Installation Commissioning and Servicing manual Logano plus GB102/GB102S. Regular boiler 16, 30, 42 System boiler 16, 30

Transcription

1 Floor-standing gas-fired condensing appliance (04/03) Installation Commissioning and Servicing manual Logano plus GB0/GB0S Regular boiler 6, 30, 4 System boiler 6, 30 Read carefully before installation and maintenance.

2 Contents Contents Key to symbols and safety precautions Key to symbols Legislation and regulations Appliance information General information Intended use Declaration of conformity Type plate Type overview Electrical supply Gas supply Dimensions and description Regular boiler layout and components Regular boiler wiring diagram Regular boiler Technical data Gas type and installation type Output power reduction due to altitude System boiler layout and components System boiler wiring diagram System boiler Technical data Regulations Country specific regulations Approvals and notifications Quality of the heating water Connection to combustion air and flue gas systems Room air dependent operation Flue gas systems type Bxx Flue gas systems type Cxx Combustion air quality Disposal Inspection, service and maintenance Pre-installation Cleaning primary systems Hydraulic connections Connecting flow and return Expansion vessel and drain valve Water systems and pipework Condensate drain To remove the condensate trap Boiler location and clearances Installation Installations and servicing clearances: Installation Unpacking the boiler Boiler room requirements Positioning the appliance Mounting the boiler and flue opening Flue options Electrical Electrical Commissioning Pre-Commissioning checks Filling the system and checking for leaks Water treatment Starting the appliance Checking gas inlet pressure Measuring the inlet pressure Checking the gas rate Finishing commissioning Commissioning checklist Thermal disinfection Perform thermal disinfection Thermal disinfection for system with a hot water tank. 5 9 Operating the appliance Controls overview Screen display Appliance on/off switch Heating mode Heating mode on/off Set the maximum flow temperature Setting the DHW DHW on/off Setting the DHW temperature Control unit setting Summer mode ON/OFF Setting frost protection Servicing and spares Inspection and service Service function Selecting service menus Selecting the Information menu Selecting menu Selecting menu Selecting menu Selecting the Test menu Setting the boiler to maximum output Flue integrity Service inspection - Component access Control panel - Service position Checking the gas inlet pressure Fan pressure test Flue gas analysis Setting the air/gas ratio Cleaning the heat exchanger Inspection and servicing checklist Demand dependant maintenance Replacement parts Replacement parts Access to components Fan assembly Sensors To remove the condensate trap Gas Valve Primary Heat Exchanger Fault finding and diagnostics Status codes and faults Troubleshooting Information and service menus Selecting the information menu Selecting service menus Menu - System parameters Menu - Boiler parameters Reset to factory settings Menu 3 - Boiler maximum & minimum limits Using the test menu Fault codes Logano plus GB (04/03)

3 Key to symbols and safety precautions KEY TO SYMBOLS AND SAFETY PRECAUTIONS. Key to symbols Warnings The following keywords are defined and can be used in this document: NOTICE indicates a situation that could result in damage to property or equipment. CAUTION indicates a situation that could result in minor to medium injury. WARNING indicates a situation that could result in severe injury or death. DANGER indicates a situation that will result in severe injury or death. Appliance operation: This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision. Important information Additional symbols Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. This symbol indicates important information where there is no risk to people or property. Symbol Explanation Step in an action sequence Cross-reference to another part of the document List entry List entry (second level) Symbols used in the manual Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Gas Supply Please read these instructions carefully before starting installation. Ø Diameter Equal to or less than Equal to or greater than < Less than > Greater than NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve ECV Emergency Control Valve Table Abbreviations use in this manual If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. Prevent flames or sparks: Do not smoke, use a lighter or strike matches. Do not operate any electrical switches or unplug any equipment. Do not use the telephone or ring doorbells. Turn off the gas at the meter or regulator. Open windows and doors. Warn your neighbours and leave the building. Prevent anyone from entering the building. Well away from the building, call the Emergency Services. L.P.G. boilers: Call the supplier s number on the side of the gas tank. Combustion and corrosive materials Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance. Chemically aggressive substances can corrode the appliance and invalidate any warranty. Fitting and modification Flue systems must not be modified in any way other than as described in the fitting instructions. any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights. Servicing Advise the user to have the system serviced annually by a competent registered engineer. Approved spares must be used to help maintain the economy, safety, and reliability.. Legislation and regulations Installation regulations The appliance must be installed by a competent person in accordance with all the legislation and regulations that are in force at the time of installation, paying particular attention to any provisions or regulations made by the local authorities. Logano plus GB (04/03) 3

4 Appliance information Appliance information. General information Boiler features and checklist Pre-wired and pre-plumbed Galvanised steel inner frame Bosch EMS control system Automatic ignition Direct burner ignition electrodes Built-in frost protection Built-in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor and control Flue gas overheat sensor CHECK LIST - LITERATURE PACK: Qty. Installation, Commissioning and Servicing Instructions Users Instructions Table Literature pack - checklist CHECK LIST - INSTALLATION PACK: Qty. PRV discharge pipe 3 Condensate discharge pipe Table 3 Installation pack - checklist 3.4 Type plate The type label contains information on device performance, the registration data and the serial number..5 Type overview System boiler, heat only gas-fired condensing boilers with an integrated circulating pump and optional 3-way valve for the connection of the hot water tank. Regular boiler, heat only, gas-fired condensing boilers without a circulating pump or optional three way valve, for use in systems where this is provided externally..5. Electrical supply Supply: 30V - 50 Hz External Quick blow 3A fuse The appliance must be earthed IPX4D The wiring between the appliance and the electrical supply must comply with the latest IEE wiring regulations that apply to wiring a to a fixed appliance Any system connected to the appliance must not have a separate electrical supply.5. Gas supply Boilers using Natural Gas (NG) must be connected to a governed meter. Liquid Petroleum Gas (LPG) must be connected to a regulator. Installation and connection of the gas supply to the boiler must be in accordance with country and local regulations. Under no circumstance should be size of the gas supply pipe be less than DN0. The meter or regulator and pipe work to the meter must be checked, by the gas supplier. This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements, in addition to the demand from any other appliance being served. Fig. Standard package Wo. Intended use These appliances may only be used in a closed loop hot water central heating system. Any other purpose is considered improper use. Any damage resulting from misuse is excluded from the manufacturer s guarantee. The commercial or industrial use of the appliance to produce process heat is not permitted. Only use genuine gas from official gas suppliers. Ensure the appliance is operated within the limits on the data label and parameters in this manual...3 Declaration of conformity This product, in design and operation, conforms to the European Directives and supplementary national requirements. Compliance is demonstrated by the CE marking. You can request the declaration of conformity of the product. To do so, send your request to the address on the back of the manual. The appliances meet the requirements for gas-fired condensing boilers in terms of energy saving regulations. The appliances are tested according to EN Logano plus GB (04/03)

5 Appliance information.6 Dimensions and description 6 Ø80 Ø * * Wo Fig. Pipe work connector location Regular boiler: [] Hot water flow ( ) [] Gas (3/4 ) [3*] Not used on the regular boiler [4] Hot water return ( ) [5] Condensate outlet [6] 80/5 Flue outlet System boiler: [] Heating and DHW flow ( ) [] Gas (3/4 ) [3*] DHW return ( ) (only if optional diverter valve kit is fitted) [4] Heating return ( ) [5] Condensate outlet [6] 80/5 Flue outlet Logano plus GB (04/03) 5

6 Appliance information.7 Regular boiler layout and components Wo Fig. 3 Component layout KBR Legend to figure 3: [] Flue connector [] ON/OFF switch [3] Display [4] Pressure gauge [5] Spark generator [6] Flame sense electrode [7] Electrode assembly [8] Flow temperature sensor [9] High limit thermostat [0] Heat exchanger inspection cover [] Condensate pan [] Pressure relief valve [3] Drain cock [4] Condensate trap [5] Gas valve [6] Flue overheat thermostat [7] Air Intake pipes (30 and 4kW boilers only) [8] Manual vent [9] Mixing device [0] Flue exhaust [] Fan [] Combustion chamber cover 6 Logano plus GB (04/03)

7 Appliance information.8 Regular boiler wiring diagram L N L N N Wo Fig. 4 [] Appliance terminal connector block [] Mains supply [3] Heat control module (HCM) [4] Spark generator [5] Spark electrodes [6] Flame sense electrode [7] High limit thermostat [8] Flow temperature sensor [9] Flue overheat thermostat [0] Gas valve [] Fan Logano plus GB (04/03) 7

8 Appliance information.9 Regular boiler Technical data All the technical data quoted in the table below refer to an appliance tested at sea level. Power outputs are reduced due to altitude, refer to figures 5 and 6 for the percentage reduction power output due to altitude DESCRIPTION Units Natural Gas Propane 6kW 30kW 4kW 6kW 30kW 4kW Central Heating Input/Output Max. rated heat output net 50/30 C kw xx.x xx.x xx.x xx.x xx.x xx.x Max. rated heat output net 80/60 C kw xx.x xx.x xx.x xx.x xx.x xx.x Max. rated heat input net kw Min. rated heat output net 50/30 C kw x.x x.x xx.x x.x xx.x xx.x Min. rated heat output net 80/60 C kw Min. rated heat input net kw Max. flow temperature C Max. permissible operating pressure bar Gas flow rate - Max. 0 minutes from lighting Natural Gas G0 m3/h Natural Gas G5 m3h Propane Gas G3 kg/h Gas supply pressure Natural Gas G0 mbar Natural Gas G5 mbar Propane Gas G3 mbar Flue Flue Gas Temp. 80/60 C, rated min. load C 67/55 67/55 67/55 67/55 67/55 67/55 Flue Gas Temp. 40/30 C, rated min. load C 43/ 43/ 43/ 43/ 43/ 43/ CO level at max. rated heat output % CO level at min. rated heat output % NOx - classification class Exhaust gas flow rate Maximum g/s Minimum g/s Condensate Max. condensation rate l/h ph value, approx Electrical Electrical power supply voltage AC...V Frequency Hz Max. power consumption (excluding external pumps) W General Data Appliance protection rating IP X4D X4D X4D X4D X4D X4D Permissible ambient temperatures C Nominal water capacity of appliance Itr Noise output level (at maximum CH output) db(a) Weight (excluding packaging) kg Table 4 Appliance technical data KBR 8 Logano plus GB (04/03)

9 Appliance information.0 Gas type and installation type Rated gas pressure (mbar) Gas Factory setting (gas family, Factory setting rated Country Natural gas LPG category gas group and test gas) gas pressure (mbar) Installation type Austria AT 0 50 Cat II H 3P G0 0 B 3, B 3P, B 33, C 3X, France FR 0 37 Cat II E SI 3P G0 0 C 33X, C 43X, C 53X, C 63X, Italy IT 0 37 Cat II C 83X, C 93X H 3B/P G0 0 Czech Republic CZ 0 37 Cat II H 3B/P G0 0 Russia RU 3 37 Cat II H 3B/P G0 0 Poland PO 0 37 Cat II H 3P G0 0 Belgium BE 0/5 Cat II E G0/G5 0 B 3, B 33, C 3X, C 33X, Belgium BE 37 Cat II 3P G3 37 C 43X, C 53X, C 83X, C 93X Table 5 Gas type and installations per country Wobbe index (WS) (5C) gas group Gas group.5 to 5. kwh/m 3 Natural gas H.4 to 5. kwh/m 3 Natural gas E 9.5 to.5 kwh/m 3 Natural gas LL 0. to 4.3 kwh/m 3 LPG 3B/P 0. to.4 kwh/m 3 LPG 3P Table 6 Test gas disclosures with code and gas group (EN437). Output power reduction due to altitude The graph in figure 5 below applies to all boiler sizes using natural gas, and the graph in figure 6 below applies to all boiler sizes using LPG. The power output of the boilers quoted in tables 4 and 7 are reduced due to the altitude of the installation, refer to the graphs below for the percentage output reduction. Output power reduce on natural gas boilers due to altitude 00% 95% 90% kw (%) 85% 80% 75% A (Metres) Fig. 5 Output reduction due to altitude for natural gas [] Percentage output at elevation [] Percentage estimated output at elevation [A] Altitude in metres [kw(%)] Percentage kilowatt output Wo Logano plus GB (04/03) 9

10 Appliance information Output power reduce on LPG boilers due to altitude 00% 95% 90% kw (%) 85% 80% 75% A (Metres) Fig. 6 Output reduction due to altitude for LPG Pressure loss in the system versus system flow p [mbar] Wo V [l/h] Fig. 7 [p mbar] Pressure loss in millibars [V l/h] Re-circulated quantity of water in litres per hour Wo 0 Logano plus GB (04/03)

11 Appliance information. System boiler layout and components Wo Fig. 8 Component layout KSBR Legend to figure 5: [] Flue connector [] ON/OFF switch [3] Display [4] Pressure gauge [5] Spark generator [6] Flame sense electrode [7] Electrode assembly [8] Flow temperature sensor [9] High limit thermostat [0] Heat exchanger inspection cover [] Condensate pan [] Auto air vent [3] Diverter valve assembly [4] Pump [5] Drain cock [6] Pressure relief valve [7] Condensate trap [8] Gas valve [9] Flue overheat thermostat [0] Air Intake pipes (30kW boiler only) [] Manual vent [] Mixing device [3] Flue exhaust [4] Fan [5] Combustion chamber cover Logano plus GB (04/03)

12 Appliance information.3 System boiler wiring diagram L N L N N Wo Fig. 9 [] Appliance terminal connector block [] Mains electrical supply connector [3] Heat control module (HCM) [4] Spark generator [5] Spark electrodes [6] Flame sense electrode [7] High limit thermostat [8] Flow temperature sensor [9] Diverter valve connection [0] Pump [] Flue overheat thermostat [] Gas valve [3] Fan Logano plus GB (04/03)

13 Appliance information.4 System boiler Technical data All the technical data quoted in the table below refer to an appliance tested at sea level. Power outputs are reduced due to altitude, refer to figures 5 and 6 for the percentage reduction in power output due to altitude DESCRIPTION Units Natural Gas Propane 6kW 30kW 6kW 30kW Central Heating Input/Output Max. rated heat output net 50/30 C kw XX.X XX.X XX.X XX.X Max. rated heat output net 80/60 C kw XX.X XX.X XX.X XX.X Max. rated heat input net kw Min. rated heat output net 40/30 C kw Min. rated heat output net 50/30 C kw X.X X.X X.X XX.X Min. rated heat output net 80/60 C kw Min. rated heat input net kw Max. flow temperature C Max. permissible operating pressure bar Gas flow rate - Max. 0 minutes from lighting Natural Gas G0 m3/h Natural Gas G5 m3/h Propane Gas G3 kg/h Gas supply pressure Natural Gas G0 mbar 0 0 Natural Gas G5 mbar 5 5 Propane Gas G3 mbar Flue Flue Gas Temp. 80/60 C, rated min. load C 69/55 69/55 69/55 69/55 Flue Gas Temp. 40/30 C, rated min. load C 5/3 5/3 5/3 5/3 CO level at max. rated heat output % CO level at min. rated heat output % NOx - classification class Exhaust gas flow rate Maximum g/s Minimum g/s Condensate Max. condensation rate l/h ph value, approx Electrical Electrical power supply voltage AC...V Frequency Hz Max. power consumption (including pump) W General Data Appliance protection rating IP X4D X4D X4D X4D Permissible ambient temperatures C Nominal water capacity of appliance Itr Noise output level (at maximum CH output) db(a) Weight (excluding packaging) kg Table 7 Appliance technical data KSBR Logano plus GB (04/03) 3

14 3 Regulations 3 Regulations The boiler is designed to operated in conformity with the following requirements: EN 677, EN 483, EN 550 EN 437 Gas appliance directive 009/4/EG Efficiency directive 9/4/EWG EMV directive 004/08/EG Low voltage directive 006/95/EG 3. Country specific regulations For installation and operation, please refer to country specific standards and regulations. Critical are: Local standards and regulations for siting the appliance Local standards and regulations for combustion air supply, ventilation and and connection to a flue gas system Regulations for connection to an electrical mains supply Regulations of the gas supplier for connecting a gas appliance onto the local distribution network Standards and regulations for safety equipment on wet heating systems Belgium NOTICE: Adjustment to appliances are not permitted! The boiler is factory set for operating on natural gas (G0/G5) IE(S) so that the appliance will be able to operate in both regions without adjustments be made or changing any parts. Only when replacement of a part from the gas block, it sometime may require an adjustment to the gas setting. These adjustments may only be done by a certified technician and My Service. Belgium; Royal decree This product fulfils the requirements of the Royal Decree from 7/07/009 (CO value at 00% burner output is <0mg/kWh and Nox <70mg/kWh). Also refer to the Declaration of Conformity. NBN D Natural gas installations NBN D Connection to a natural supply 3. Approvals and notifications The installation of a gas boiler must be declared to and approved by the gas supplier. Please note, local regulations may require third party approval when connecting to a flue gas system or drain condensate into the local sewage system "Where required, inform local representative (i.e. chimney sweeper) before installing the boiler 3.3 Quality of the heating water Use water to drinking water quality when filling and toping up the heating system. Water quality is an important factor to increase the efficiency, safety, reliability and availability of your heating system. Unsuitable or contaminated water can lead to problems or damage of the heat exchanger and water supply caused by i.e. sludge, corrosion and scale build up. Apply the following steps: Thoroughly flush the system before filling Water from wells and springs are not suitable as fill water Consider the total volume of scale introduced into the heating system over its lifetime, by fill and top up water, and protect it against damage with that in mind For systems with a volume 50litres/kW (i.e. when using buffer vessels) the water must be treated. An approved solution is the full removal of salts from the fill and top up water, achieving a conductivity of 0μsiemens/cm (= 0μS/cm). Instead of a the water treatment solution you could install a means of system separation (i.e. plate heat exchanger) directly after the boiler. Please contact the manufacturer of the appliance for additional inhibitors and anti freezes. Always refer to the manufacturer's advice for filling and continuous maintenance when using these solutions. 3.4 Connection to combustion air and flue gas systems Always refer to the latest version of the applicable local standards and regulations Further information about combustion air supply and connection to flue gas systems can be found in chapter <reference in the manual> in this manual. Also refer to the documentation supplied with the flue gas system. 3.5 Room air dependent operation The boiler can be operated room air sealed if room air dependent operation is not desired or possible. Provide sufficient boiler room ventilation when operating the appliance room air dependent Do not obstruct or block any ventilation openings Ventilation openings must always be kept clear 3.6 Flue gas systems type B xx DANGER: Risk to life from flue gas poisoning. Insufficient combustion air supply can lead to flue gas escaping. Ensure combustion air supply Supply and extract vents in doors, windows and walls must not be closed off or reduced in size. Ensure a sufficient combustion air supply, also with equipment installed afterwards: i.e. kitchen extract fans and air conditioning units extracting air to the outside Do not operate the appliance if combustion air supply is insufficient. Type B flue gas systems take combustion air from the boiler room. Flue gas exits the appliance via the flue gas system. Special regulations apply for installations of this type - comply with these requirements. Sufficient combustion air must be available. 3.7 Flue gas systems type C xx Type C flue gas systems take combustion air from outside the building. Flue gas exits the appliance via the flue gas system to the outside. To ensure this, the combustion chamber door is air tight. Therefore always ensure the combustion chamber door is closed when operating the appliance room air sealed. Refer to the installation instructions of the flue gas system when installing the appliance 3.8 Combustion air quality To avoid corrosion, combustion air must be free from aggressive substances (hydrogen halide, chlorines and fluorine). 4 Logano plus GB (04/03)

15 Pre-installation Disposal Dispose any part of the heating system via an authorised facility 3.0 Inspection, service and maintenance The heating system should be service regularly for the following reasons: To achieve and maintain a high efficiency and low fuel consumption To ensure operational safety To keep combustion clean and emissions low Service interval NOTICE: Damage to boiler from contaminated combustion air and contaminated air in the vicinity of the appliance! Never operate the boiler in an dusty and chemically aggressive environment i.e. spray painting, hair dressing and farming facilities Never operate the boiler in places where using or storing trichlorethane, hydrogen halide and other aggressive chemical substances. These substances can be contained in spray cans, various glues, primers, paints and cleaning substances. In this case always install the appliance room air sealed in a hermetically sealed plant room with ventilation directly to the outside. 4. Hydraulic connections NOTICE: Damage to property caused by leaking connections: Ensure the pipes are installed without mechanical strain onto the appliance connections Refurbish seals when loosening or removing connection joints Check gaskets and connections for signs of damage We recommend the installation of a line strainer in the system return to protect the heating system Fit isolating valves before and after the line strainer to allow for servicing 4.. Connecting flow and return Fit isolation valves in the flow and return to allow servicing of the appliance Ø5 NOTICE: Damage to the system caused by a lack of or insufficient cleaning and servicing. Get the heating system inspected at least annually by an authorised heating engineer Carry out a service as required. Carry out any repairs immediately to avoid any damage to the system 4 Pre-installation 4. Cleaning primary systems NOTICE: Before installation All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installations. CAUTION: MAINS POWER ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. NOTICE: Protect the boiler Debris from the system can damage the boiler and reduce efficiency.failure to comply with guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. WARNING: Sealing agents The addition of sealing agents to the system water is not permitted, this can cause problems with deposits left in the heat exchanger * Fig. 0 Pipe work connector location Regular boiler: [] Hot water flow ( ) [] Gas (3/4 ) [3*] System boiler only ( ) [4] Hot water return ( ) [5] Condensate outlet System boiler: [] Heating and DHW flow ( ) [] Gas (3/4 ) [3*] DHW return ( ) (only if optional diverter valve kit is fitted) [4] Heating return ( ) [5] Condensate outlet Wo Logano plus GB (04/03) 5

16 4 Pre-installation 4.. Expansion vessel and drain valve Connect an expansion vessel EN88 requires and expansion vessel to be installed with the boiler. Install an expansion vessel in the return to the pump Fill and drain connections EN77 requires a filling of the heating system with drinking water only via a fixed connection between water supply and heating circuit. Fit an external drain valve in the return to the appliance 4.3 Water systems and pipework Primary system plastic pipework Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper connected to the boiler. Plastic pipe work used for under floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C. The pipe work from the boiler to the blending valve must be in copper. Primary system/connections/valves: Do not use galvanised pipes or radiators. All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar. Drain cocks are required at all the lowest points on the system. Air vents are required at all high points on the system. Filling primary sealed systems: The filling point must be at low level and must never be a permanent direct fixing to the mains water supply. 4.4 Condensate drain DANGER: Danger to life by poisoning from escaping flue gas. Flue gas can escape if condensate trap is not filled with water or connections are not sealing properly. Fill the siphon with water NOTICE: Additional advice on draining condensate Any condensate in the appliance and the flue gas system must be drained in an appropriate manner (flue gas system must have sufficient fall towards the appliance) Comply with country specific standards and regulations when connecting the condensate into the sewage system Comply with local regulations Condensate neutralisation systems are available as an accessory. Fig. Condensate trap Install condensate neutralisation systems (optional accessory) in line with the installation instructions Ensure that the condensate pipework leading away from the appliance falls away towards the drainage point Connect into the sewage system based on national and local standards and regulations 4.5 Boiler location and clearances 4.5. Installation This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combustible surface at least the same size as the boiler and capable of supporting the boiler weight. The boiler is not suitable for external installation unless a suitable enclosure is provided Installations and servicing clearances: The dimensions below are the minimum space required to install, service and perform maintenance on the boiler only Wo 3 Ensure that the condensate trap has at least 50ml of clean water in it before the boiler is run. If the flue has not been fitted yet, the water can be poured down the inner flue pipe. If the flue has already been fitted, the condensate trap will have to be removed and filled To remove the condensate trap Release the hose clamp [] Remove the screw retaining the trap [] Pull the trap down to remove the trap from boiler Pour 50ml of clean water into the top of the trap Re-fit the trap to the boiler Fig. Installation clearances [] 900mm [] 500mm [3] 000mm [4] 70mm Wo 6 Logano plus GB (04/03)

17 INSTALLATION 5 5 INSTALLATION NOTICE: Boiler start up All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. 5. Unpacking the boiler B A C NOTICE: Boiler handling At all times the correct method for handling heavy objects should be strictly observed. Take care not to damage the boiler panels or the floor. The boiler may contain some water due to factory testing Store the boiler in a dry area prior to installation Unpacking:. Undo the ties securing the carton If a sharp implement is used, care must be taken not to pierce the carton or cause injury.. Before removing the carton it is advised that the top flaps are opened and the ancillary items (A, B, C & D) are removed and set to one side. 3. The carton can now be lifted off the boiler. 3 Remove the plastic bag protecting the boiler surfaces and place safely away from the working area. General handling guidelines: Lift only a manageable weight, or ask for help. When lifting, bend the knees, and keep the back straight and feet apart. Do not lift and twist at the same time. Lift and carry items close to the body Wear protective clothing and gloves to protect from any sharp edges Wo Fig. 3 Unpacking [A] [B] [C] Literature pack Condensate disposal pipe PRV disposal pipe 5. Boiler room requirements DANGER: Danger from explosive and flammable materials Do not store flammable materials (paper, curtains, clothing, primer, paint, ) in proximity to the boiler NOTICE: Damage to property from contaminated combustion air Do not use any cleaners containing chlorine or hydrogen halide (i.e. spray cans, primers, cleaners, paint and glue) Don t store or use these substances in the boiler room Avoid the build up of dust NOTICE: Damage from overheating. Excessive ambient temperatures may cause damage to the heating system. Ensure the ambient temperature is above 0 C and below 35 C NOTICE: Frost damage to property Fit the boiler in a frost free room Logano plus GB (04/03) 7

18 5 INSTALLATION 5.. Positioning the appliance The boiler must be adjusted to be level. This ensures air can escape from the heat exchanger and condensate drains freely. NOTICE: Damage caused by insufficient load bearing or unsuitability of the boiler room floor Ensure the floor area is suitable for installing a boiler and can take the wet weight of the appliance. 8 C L NOTICE: Damaged caused by mechanical strain on the hydraulic and flue gas connections when adjusting the position of the appliance. Do not apply any strain the connections when adjusting the boiler position Place boiler in its final location Release the locknuts on the boiler feet Adjust the boiler feet until the boiler is level vertically and horizontally, check using a spirit level Secure in position with the locknuts 3* Ø5 Ø80 53 C L Wo Fig. 4 Levelling the boiler 5.3 Mounting the boiler and flue opening Safety All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. 3* 5 4 CAUTION: Isolate the mains gas supply before starting any work and follow all relevant safety precautions. Running pipes behind the boiler The boiler should sit at least 70mm from the rear wall (not the skirting board) to allow enough room for access to the pipe work. Do not cross a pipe over another. Fig. 5 Pipe Connections System boiler: [] Heating and DHW flow ( ) [] Gas (3/4 ) [3*] System boiler - DHW return ( ) (only if optional diverter valve kit is fitted) Regular boiler - Not used [4] Heating return ( ) [5] Condensate outlet Wo 8 Logano plus GB (04/03)

19 INSTALLATION 5 Gas connections DANGER: Risk to life from explosion of flammable gases Work on components in contact with gas must only be carried out by a competent and authorised person. Comply with national and local standards and regulations Only use approved methods of making gas tight connections L 0 mm Surplus water may be present due to factory testing. L 0 mm Flue opening Any horizontal flue sections must rise away from the boiler by 5mm per metre to ensure that condensate flows back into the boiler for safe discharge via the condensate waste pipe. 5.4 Flue options CAUTION: Non accessible flue systems: Where a flue system is not going to be accessible, provision must be made for service and inspection. Voids containing concealed flues must have at least one inspection hatch no less than 300mm square. Flue joints within the void must not be more than.5 metres from the edge of the inspection hatch. Inspection hatches should be located at changes of direction. If this is not possible, bends should be viewable from both directions. 3 L 0 mm Pitched roof 500 mm 300 mm Flat roof L NOTICE: Effective flue lengths: each 90 bend used is equivalent to.0 metres of straight flue each 45 bend used is equivalent to.0 metre of straight flue 4 Maximum total Flue type flue length L (mm) High level horizontal flue 000 High level horizontal flue with x 90 bends High level horizontal flue with 3 x 90 bends Vertical balanced flue assembly Vertical balanced flue with x 90 bends Vertical balanced flue with x 45 bends Table 8 Flue options 0 mm 5 L L 0 mm Wo Fig. 6 Flue options Logano plus GB (04/03) 9

20 6 ELECTRICAL 6 ELECTRICAL DANGER: Risk of fire from hot boiler components. Hot boiler components can damage electrical cables. Ensure all electrical cables are in the correct cable guides and away from hot boiler components Access to electrical connections: Access to all wiring connections are via the Installer access cover at the bottom front of the control panel. No access is required to other parts of the control board. Release the three screws in the connections cover and remove the cover. 6. Electrical Run power cables separately from signal cables. Interference from power cables can induce spurious faults on signal cables, ensure that there is at least 300mm separation from each other. CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS All electrical work must be carried out by a competent and authorised person All work must be in line with country specific and local standard and regulations The isolator must have contact separation of 3mm minimum between poles. Any system connected to the boiler must not have a separate electrical supply. External fuse 3 Amps. When stripping the wires ensure copper strands do not fall into the control box. Access to the electrical connections: Remove the boiler front panel to gain access to electrical connections. Pull the top corners of the front panel away from the case until the ball catches are released. Lift the panel off the lower brackets and set the panel safely aside. 3 Fig. 8 [] Mains voltage connections [] Low voltage connections [3] Cable retainers FR FS LR LR 30V OUT N L N Wo 30V IN L N L N L N L Wo Fig. 9 Mains voltage connections Mains voltage terminal strip External frost thermostat 30 V A.C. switched live inputs 3 30 V A.C. mains output 4 DHW charge pump 5 DHW circulation pump 6 CH circulation pump 7 Boiler 30 V A.C. mains supply Table 9 Key to figure 9 EMS Wo Fig. 0 Low voltage connections Fig. 7 Electrical connections access Wo Low voltage terminal strip 8 Input for external demand 9 EMS bus connections 0 External cut off switch (supplied with factory fitted link) Outside sensor DHW cylinder sensor 3 Low Loss Header sensor Table 0 Key to figure 0 0 Logano plus GB (04/03)

21 COMMISSIONING 7 Cable retainer clamps. Unclip the cable clamp [A}.. Cut off the tapered cable entry to suit the cable diameter R Fig. Cable retainer 3. Unscrew the cable retaining screw [B}. Run the cable through the cable clamp ensuring there is ample cable to reach the connectors. 4. Tighten the cable retaining screw to secure the cable and replace clamp into the control panel. 7 COMMISSIONING 7. Pre-Commissioning checks CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.. Check that the service and water pipes are connected to the correct points on the back of the boiler; - CH flow ( ) - Gas inlet (3/4 ) 3* - DHW return ( ) - System boiler with optional diverter valve kit only 4 - CH return ( ) 5 - Condensate out A 3* 5 A 4 Fig. 4 Cable retainers 3 B Wo Wo Fig. 3 Pre-commissioning checks. Check all system and boiler drain points are closed. 3. Check the gas type specified on the identification plate matches that of the gas supply. Turn on the main gas supply and purge the gas supply to the boiler ensuring that the room is well ventilated. Test the gas supply for tightness. 4. Check the flue is correctly fitted and the connections are secure. 5. Check the condensate pipe work is correctly fitted and connected. 6. Refit inner case cover onto the bottom clip and secure with the two screws. NOTICE: If the boiler is not commissioned immediately then, after successfully completing all of the checks and any rectification work, shut off the gas supply and electrically isolate the boiler. 7. Filling the system and checking for leaks NOTICE: Damage due to the ingress of air into the system The appliance is only suitable for installation and operation on pumped, sealed and pressurised heating systems in line with EN88. Do not connect onto gravity and/or open vented systems Check the heating system for leaks to avoid problems during commissioning and operation. Ensure good ventilation, ensure all isolating valves in the heating circuits and radiation temperature regulating valves are fully open Open all automatic air vents Logano plus GB (04/03)

22 7 COMMISSIONING CAUTION: Risk to health from contaminated drinking water: Comply with country specific standards and regulations for avoiding contamination of drinking water In Europe, also comply with EN Starting the appliance NOTICE: Damage to property from overpressure during pressure tests! Pressure, control and safety devices may be damaged by excessive pressure. After filling the system pressure test to the release pressure of the safety valve NOTICE: Damage caused by cracks from thermal shock! Cracks can occur when toping up a warm heating system with cold mains water. The boiler could start leaking. Only fill and top up the heating system when cold (maximum flow temperature 40 C) Comply with the requirements for water quality Have a fixed connection between mains water supply and filling point in line with EN 77. Fit the appropriate safety device. Open all the system and radiator valves. Turn on the water main stop cock. Sealed System. Monitor the pressure gauge on the control panel of the appliance. Slowly fill the system via the external filling link 3. Set the pressure between and.5 bar pressure. Fig. 4 Setting the system pressure Close the external filling valve Check the pipe work and connections for leaks and rectify as necessary Vent all radiators, retighten when completed. If the test pressure drops off as a result of the air bleeding: Top up with domestic cold mains water Complete pressure test based on the local requirements Once the pressure test is completed and no leaks are present: Set correct working pressure 7.3 Water treatment bar Min.5 bar.. 3. NOTICE: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. Max Wo reset 3 Fig. 5 [] Main on/off switch [] Diagnostic port (Service engineers only) [3] DHW button [4] Heating button [5] Display [6] Minus button [7] Plus button [8] ok button [9] Back button [0] Pressure gauge [] Service button [] Reset button [3] Summer/Winter mode button NOTICE: Never run the appliance when the appliance or system is empty or unpressurised. Switching the appliance on/off:. Turn on the mains power supply. Turn on any external controls. Set the TRV controls to maximum. Set the clock or programmer, if fitted, to continuously ON and the room thermostat to maximum temperature.. Switch on the appliance with the ON/OFF switch on the control panel. The display lights up and initially shows the appliance temperature Wo The condensate trap fill program starts each time the appliance is turned on. The appliance runs at minimum output for about 5 minutes to fill the condensate trap. The symbol. flashes while the program is active. NOTICE: The quality of the system water must be checked regularly. Please contact the appliance manufacturer for further guidance. The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger O Fig. 6 Main power switch Logano plus GB (04/03)

23 COMMISSIONING 7 Setting the boiler to maximum output 3. Press the / button together with the button to enter the Chimney sweep mode, the display shows the current flow temperature and flashes the percentage heat output in the alphanumeric display. The burner symbol will be shown in the display. Press the + or - buttons until the required percentage output is displayed. Set the output to 00% initially. Measure the pressure with the boiler running at maximum output. Check the gas supply working pressure at the gas valve conforms to values shown in table. Ensure inlet pressure is satisfactory with all other gas appliances working. Gas type min.pressure (mbar) max. pressure (mbar) G0 7 5 G5 30 G Table Gas pressure range Gas pressure within the system If the gas pressure, for your gas type, is below the minimum shown in table, then this would indicate a problem with the pipe work or connections within the system. Fig. 7 Operating the boiler 4. If the boiler fails to light, press the reset button until the reset line of text displays. The device goes back into operation and the flow temperature is displayed. 5. Press the button at any time to return to normal operation. 7.5 Checking gas inlet pressure Belgium The boiler will only run at maximum output for 5 minutes before switching back to normal operation. NOTICE: Adjustment to appliances are not permitted! The boiler is factory set for operating on natural gas (G0/G5) IE(S) so that the appliance will be able to operate in both regions without adjustments be made or changing any parts. Only when replacement of a part from the gas block, it sometime may require an adjustment to the gas setting. These adjustments may only be done by a certified technician and My Service Measuring the inlet pressure Remove the front panel figure 7 Remove the combustion chamber cover. The inlet pressure to the appliance must be checked using the following procedure: A Fig. 8 Inlet test point Close gas isolation valve. Slacken the screw in the inlet pressure test point and connect a manometer. Open gas isolation valve Wo O NOTICE: Do not continue commissioning until the correct gas pressure is achieved. If pressure is satisfactory press the button and the boiler will return to normal operation. If left in the central heating boost mode the control will return to normal operation after 5 minutes. Re-seal the screw in the gas inlet pressure test point Checking the gas rate The gas rate should be measured at the gas meter after 0 minutes operation at maximum. See technical data section at the front of this manual. Where a gas meter is not available (e.g. L.P.G.) the CO/CO must be checked to the units shown in section Setting the air/gas ratio. If pressure and gas rate are satisfactory press the button and the boiler will return to normal operation. If left in the Chimney sweep mode the control will return to normal operation after 5 minutes. Close the gas isolation valve. Remove the manometer. Re-seal the screw in the gas inlet pressure test point. Open the gas isolation valve. Ensure that there are no gas leaks. Replace the outer case. 7.6 Finishing commissioning At the time of commissioning, complete all relevant sections of the Commissioning Checklist supplied.. Refit and secure the inner combustion chamber cover with the four screws removed earlier.. Locate the lower slots on the front panel onto bottom screws and engage ball catches into the receptors in each side panel. HANDOVER: Complete the Commissioning checklist supplied. Set up the controls and show the user how to operate all the controls shown in the User Guide. If appropriate instruct the customer how to repressurise the system. If the appliance is unused and exposed to freezing conditions, advise the customer of the precautions necessary to prevent damage to the boiler, system and building. In the event of the appliance being inoperative, isolate the boiler and drain the system and boiler. Logano plus GB (04/03) 3