 2. PREMIX BURNER UNIT (GA MANIFOLD & BURNER) 3. HEAT EXCHANGER CONDENATE DRAIN PIPE 4. IONIATION ELECTRODE 5. IGNITION ELECTRODE 6. FAN 7. VENTURI 8. IGNITION TRANFORMER 9. ELECTRONIC GA VALVE BAR PREURE RELIEF VALVE - HEATING CIRCUIT 11. AUTOMATIC AIR VENT VALVE 12. HEATING AFETY THERMOTAT 13. HEATING ENOR 14. PUMP WITH AIR VENT 15. WATER PREURE WITCH 16. FLUE HOOD 17. FLUE AFETY THERMOFUE 18. EXPANION VEEL 19. ROOM EALED CHAMBER 20. CONDENATE TRAP 21. WATER PREURE GAUGE 22. AUTOMATIC BYPA 23. CONDENATE DRAIN PIPE 24. YTEM DRAIN VALVE 25. DHW ENOR 26. FLOW LIMITER 27. ELECTRONIC FLOWWITCH 28. DHW EXCHANGER WAY VALVE HF HEATING FLOW 22mm G GA 22mm CWI COLD WATER INLET 15mm HWO HOT WATER OUTLET 15mm C CONDENATE DRAIN 25mm 11

14 TECHNICAL CHARACTERITC 3.5 Circulation pump performance curves Head (kpa) III I II III II I Available head at maximum speed Available head at second speed Available head at minimum speed Flow l/h Appliance Loss Figure 5: Pump performance curves 12

15 TECHNICAL CHARACTERITC 3.6 Control Panel and display The appliance MUT 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 Layout 1. ON/OFF button CH Control knob ON TIME OFF 3. DHW Control knob 4. DIPLAY button 5. ERVICE button MODE 6. MODE button ON / OFF 7. Mains supply terminal board 8. Digital LCD display 9. Programmer location Boiler operation Figure 6: Control Panel Mode / Control Input Display will show: Boiler switched off Press ON/OFF button (to switch the boiler on) OFF Primary circuit temperature in ºC Either, or & Icons (see ection 3.6.3) MODE button pressed Cycles through, or & Icons (see ection 3.6.3) CH controls call for heat DHW tap opened Primary circuit temperature in ºC Icon flashes whilst CH mode is active Primary circuit temperature in ºC Icon flashes whilst DHW mode is active DIPLAY button pressed & held DHW flow temperature in ºC DIPLAY button pressed & held for 5 seconds CH Control knob turned CH Control knob turned (Outside ensor fitted) DHW Control knob turned ERVICE button pressed & held for 7 seconds Boiler protection function activated (automatically) Boiler locked out Outside temperature in ºC (if Outside ensor fitted) (see ection 7.2.2) CH set point temperature in ºC displayed for 3 seconds Weather compensating control profile displayed for 3 seconds (if Outside ensor fitted) (see ection 7.2.2) DHW set point temperature in ºC displayed for 3 seconds Function Code 07 flashes whilst activated (see ection 3.6.4) Function Code 08 or 09 flashes whilst activated (see ection 3.6.4) Error Code flashes whilst locked out (see ection 6.9.1) Table 3: Control panel display 13

16 TECHNICAL CHARACTERITC Operating modes Heating Only Mode Hot Water Only Mode & Heating & Hot Water Mode Function codes Code Function Description 07 Commissioning Mode 08 CH Frost Protection Mode 09 DHW Frost Protection Mode Operates the boiler at maximum CH output for 15 minutes without modulation. Activated by pressing and holding the button for 7 seconds. 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. Operates the boiler at minimum DHW output in Hot Water Only Mode. Activated when the DHW sensor detects below 4 C. Deactivated when the DHW sensor detects above 8 C. Table 4: Function codes 14

17 INTALLATION INTRUCTION 4 INTALLATION 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 The installation must be carried out in accordance with the relevant requirements of the: - Gas afety Regulations; - The appropriate Building Regulations either the Building Regulation, the Building Regulations (cotland) or the Building Regulations (Northern Ireland); - The Water Fittings Regulations or Water Byelaws in cotland; - The current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British tandards Code of Practice. In the United Kingdom, the following Codes of Practice apply: B 5440: Part 1 B 5440: Part 2 B 5546 B 5449 B 6700 B 6798 B 6891 B 7074 B 7593 B 7671 Flues Air upply Installation of hot water supplies for domestic purposes Forced circulation hot water systems Installation of cold water supplies for domestic purposes Installation of gas-fired hot water boilers Gas Installation Expansion Vessels and ancillary equipment for sealed water systems Treatment of water in domestic hot water central heating systems 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. 15

18 INTALLATION INTRUCTION 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. tand the boiler up on its end as shown, supporting it from underneath; C. Lift off the box and remove all packaging. TORAGE & 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 16

19 INTALLATION INTRUCTION 4.3 Installing the boiler 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. A B X L Y H MINIMUM DITANCE IN mm Model X Y L X H Y A L B H RKR A B 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. Figure 8: Access clearances 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 Compartment ventilation Figure 9: Mounting procedure Where the appliance is installed in a compartment, no air vents are required. B 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 17

20 INTALLATION INTRUCTION 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 and DHW 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 and DHW 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 HR HWO G Figure 10: Location of connections CWI HF Domestic hot water circuit In order to prevent scaling and eventual damage to the DHW heat exchanger the mains water supply must not have a hardness rating of more than 17.5 ºCk. It is nevertheless advisable to check the properties of the water and install the appropriate treatment devices where necessary. The cold water supply pressure at the inlet to the boiler must be between 0.5 and 6 bar. In areas of higher water inlet pressure a pressure reducing valve must be fitted before the boiler. The frequency of cleaning of the DHW heat exchanger depends on the hardness of the water supply and the presence of residual solids or impurities, which are often present in the case of a new installation. If the characteristics of the mains water supply are such that require it to be treated, then the appropriate treatment devices must be installed, while in the case of residues, an inline filter should be sufficient. All DHW circuits, connections, fittings, etc comply with all the relevant standards and water supply regulations (e.g. WRA). HR Ø mm Ø 15 mm Ø 22 mm HF CWI G HWO Ø 22 mm Figure 11: Fittings kit LEGEND HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GA 22mm CWI COLD WATER INLET 15mm HWO HOT WATER OUTLET 15mm C CONDENATE DRAIN 25mm 18

21 INTALLATION INTRUCTION Central heating circuit The boiler is designed for use in a sealed central heating system in accordance with the requirements of B 5449 and B 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 B 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 B 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. Boiler Automatic air vent Filling point (see fig. 2) DHW outlet Lockshield valve Radiator valve Heating return Pressure reducing valve reccomended for inlet supplies in excess pf 3.5 bar Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance ystem drain tap Mains water inlet Figure 12: Central heating system layout 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 ection 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 B 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 19

22 INTALLATION INTRUCTION 4.5 Condensate drain Boiler Termination to an internal soil and vent pipe 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. 50mm per metre of pipe run 2.5 Minimum fall 450mm min 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. Boiler External termination via internal discharge branch e.g. sink waste - downstream 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. ink 50mm per metre of pipe run 2.5 Minimum fall Pipe must terminate above water level but below surrounding surface 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 50mm per metre of pipe run 2.5 Minimum fall Pipe must terminate above water level but below surrounding surface External termination to a purpose made soak-away 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. Boiler 500mm min 50mm per metre of pipe run 2.5 Minimum fall Holes in the soak-away must face away from the building Figure 14: Condensate drain configuration 20

23 INTALLATION INTRUCTION 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 ulphide build-up within gas supply pipes (such as in Northern Ireland) an inline 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. 21

24 INTALLATION INTRUCTION 4.7 Electrical connections 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. 22

25 INTALLATION INTRUCTION 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 ection 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 MUT 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 e 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 ection 7. ON TIME ON / OFF OFF L N Ta Ta e e A B blue green/yellow brown Figure 15: Power supply connections 23

26 0.5 ON O N ON ON O N INTALLATION INTRUCTION 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. 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. C33 C13 C53 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 the duct must slope downwards towards the exterior to prevent the entry of rainwater, dust or foreign bodies. C43 C83 Figure 16: Appliance and flue types 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. 24

27 INTALLATION INTRUCTION Flue position The flue system MUT be installed in accordance with the recommendation contained in B 5440:1. The boiler MUT 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 EENTIAL TO ENURE, 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 MUT 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 MUT be protected by a purpose designed guard. TERMINAL AEMBLY 300 min K G L N B.C TOP VIEW REAR FLUE PROPERTY BOUNDARY LINE D G J E M A G F A F D H,I Figure 17: Flue terminal positions B5440:1 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 25

28 INTALLATION INTRUCTION Horizontal coaxial balanced flue Ø 60/100 (Kit K) FOR CONDENING BOILER ONLY Ø 60/100 MAXIMUM FLUE LENGTH = 3 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 3 metres is required, use the Ø 80/125 system. Figure 18: Ø 60/100 Horizontal Kit K Figure 19: Ø 60/100 Horizontal Kit K dimensions 26

29 INTALLATION INTRUCTION Horizontal coaxial balanced flue Ø 80/125 FOR CONDENING BOILER ONLY Ø 80/125 MAXIMUM FLUE LENGTH = 8 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 8 metres is required, use the Twin Pipe system. Figure 20: Ø 80/125 Horizontal Kit Figure 21: Ø 80/125 Horizontal Kit dimensions 27

30 INTALLATION INTRUCTION Vertical coaxial balanced flue Ø 60/100 (Kit V) FOR CONDENING BOILER ONLY Ø 60/100 MAXIMUM FLUE LENGTH = 3 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 3 metres is required, use the Ø 80/125 system. Figure 22: Ø 60/100 Vertical Kit V max mt. Ø60 Ø100 Ø60 Ø Figure 23: Ø 60/100 Vertical Kit V dimensions 28

31 INTALLATION INTRUCTION Vertical coaxial balanced flue Ø 80/125 FOR CONDENING BOILER ONLY Ø 80/125 MAXIMUM FLUE LENGTH = 8 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 8 metres is required, use the Twin Pipe system. Figure 24: Ø 80/125 Vertical Kit max mt. Ø80 Ø125 Ø80 Ø Figure 25: Ø 80/125 Vertical Kit dimensions 29

32 INTALLATION INTRUCTION Twin pipe flue system Ø 80/80 (Kit H) FOR CONDENING BOILER 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 HR HWO G CWI HF Figure 27: Ø 80/80 Twin Pipe Kit H dimensions 30

33 COMMIIONING INTRUCTION 5 COMMIIONING 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 B 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 witching the boiler on for the first time means checking that the installation, regulation and operation of the appliance are correct. The commissioning engineer MUT 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 both the central heating and domestic hot water circuits (see ection 5.3); Turn the gas supply on and purge according to B6891. Test for gas soundness. 31

34 COMMIIONING INTRUCTION 5.2 Filling the system Use only a WRA approved filling loop for connection and filling of the primary system. This should be disconnected when not in use (see ection 4.4.3). 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. AIR VENT VALVE AIR VENT VALVE PLUG PUMP PUMP PLUG 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: lacken 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. Once 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; 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 ection 3.6); Figure 28: Air vent and pump bleed plugs R Figure 29: Pressure gauge and boiler drain 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. M 32

35 COMMIIONING INTRUCTION 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 B7593. 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 ection 5.2; a. Continue to fill the system until the pressure gauge reaches 1 bar. 5.4 Filling the condensate trap The condensation trap MUT 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 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. T Figure 30: Condensate Trap 33

36 COMMIIONING INTRUCTION 5.5 tarting the boiler 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 and DHW circuits and gas) witch on the power supply to the boiler; witch the boiler on using the ON/OFF button on the Control Panel (see ection 3.6). After a few seconds the circulating pump will start to run; Ensure that the boiler controls, the time clock and any external system controls are calling for heat; 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; 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 ection 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 CO 2 value. The value should correspond to those in Table 5; Gas Type CO 2 Concentration / % Natural Gas (Methane) G LPG (Butane) G LPG (Propane) G Table 5: Correct gas analyser readings If the CO 2 value does not correspond to those in the table, adjust screw V on the venturi (see Figure 31) clockwise to reduce the CO 2 value or anticlockwise to increase it. PF Figure 31: Flue sampling and commissioning points V 34

37 COMMIIONING INTRUCTION 5.6 Control parameters PARAMETER NUMBER PARAMETER NAME 1 Boiler type 2 Fuel type 3 CH flow temperature 4 CH pump mode 5 6 Water Hammer prevention (Delays operation of DHW flow switch) hort cycling prevention (CH delay timer) 7 CH pump overrun timer 8 DHW pump overrun timer PARAMETER VALUE (default = 36) (default = 36) (default = 18) FUNCTION Non-storage boiler torage boiler (type 1) torage boiler (type 2) Natural gas LPG tandard (30-80 C) for radiators Reduced (25-40 C) for under floor Runs when controls call for heat. Runs continuously when appliance is on. Off On (2 second delay) 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) Expressed in steps of 5 seconds (Default = 18 x 5 sec = 90 sec) Not applicable to this appliance Not applicable to this appliance Not applicable to this appliance Not applicable to this appliance 13 Priority DHW (Delays switching back to CH mode) 14 Burner type Off On (2 minute delay) Atmospheric Premix 25 kw Premix kw Premix 50 kw Not applicable to this appliance 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 Table 6: Control Parameters (default = 56) (default = 143) (default = 56) (default = 143) (default = 110) Expressed in Hertz (Hz) (Default = 56 Hz) Expressed in Hertz (Hz) (Default = 143 Hz) Expressed in Hertz (Hz) (Default = 56 Hz) Expressed in Hertz (Hz) (Default = 143 Hz) Expressed in Hertz (Hz) (Default = 110 Hz) Off On (displays fan speed for 10 minutes) NOTE 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. 35

38 COMMIIONING INTRUCTION 5.7 Control parameter adjustment Accessing the parameters menu OFF tep 1: witch the appliance off using the ON/OFF button. PL tep 2: Press and hold both the & buttons. witch the appliance on using the ON/OFF button. Release the & buttons. 0 tep 3: Press and hold the button. Use the button to cycle up through the parameters. 1 tep 4: Release the button. Press and release the button again. The value of the selected parameter will be displayed. Follow the instructions in the following section (ection 5.7.2) to adjust parameter values. 36

39 COMMIIONING INTRUCTION Adjusting the parameters 00 1 Parameter 1 Boiler type Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = Non-storage boiler; 01 = torage boiler (type 1); 02 = torage 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 ection 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 ection Use the & buttons to adjust the parameter value: 00 = tandard (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. 37

40 COMMIIONING INTRUCTION 00 1 Parameter 4 CH pump mode Access the parameters menu as described in ection 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 Water Hammer prevention Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = Off 01 = On (default = 2 ) Press and release the button. The parameter number (5) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button Parameter 6 hort-cycling prevention (CH delay timer) Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = 0 x 5secs = 0 minutes (minimum) 90 = 90 x 5secs = 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. 38

41 COMMIIONING INTRUCTION Parameter 7 CH pump overrun timer Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = 0 x 5secs = 0 minutes (minimum) 90 = 90 x 5secs = 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 Parameter 8 DHW pump overrun timer Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = 0 x 5secs = 0 minutes (minimum) 90 = 90 x 5secs = 450 seconds (maximum) Note: Factory preset to 18 = 90 seconds Press and release the button. The parameter number (8) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 9 through 12 Not applicable to this appliance 39

42 COMMIIONING INTRUCTION Parameter 13 Priority DHW Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = Off 01 = On (2 minute delay) Press and release the button. The parameter number (13) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button Parameter 14 Burner type Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 00 = Atmospheric burner (all outputs); 01 = Premix burner 25 kw; 02 = Premix burner 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 40

43 COMMIIONING INTRUCTION Parameter 17 Minimum fan speed Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 55 = 55 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 ection Use the & buttons to adjust the parameter value: Minimum value determined by Parameter = 202 Hz (maximum) Note: Factory preset to 164 = 164 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 Parameter 19 Minimum fan speed (in CH mode) Access the parameters menu as described in ection Use the & buttons to adjust the parameter value: 33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 55 = 55 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 ection Use the & buttons to adjust the parameter value: Minimum value determined by Parameter = 202 Hz (maximum) Note: Factory preset to 164 = 164 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. 41

44 COMMIIONING INTRUCTION Parameter 21 Ignition sequence fan speed Access the parameters menu as described in ection 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 ection 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. 42

45 COMMIIONING INTRUCTION 5.8 Gas data Technical reference tables Gas Type CO 2 Concentration / % Natural Gas (Methane) G LPG (Butane) G LPG (Propane) G Table 7: Reference Carbon Dioxide concentrations Gas Type Minimum Fan peed / Hz Maximum Fan peed / Hz Natural Gas (Methane) G LPG (Butane) G LPG (Propane) G Table 8: Reference fan speeds Lower Wobbe index (15ºC; 1013 mbar) Natural Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 MJ/Nm Nominal upply Pressure mbar Consumption (15ºC; 1013 mbar) Consumption (15ºC; 1013 mbar) Table 9: Reference gas data m 3 /h kg/h Heating Power kw L.P.G. (G30/G31) Natural gas(g20) Frequency Hz Figure 32: Heating Output vs Fan Frequency 43

46 MAINTENANCE INTRUCTION 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 ections 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 ection 6.7.3); 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 ection 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 ection 4.7) correct where necessary; The electrical connections inside the control panel correct where necessary; The DHW flow rate and temperature (refer to ection 3.1) service the DHW circuit if 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. 44

47 MAINTENANCE INTRUCTION 6.3 Accessing the boiler All maintenance operations require one or more of the boiler casing panels to be removed 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 ide 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). Figure 34: ide panel removal Control panel access Remove the front panel (refer to 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 35: Control panel access 45

48 MAINTENANCE INTRUCTION 6.4 Draining the central heating system If the ENTIRE YTEM needs to be drained: witch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to ection 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; When the system has been drained, close the radiator air vents and the boiler drain valve. If ONLY THE BOILER needs to be drained: witch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to ection 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 ection Draining the domestic hot water system Close the mains water supply valve. Open all the hot and cold water taps. On completion, close all the opened taps. Figure 36: Boiler drain valve 46

49 MAINTENANCE INTRUCTION 6.7 Maintenance operations Before carrying out any cleaning or part replacement operations, ALWAY turn off the ELECTRICITY, WATER and GA 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. ection 6.3 gives instructions on accessing the boiler, removing casing panels, and accessing the control panel. Expansion vessel Burner unit Ionisation electrode Primary heat exchanger Ignition transformer Ignition electrode Heating sensor afety thermostat Electric fan DHW sensor Gas valve DHW heat exchanger Circulating pump Condensate trap 3-way diverter valve Figure 37: Key components 47

50 MAINTENANCE INTRUCTION 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 tainless steel exchanger coils Burner Ignition electrode Primary heat exchanger Premix burner unit B A Ionisation electrode Flue manifold Ceramic fibre Figure 39: Primary heat exchanger 48

51 MAINTENANCE INTRUCTION DHW heat exchanger Isolate the electricity, water and gas supplies to the appliance; Drain the domestic hot water circuit and central heating circuit of the boiler (see ections 6.4 & 6.6); Use a 4 mm Allen key to remove the screws securing the heat exchanger to the manifold; Remove the heat exchanger from the left side of the boiler, noting its orientation; De-scale the heat exchanger by chemically washing the plates Fit new rubber washers, inserting them in their housings on the manifold; Reassemble the heat exchanger and manifold components following the above procedure in reverse order; Refill the system (see ection 5.2) and check for any leaks from the joints Ignition and ionisation electrodes Figure 40: DHW heat exchanger Isolate the electricity, water and gas supplies to the appliance; Unplug the electrode wires; lacken 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; witch on the power supply and restart the appliance; Ionisation electrode Ignition electrode 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. Figure 41: Ignition and ionisation electrodes 49

52 MAINTENANCE INTRUCTION afety 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; Heating sensor 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 ections 5.2) and check for any leaks Gas valve afety thermostat Figure 42: afety thermostat and heating sensor 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; witch on the gas supply and check for any gas leaks using soapy water or leak detector spray; witch on the electricity and water supplies, switch on and fire the appliance and repeat the checks for leaks. Gas valve Couplings Figure 43: Gas valve 50

53 MAINTENANCE INTRUCTION Electric fan Isolate the electricity, water and gas supplies to the appliance; Remove and dismantle the entire burner unit (see ection 6.7.1); 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 44); 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. witch on the electricity, water and gas supplies and check the soundness of the joint by measuring the CO 2 levels; Expansion vessel Fan Venturi Figure 44: Fan assembly Isolate the electricity, water and gas supplies to the appliance; Drain the central heating circuit of the boiler (see ection 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; witch on the electricity, water and gas supplies; Refill the system (see ections 5.2) and check for any leaks. Fixing bracket Expansion vessel Vessel pipe Figure 45: Expansion vessel 51

54 MAINTENANCE INTRUCTION Circulating pump motor body Isolate the electricity, water and gas supplies to the appliance; Drain the central heating circuit of the boiler (see ection 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; witch on the electricity, water and gas supplies; Refill the system (see ections 5.2) and check for any leaks way diverter valve Pump impeller body Figure 46: Circulating pump Pump motor body Replacing the valve motor Isolate the electricity, water and gas supplies to the appliance; Unscrew the fixing screws securing the transparent cover of the diverter valve and remove the cover; Unscrew the two motor fixing screws and disconnect the wires; Replace the motor and reassemble the components following the above procedure in reverse order; Replacing the valve body Isolate the electricity, water and gas supplies to the appliance; Drain the central heating circuit of the boiler (see ection 6.4); Unscrew the fixing screws securing the transparent cover of the diverter valve and remove the cover; Unscrew the four fixing screws and remove the diverter valve body and washer; Replace the valve body and reassemble the components following the above procedure in reverse order; witch on the electricity, water and gas supplies; Refill the system (see ections 5.2) and check for any leaks. Diverter valve motor Figure 47: 3-way diverter valve Diverter valve body 52

55 MAINTENANCE INTRUCTION Modulation circuit board Isolate the electricity, water and gas supplies to the appliance; Access the control panel (see ection 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; witch on the electricity, water and gas supplies; Program the boiler control parameters following the instructions in ections 5.7. Modulation circuit board Electric fan circuit board Figure 48: Circuit boards Electric fan circuit board Isolate the electricity, water and gas supplies to the appliance; Access the control panel (see ection 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 Figure 49: Circuit boards Primary heat exchanger replacement Isolate the electricity, water and gas supplies to the appliance; Drain the central heating circuit of the boiler (see ection 6.4); Remove and dismantle the entire burner unit (see ection 6.7.1); Remove the gas valve (see ection 6.7.6); 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; witch on the electricity, water and gas supplies; Refill the system (see ections 5.2) and check for any leaks; Fire the boiler and check for any flue gas leaks. 53

56 MAINTENANCE INTRUCTION 6.8 Wiring diagram PRINTED CIRCUIT BOARD KOND DT - K11003 COD LA PRINTED CIRCUIT BOARD DIGITECH - M20019 COD LA POWER UPPLY N L EXHAUT FAN type RG128/ DHW brown black blue brown blue CH orange brown orange blue brown blue brown red blue orange M5 blue brown white-black CVI-M VK 4105 G black red-black black orange Comando telefonico Comando remoto EXTERNAL CONTROL orange M9 blue brown torage cylinder timer (option) black brown blue black black black M7 Zone valve management + option remote controller board Zone valve contact closure Key IG ON/OFF button PA Air pressure switch T Heating safety thermostat TF Flue safety thermofuse R Heating sensor DHW sensor EV Fan E Outside sensor (optional) ER Ionisation electrode EA Ignition electrode TRA Ignition transformer VD 3-way valve C Circulating pump MF Micro flow switch PACQ Water pressure switch DHW Domestic hot water CH Central heating remote controller zone valve M10 M1 M2 M6 M4 Figure 50: Internal wiring 54

57 MAINTENANCE INTRUCTION 6.9 Troubleshooting Error codes CODE PROBLEM POIBLE CAUE REMEDY E01 NO FLAME (FLAME FAILURE DURING TART- UP) IF BOILER FAIL TO FIRE a. NO GA b. GA INLET PREURE TOO HIGH c. MECHANICAL MINIMUM OR IGNITION EQUENCE GA PREURE TOO LOW d. IGNITION ELECTRODE BROKEN OR EARTHED e. GA VALVE MALFUNCTION a. CHECK MAIN UPPLY b. CHECK INLET PREURE c. CHECK AND ADJUT MECHANICAL MINIMUM AND IGNITION EQUENCE ETTING d. REPLACE PART e. REPLACE PART IF BOILER FIRE NORMALLY f. MAIN LIVE AND NEUTRAL WIRE REVERED g. IONIATION ELECTRODE CABLE DICONNECTED h. IONIATION ELECTRODE MALFUNCTION f. CORRECT MAIN WIRING g. CHECK ELECTRODE WIRING h. REPLACE PART E02 AFETY THERMOTAT TRIPPED (95 C) a. THERMOTAT CABLE DICONNECTED b. THERMOTAT MALFUNCTION a. CHECK THERMOTAT WIRING b. REPLACE PART E03 FLUE THERMOTAT TRIPPED a. THERMOTAT CABLE DICONNECTED b. THERMOTAT LOCK OUT (DUE TO HIGH FLUE TEMPERATURE) c. THERMOTAT BROKEN a. CHECK THERMOTAT WIRING b. RETART APPLIANCE AND CHECK THERMOTAT OPERATION c. REPLACE PART H20 LOW YTEM PREURE a. WATER PREURE WITCH CABLE DICONNECTED b. INUFFICIENT WATER PREURE IN THE YTEM c. WATER PREURE WITCH MALFUNCTION a. CHECK WITCH WIRING b. FILL OR TOP UP THE YTEM c. REPLACE PART E05 HEATING ENOR FAULT a. ENOR CABLE DICONNECTED OR WET b. ENOR MALFUNCTION OR OUT OF CALIBRATION (REITANCE VALUE 10 kohms AT 25 C). a. CHECK ENOR WIRING b. CHECK ENOR REITANCE. REPLACE IF INCORRECT E06 DHW ENOR FAULT a. ENOR CABLE DICONNECTED OR WET b. ENOR MALFUNCTION OR INCORRECT (REITANCE VALUE 10 kohms AT 25 C). a. CHECK ENOR WIRING b. CHECK ENOR REITANCE. REPLACE IF INCORRECT E16 FAN FAULT a. BURNT FAN a. REPLACE PART E22 PARAMETER PROGRAMMING REQUET a. LO OF MICROPROCEOR MEMORY a. REPROGRAM PARAMETER E35 IONIATION ELECTORDE FAULT a. IONIATION ELECTRODE WET, DAMP OR EARTHED b. IONIATION ELECTRODE MALFUNCTION c. IONIATION ELECTRODE CABLE MALFUNCTION d. MODULATION PCB MALFUNCTION a. CHECK COMBUTION CHAMBER b. CLEAN PART (REPLACE IF FAULT REMAIN 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 55

58 MAINTENANCE INTRUCTION 6.10 Parts lists Main components CODE DECRIPTION PLATE EXCHANGER 20 PLATE PRIMARY EXCHANGER IOTHERM KW PUMP RL 15/5-3-KU-CLF6 w/open C1+C CONDENATE TRAP ELECTRONIC GA VALVE VENTURI 57 kw FAN WAHER/OR CLIP KIT FOR MULTIPLEX WATER PREURE WITCH PC 5411 BRA DHW-HEATING 1/8" WHITE ENOR HTG CLIP ENOR X PIPE 17/18 mm. BLUE THERMO FUE 102 C RED ITMQ 1/4" 4X PRINTED CIRCUIT BOARD BMBC c/diplay PRINTED CIRCUIT BOARD KOND DT AFETY THERMOTAT 95C X EL.TB 1NT WATER PREURE GAUGE M3A-AB G1/8C/D+C TRANFORMER AC1 230VAC 25HZ 39/3200Y EXPANION VEEL LT.7 3/8" WAY VALVE C/MOLEX ATV-03 M.PLEX WAY VALVE MOTOR NYM-16H BAR PREURE RELIEF VALVE -HTG CIRCUIT Table 11: hort parts list 56

59 MAINTENANCE INTRUCTION MULTIPLEX unit Figure 51: Multiplex assembly 57

60 MAINTENANCE INTRUCTION PLATE EXCHANGER 20 PLATE PUMP MANIFOLD MULTIPLEX DHW OUTLET CONNECTION INTANTANEOU MOD. - M.PLEX MOD COLD WATER HEATING FLOW CONNECTION - M.PLEX 2006 GB ENOR HOLDER PUMP CONNECTION BODY M.PLEX FLOWWITCH FILTER WAHER D.18.5x10.2x2 1/2" AFM WAHER D.15x8x2 3/8" AFM BY PA O-RING WAY VALVE WAHER PLATE EXCHANGER O-RING WAY VALVE MOTOR O-RING MULTIPLEX EAL O-RING WAHER EPDM 80 H M.PLEX 16x24x2, OR 4081 EPDM Di18,68x3,53 - OR4081E OR EPDM 17,00x4 - OR17,00x FIXING CLIP BYPA PRING FIXING CLIP TAINLE TEEL WATER PREURE WITCH PC BRA FLOWWITCH PITON FLOWWITCH CAP MULTIPLEX WAY VALVE UPPER ECTION FOR ITANTANEOU MODEL BYPA MULTIPLEX ZYTEL 70G BYPA BUH IN NYLON PUMP MANIFOLD CONNECTION BEND M.PLEX PUMP CONNECTION ECTION M.PLEX WAY VALVE BOTTOM ECTION M.PLEX 2006 ZYTEL FLOWWITCH GROUP FOR ITANTANEOU MODEL DHW-HEATING ENOR 1/8" WHITE BYPA PIPE D WATER PREURE GAUGE M3A-AB PB GALVANIED CREW 5x16 T.C. 3-LOBE CROHEAD DIN GALVANIED CREW 5x13 T.C. 3-LOBE CROHEAD DIN CREW 5x14 FOR PLATE HEAT EXCHANGER WAY VALVE C/MOLEX ATV 03 MULTIPLEX WAY VALVE MOTOR MULTIPLEX BAR PREURE RELIEF VALVE M.PLEX 2006 Table 12: Multiplex assembly parts list 58

61 OPTIONAL CONTROL 7 OPTIONAL CONTROL 7.1 External controls, programmers and room thermostats All external controls used with this appliance MUT BE ZERO-VOLT WITCHING ONLY! If mains voltage, i.e. a switched live, is fed to the control terminals THE APPLIANCE WILL NOT FUNCTION and could be EVERELY DAMAGED! 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. Ta Ta e e N B L A External Controls: - Programmer - Room thermostat - -Plan system Figure 52: Connection of external controls 59

62 60 Figure 53: -Plan wiring schematic Permanent Live Neutral Heating Zone Room Thermostat 2-port zone valves Hot Water Cylinder Cylinder Thermostat Add more valves & programmers as required Boiler Terminal Block Plan wiring schematic OPTIONAL CONTROL Zone valve microswitches Zero-volt witching Circuit

63 OPTIONAL CONTROL 7.2 Weather compensating controls An Outside ensor is available for use with this appliance and is strongly recommended in order to maximise appliance efficiency and user comfort. The sensor is easy to wire, connecting directly to the e terminals of the mains supply terminal board. The control system carefully modulates the central heating flow temperature in accordance with the outside temperature as measured by the sensor Fitting the outside sensor To fit the outside sensor: 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; Connect the two wires of the sensor to the connections marked e on terminal block B; Replace terminal block cover A. Outside temperature sensor 2 M1 1 N Ta Ta e e B L A External Controls: - Programmer - Room thermostat - -Plan system Figure 54: Outdoor ensor connection Controlling the appliance With the sensor fitted, the CH Control knob no longer sets the CH flow temperature. This is now governed by the control system. Instead, the CH Control knob is used to set the response of the control system to the outside temperature. When the CH Control knob is turned, numbers between 0 and 9 are temporarily displayed on the control panel display. The numbers correspond to the control profiles depicted in Figure 55, relating the CH flow temperature, Tm, to the outside temperature, Te. The appliance will control the CH flow temperature between the minimum and maximum temperatures as set by Control Parameter 3 (see ections 5.6 & 5.7). 61

64 OPTIONAL CONTROL Tm CH Flow Temperature, Tm / ºC Reduced Temperature Range 40 MAX MIN 30 tandard Temperature Range Outside Temperature, Te / ºC Figure 55: Weather compensating control profiles 62

65 INTALLATION, COMMIIONING & ERVICE RECORD INTALLER & COMMIIONING ENGINEER DETAIL Installer Details Company Name Installation Date Address CORGI Registration No. CORGI ID erial No. Commissioning Engineer Details (if different from Installer) Company Name Installation Date Address CORGI Registration No. CORGI ID erial No. APPLIANCE & CONTROL DETAIL Boiler Make & Model erial No. Location EDBUK Efficiency % New ystem or Replacement boiler Controls To comply with Building Regulations, each section must have a tick in one or more boxes Requirement 1. Time and Temperature Control to Heating 2. Time and Temperature Control to Hot Water Room Thermostat and Programmer / Timer Cylinder Thermostat and Programmer / Timer Measures Provided Programmable Room Thermostat Combi Boiler 3. Heating Zone Valves Fitted Not Required 4. Thermostatic Radiator Valves Fitted 5. Automatic Bypass to ystem Fitted Not Required 6. Boiler Interlock Provided

66 INTALLATION, COMMIIONING & ERVICE RECORD COMMIIONING 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 Burner Operating Pressure kw 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 Maximum Burner Operating Pressure Maximum Operating Water Pressure kw mbar bar Cold Water Inlet Temperature ºC Hot Water Outlet Temperature ºC Water Flow Rate at Maximum etting 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? 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? Have you left all the manufacturer s literature with the customer? Competent Person s ignature Customer s ignature Yes Yes Yes Yes (To confirm demonstrations of equipment and receipt of appliance instructions)

67 INTALLATION, COMMIIONING & ERVICE RECORD ervice 1 Date: ervice 2 Date: Engineer Name Engineer Name Company Name Tel. No. CORGI ID erial No. Comments Company Name Tel. No. CORGI ID erial No. Comments ignature ignature ervice 3 Date: ervice 4 Date: Engineer Name Engineer Name Company Name Tel. No. CORGI ID erial No. Comments Company Name Tel. No. CORGI ID erial No. Comments ignature ignature ervice 5 Date: ervice 6 Date: Engineer Name Engineer Name Company Name Tel. No. CORGI ID erial No. Comments Company Name Tel. No. CORGI ID erial No. Comments ignature ignature ervice 7 Date: ervice 8 Date: Engineer Name Engineer Name Company Name Tel. No. CORGI ID erial No. Comments Company Name Tel. No. CORGI ID erial No. Comments ignature ignature ervice 9 Date: ervice 10 Date: Engineer Name Engineer Name Company Name Tel. No. CORGI ID erial No. Comments Company Name Tel. No. CORGI ID erial No. Comments ignature ignature

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70 WARMFLOW Engineering Company Limited Lissue Industrial Estate, Moira Road, Lisburn BT28 2RF Tel: Fax: Warmflow Customer Care Centre UK ROI THE TECHNICAL DATA AND MEAUREMENT ARE PROVIDED FOR INFORMATION PURPOE ONLY AND ARE NOT BINDING. THE COMPANY REERVE THE RIGHT TO APPLY VARIATION WITHOUT PRIOR NOTIFICATION. NEITHER WILL THE COMPANY BE HELD REPONIBLE FOR ANY INACCURACIE IN THI HANDBOOK DERIVING FROM PRINTING OR TRANLATION ERROR. E+OEALL RIGHT REERVED. NO PART OF THI DOCUMENT MAY BE REPRODUCED, MEMORIED IN ANY FILING YTEM OR TRANMITTED IN ANY FORM WHATOEVER, INCLUDING ELECTRONIC, MECHANICAL, PHOTOCOPIE, RECORDING OR ANY OTHER MEAN WITHOUT THE COMPANY PRIOR WRITTEN APPROVAL.